DOCUMENT R ED 139 942 CB 010 960 AUTHOR Tidwell, Joseph TITLE Diesel Mechanics. Performance Objectives. Intermediate Ccurse. INSTITUTION Du-Val County School Board, Jacksonville, Fla. PUB DATE Dec 74 NOTE 31p.; For a relat-d document see CE 010 959; Best copy available EBBS PRICE MF-$0.83 Rc-$2.06 Pius Postage. DESCRIPTORS *Auto Mechanics; *Behavioral Objectives; *Criterion Referenced Tests; *Diesel Engines; Equipment Maintenance; Mechanical Skills; Repair; Secondary Education; shop curriculum; Skill Development; Vocational Education ABSTRACT Several intermediate performance objectives and corresponding criterion measures are listed for each of six terminal objectives for an intermediate diesel mechanics course (two aemesters, 3 hours daily) designed for high school students who upon completion would be ready for an on-the-job_training experience in diesel service and-repair. Through shop manipulative practice in addition to related classroom instruction, the course covers operation and safety, electricity, intake and exhaust systems, starting methods, cil and gaseous fuels, tune-up and troubleshooting, engine rating and performance, and mechanical and hydraulic drives. Titles of the six terminal objectives are. Orientation--Human Relations and Safety, Electrical System, Starting Methods, Power Trains, Brake Systems, and Chassis Components. (This manual and 54 others were developed for various secondary letel vocational courses using the System Approach for Education (SkFE) guidelines.) (HD)

**** ************** ***** * ***************************************** Documents acquired by ERIC include many informal unpublished * materials mot available from other sources. ERIC makes every effort * * to obtain the best copy available. Nevertheless, items of marginal * reproducibility are often encountered and this affects the quality * of the microfiche and hardcopy reproductions ERIC makes available * via the ERIC Document Reproduction Service (EDRS) .EDRS is not * responsible for the quality of the original document. Reproductions * * supplied by EDRS are the best that can be made from the original. ***************************************************** ***************** V11LML BEST

-FtliRMANCE IVES INTE4MEDIATE COURSE

2

Dyym: COUNTY SCHOOL BOARD Dr. John T. Gunning Superintendent of Schools

DUVAL COUNTY SCHOOL BOARD

Mr. William E. Carter, Chairman Mr. Wendell P. Holmes, Jr., Vice Chairman Ir. Joseph Cullen

. James S. Hornsby William S. Mathias, Gene W. Miller Nathan Wilson

Dr. Donald W. Johns-_-_- Associate Superintendent, Curriculum

Mr. David A. RigSby Director of Vocational-Technical Education

Mr. Charles L. Downing Supervisor of Vocational-Technical Education

Mr. David A. Brown Sup rvisor of Industrial Education

Duval County Public Schools 'Revised: December, 1974

3 ACKN --EDGEMEN1S

This manual was developed using System Approach For Educa ion (SAFE) g-idelines.

Appreciation and recognition are extended to the following educators who have assisted in the preparation of this manual:

Tom Cartei Coordinator School Industry Education

Joseph Killough, Coordinator School Industry Education

Mr. Char es Downing, Supervisor Vocational-Technical Education

The follo ing educator participated as the writer uf this manual:

Joseph Tidwell, Instruc or

Cover design and printin by: Mr. Chester Seivert Typist: Linda Creech DIESEL MECHANICS-INTERMEDIATE Accreditation No.: 9245 Length of Course: 2 Semesters Time Block: 3 Hou's Daily

COURSE DESCRIPTION

This course is prepared to train intermediate students who i tend to become diesel service and repair mechanics. The tra ning includes shop manipulative practice in addition to related classroom instruction.

Intermediate instruction includes: operation and safety, electricity, intake and exhaust systems, starting methods, oil and gaseous fuels, tune-up and trouble-shooting, engine rating and performance, mechan cal and hydraulic drives. Students who have at least 540 hours of instruction in basic and inte mediate courses and exhibit nece sary skills and attitudes may be placed in the S.I.E. Programon recommendation of the instructor.

540 Hours 9245

DIESEL MECHANICS-INTERMEDIATE Syllabus of Ter_ inal Performance Objectives

13.0 Orientat _n, Human Relati ns Safe 14.0 Electrical System 15.0 Starting Methods

16.0 Power Trains 17.0 Brake Systems 18.0 Chassis Components

6 COURSL DIATE

TERMINAL PERFORMANCE OBJECTIVE NO. _1_3.0 Orientation Human Rela ions Safety Upon completion of the unit on orientation, human relations and safety, 90% of the students will demonstrate 80% correct responses to a criterion test objective knowledge of orientation,- human relations and safety.

I N1 LRAEDI A NO. PERFORMANCE 00,ECTIVE: TERION lEASURES

Test attached.

_.1 The student will demon- Correctly.state, orally or in strate, by stating orally writing with 80% accuracy, or in writing with 80% shop foreman's duties: accuracy, knowledge of 1. Starting and dismissal school shop foreman's time of class. assignment and routing 2. Rest room check out relating to: procedure. 1. Starting and dismissal 3. Tool room and shop clean-up time of class. detail duties. 2. Rest room check out 4. Student locker assignment :procedure. and regulations. 3. Tool room check out assignment and regulations. 13.2 The student will demon- Correctly state, orally of in strate, by stating orally writing with 80% accuracy, on in writing with 80% knowledge of tool room manage- accuracy, his knowledge ment and inventory: of tool room management 1. What is in the shop. and inventory relating 2. Knowing where each item is. to: 3. Have proper storage and 1. Knowing what is in keep each item in its the shop. place. 2. Knowing where each 4. Have a procedure to item is. systematically replace 3. Have proper storage items and material lost, and keep each item broken or consumed. inits place. 4. Have a procedure to systematically replace items and material lost, broken and consumed. IEDIATE

TERMINAL PERF RMANCE

OBJECTIVE NO. 13,0 _ _(cont'd) Safety

INTERMEDIATI NO. PERFORMANCE OBJECTIVIS CRITERION MEASURES

13.3The student will demonstrate Complete the basic and inter- his commitment to participate mediate course objectives with in the S.I.E. program by 80% proficiency and 540 shop_ completing the SIE program hours. After being recommended application upon completing by instructor, complete the the basic and intermediate S1E program application. course objectives with 80% proficiency and minimum of 540 shop hours and being recommended by his instructor.

13.4The student will exhibit his 4Using job interview information ability to prepare for and by VICA and Kiwanis Club pre- to carry out a job interview pare for and carry out a dots with a rating of 80% or interview. Attain a rating of better using the VICA rating 80% using the VICA Rating Scale. scale. COHWIE DIESEL MECHANICS INTE AEDIATE

'TERMINAL PERFORMANCE OBJECTIVE NO. 13.0 (cont'd) Orientation, Human Relations SUMy

INTERMEDIATEA_ NO. PERFORMANCE OBJECTIVE CRITERION v-ASURES

13 The student will demonstrate 13.5 Correctly state orally or in his knowledge of Human Rela- writing knowledge of Human tions relating to_job perfor- Relations "Why we Work" by mance by stating in writing, submitting a written report his understanding of "Why We of 200 words or give a ten Work", by submitting a minute oral presentation written report of at least and respond to oral questions two hundred words or by on the topic. giving an oral presentation for at least ten minutes responding to oral questions from the class correctly.

13.6 The student will demonstrate 13.6 Correctly demonstrate knowledge his knowledge of safety by of safety by stating orally or stating orally or in writing in writing, understanding two his understanding of the basic causes of accidents: basic causes contributing "Unsafe Conditions" and "Unsafe to accidents: "Unsafe Acts" Acts." Submit a written report and "Unsafe Conditions." of 100 words or give a five The student will submit a minute oral presentation and written report of at least respond to oral questions on one hundred words or by the topic. giving an oral presentation of five minutes and respond to oral questions from the class correctly.

9 COURS- Di SEL MECHANCS - INTERMEDIATE

-TERMINAL PERFORMANCE OBJECTIVE NO. 13.0 (cont'd) Orienta _on, Human Relations a

INTERMEDIATE NO. PERFORMANCE OBJECTIVES No. CRITERION MEASURES

13.7The student will demonstrate 13.7 Correctly demonstrate under- his understanding of shop standing of eye irOury sources Eye injury Sources by stating orally or in writing with 80% in writing his understanding accuracy the following: of the following by submit- 1. Flying Metal Chips, frag_ ting a written report of at ment of striking tools, least two hundred words or nails, rivits and splinters oral presentation of ten of wood. minutes and respond to oral 2. Small flying particles from questions from the class grinding and scaling opera- correctly. tions and air-born dust. 1. Flying metal chips, 3. Splashes of Molten metal fragments of striking during soldering, brazing, tools, nails, rivits welding, furnace operations, and splinters,of wood. casting and pouring. Small flying particles 4. Splashes of liquids, handling grinding and scaling acids, akalies and corrosives operations and air-bone from hot tanks. dust. Poisonous dust, gases and Splashes of Molten Metal vapors which effect.the during soldering, brazing, eye directly. welding, furnace opera- Radiant Energy and Welding. tions, casting and pour- ing. Splashes of liquids, handling acids, alkalies, and corrisive From hot tanks.- Poisonous dust, gases and vapors which effect the eye directly. Radiant Energy and Welding.

_to COURSE DESEL TEC1I -TICS TERMEDIATE

TERMINAL PERFORMANCE OBJECTIVE NO. 14 0_ Electric Srstem Upon completiOn of the unit on Electrical System consisting of: Fundamentals of Electricity, Magnetism, Electrical Measuring Instruments, Storage Battery Ignition System, Cranking System, and Charging System 90% of the students will demonstrate through 80% correct responses to a criterion test, Objective Knowledge of the Electrical SyJtem. The student will demonstrate his ability to perform required service operations on components during laboratory assignments. Using service manuals tools, L LD TE PERFORMANCE OBJECTIVES NO CRITERION MEASURES 14.0 Test Attached 14.1 Given a lis_ of ten terms 14,1 Correctly explain the following related to fundamentals related to fundamentals of by explaining orally or in Electricity: writing seven of ten terms 1. Atom with 100% accuracy. 2. Electron Theory 1. Atom 3. Conductor 2. Electron Theory 4. Insulators 3. Conductors S. Voltage 4. Insulators 6. Ampere S. Voltage 7. Resistance 6. Ampere 8. Series Circuits 7, Resistance 9. Parallel Circuits 8. Series Circuits 10. Series Parallel Circuits 9. Parallel Circuits 10. Series Parallel

14.2 Given a list of four terms 14.2 Correctly explain the following 'related to magnetism the four terms related to magnetism: student will demonstrate 1. Magnetism his understanding of 2. Permanent 'gnets magnetism by explaining 3. Electromag ts orally or in writing three 4. Solenoids or four terms with 100% accuracy. 1. Magnetism 2, Permanent Magnets 3. Electromagnets 4. Solenoids

14.3 Given a shop laboratory 14 3 Use Voltmeter, Ammeter, and of customer engine the Ohmmeter correctly and student will demonstrate accurately during test on his understanding and Engine starter. ability to use voltmeter, ammeter and ohmmeter checking voltage at Starter. cou DIESEA.. AEC CS - INTERMEDIATE

TERMINAL 1, Ezzy(. :E OBJa:TIVE NO. 14.0 t Electric System _ parts and materials; voltage measurement must be .1 volt, clearance .measurement .002 no abnormal time used. iNTEE7u1),ATE NO. PERFOEN;M:CE

14.3 Amperage, Draw at starter and ground reading with Ohmmeter. Starter voltage must be 10 volts at starter. Amperage draw must not exceed 45 amperes. With ground brushes insulated or field coil ground disconnected check field windings with Ohmmeter reading should be 100,000 OHMS or higher. Take two reading on all test readings should be within 5% of above values.

14.4 Given an illustration 14.4 . Correctly state function of the of storage battery the storage battery and identify 10 student will demonstrate of 14 components correctly. his understanding of storage battery by stating the function of the battery and identifying 10 of 14 components correctly,

14 Same Performancr Ob- 14.5 Using cell tester check battery for jective. shorted cell correctly and ac- curately. Take two readings using Hydrometer Test and Electrolyte Specific Gravity correctly and accurately. Take,two readings. COURSE D E EL MECHANICS -INTE_ _EDIATE

RMINAL PERFORMANCE ABJECTIVE NO. 14.0 (cont'd) Electrical System

INTERMED ATE PERFORMANCE OBJECTIVES CRITERION MEASURES diVen a shop laboratory or 14.6 Install brusher in starting _tustomer engine the studen motor correctly. Test Will demonstrate his ability starter for no load running, -to:replace brushes of a end thrust and starting load 'starter motor. Using brushes amperace.t. necessary tools and cleaning Materials. Test starter daWiiiii-16id, end play 'must be .025 ± .005 and run -free, starter must not exceed 45 amps underload on vehicle. Install contact points in ignition distributor cor- rectly,and set contact dwell accurately.

-i4.8 diven a shop laboratory or 14.8 Install alternator correctly customer engine the student and check correctly,the will demonstrate his ability alternator output forJ6 volts to service the charging at 1,500 RPM. system by replacement altet- naton tools, ammeter and tachometer. Check alter- nator output at 1,500 RPM. For 16 volts must be above 125 COURSE EDIATE

INAL PERFORMANCE r-OBJECTIVE NO. AlpoiCcompletion of the unit on Starting Methods, 90% of the students 0/111 demonstrate through 80%, correct responses to a criterion test; l'objective knowledge of starting methods. The student will demonstrate -his ability to perform required' service operations on components during 'llaboratory assignments. Using service manuals, parts, and materials. -0earance measurements must be to specifications t .002 andno abnormal imes used.

PERFORMANCE OBJECTIVES NO :RITERION MEASURES

.0 Test Attached

-Given a. list of six methods .1 Correctly explain four of the of starting diesel engines, six methods of starting diesel the student will demonstrate engines. his understanding of starting 1. Hand Starting methods by explaining orally 2. Electric Starting or in writing four of the 3. Compressed Air ,six--methodswith 100% 4. Small Gas Engines accuracy. 5. Hydraulic 1. Hand Starting 6. Inertia 2. Electric Starting 3, Compressed Air 4, Small Gas Engines S. Hydraulic 6. Inertia

15.2 Given a shop laboratory the 15.2 Correctly hook up electrical student will demonstrate his starting system on shop ability to wire up the Jaboratory engine. electrical starting system. Using battery, battery wire leads, solonoid, starter button, and leads, tools, materials and shop manual. Wiring hook up must conform to manufacturers wiring diagram and starting amperage not exceed SO amps. Given a diagram of a air 15.3 Correctly identify and explain starting system employing the function of the four of fiVe components on the five air starting syste'm engine. The student will components. demonstrate his understanding 1. AirStartingControl yalve of air starting methods by 2. AirStartingManifold identifying and explaining 3. AirStartingDistributor Valves COI 4 DIESEL MEChANICS -INTERMEDIATE

ci-TERMINAL PERFORMANCE ';',=OBJECTIVE NO. 15.0 ( ont,d) Starting ethods v

INTERMEDIATE O. PERFORMANCE OBJECTIVE NO. CRITERION lEASURES

the function of four of the 5.3 4. Air S arting Supply Idnes Cont) five components correc ly. S. Air Starting Check Valves CO1JRS1 DIE L MECHANICS INTERMEDIATE

:1!TERMINAL PERFORMANCE OBJECTIVE NO. 15.0 ontid) in Method

INTERMEDIA PERFORMANCE OBJECT VP CRITERION NIEASURES

15.4 Given a ;shop laboratory 15.4 Correctly remove, inspect, or customer engine the reinstall and adjust gaso7 student will demonstrate line starting engine pinion his ability to remove', and for caterpillar inspect, adjust and re- diesel. place a gasoline engine -starting_pinion used on a caterpillar diesel. Using necessary tools, materials, and shop manual. Check clutch plate; Thickness. 125 .002 starting pinion clutch must release at 5,000 RPM maximum.

15. Given a diagram of a 15.5 Correctly identify and explain _hydraulic engine start- the function of four of five

ing system employing hydraulic starting system ' five components.. The components. student will demonstrate 1. Starter assembly his understanding of 2. Accumulator hydraulic starting system 3. Hand pump methods by identifying 4. Engine driven pump and explaining the_ 5. Reservoir function of four of the five components cor- rectly.

1: 6 Given_a diagram of an 1 .6 Correctly identify three of inertia engine starting four components and explain system, the student inertia starting pethod. will demonstrate his 1. Wind handle and housing knowledge of inertia 2. Spring starting methods by 3. Release explaining inertia start- 4. Bendix drive assembly. ing and correctly identify three of four -components. COURSE DIESEi..MEq1ANCS - INTERMEDIATE

L P ERFORMANCE NO. 15.0 ted) Starting Methods

INTERNED LATE PERFORMIWEE Oflhl CT :CV ES

Given a list of four 15.7 Correctly explain, orally or in methods of starting writingi three of four methods of diesel engines in cold starting diesel engines in cold weather, the-student cold weather. wiJ1 demonstrate his 1. Grid resistor understanding of cold 2. Glow plugs weather start- ig aids;. 3. Flame primer orally or in whiting, 4. Ether capsule primer by explaining three of four methods. 1. Grid resistor 2. Glow plug 3. Flame primer 4. Ether capsule primer. _ 158 The student given a 15.8 Correctly perform the require& shop laboratory or service operations on a electric customer engine electri starting motor to replace armature starter will demon- brushes, check commutator sgments strate his abilility for wear and grounds and replace to perform the re- worn armature shaft bushings. quired operations to replace armature brushes, inspect com- mutator and replace armature bushings. Using necessary tools, parts, and material. Commutator segments must show no grounds ontest or wear deeper than ..005. Replace brushes 50% worn and armature hushing clearance must he .004 .001. COUR- DIESEL MECHANICS - INTER-ED ATE

NAL PERFORMANCE OBjECtIVE NO. 16.0 Power Trains

, tion of this unit on power trains, 90% of tSe students will Ofluinstrate'through 80% correct responses to a criterion test; objective jedgeof-power trains-. The student will demonstrate his ability erforerequired service operations on components during laboratory sp:numents.-%Using service manuals, tools,:parts, and materials. -tiara-Ude measurements must be to manufacturers shop manual specifica- xons .002 and no abnormal times used.

O. PERFORMANCE OBJECTIVES NO I CRITERION MEASURES 16.0 Test Attached Given an illustration of a 16.1 Correctly define and explain liowOr-train employing eight the function of the following ,,components, the student will eight power train components: -deMonstrate his knowledge 1. Clutch _Of power trairiS,- orally or 2. in writing, by defining and 3. Universal Joints -explaining the function of 4. Propeller Shaft Six, of eight-pOwer train S. Housing .CompOnents. 6. Axle Shaft 7. Differential 8. Propeller Shaft Support Bearing. Given a shop laboratory or 16.2 Correctly perform the required customer engine the student. service operations to remove, will demonstrate his ability inspect and replace a clutch to perform the required plate and clutch release yoke service operations to remove and bearing. and replace a clutch plate and inspect the clutch release bearing. Using manufacturers shop manuals, necessary tools, parts and material. Flywheel surface :.must show no heat cracks or scores deeper than .025 in :clutch plate contact area :and the pressure plate ,contact face. Clutch shaft splines no wear in eicess, of .015 deep. Release bearing must be quiet and ilave,ho rough spots when :rotated; clutch reassembled and,:tested; must release and operate quietly. COURSE DIESEL MECII INTERMEDIATE gl'-ERMINAL PERFORMANCE -OBJECTIVE NO. 16.0 cont'd Power Trains

PERFORMANCE OB-ECTIVES NO. RITERION MEASURES

Given as-Illustration of a 16.3 Correctly identify sliding sliding gear transmission gear and constant mesh type and a constant mesh transmis- transmissions and state the sion, the student will demon- major difference of each type. sIrate his knowledge of transmissions, orally or in writing, by identifying each type and stating the major differences of each type with 10DI_accuracy.

Given a shop_laboratory or 16 4 Correctly perform the required customer_engine the stUdent service operations to remove!). will demonstrate his ability disassemble, clean, inspect for to perform the required wear, or faulty parts. Reas- service operat,ions to remove, semble and install; and test a disassemble, ihstall and test transmission. for proper operations. A transmission gear must be inspected for excessive wear ..025 backlash and tooth failure. Splines no_wear exceeding .025, bearings must be quiet and'have no rough spots when rotated. Reassemble, install, and test. Transmission must shift smoothly and operate quietly. DIESEL ENGINES - INTERMEDIATE

:TERMiNAL PERFORMANCE 'OBJEGTIVE;NO. 16.0 (cont'd) Power Trains

-INT1RMEDIATE NO. -PERFORMANCE OBJECTIVES No. CRITERION MEASURES

Given an illustration of two 16.5 Correctly identify and explain types of propeller shaft the design characteristics of arrangements and four gear the two type propeller shafts .arrangements used in final and four final drive gear firives, the student will arrangements illustrated. -demonstrate his knowledge, Propeller Shafts orally or_in writing, by 1. Torgue Tube Type identifying and explaining 2. Hotchkiss Drive the design characteristics Final Drive Gears of the two propeller shafts 1. Worm Gear and four f-nal drive gear 2. Spiral Bevel Gear arrangemen s with 100% 3. Spur Bevel Gear acCuracy. 4. Hypoid Gear Given a shop laboratory or 16.6 Correctly perform the required customer engie the student service operations to remove, will demonstrate his ability inspect lubricate, and-replace to perform the required a prope ler shaft universal service operations to remove joint. and replace a propeller shaft . Using the manufacturers shop manual, necessary tools, parts, and material. Remove lock rings bearings, and cross from joint. Inspect trunnion beatings for broken needles and pitteclareas cross for Wear, cracked, or pitted journals, yokes for cracks .or excessive bearing clear- ance in yoke bore .002+ 1. Replace grease seals if damaged in disassembly, _grease and reassemble universal joint, it must flex freely with no backlash and operated quietly under load.

1 0 COURSE DIESEL MEC AN1CS DIATE

TERMINAL PERFORMANCE OBJECTIVE NP. 16.0 Power _rains

"7-7-1-1111=7)_AT NO PERFORMANCE OBJECTIVES N0. CRTTERION MEASURES

'Given an illustration of 16.7 Correctly explain the function a- differential the Student of differentials and identify will demonstrate his know- the following ten components; ledge:of differentials by 1. Companion Flange 'explaining the function 2. Pinion Shaft orally or in writing, and Pinion Bearing identify seven of ten Bevel Drive Pinion components. 5. Bevel:Drive Gear 6. Differential Pinions 7. Differential Side Gears S. Differential.Case 9. Tapered Roller Bearings 10. Axle Shaft Given a shop laboratory or 16 8 Correctly perform the required customer differential as- serv!ce operations to remove, sembly the student will disassemble, clean, inspect demonstrate his ability for wear or faulty parts. to perform the required Reassemble, install, and services operations to test a differential. remove, disassemble, in- spect for wear or faulty parts, reassemble, in- stall, and test for proper operation, gears must be inspected for excessive wear or failure .115 backlash with dial indi- cator. Bearings must be quiet andliave no rough spots when rotated bearing cups-must have no pitted areas. Reassemble, install, and test. Dif- ferential must operate smoothly and quietly.

Given an illustration of 16.9 Correctly explain the opera- a tergue converter the ting principle.of a torgue .student will demonstrate converter and identify the his knowledge of it by following ten parts: explaining the principle 1. Flywheel of operations, orally or 2. Pump Cover in- writing, and identify 3=Turbine seven of the ten parts. 4. Secondary Stator 5. Primary Stator 6. Secondary Pump COURSE DIESEL MECHANICS - INTERMEDIATE r&i-TERMINAL PERFORMANCE OBJECTIVE NO. (cont'd) Power Trains

ED T PERFORMANCE OBJECTIVES CRITERION MEASURES

16.9 7. Primary Pump 8. Input Shaft- 9. Free Wheeling 10. Reaction Shaft

16.10 Given an illustration of 16.10 Correctly_identyy the four a simple gear system the members of a sitple planetary student will demonstrate- gear system and correctly state his knowledge by identify- three conditions that must be ing the four members of met for power to be transmitted. the system and stating the three conditions that must be met for power to be transmitted in a plane- tary gear system with 100% accuracy. Members: 1.- -Planetary Sun Gear 2. Planetary Pinion 3.- Planetary Carrier 4. PlanetarY Ring Gear

Conditions: 1. Engine_delivering power to one of the three members. -2. The propeller shaft is connected to one -of the other members. 3. The_remaining member is held against COURSE DIES MECHANICS - INTERMEDIATE

34,ERMINAL PERFORMANCE gOBJECTIVE NO. 17.0 Brake Systems Rtyp?n completion of this unit on Brake Systems 90% of the students will Ahmonstrate through 80% correct responses to a criterion test; objective , , knowledge of Brake Systems. The student will demonstrate his ability o'perform required service operations on componhnts during laboratory assignment; using service manuals, tools, parts, and materials. Clearance Idsurements must be to manufacture shop manual specification ±.002 and

-PERFO AANCE OBJECTIVE CRITERION MEASURFS

Test Attached

,17.1:The student will demonstrate Correctly state four types Of 'his knoNiedge of BfWe-- Brake Systems: .Systems'by stating four types A. Mechanical -of Brake Systems with 100% B. Hydraulic accuracy. C. Air D. Electric 17.2 Given an illustration of 17.2 Correctly state the use of -EXternal Contracting and External Contracting and -.internal expanding mechanical internal Expanding Mechanical brakes the student will Brakes and identify the State their use and identify components illustrated. -the components, with 100% aCcuracy.

7 The student will demonstrate:17.3 Co rectly explain the operating his knowledge Of Hydraulic principle of Hydraulic Brakes Brake Systems by explaining and identify five of six the operating principle and components: identifying five of six 1. Pedal major components. 2. Master-cylinder 3. Brake-line 4. Cylinders S. Brake Shoes 6. Brake DTUMS

1= COURSE DIESEL MECHANICS - INTERMEDIATE

TERMINAL FERFORMANCE 'OBJECTIVE NO. 17.0 (cont'd) Brake Sytems

TE NO. PERFORMANCE OBJECTIVFS C ITERION NA URES

17 4 Given a shop laboratory or 17.4 Corectly perform the required customer job the student service operations to remove, will- demonstrate his abilit r-epair, replace, and adiust to perform the required wheeel units of a Hydraulic service operations to re- Brake System. -move, repair,- replace, and adjust wheel- Units of a System. Using_manufacturers shop manual, necessary equipment, tools and parts, hone wheel "Cylinder units bore must be free of pits. Check piSton in cylinder bore .025 maximum-clearance. Install -new piston cups; Return spring must be free of pits; Install new , cylinder boots-, replace brake shoes and lining assemblies. Turn brbke drums to removed .scored surface areas not exceed .090. Reassemble brake, adjust and test, must not -drag, grab, or be noisy in operation. COURSE DIESEL 'CHANICS INTE EDIATE

JERMINAL PERFORMANCE rADBJECTIVE NO. 17.0 cont'd) Ara

ED T NO PERFORMANCE OBJECTIVES_ NO. CRITERION MEASURES

17.5 The student will demonstrate 17.5 Correctly explain the operating his knowledge of air brake principle_of Air Brake Systems systems by explaining the and identify the,following operating principle and twelve major components: identifying nine of twelve 1. Brake Chamber major components. 2. Slack Adjuster 3. Rubber Hose 4. Quick.Release Valve 5. Compressor 6. Reservoir 7. Governor 8. Guage 9. Brake Pedal 10. Brake Valve 11. Relay Valve 12. Copper Tubing COURSE DIESEL MECHANIC- - INTERMEDIATE

:ER INAL PERFORMANCE IAJBJ CTIVE:NO. -ont'd) Brake_Systems_

r 11; PERFORMANCE OBJECTIVES NO. CRITERION MEASURES

17.6 Given a shop laboratory or 17.6 Correctly perform the required tuttomer job the student service operations to remove, -will demonstrate his ability repair, replace, and adjust to perform the required, wheel units of an Air Brake services, replace and adjust System.' wheel units of- an air brake system.. Using manufacturers :shop manual, necessary -equipment, tools, parts, and material, remove brake drum, brake shoe and lining as- semblies, slack adjusters, brake camshaft and wheel bearings. Turn brake drums to remove score surface areas; not to exceed .120 student must inspect and reject'faulty,partS and measure clearance to with- in ±.002 and work at an acceptable rate. Reas- semble air brake wheel unit, adjust and test, must not drag, grab, or operate noisily. COHRmiDIESEL MECHANCS INTERMEDIATE

TERMINAL PERFORMANCE OBJECTIVE NO. 17.0 (cont'd) Brake S stem

E_ D T NO. PERFORMANCE OBJECTIVES NO. CRITER ON MEASURES

17.7 The student will demonstrate 17.7 Correctly explain the operating his knowledge of a vacuum principle of vacuum power brake power_brake cylinder by cylinder and identify the fol- explaining the operating lowing components: principle and identifying 1. Wheel Cylinder nine of twelve components 2. Brake Lines of a Hydraulic vacuum 3. Hydraulic Slave Cylinder brake system. 4. Brake Pedal & Master-cylinder S. Engine Intake Manifold 6. Vacuum Check Valve 7. Relay Valve 8. Front and Rear Pistons 9. Center Plate 10. Piston Rod 11. Push Rod 12. Piston RetUrn Spring 17.8 The student will demonstrate 17.8 Correctly explain the operating his knowledge of electric principle of electric brake Sys,tem brake system by explaining and identify the following the operating principle and components in the brake wheel identifying four of the six unit: components in an electric I. Armature or Disk brake wheel unit-.. 2. Electromagnet 3. Lug 4. Cam Lever S. Brake Band 6. Brake Drum COURSE DIESEL MECHANICS - INTERMEDIATE

TERMINAL PERFORMANCE OBJECTIVE NO. .18.0 'hassis Com on

Upon completion of the unit on ChassisComponents 90% of the students will demonstrate through 80%correct response to a criteriontest, objective knowledge of Chessis Components. The student will demonstratehis ability to perform required service operationsduring laboratory assignment. -Using service manuals, tools,parts, and materials. Clearance measurements inust be to manufacturers specifications.002 and no abnormal times used. INIERMED ATE o. PERFORMANCE OBJECTIVES NO. CRITERION MEASURES

18.0 Test Attached 18.1 The student will demonstrate 18.1 Correctly state the function his knowledge of the Vehicle of the Chassis and the six Chassis by stating orally or major components: in writing the six major 1. Frame components that make up the 2. Springs chassis with 100% accuracy. 3. Shock absorbers 4. Mechanism 5. Wheels 6. Brakes 18.2 Given an illustration of a 18.2 Correctly identify the six frame the student will main strength members of the identify five or six main frame on the illustrations. strength members correctly: 1. Side Member X member Front Cross member 4. Rear Engine Support Rear Cross Member Body to Frame Attachment

18. Given a shop laboratory or 1 Correctly perform the required customer job the student will service operations to remove, demonstrate his ability to repair, replace, and test a perform the required service leaf or coil spring unit of the operations to remove, repair, suspension system. replace either a leaf or coil spring unit of the suspension system. Inspect pring leaves or_coils for cracks of-excessive pits, shackle pins, and bushings must show no excessivo wear. C,OURSL DIESEL MECHANICS -I NTERNEDIATE

TERMINAL PERFORMANCE OBJECTIVE- NO.- 18;0 ont'd) Chassis J;AljuuaiAuLLL_____

_ T NO PERFOIIMANCE OBjECTIVES NO CRITERION ASURE

18 To within +.002 and work at art atceptable rate, spring- Unit-tuSt'operate'proPerly and without,excessive,noise.

8.4 The student will demonstrate 18.4 Correctly state the two basic his knoWledge 'of wheeI'rithS type whol .s and the function And by-stating,'oraliy of -tout- of fiire components: ot in wtiting; the'tw-basic I. 'Tread' type-of:wheelrimS ahd the' 2; Bteaker function-Of fourcif'five- S; Cushion tire'dcimponents-cdirettiy. 4; Eljes 5: 00a4 Wil7es

18. Given a shop laboratory or 18.5 Correctly perform the required customer jcib the student'wil service 'operations to remove, demonStrate his ahility.to clean.; inspect; tepair, and perform the required service replace a cam:and lever or operations to remove, disas- recirculating-ball type steei semble, clean, inspect for ing geat'Unit. wear or damaged:Parts a cam and lever type or 'recircula ing ball type steering gear unit. Using manufacturers shop manual, tools, parts, and material. The student must be able to reject faulty parts and measure clearance to .4ithin ±.002 and work at an acceptable rate. Steering gear unit must operate freely and quietly throughout the en- tire turning range. 'COURSE DIESEL MECAN CS - INTERMEDIATE

TERMINAL PERFORtIANCE OBJECTIVE SO. 18.0 (cont'd) Chassis Components

NO. PERFORMANCE OBJECTIVES CRITERION EASURES 18.6 The student will demonstrate 18.6 Correctly explain four of the his knowledge of wheel five terms related to Vehicle alignment by explaining . orally or in writing four 1. Pivot Inclination of the five terms related 2. Wheel Caster to vehicle wheel alignment: 3. Wheel Camber 1. Pivot Inclination 4. Toe-In 2. Wheel Caster 5. Toe-Out 3. Wheel Camber 4. Toe-in 5. Toe-Out

18-7 Given an illustration of a 18.7 Correctl identify and explain Hydraulic the function each of the System employing thirteen thirteen components in the components, the student will Hydraulic power system shown identify and explain the on the illustration. function of ten of the thirteen components cor- rectly: 1. Steering Arm 2. Piston Arm Assembly 3. Power Cylinders 4. Roller and Worm 5. Spur Gears 6. Valve Operating Block 7. Left Turn Reaction Valve 8. Right Turn Distribution Valve 9. Left Turn Distr-_bution Valve 10. Right Turn Reaction Valve 11. Flexible 12. Oil Pump 13. Oil Pump Drive

18.8 Given a shop laboratory or 18.8 Correctly perform the required ciwtomer job the student service operations to remove will demonstrate his ability disassemble, -inspect and repair to 'perform the_required a vehicle body window regulator service operations on a unit. vehicle-body window lift unit. Remove, disassemble, inspect for worn or damaged parts; the door window lift unit. 3 0 COURSEDIESELILDIANICS 'ERMEDIATE

TERMINALPERFORMANCE OBJECTIVE NO. 18.0 ont'd) Chassis Comsonents

TE1tED AT, NO. PERFORKANCE OBjEC IVES NO. CUTER-I- WSURES 18. Cont'd)

Using manufacturers shop manual, tools, parts, and material, students must be able to reject faulty parts and measure clearance to within +.002 and work at an .acceptable rate. Window lift unit must operate freely throughout lift range and have no rattles in the unit.

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