Construction Training and Maintenance Manuals
Chapter 1 Technical Administration
Maintenance Categories
Maintenance Scheduling
Figure 1-1.—Sample preventive maintenance inspection schedule.
Maintenance Inspections
PM Record Cards
Figure 1-3.—Vehicle/Construction Equipment PM Record Card, NAVFAC Form 11240/6.
Repair Orders
Figure 1-5.—Shop Repair Order Continuation Sheet.
Figure 1-6.—Equipment Repair Order (ERO), NAVFAC 11200/41.
Figure 1-7.—Equipment Repair Order (ERO) Block Codes, NAVFAC 11200/41.
Figure 1-8.—Equipment Repair Order (ERO) Continuation Sheet, NAVFAC 11200/41A.
Figure 1-9.—Equipment Repair Order (ERO) Work Sheet, NAVFAC 11200/41B.
Figure 1-10.—Equipment Repair Order (ERO) Log
Equipment History Jackets
Figure 1-11.—DoD Property Record, DD Form 1342.
Figure 1-13.—Time card.
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Levels
Figure 1-14.—Component identification group numbers (CIDs).
Technical Manuals
Requesting Spare Parts
Figure 1-16.—Non-NSN Requisition, NAVSUP Form 1250-2.
Repair Parts Control
Figure 1-17.—DTO Log.
Repair Parts Summary Sheet
Figure 1-19.—DTO Information Sheet.
Figure 1-20.—DD Form 1348-1.
Chapter 2 Principles of an Internal Combustion Engine
Development of Power
Four-Stroke-Cycle Engine
Figure 2-5.—Four-stroke cycle in a gasoline engine.
Two-Stroke-Cycle Engine
Figure 2-6.—Strokes and events in a four-stroke-cycle diesel engine.
Figure 2-7.—Strokes and events in a two-stroke-cycle diesel engine cylinder.
Classification of Engines
Multiple-Cylinder Engines
Arrangement of Cylinders
Arrangement of Valves
Figure 2-14.—T-head engine.
Engine Measurements and Performance
Figure 2-18.—Horsepower.
Figure 2-20.—Prony brake.
Fire 2-22.—Demonstrating volumetric efficiency.
Thermal Efficiency
Linear Measurements
Engine Performance
Figure 2-26.—Typical valve timing diagrams.
Figure 2-28.—Valve opening duration.
Figure 2-31.—Ignition timing.
Chapter 3 Construction of an Internal Combustion Engine
FFigure 3-1.—Cylinder block and components.
Figure 3-2.—Requirements of a cylinder.
Figure 3-4.—Cylinder sleeves.
Figure 3-5.—Cylinder sleeve casualties.
Figure 3-8.—Aircooled crankcase.
Cylinder Head
Figure 3-11.—Combustion chambers.
Figure 3-13.—Cylinder head sealing.
Exhaust Manifold
Figure 3-15.—Typical intake manifold.
Gaskets
Moving Parts of an Engine
Figure 3-20.—Synthetic rubber oil seals.
Piston Assembly
Figure 3-23.—The parts of a piston.
Figure 3-25.—Controlling piston expansion.
Figure 3-26.—Cam-ground piston action.
Figure 3-29.—Piston pin.
Figure 3-31.—Purpose of piston rings.
Figure 3-32.—Types of piston rings.
Figure 3-35.—Ring gap variations.
Connecting Rods
Crankshaft
Figure 3-40.—Crankshaft construction.
Figure 3-41.—Crankshaft throw arrangements.
Figure 3-43.—Typical insert bearing installation.
Vibration Damper
Valve and Valve Mechanisms
Camshaft
Figure 3-48.—Hydraulic tappets.
Valve and Valve Seats
Valve Guides
Figure 3-54.—Valve rotators.
Figure 3-56.—Valve-refacing machine.
Valve Guide Service
Figure 3-59.—Puller used in removing valve seat inserts.
Rocker Arm Service
Timing Gears (Gear Trains)
Engine Bearings
Bearing Lubrication
Bearing Characteristics
Engine Adjustment and Testing
Valves in Block
Compression Test
Vacuum Gauge Test
Cylinder Leakage Test
Cylinder Leakage Test - Continued
Chapter 4 Gasoline Fuel Systems
Air-Fuel Ratio
Gasoline Fuel System Components
Fuel Tank
Fuel Gauges
Figure 4-5.—Thermostatic fuel gauge: self-regulating.
Fuel Filters
Fuel Pump
Figure 4-9.—Fuel filter elements.
Figure 4-10.—Mechanical positive fuel pump installation.
Figure 4-11.—Mechanical nonpositive fuel pump.
Figure 4-13.—Bellows-type electric fuel pump.
Fuel Lines and Hoses
Air Cleaner
Principles of Carburetion
Figure 1-17.—Example of atomization.
Carburetor
Float System
Idle System
Figure 4-23.—Diaphragm accelerator pump.
High-Speed System
Figure 4-26.—Mechanically operated metering rod.
Full-Power System
Choke System
Figure 4-29.—Manual choke system.
Figure 4-34.—Engine coolant heated choke.
Figure 4-36.—Exhaust-manifold heat-tube choke.
Carburetor Accessories
Figure 4-40.—Antidieseling solenoid operation.
Computer Controlled Carburetors
Carburetor Troubles
Gasoline Fuel Injection Systems
Figure 4-43.—Mechanical-timed injection.
Figure 4-44.—Electronic-timed injection.
Timed Fuel Injection Systems - Continued
Continuous Fuel Injection Systems
Throttle Body Injection System
Exhaust and Emission Control Systems
Exhaust Manifold
Figure 4-48.—Manifold heat control valve.
Catalytic Converters
Air Injection System
Figure 4-51.—Air injection system.
Figure 4-52.—PCV system.
Exhaust gas Recirculation System
Fuel Evaporation Control System
Figure 4-54.—Fuel evaporization system.
Fuel Evaporation Control System - Continued
Chapter 5 Diesel Fuel Systems
Figure 5-1.—Comparison of sequence of events in diesel and gasoline four-cycle engines.
Diesel Fuel Oil Grades
Viscosity
Open Combustion Chamber
Turbulence Chamber
Figure 5-5.—Spherical chamber.
Governors
Types of Governors
Figure 5-6.—Mechanical (centrifugal) governor.
Hydraulic Governors
Electronic Governors
Diesel Fuel System Components
Water Separators
Methods of Injection
Catterpillar Fuel Systems
Figure 5-10.—Sleeve metering barrel and plunger assembly.
Governor Action
Automatic Timing Advance Unit
Transfer Pump
Distributor-Type Fuel Systems
Figure 5-14.—Transfer pump.
Figure 5-15.—Rotor in charge position.
Injection Pump Accessories
Governor
Detroit Diesel Unit Injection Systems
Figure 5-23.—Diagram of typical Detroit diesel fuel system.
Fuel Pump
Injectors
Injector Timing
Equalizing Injectors
Governor
Cummins Diesel Fuel Systems
Figure 5-29.—Pressure-time (PT) gear pump.
Injectors
Celect System
Figure 5-30.—Pressure-time injector operation.
Celect System - Continued
Celect System Operation
Figure 5-31.—Metering and distributing fuel pump assembly-left sectional view.
American Bosch Fuel Injection Systems
Figure 5-33.—Fuel intake flow diagram.
Types of Nozzles
Figure 5-38.—Fuel density compensator.
Superchargers and Turbochargers
Figure 5-39.—Centrifugal supercharger.
Turbochargers
Turbo Lag
Cold Weather Starting
Ether
Diesel Fuel System Maintenance
General Troubleshooting
Quick Injector Misfire Check
Quick Injector Misfire Check - Continued
Chapter 6 Cooling and Lubricating Systems
Air-Cooled Systems
Fan and Shroud
Liquid-Cooled System
Radiator
Radiator Hoses
Water Pump
Fan and Shroud
Figure 6-9.—Variable pitch fan.
Water Jacket
Figure 6-11.—Pellet-type thermostat.
Figure 6-12.—Blocking-bypass thermostat.
Expansion (Recovery) Tank
Temperature Gauge and Warning Light
Flushing the System
Coolign Systems Tests
Combustion Leak Test
Service and Repair of Cooling System Components
Hoses
Radiator and Pressure Cap
Engine Lubricating Systems
Purposes of Lubrication
Figure 6-19.—Sources of oil contamination.
Lubricating (Oil) System Components
Oil Level Gauge
Figure 6-22.—Gear-type oil pump.
Oil Pickup and Strainer
Figure 6-24.—Oil filters.
Figure 6-25.—Filter system configurations.
Oil Pressure Warning Light
Oil Temperature Regulator
Types of Lubricating Systems
Force Feed
Lubricating System Problem Diagnosis
Lubricating System Maintenance
Pressure Relief Valve Service
Pressure Relief Valve Service - Continued
Appendix I Glossary
Appendix I - Continued
Appendix I - Continued
Appendix I - Continued
Appendix I - Continued
Appendix I - Continued
Appendix I - Continued
Appendix I - Continued
Appendix I - Continued
Appendix I - Continued
Appendix I - Continued
Appendix II Answer Key
Appendix II - Continued
Appendix II - Continued
Appendix II - Continued
Appendix II - Continued
Appendix III - References Used to Develop This Traman
Index
Index - Continued
Index - Continued
Index - Continued
Chapter 1 Technical Administration
Maintenance Categories
Maintenance Scheduling
Figure 1-1.—Sample preventive maintenance inspection schedule.
Maintenance Inspections
PM Record Cards
Figure 1-3.—Vehicle/Construction Equipment PM Record Card, NAVFAC Form 11240/6.
Repair Orders
Figure 1-5.—Shop Repair Order Continuation Sheet.
Figure 1-6.—Equipment Repair Order (ERO), NAVFAC 11200/41.
Figure 1-7.—Equipment Repair Order (ERO) Block Codes, NAVFAC 11200/41.
Figure 1-8.—Equipment Repair Order (ERO) Continuation Sheet, NAVFAC 11200/41A.
Figure 1-9.—Equipment Repair Order (ERO) Work Sheet, NAVFAC 11200/41B.
Figure 1-10.—Equipment Repair Order (ERO) Log
Equipment History Jackets
Figure 1-11.—DoD Property Record, DD Form 1342.
Figure 1-13.—Time card.
14264_28
Levels
Figure 1-14.—Component identification group numbers (CIDs).
Technical Manuals
Requesting Spare Parts
Figure 1-16.—Non-NSN Requisition, NAVSUP Form 1250-2.
Repair Parts Control
Figure 1-17.—DTO Log.
Repair Parts Summary Sheet
Figure 1-19.—DTO Information Sheet.
Figure 1-20.—DD Form 1348-1.
Chapter 2 Principles of an Internal Combustion Engine
Development of Power
Four-Stroke-Cycle Engine
Figure 2-5.—Four-stroke cycle in a gasoline engine.
Two-Stroke-Cycle Engine
Figure 2-6.—Strokes and events in a four-stroke-cycle diesel engine.
Figure 2-7.—Strokes and events in a two-stroke-cycle diesel engine cylinder.
Classification of Engines
Multiple-Cylinder Engines
Arrangement of Cylinders
Arrangement of Valves
Figure 2-14.—T-head engine.
Engine Measurements and Performance
Figure 2-18.—Horsepower.
Figure 2-20.—Prony brake.
Fire 2-22.—Demonstrating volumetric efficiency.
Thermal Efficiency
Linear Measurements
Engine Performance
Figure 2-26.—Typical valve timing diagrams.
Figure 2-28.—Valve opening duration.
Figure 2-31.—Ignition timing.
Chapter 3 Construction of an Internal Combustion Engine
FFigure 3-1.—Cylinder block and components.
Figure 3-2.—Requirements of a cylinder.
Figure 3-4.—Cylinder sleeves.
Figure 3-5.—Cylinder sleeve casualties.
Figure 3-8.—Aircooled crankcase.
Cylinder Head
Figure 3-11.—Combustion chambers.
Figure 3-13.—Cylinder head sealing.
Exhaust Manifold
Figure 3-15.—Typical intake manifold.
Gaskets
Moving Parts of an Engine
Figure 3-20.—Synthetic rubber oil seals.
Piston Assembly
Figure 3-23.—The parts of a piston.
Figure 3-25.—Controlling piston expansion.
Figure 3-26.—Cam-ground piston action.
Figure 3-29.—Piston pin.
Figure 3-31.—Purpose of piston rings.
Figure 3-32.—Types of piston rings.
Figure 3-35.—Ring gap variations.
Connecting Rods
Crankshaft
Figure 3-40.—Crankshaft construction.
Figure 3-41.—Crankshaft throw arrangements.
Figure 3-43.—Typical insert bearing installation.
Vibration Damper
Valve and Valve Mechanisms
Camshaft
Figure 3-48.—Hydraulic tappets.
Valve and Valve Seats
Valve Guides
Figure 3-54.—Valve rotators.
Figure 3-56.—Valve-refacing machine.
Valve Guide Service
Figure 3-59.—Puller used in removing valve seat inserts.
Rocker Arm Service
Timing Gears (Gear Trains)
Engine Bearings
Bearing Lubrication
Bearing Characteristics
Engine Adjustment and Testing
Valves in Block
Compression Test
Vacuum Gauge Test
Cylinder Leakage Test
Cylinder Leakage Test - Continued
Chapter 4 Gasoline Fuel Systems
Air-Fuel Ratio
Gasoline Fuel System Components
Fuel Tank
Fuel Gauges
Figure 4-5.—Thermostatic fuel gauge: self-regulating.
Fuel Filters
Fuel Pump
Figure 4-9.—Fuel filter elements.
Figure 4-10.—Mechanical positive fuel pump installation.
Figure 4-11.—Mechanical nonpositive fuel pump.
Figure 4-13.—Bellows-type electric fuel pump.
Fuel Lines and Hoses
Air Cleaner
Principles of Carburetion
Figure 1-17.—Example of atomization.
Carburetor
Float System
Idle System
Figure 4-23.—Diaphragm accelerator pump.
High-Speed System
Figure 4-26.—Mechanically operated metering rod.
Full-Power System
Choke System
Figure 4-29.—Manual choke system.
Figure 4-34.—Engine coolant heated choke.
Figure 4-36.—Exhaust-manifold heat-tube choke.
Carburetor Accessories
Figure 4-40.—Antidieseling solenoid operation.
Computer Controlled Carburetors
Carburetor Troubles
Gasoline Fuel Injection Systems
Figure 4-43.—Mechanical-timed injection.
Figure 4-44.—Electronic-timed injection.
Timed Fuel Injection Systems - Continued
Continuous Fuel Injection Systems
Throttle Body Injection System
Exhaust and Emission Control Systems
Exhaust Manifold
Figure 4-48.—Manifold heat control valve.
Catalytic Converters
Air Injection System
Figure 4-51.—Air injection system.
Figure 4-52.—PCV system.
Exhaust gas Recirculation System
Fuel Evaporation Control System
Figure 4-54.—Fuel evaporization system.
Fuel Evaporation Control System - Continued
Chapter 5 Diesel Fuel Systems
Figure 5-1.—Comparison of sequence of events in diesel and gasoline four-cycle engines.
Diesel Fuel Oil Grades
Viscosity
Open Combustion Chamber
Turbulence Chamber
Figure 5-5.—Spherical chamber.
Governors
Types of Governors
Figure 5-6.—Mechanical (centrifugal) governor.
Hydraulic Governors
Electronic Governors
Diesel Fuel System Components
Water Separators
Methods of Injection
Catterpillar Fuel Systems
Figure 5-10.—Sleeve metering barrel and plunger assembly.
Governor Action
Automatic Timing Advance Unit
Transfer Pump
Distributor-Type Fuel Systems
Figure 5-14.—Transfer pump.
Figure 5-15.—Rotor in charge position.
Injection Pump Accessories
Governor
Detroit Diesel Unit Injection Systems
Figure 5-23.—Diagram of typical Detroit diesel fuel system.
Fuel Pump
Injectors
Injector Timing
Equalizing Injectors
Governor
Cummins Diesel Fuel Systems
Figure 5-29.—Pressure-time (PT) gear pump.
Injectors
Celect System
Figure 5-30.—Pressure-time injector operation.
Celect System - Continued
Celect System Operation
Figure 5-31.—Metering and distributing fuel pump assembly-left sectional view.
American Bosch Fuel Injection Systems
Figure 5-33.—Fuel intake flow diagram.
Types of Nozzles
Figure 5-38.—Fuel density compensator.
Superchargers and Turbochargers
Figure 5-39.—Centrifugal supercharger.
Turbochargers
Turbo Lag
Cold Weather Starting
Ether
Diesel Fuel System Maintenance
General Troubleshooting
Quick Injector Misfire Check
Quick Injector Misfire Check - Continued
Chapter 6 Cooling and Lubricating Systems
Air-Cooled Systems
Fan and Shroud
Liquid-Cooled System
Radiator
Radiator Hoses
Water Pump
Fan and Shroud
Figure 6-9.—Variable pitch fan.
Water Jacket
Figure 6-11.—Pellet-type thermostat.
Figure 6-12.—Blocking-bypass thermostat.
Expansion (Recovery) Tank
Temperature Gauge and Warning Light
Flushing the System
Coolign Systems Tests
Combustion Leak Test
Service and Repair of Cooling System Components
Hoses
Radiator and Pressure Cap
Engine Lubricating Systems
Purposes of Lubrication
Figure 6-19.—Sources of oil contamination.
Lubricating (Oil) System Components
Oil Level Gauge
Figure 6-22.—Gear-type oil pump.
Oil Pickup and Strainer
Figure 6-24.—Oil filters.
Figure 6-25.—Filter system configurations.
Oil Pressure Warning Light
Oil Temperature Regulator
Types of Lubricating Systems
Force Feed
Lubricating System Problem Diagnosis
Lubricating System Maintenance
Pressure Relief Valve Service
Pressure Relief Valve Service - Continued
Appendix I Glossary
Appendix I - Continued
Appendix I - Continued
Appendix I - Continued
Appendix I - Continued
Appendix I - Continued
Appendix I - Continued
Appendix I - Continued
Appendix I - Continued
Appendix I - Continued
Appendix I - Continued
Appendix II Answer Key
Appendix II - Continued
Appendix II - Continued
Appendix II - Continued
Appendix II - Continued
Appendix III - References Used to Develop This Traman
Index
Index - Continued
Index - Continued
Index - Continued
.::"A COMMON MAN WITH A COMMON THOUGHT'S !"::.
