Maricopa Community Colleges  DIE112   19946-20086 
Official Course Description: MCCCD Approval: 07/22/08
DIE112 19946-20086 L+L 3 Credit(s) 5 Period(s)
Heavy Equipment Troubleshooting and Repair
Equipment condition evaluation, preventive maintenance, record keeping and failure diagnosis. Practical experience working on heavy equipment provided.
Prerequisites: None.
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MCCCD Official Course Competencies:
 
DIE112   19946-20086 Heavy Equipment Troubleshooting and Repair
1. Describe and perform basic procedures of equipment evaluation for engines, engine oil, clutches, transmissions, differentials, and brakes. (I)
2. Perform basic preventive maintenance for heavy equipment. (II)
3. Explain record keeping procedures, vehicle warranty, inventory control, and equipment economic life. (III)
4. Diagnose causes of specific component failures for engines, turbochargers, clutch, power train, bearings, tracks, and tires. (IV)
5. Perform preventive maintenance and repair for selected components. (V)
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MCCCD Official Course Outline:
 
DIE112   19946-20086 Heavy Equipment Troubleshooting and Repair
    I. Equipment Evaluation
        A. Engine
          1. Operational checks
            a. Electrical
          1. Starting system
          2. Battery
          3. Charging system
            b. Fuel
          1. Gauges and lines
          2. Lift pump
          3. Filters
          4. Injection pump (diesel)
          5. Carburetor
          6. Injectors (diesel)
          7. Throttle
            c. Intake and exhaust
          1. Smoke density
          2. Restriction
          3. Air cleaner
          4. Turbocharger/supercharger
          5. Intake/exhaust leaks
            d. Lubrication
          1. Gauges and lines
          2. Pump
          3. Filter
          4. Oil cooler
          5. Oil contamination
          6. Oil consumption
          7. Crankcase ventilation
            e. Cooling system
          1. Radiator
          2. Fan
          3. Water pump
          4. Thermostat
          5. Coolant
          6. Internal/external leakage
            f. Governors
          2. Testing
            a. Oil analysis
            b. Dynamometer
            c. Visual inspection
        B. Clutch
          1. Operational checks
            a. Free play
            b. Slips
            c. Grabs
            d. Noise
            e. Failure to transmit power
            f. Failure to release
        C. Transmission
          1. Operational checks
            a. Noise in neutral
            b. Noise in gear
            c. Hard to shift
            d. Slips out of gear
            e. Won't transmit power
            f. Clutches slipping (hydraulic assist)
          2. Testing
            a. Oil analysis
            b. Oil level
            c. Oil pressure (hydraulic assist)
            d. Overheating
        D. Differential
          1. Operational checks
            a. Noise
            b. Working freely on turns
            c. Lock holding
          2. Testing
            a. Oil analysis
            b. Oil level
        E. Brakes
          1. Operational checks
            a. Service
            b. Parking
            c. Emergency
      II. Preventive Maintenance
          A. Scheduling based on
            1. Type of equipment
            2. Application
            3. Manufacturer's recommendation
            4. Maintenance evaluation
            5. Equipment evaluation
          B. Procedures
            1. Adjustment
            2. Cleaning
            3. Inspection
            4. Lubrication
          C. Parts level groups
            1. Air conditioning, cab and instruments
            2. Chassis brakes
            3. Drive train
            4. Electrical
            5. Engine
            6. Hydraulics
        III. Record Keeping
            A. Advantages
              1. Maintenance cost control
              2. Vehicle warranty
              3. Inventory control
              4. Cost comparisons
              5. Company operations
              6. Equipment economic life
          IV. Failure Analysis
              A. Engine
                1. Pistons
                  a. Cracking/breakage
                  b. Wear
                  c. Scuffing/seizure
                  d. Erosion
                2. Rings
                3. Liners
                4. Journal bearings
                  a. Dirt
                  b. Lack of lubrication
                  c. Overloading
                  d. Corrosion
                5. Valve gear trains
                  a. Valves
                  b. Rocker arms
                  c. Push rods
                6. Turbochargers
                  a. Wheels/impellers
                  b. Shafts
                  c. Bearings
                  d. Housings
              B. Clutch
                1. Discs
                2. Covers/pressure plates
                3. Center plates
                4. Release bearings
              C. Power train
                1. Gears
                  a. Wear
                  b. Fatigue
                  c. Impact
                2. Shafts
                3. Axles
                4. Spindles
                5. Universal joints
              D. Anti-friction bearings
                1. Contamination
                2. Improper lubrication
                3. Improper installation
                4. Severe service
              E. Tracks and tires
                1. Links
                2. Sprockets
                3. Rollers
                4. Fabric breaks
                5. Wear
              F. Seven basic steps of diagnosis
                1. Know the system
                2. Ask the operator
                3. Inspect the system
                4. Operate the machine
                5. List possible causes
                6. Reach a conclusion
                7. Test the conclusion
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