Manual Darr en Ingles

SERVICE DEPARTMENT
EMPLOYEE EVALUATION GUIDE

DEFINITION
PERFORMANCE SKILL 1
TITLE:
Demonstrate Measuring and Adjusting Fuel Rack Setting on Forged Body

Injection Pump.
EQUIPMENT REQUIRED:
Engine with Forged Body Fuel injection pump. (D398, D399, D343 S/N 62B or
D342 S/N 31B)
Fuel Setting Information
6V-9128 Tool Group or (9S0240 Tool Group or 3H1690 Gauge Rack Setting)
PROCEDURE:
Install correct tooling
Measure fuel setting
Adjust fuel setting
Seal with governor seal
REFERENCE:
Service Manual
Check S.I.S. or S.I.R.S and FIND for the latest updates
I have studied the listed material and have demonstrated the skill listed on this sheet.
_____________________
(Signature & Emp #).
This skill has been demonstrated to me by the individual listed above.
__________________________________________________(Signature & Emp #)
Signature of Supervisor
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL 2
TITLE:
Demonstrate Measuring and Adjusting Fuel Rack and Air Fuel Ratio
Valve Setting on a Compact Fuel System
EQUIPMENT REQUIRED:
9S0240 Tool Group(Disc.) or 6V9128 Tool Group
Compact Fuel System (3304, 3306 or D343 Engine)
Continuity Light or Multimeter
Rack Setting Charts or Engine Performance Specs.
5P1660 Governor Sealing Tool Group (Disc.) or Plastic Governor Seal
PROCEDURE:
1.
2.
3.
4.
Install correct tooling.

Measure fuel setting using continuity light or multimeter.
Adjust fuel setting.
Seal with governor seal group.
REFERENCE:
Service Manual
Special Instructions SEHS8436
Video Tape 42 Hydraulic Air-Fuel Ratio Control Adjustment - JEGO9042 ( )
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL 3
TITLE:
Demonstrate Measuring and Adjusting Fuel Setting (Sleeve Metering

Fuel System)
EQUIPMENT REQUIRED:
5P4203 Gauge Group
Fuel Setting Charts or Engine Performance Specs.
Sleeve Metering Fuel System
Continuity Light (or Multimeter)
PROCEDURE:
1.
2.
3.
4.

Measure fuel setting using continuity light or multimeter.
Adjust fuel setting.
Seal with governor seal.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL 4
TITLE:
Demonstrate Measuring Engine speed and Set Point with 6V3121

Multitach and 6V4060 Set Point Indicator or 9U7400 Tool Group
EQUIPMENT REQUIRED:
6V3121 Multitach Group (Disc.)
6V4060 Set Point Indicator (Disc.)
9U7400 Tool Group
Fuel Setting Information or Engine Performance Specs.
Tachometer Drive Adapters
5P7360 Tachometer Generator or 6V4950 Injection
Line Speed Pickup Group
PROCEDURE:
1. Install correct tooling.
2. Measure high idle RPM using tach generator, photo cell
and fuel line pickup.
3. Measure low idle RPM.
4. Measure Set Point
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL 5
TITLE:
Demonstrate Proper Use of Electric Lift Truck Battery Charger
EQUIPMENT REQUIRED:
Electric Lift Truck Battery
Charger
PROCEDURE:
1. Check battery for proper electrolyte level.
2. Properly connect charger leads to battery or multimeter.
3. Charge battery according to Battery Service Manual procedure.
REFERENCE:
Lift Truck Video Tape 32 - PM on Electric Lift Trucks SEVV7032 ()
Battery Service Manual - SEBD0625 Pages 29 - 32
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL 6
TITLE:
Retired
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL 7
TITLE:
Demonstrate Use of 5P4767 or 4C3048 Battery Lifting Bar Assembly
EQUIPMENT REQUIRED:
Electric Lift Truck with Battery
5P4767 or 4C3048 Battery Lifting Bar
PROCEDURE:
1. Properly remove and install electric lift truck battery according
to Service Manual procedure.
CAUTION: If using lift truck, properly secure lifting bar to lift truck to keep
lifting bar from sliding off forks.
REFERENCE:
Service Manual
L.T. Technical Bulletin Feb. 19, 1971
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL 8
TITLE:
Demonstrate Measuring Timing Dimension (Compact Fuel System)
EQUIPMENT REQUIRED:
5P6600 Lifter Setting Tool Group
5P4165 Indicator Group
6V2012 Gauge Group
PROCEDURE:
1.
2.
3.
4.
Install correct tooling for fuel system being calibrated.

Measure timing dimension using depth micrometer.
Measure timing dimension using dial indicator.
Adjust timing dimension on one pump using either tool.
REFERENCE:
Service Manual
Special Instructions - SEHS8980
Video Tape 88 Fuel Injection Pump Recon. SEVV9088 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL 9
TITLE:
Demonstrate Torque procedure using Torque Wrench, Torque Multiplier,

and Torque Wrench Extension.
EQUIPMENT REQUIRED:
9S7353 Torque Wrench or equivalent
Torque Wrench Extension
Torque Multiplier
PROCEDURE:
1.
2.
3.
4.
5.
Make sure hardware is clean and lubricated.

Make correct initial torque.
Rotate hardware to correct final position.
Calculate torque using a torque wrench extension.
Demonstrate tightening hardware using torque wrench and
torque multiplier and calculate resulting torque.
REFERENCE:
Service Manual
Video Tape 44 Part 2 - Working with Pullers, Torque Wrenches, Multipliers SEVN9044 ()
Slide Rule Computer - SEHS7150
Special Instructions - SMHS7657
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL 10
TITLE:
Retired
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
TITLE:
Demonstrate Use of the 6V7070 or 6V7800 Digital Multimeter, using the

Voltage, Resistance, and Diode Switch Positions.
EQUIPMENT REQUIRED:
Digital Multimeter
Electrical Components:
1. Fixed Value Resistor
2. Capacitor
3. Diode
4. Power Transistor
5. Zener Diode
6. DC Power Source
PROCEDURE:
Follow Procedure Outlined in the Reference Literature
NOTE: Obtain Specifications from the Service Manual for Power Transistor
REFERENCE:
Service Manual
Special Instruction - SEHS7734
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
TITLE:
Demonstrate Correct Liner Projection Measurement
EQUIPMENT REQUIRED:
LIFT TRUCK
XN1P Gas Engine
8T0501 Dial Indicator
8T0502 Indicator Base
8T0472 Liner Compressor Tool
8T0476 Cylinder Liner Clamp
HEAVY EQUIPMENT
1P5510 Tool Group
Engine
T - Bar
PROCEDURE:
1. Measure liner projection of all cylinders
according to Service Manual or Special Instructions.
2. Follow procedure and measure carefully.
3. Note all readings for reference and comparison.
4. For XNIP Engine, use selection chart in Service
Manual to determine liner gasket.
5. Record your findings on worksheet # 13 - 13A and
attach to this form.
REFERENCE:
Service Manual
Video Tape 43 Cylinder Block Counterboring JEGO9043 ()
Video Tape 47 Cylinder Block Liner Seat Sleeving JEGO9037 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
TITLE:
Demonstrate Measuring Piston Ring Land Wear
EQUIPMENT REQUIRED:
Standard Design Piston
Keystone Design Piston
5P3519 Piston Ring Groove Gauge
5P4812 Piston Ring Groove Gauge
8S2304 Piston Ring Groove Cleaner
PROCEDURE:
1. Measure ring grooves according to instructions
in Reusable Parts Guide.
2. Record your findings on worksheet #15 and attach
to this form.
REFERENCE:
Guideline for Reusable Parts - Form SEBF8049
Instruction Card - SEES5544
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
TITLE:
Demonstrate Measuring Clearance of Rod and Main Bearings and

Checking Crankshaft for Reusability
EQUIPMENT REQUIRED:
Engine
Micrometers
Plastigage
"V" blocks and Dial Indicator
Torque Wrench
PROCEDURE:
1. Measure clearance according to specifications.
2. Make recommendation for reusability of bearings.
3. Make recommendation for reusability of crankshaft.
NOTE: Lead wire no longer used.
to this form.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
15
Demonstrate Measuring Turbocharger Shaft Straightness
EQUIPMENT REQUIRED:
Turbocharger Shaft
5P6518 Parts Reusability Fixture Group
PROCEDURE:
1. Measure shaft according to guidelines in special instruction.
2. Check for excess bend and compare to specifications
REFERENCE:
Special Instructions SMHS6998
Video Tape 54 - Turbo Reconditioning 1 - JEGO8054 ()
Video Tape 56 - Turbo Reconditioning 2 - JEGO9056 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
TITLE:
Demonstrate Checking Air Intake System for Leaks at Joints
EQUIPMENT REQUIRED:
Engine - with Complete Air Intake System
Plastic Bag
Air Pressure Regulator
Soap Solution
PROCEDURE:
1. Conduct test according to P.M.P. special test #6.
2. Make recommendation for corrections if necessary.
REFERENCE:
Special Tests - SENU6176 or SENU6179
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
17
Demonstrate on Engine Adjustment of Hydraulic Air Fuel Ratio Control on New

Scroll Fuel Systems
EQUIPMENT REQUIRED:
1. Engine with Hydraulic Air Fuel Ratio Control and New Scroll Fuel System.
2. 6V6070 Tool Group
PROCEDURE:
1. Follow procedure outline in the Service Manual
REFERENCE:
Service Manual
Video Tape 182 - Test And Adjusting The Hydraulic Fuel Ratio Control on B
Series Engines - SEVV9182 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE__________
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
18
Demonstrate Adjusting of Hydraulic-Air Ratio Control on Compact Fuel System
EQUIPMENT REQUIRED:
9S0240 Rack Setting Tool Group (Disc) or 6V9128 Tool Group
8S4627 Continuity Light (Disc) or 8T0500 Continuity Light
PROCEDURE:
1. Install correct tooling
2. Follow guidelines in Service Manual
REFERENCE:
Service Manual
Video Tape 42 - Hydraulic Air-Ratio Control Adjustment - JEGO9042 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
19
Demonstrate Correct Valve Lash and Jake Brake Adjustment

on Current Engines
EQUIPMENT REQUIRED:
Engine (Pushrod) (Heavy Equipment and Lift Truck
Technicians)
Engine With Jake Brake (Truck Engine Technicians)
Engine Turning Tool
Feeler Gauge
Jake Brake Gauge
PROCEDURE:
1. Follow procedure as outlined in Service Manual.
2. Follow procedure as outlined in the Jake Brake
Service Manual. (Truck Engine Technicians only)
REFERENCE:
Service Manual
Lubrication and Maintenance Guide
Jake Brake Installation Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
20
Demonstrate Refacing Valves and Valve Seats
EQUIPMENT REQUIRED:
Valves
Valve Refacing Machine
Cylinder Head
Valve Seat Refinishing Tools
PROCEDURE:
1. Clean valves.
2. Reface valves and valve seats according to guidelines.
3. Show line contact between valve and valve seat.
4 . Be aware of difference between seat angle and valve angle
for "Interference Grinding."
REFERENCE:
Service Manual
Video Tape 55 - Knurling Valve Guides LEVN9055 ()
Video Tape 62 Cylinder Head Reconditioning JEGO9062 ()
Video Tape 63 Valve Grinding JEGO9063 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
21
Demonstrate Checking Cylinder Head for Reusability
EQUIPMENT REQUIRED:
Cylinder Head
Feeler Gauge
Liquid Dye Kit
Straight Edge
Magna-Flux Group
PROCEDURE:
1. Clean head thoroughly.
2. Follow videotape instructions.
REFERENCE:
Service Manual
Video Tape 62 - Cylinder Head Reconditioning JEGO9062 ()
Check S.I.S. or S.I.R.S. and FIND for the latest updates
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
22
Demonstrate Testing Load Sensing, Pressure Compensating

Hydraulic System
EQUIPMENT REQUIRED:
Gauge Group
Appropriate Machine
PROCEDURE:
1.
2.
3.
4.
Measure system maximum pressure.

Measure system margin pressure.
Measure system low pressure standby.
Record your findings on worksheet #16 and attach
to this form.
REFERENCE:
Service Manual
Video Tape 202 - Pressure Compensated Load Sensing
Hydraulic System SEVN9202 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
23
Demonstrate Measuring Fuel For Specific Gravity
EQUIPMENT REQUIRED:
1P7408 Thermo-Hydrometer Range 29- 41 API
5P2712 Thermo-Hydrometer Range 39- 51 API
1P7438 Beaker
Diesel Fuel
PROCEDURE:
1. Measure fuel apparent specific gravity using hydrometer and beaker.
2. Correct API reading for barometric pressure, ambient temperature, etc.,
according to Special Instructions.
3. Record your findings on worksheet # 17 and attach to this form.
REFERENCE:
Special Instructions - GMGO0977, and SEHS7067
Service Magazine - 8/29/74
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
24
Demonstrate Testing Fuel Injection Nozzles
EQUIPMENT REQUIRED:
5P4150 Nozzle Tester Group
Direct Injection Nozzle (Pencil Style)
Precombustion Chamber Nozzle
Direct Injection Nozzle (Capsule Type)

Fuel Collector
PROCEDURE:
1. Test all three types of fuel nozzles according to guidelines.
Sequence DI Nozzle:
1. Install nozzle.
4. Flush nozzle
2. Pressure loss test.
5. Tip Leakage Test.
3. Valve opening pressure (VOP) test. 6. Orifice restriction test.
.
2.
Sequence PC Nozzle: (NOT REQUIRED FOR TRUCK ENG.SPEC.)

1. Install nozzle.
2. Pressure loss test.
3. Valve Opening Pressure (VOP) test.
4. Record your findings on worksheet #18 and attach to this form.
REFERENCE:
Service Manual
Video Tape 139 Testing Pencil-Type Nozzles SEVV9139 ()
Video Tape 167 Fuel Nozzle Testing SEVV9167 ()
Special Instructions - SEHS7292, SEHS7350, SEHS7390
Lift Truck Video Tape 42 - Testing Perkins Nozzle SEVV7042 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
25
Demonstrate Testing a Cooling System and Components.
EQUIPMENT REQUIRED:
9S8140 Pressurizing Pump
Machine
Thermometer
Coolant Tester
Regulators
Heat Source
Conditioner test kit
Radiator Cap
PROCEDURE:
1. Pressurize system with air and check for leaks.
2. Heat regulators and measure opening temperature and
fully open temperature.
3. Measure Coolant freeze point and conditioner
concentration.
4. Test cap with pump and compare with specifications.
REFERENCE:
Service Manual
Know Your Cooling System - SEBD0518
Video Tape 96 How to Use Cooling System Diagnostic Tools Pressurizing
Pump SEVN9096 ()
Lift Truck Video Tape 23 Lift Truck Cooling Systems Troubleshooting
SEVV7023 ()
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__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
26
Demonstrate Testing Water Temperature Regulators
EQUIPMENT REQUIRED:
Regulators
Thermometer (6H3050 or 7F7112 or 9S9102)
Container of water
Heat Source
PROCEDURE:
1. Measure opening temperature.
2. Measure temperature regulator when fully open, compare to specifications.
REFERENCE:
Service Manual
Know Your Cooling Systems- SEBD0518
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
27
Demonstrate Measuring Coolant for Freezing Point and Inhibitor Concentration
EQUIPMENT REQUIRED:
Coolant Samples
5P0957 Coolant Tester
5P9734 Coolant Syringe
8T5296 Coolant Conditioner Kit

Commercial Anti-freeze Tester
PROCEDURE:
1. Measure freezing point of ethylene glycol solution using both testers.
2. Test sample for conditioner concentration.
REFERENCE:
Know Your Cooling System Booklet SEBD0518
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
28
Demonstrate Testing Glow Plugs
EQUIPMENT REQUIRED:
Glow plugs form Caterpillar engine
Electric test bench
Digital Multimeter
or
Lift Truck engine with glow plugs

Digital Clamp on ammeter
Digital multimeter
PROCEDURE:
Caterpillar Engines
1. Test glow plugs on electric test bench for operation and current draw.
2. Test glow plugs on machine using vehicle ammeter.
Lift Truck
1. Follow procedure as written in Service Manual.
REFERENCE:
Service Manual
Video Tape 86 Cold Weather Starting and Operation SEVN9086 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
29
Retired
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
30
Demonstrate Proper Use of Battery Charger, and testing a Lead

Acid Battery.
EQUIPMENT REQUIRED:
Battery
4C4910 or 4C4921 Battery Charger (or Commercial Charger)
5P9735 Coolant and Battery Tester
VOM, 8T0900 Ammeter, 4C4911 Battery Load Tester
PROCEDURE:
1. Correctly connect charger to battery for charging.
2. Check electrolyte level and specific gravity.
3. Test Battery according to guidelines in Special Instructions
4. Charge according to Special Instructions.
REFERENCE:
Battery Service Manual - SEBD0625
Electric Lift Truck T/S Series Part 1 Module 4
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
31
Demonstrate Test a Lead Acid Battery
EQUIPMENT REQUIRED:
Battery
Digital Multimeter
Clamp on Ammeter
5P9735 Battery Fluid Probe

5P0957 Coolant and Battery Tester
5P0300 Electrical System Tester
or 6V4930 Battery Load Tester
PROCEDURE:
1. Use battery tester and check specific gravity.
2. Test battery according to guidelines in Special Instructions
REFERENCE:
Battery Service Manual SEBD0625
Lift Truck Video Tape 25 Lift Truck Battery Servicing SEVV7025 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
32
Demonstrate Use of Battery Jumper Cables
EQUIPMENT REQUIRED:
Electrical System with Discharged Battery or Batteries
Booster Battery or Batteries
Jumper Cables
PROCEDURE:
1. Connect one end of the first jumper cable to the positive post of
the discharged battery (for 24Vconnect to the positive post closest
to the starter).
2. Connect the other end of the first jumper cable to the positive post
of the charged battery (for 24V connect to positive post closest to starter).
3. Connect the second jumper cable to negative post of charged battery
(for 24V, connect to the negative post closest to the frame or ground).
4. Connect the other end of the second cable away from the battery to the
frame or suitable ground of the machine with the discharged battery or
batteries.
REFERENCE:
Battery Service Manual - SEBD0625
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
33
Demonstrate Measuring Stall Speed of Torque Converter/Divider
EQUIPMENT REQUIRED:
6V3121 Multitach Group
Fuel Setting Charts
Tachometer Drive Adapters (if needed)
Machine Equipped with Torque Converter/Divider
6V4160 Transmission Test Group (if needed)
PROCEDURE:
1. Connect correct tooling to measure machine being tested.
2. Measure engine high idle and low idle RPM.
3. Measure torque converter/divider stall speed.
PRECAUTION - Run torque converter stall only as long as absolutely
necessary. Damage could result if prolonged stall
conditions exist.
REFERENCE:
Service Manual
Lift Truck Video Tape 8 Troubleshooting The 2-speed Power Shift
Transmission SEVV7008 ()
Lift Truck Video Tape 9- Troubleshooting The 3-speed Power Shift
Lift Truck Video Tape 52- Single Speed Power Shift Transmission
Orientation, Test & Adjust SEVV7052 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
34
Demonstrate Testing Steering and Brake Pressure on a High Drive Tractor
EQUIPMENT REQUIRED:
High Drive Track Type Tractor
6V4161 Pressure Gauge Kit
PROCEDURE:
1. Test steering and pressures as outlined in Service
Manual. Record your findings on worksheet #19 and
attach to this form.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
35
Demonstrate Use of the 8T0450 Thread Identification Kit
EQUIPMENT REQUIRED:
8T0450 Thread Identification Kit
Assortment of Metric and Standard bolts, nuts,
and fittings.
PROCEDURE:
1. Measure thread diameter using the 8T0447 Dial Caliper.
2. Measure thread pitch using the 8T0448 Pitch Gauge.
3. Measure fitting seat angle using the 8T0449 Seat
Gauge.
4. Measure line seat angle using the 8T0451 Seat Angle
Gauge.
REFERENCE:
Check the S.I.S. or S.I.R.S. and FIND for the latest updates
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
36
Demonstrate Checking Pressures of Transmission System
EQUIPMENT REQUIRED:
Track-Type Tractor
6V4160 Transmission Test Group
PROCEDURE:
1. Connect tooling to test pressures of transmission
pump, torque converter inlet, torque converter outlet,
transmission lube, initial pressure, speed clutch,
directional clutch, steering clutch and brakes.
2. Conduct test according to guidelines in Service Manual.
3. Record information and compare to specifications.
to this form.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
37
Demonstrate Bevel Gear/Pinion Adjustments
EQUIPMENT REQUIRED:
Bevel Gear/Pinion
8S2328 Dial Indicator
Lubriplate or suitable substitute
Spring Gauge
1P2390 Pinion Depth Gauge
1P67 Spreader
PROCEDURE:
1. Measure bevel gear shaft bearing preload.
2. Measure and adjust bevel gear/pinion backlash.
3. Measure and adjust tooth contact pattern.
REFERENCE:
Service Manual
Video Tape 176 936 Wheel Loader Differential Bearing Adj. SEVN9176 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
38
Demonstrate Evaluation of Duo-Cone Seal Groups
EQUIPMENT REQUIRED:
Duo-Cone Seal Groups
PROCEDURE:
1. Compare worn seal groups with guidelines and determine reusability.
REFERENCE:
Video Tape 188 - Duo-Cone Seal Assembly SEVV9188 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
39
Demonstrate Measuring Steering Clutch Springs
EQUIPMENT REQUIRED:
New and Worn Steering Clutch Springs
5P4145 Tester
1P7460 Torque Tester
PROCEDURE:
1. Test springs according to guidelines in Service
Manual.
REFERENCE:
Service Manual
Video Tape 71 Rebuilding Oil-type Steering Clutches SEVN9071 ()
Special Instructions - GMGO2591
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
40
Demonstrate Proper Completion of S.I.M.S. (Service Information

Management Systems) and Service Report.
EQUIPMENT REQUIRED:
Service Reports
Parts Book or Parts Fiche or SIS CDs or SIS Web
PROCEDURE:
1. Fill out report
2. Follow directions found in reference material.
REFERENCE:
Guidelines to follow in Reporting SIMS Information (SEBD0809)
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
41
Demonstrate Adjusting Motor Grader Circle Drawbar
EQUIPMENT REQUIRED:
"G" Series Motor Grader
Hand Tools
Feeler Gauges
PROCEDURE:
1. Follow procedures outlined in the Service Manual or Maintenance Manual.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
42
Demonstrate Testing I.C.M. Transmission Using Electronic Switching Control
EQUIPMENT REQUIRED:
Machine with I.C.M. Transmission
Hand Tools
PROCEDURE:
1. Follow procedures outlined in the Service Manual.
TEST: Transmission hold switch, lever switch, transmission gear switch,
upshift, downshift, and lockup solenoids.
REFERENCE:
Service Manual
Video Tape 177 Electronic Transmissions Control System with Individual
Clutch Modulations SEVN9177 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
43
Demonstrate Proper Disassembly and Assembly of Sealed and Lubricated

Track
EQUIPMENT REQUIRED:
Section of Sealed Track
Track Press
PROCEDURE:
1. Demonstrate correct procedure in turning pins and bushings.
REFERENCE:
Reconditioning Bulletin MP-12 (4/79) - SEBF8518
Video Tape 98 Sealed and Lubricated Track Reconditioning SEVN9098 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
44
TITLE: Demonstrate Proper Disassembly and Assembly of Sealed and Lubricated

Track
EQUIPMENT REQUIRED:
Section of S.A.L.T.
5P3010 Deburring Tool
Track Press
5P7419 Plug Installer
5P7392 Stopper Installation Group
5P2420 Testing and Lubricating Group
5P2384 Pump Assembly (w/5P2383 Brush)
PROCEDURE:
1. Turn pins and bushings according to guidelines.
2. Follow warnings given in Service Manual.
3. Compare Track Parts to guidelines and determine reusability
REFERENCE:
Guideline for Reusable Parts - SEBF8022
Reconditioning Bulletin MP-12 (4/79) - SEBF8518
Video Tape 98 Sealed and Lubricated Track Reconditioning SEVN9098 ()
Wall Chart - SEWV1339
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
45
Demonstrate Shoe Brake Adjustment
EQUIPMENT REQUIRED:
Wheel Machine
PROCEDURE:
1. Adjust shoe brake according to guidelines.
2. Use correct sequence and proper dimensions.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
46
Demonstrate Charging Nitrogen Accumulator
EQUIPMENT REQUIRED:
7S5437 Charging Group or equivalent
Nitrogen Accumulator
Nitrogen Bottle
PROCEDURE:
1. Charge accumulator according to guidelines.
2. Correct for ambient temperature.
3. Follow procedure in appropriate Service Manual.
REFERENCE:
Service Manual
Special Instruction - SMHS7215
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
47
Demonstrate Connection of a Hydraulic Flow Meter
EQUIPMENT REQUIRED:
Hydraulic Flow Meter
Machine
PROCEDURE:
1.
2.
3.
4.
Connect correct tooling for machine being tested.

Perform systems test according to Service Manual.
Interpret results according to Service Manual guidelines.
Record your findings on worksheet # 23 and attach to this form.
REFERENCE:
Service Manual
Special Instructions - SEHS7097-01 and SMHS7308-00
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
48
Demonstrate Use of Torque Multiplier
EQUIPMENT REQUIRED:
Torque Wrench
Torque Multiplier
PROCEDURE:
1. Demonstrate tightening hardware using torque wrench and torque multiplier.
2. Calculate resulting torque applied to hardware.
REFERENCE:
Video Tape 44 - Torque Wrenches, Multipliers SEVN9044 ()
Video Tape 77 - Reconditioning Hydraulic Cylinders SEVV9077 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
49
Demonstrate Four Step Hydraulic Cylinder Drift Rate Test
EQUIPMENT REQUIRED:
Stopwatch
Machine with double acting cylinders
Scale or Tape Measure
PROCEDURE:
1. Perform drift rate measurements according to guidelines.
2. Measure drift both in and out; with control valve in hold and shifted.
3. Evaluate results.
REFERENCE:
Service Manual SENR4178 (D7H Tractor Hydraulics) or other text with
four step method
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
50
Demonstrate Evaluating Worn Vane Pumps
EQUIPMENT REQUIRED:
Worn Vane Pumps
PROCEDURE:
1. Evaluate worn vane pumps according to Failure Analysis Book.
2. Analyze what original cause of failure was and steps to correct.
REFERENCE:
Guidelines for Reusable Parts - SEBF8080 - SEBF8025
Diagnosing Hydraulic Pump Failures - SEBD0501
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
51
Demonstrate Evaluating Worn Gear Pumps
EQUIPMENT REQUIRED:
Worn Gear Pumps
PROCEDURE:
1. Evaluate worn pumps according to guidelines.
REFERENCE:
Diagnosing Tyrone Gear Pump Failures - FEG45137
Service Manual - REGO0756 - Series "30" Pump
Guidelines for Reusable Parts - SEBF8073
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
52
Demonstrate Use of the 6V2150 Starting and Charging System

Analyzer Group.
EQUIPMENT REQUIRED:
6V2150 Starting and Charging System Analyzer Group
Appropriate Machine
PROCEDURE:
1. Connect the harness from the 6V2150 starting and
charging analyzer to the vehicle diagnostic connector.
Do the test procedure in four steps in order.
A. Hookup
C. Start Aid
B. Crank
D. High Idle
to this form.
REFERENCE:
Appropriate Service Manual
Video Tape 165 6V2150 Starting/Changing Analyzer Group
SEVV9165 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
53
Demonstrate These Reinforcements: 1) Standard Beam, 2) Mounting Plate,

3) Corner, 4) Gusset
EQUIPMENT REQUIRED:
Welding Machine
Electrodes
Metal
PROCEDURE:
1. Demonstrate standard beam weld reinforcement.
2. Compare to welding standard for appearance quality.
3. Demonstrate other reinforcements with cardboard patterns.
REFERENCE:
Hobart Pocket Welding Guide
Service Welding Guide - SEBD0512
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
54
Demonstrate These Types of Welds: 1) Fillet, 2) Groove, 3) Bead, 4) Plug
EQUIPMENT REQUIRED:
Welding Machine
Metal
Electrodes
PROCEDURE:
1. Demonstrate each type of weld bead.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
55
Demonstrate These Types of Weld Joints: 1- Butt, 2- Corner, 3- Lap, 4- Tee
EQUIPMENT REQUIRED:
Welding Machine
Electrodes
Metal
PROCEDURE:
1. Demonstrate each type of weld joint.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
56
Demonstrate These Weld Positions: 1- Flat, 2- Horizontal, 3- Vertical,

4- Overhead
EQUIPMENT REQUIRED:
Welding Machine
Electrodes
Metal
PROCEDURE:
1. Demonstrate each weld position.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
57
Demonstrate Proper Completion of Predelivery Inspection Report
EQUIPMENT REQUIRED:
A rubber tire machine or
a track-type tractor or a lift truck or engine
Correct predelivery inspection report for each machine
PROCEDURE:
1. Inspect machine following the guidelines found on the "Predelivery
Inspection Report."
2. Mark this report as a "SAMPLE" if it is not going to be processed
via dealer terminal.
REFERENCE:
Guidelines to Follow in Reporting SIMS Information
SEBF0809
Video Tape SENN8003 - Time Well Spent ()
Check S.I.S. or S.I.R.S. and FIND for the latest updates.
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
58
Demonstrate Use of Technical Information File
EQUIPMENT REQUIRED:
Technical Information File
Microfiche Viewer
PROCEDURE:
1. Locate three (3) items for industrial engines,
2. Locate three (3) items for truck engines.
3. Locate three (3) items for electric sets.
Record your findings on worksheet # 21 listing each item, date and media number
of the Microfiche where found and attach to this form.
REFERENCE:
Instruction with Microfiche
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
59
Demonstrate Use of Specifications Manual or Microfiche or Service Information

Systems (SIS)
EQUIPMENT REQUIRED:
Specification Manual or Microfiche or Service Information Systems (SIS)
PROCEDURE:
1.
2.
3.
4.
Locate three (3) specifications for industrial engines.

Locate three (3) specifications for vehicle engines.
Locate three (3) specifications for power train.
Locate three (3) specifications for
Record your findings on worksheet # 21 listing each item, date and media
number where found and attach to this form.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
60
Demonstrate Use of Service Manual and Service Manual Microfiche
EQUIPMENT REQUIRED:
Service Manual
Service Manual Micro Fiche and Viewer
PROCEDURE:
1. For each Section give page number date and media number of:
A. One testing and adjusting procedure.
B. Two specifications.
C. Two disassemble and assemble procedures.
D. Lubrication Intervals Chart
Record your findings on worksheet # 21 listing each item, date and media
number where found and attach to this form.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
61
Demonstrate Use of Fuel Setting and Related Information Microfiche
EQUIPMENT REQUIRED
:
Fuel Setting and Related Information
Microfiche Viewer
Microfiche Library
PROCEDURE:
1. Find three (3) settings for vehicles.
2. Find three (3) settings for truck engines.
3. Find three (3) settings for industrial engines.
List following information:
a. Equipment Model
b. Serial Number
c. Application
d. Altitude
REFERENCE:
Check Special Instructions for the latest update.
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
62
Demonstrate Checking Radial and Axial Alignment
EQUIPMENT REQUIRED:
8S2328 Dial Indicator Group or
8T1000 Electronic Position Indicator Group (if available)
PROCEDURE:
1. Check axial and radial eccentricity according to Service Manual procedure.
2. Analyze results and make recommendations for corrections if needed.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
63
Demonstrate Use of SIRS Index and FIND SIRS to Service Literature.
EQUIPMENT REQUIRED:
Microfiche Library Microfiche Viewer
Corporate Computer
PROCEDURE:
1. Find the date & form # for LTTB that talks about "Use the correct bolts
to mount the drive axle". (For Lift Truck)
2. Find the date & form # for LTTB that talks about "Discharge head capacitor
so self diagnostics will function" on model MC60D. (For Lift Truck)
3. Find LTSL date & PSP # that talks about "Replacing the spools in
transmission pump relief valve" on model V50D. (For Lift Truck)
4. Find the Service Letter date for "Replacing the 7W1454 or 7W1455 actuator
assemblies 9Y4603 throttle assembly on certain 3408". (For Power
Generation)
5. Find the SL date for "PS0482" for replacing failed fuel injection nozzles on
certain 3208 truck engines. (For Truck Engines)
6. Find how many Service Magazine articles on component code 4001 make
reference to the CH65 S/N 7YC. (For Heavy Equipment)
REFERENCE:
SEBD0547 - SIRS User Instructions
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
64
Demonstrate Proficiency in Using Caterpillar Service Literature
EQUIPMENT REQUIRED:
None
PROCEDURE:
1. Define the below listed Service Literature Publication abbreviations and
describe what each publication is for.
P.I.P.
0.T.
S.I.R.S.
T.I.B.
P.S.P.
S.M.C.S.
S.I.S.
FIND
REFERENCE:
SEBD0547 SIRS User Instructions
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
65
Demonstrate Proper Removal and Installation of Crankshaft Seal and Wear

Ring.
EQUIPMENT REQUIRED:
Seal Removal and Installation Tools
Engine
PROCEDURE:
1.
2.
3.
4.
5.
Remove and install seal and wear sleeve according to Special Instructions.
Check surfaces for cleanliness.
Lightly lubricate seal.
Use caution to prevent seal damage.
Check alignment to prevent damage to seal.
REFERENCE:
Service Manual
Video Tape 33 SEVV9033 ()
Special Instructions - SMHS7100 and SMHS8301
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
66
TITLE: Demonstrate Procedure to Properly Shim Idler on Low-Sprocket Machine
EQUIPMENT REQUIRED:
Idler Assembly
Roller Frame
PROCEDURE:
1. See Special Instructions.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
67
Demonstrate Use of Thermistor Thermometer Group
EQUIPMENT REQUIRED:
9S9102 Thermistor Thermometer Group
Hydrostatic Transmission
Engine
PROCEDURE:
1. Measure ambient air temperature.
2. Measure water temperature before and after the radiator.
3. Measure oil temperature at outlet of transmission.
REFERENCE:
Video Tape 92 How To Use Cooling System Diagnostic Tools
Themistors SEVN9092 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
68
Demonstrate Machining Powershift Transmission Clutch Housing for

Oversize Rings
EQUIPMENT REQUIRED:
Lathe
Worn Clutch Housing
Oversize Piston Ring
PROCEDURE:
1. Install housing on fixture group.
2. Align radially and axially.
3. Machine piston ring surface to oversized dimension.
REFERENCE:
Guideline for Reusable Parts - SEBF8006 and SEBF8014
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
69
Demonstrate Refacing Powershift Transmission Piston
EQUIPMENT REQUIRED:
Lathe
Powershift Transmission Piston
PROCEDURE:
1. Install piston on fixture group.
2. Align radially and axially.
3. Machine face to remove wear grooves.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
70
Demonstrate Boring of Loader Lift Arm Group
EQUIPMENT REQUIRED:
Lift Arm Group
Line Boring Equipment
PROCEDURE:
1. Set up tooling.
2. Bore pin locations.
3. Install sleeves or bushings if necessary.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
71
Demonstrate Checking a Fixed Value Resistor
EQUIPMENT REQUIRED:
Multimeter
Fixed Value Resistor
PROCEDURE:
1. Select proper scale.
2. Attach leads correctly.
3. Remove any wiring or component that may cause an inaccurate reading if
testing is done on a regulator.
4. Determine value in ohms and test resistor for open and shored circuit.
REFERENCE:
SR4 Generator Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
72
Demonstrate Checking a Variable Resistor (Potentiometer)
EQUIPMENT REQUIRED:
Multimeter
Variable Resistor
PROCEDURE:
1.
2.
3.
4.
Select proper scale

Attach leads correctly.
Disconnect any wires that may cause an incorrect reading.
Determine values in ohms and test resistor for open and shorted circuit.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
73
Demonstrate Checking a Capacitor
EQUIPMENT REQUIRED:
Multimeter
Capacitor
PROCEDURE:
1.
2.
3.
4.
Select proper scale.

Attach leads correctly.
Reverse Polarity.
Determine Condition of Capacitor
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
74
Demonstrate Use of the Rockwell Hardness Tester
EQUIPMENT REQUIRED:
Rockwell Hardness Tester
Samples of Metal
PROCEDURE:
1. Use spring-loaded punch, provided, to make hole in piece being tested.
2. Set magnifying glass with scale over hole.
3. Align scale on one side of the hole and read the scale where the other
side of the hole intersects the scale.
REFERENCE:
PTC Data Bulletin 2112-2
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
75
Demonstrate the Use of Temperature Crayons in Measuring Weld Joint

Temperature
EQUIPMENT REQUIRED:
Metal
Temperature Crayon
Acetylene Torch with Heating Tips
PROCEDURE:
1. Heat metal.
2. Using three (3) different temperature crayons.
Determine metal temperature at different distances.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
76
Demonstrate the Operation and Servicing of the Glass Cleaning Machine
EQUIPMENT REQUIRED:
Several Items for Cleaning
Bead Cleaning Machine
PROCEDURE:
1.
2.
3.
4.
Demonstrate precaution to follow when using different types of metals.

Steam clean greasy parts first.
Never put wet parts in cleaner.
Clean valves and change the cleaning media.
REFERENCE:
Guideline for Reusable Parts
Fundamental Skills Development Guide - SEGV2505
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
77
Demonstrate Proper Use of Caterpillar Adhesives
EQUIPMENT REQUIRED:
7M7260 Adhesive
9S3262 Sealant Kit
5S1454 Sealing Compound
4H5363 Permatex No. 1
5H2471 Adhesive
5M2941 Epoxy Cement
7F2770 Rubber Cement
PROCEDURE:
1. Determine what adhesive or sealant should be used.
NOTE: 7M7260 - .10" gasket - final drive cover and bevel gear case
5H2471 - Bonds cork, leather or rubber to metal
9S3262 - Locks and seals nuts, bolts, screws, and studs
2. Apply adhesive or sealant for several applications.
REFERENCE:
Service Manual
One Safe Source Book
NEXG4502 - Questions & Answers about Caterpillar
Adhesives, Sealants and Maintenance Products
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
78
Demonstrate Proper Tightening of Cylinder Head Bolts
EQUIPMENT REQUIRED:
Engine
8T9293 Torque Wrench or 9S7353 Torque Wrench
PROCEDURE:
1. Tighten cylinder head bolts according to correct sequence.
REFERENCE:
Service Manual
Check the S.I.R.S. and Find System for the latest updates.
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
79
Demonstrate Proper Installation of Cylinder Block Liner Insert
EQUIPMENT REQUIRED:
Engine Block
8S3140 Counterboring Tool Group
5P4175 Insert Tooling Group
PROCEDURE:
1. Machine block.
2. Install insert and measure for correct liner
projection.
REFERENCE:
Special Instructions - FMO55228, GMG02442 and SMHS7221
Video Tape 43 Cylinder Block Counterboring JEGO9043 ()
Video Tape 47 Cylinder Block Liner Seat Sleeving JEGO9047 ()
Video Tape 147 D342 & D353 Spacer Plate Block Salvage SEVV9147 ()
Check S.I.R.S. and Find System for the latest updates.
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
80
Retired
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
81
Demonstrate Use of Infrared Thermometer Group\
EQUIPMENT REQUIRED:
Infrared Thermometer Group
Engine
PROCEDURE:
1. Properly calibrate instrument for area being tested.
2. Operate engine and record temperatures of exhaust, cooling, or
hydraulic system.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
82
Retired
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
83
Demonstrate Troubleshooting the Electronic Monitoring System (EMS)

Operator Panel
EQUIPMENT REQUIRED:
Machine with EMS
5P7277 Voltage Tester
Digital Multimeter or Simpson 260 VOM or Equivalent
8S4627 Continuity Tester
PROCEDURE:
1. Conduct test as outlined in Service Manual.
2. If incorrect results are obtained, refer to Service Manual
Troubleshooting Guide.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
84
Demonstrate Proper Track Adjustment of Track-Type Tractor or Loader
EQUIPMENT REQUIRED:
Track-Type Tractor or Loader
8F9866 Hand Grease Gun
Straight Edge or Ruler
String
PROCEDURE:
1. Properly adjust both tracks of machine for both high drive and
conventional machines.
REFERENCE:
Service Manual
Video Tape 113 Track Adjustment Procedure SEVN9113 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
85
Demonstrate Proper Method of Lubricating Track Roller

(Lifetime Lubricated)
EQUIPMENT REQUIRED:
Bottom Roller
5M2080 Lubricator Nozzle
5P2387 Pump Group
PROCEDURE:
1. Properly fill roller.
2. Leak test using the regulated pressure method
REFERENCE:
Service Manual
Undercarriage Recondition Bulletin - SEBF8515
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
86
Demonstrate Use of Bearing/Gear Puller Group.
EQUIPMENT REQUIRED:
Shaft with Gear or Bearing
1P2321 or 1P2322 Puller
PROCEDURE:
1.
2.
3.
4.
5.
Properly set up tooling.

Safely remove bearing or gear.
Safely remove a bearing cup.
Safely use the bearing heater.
Safely install a gear or bearing.
REFERENCE:
Service Manual - SENR3193
Video Tape 44 Working With Pullers SEVN9044 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
87
Demonstrate Removal and Installation of Sprocket (Track-Type Tractor)
EQUIPMENT REQUIRED:
Track-Type Tractor
Tooling for Machine being used
5P3100 Pump Group (or 9S8550 or 2P5550 or 3S6224)
PROCEDURE:
1. Select correct tooling from Tool Room.
2. Remove sprocket according to Service Manual procedure. Make
repairs if needed.
3. Install sprocket according to Service Manual procedure.
REFERENCE:
Service Manual
Video Tape 46 D7F Track-Type Tractor Bearing and Sprocket
Removal and Installation SEVN9046 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
88
Demonstrate Installation of Piston Assembly into a Cylinder
EQUIPMENT REQUIRED:
Piston with Rings, attached to Connecting Rod
Ring Compressor
Liner or Block
PROCEDURE:
1.
2.
3.
4.
Correctly position rings on piston.

Properly lubricate piston.
Properly prepare rod and rod bolts to protect crankshaft.
Install piston assembly according to Service Manual procedure.
REFERENCE:
Service Manual
Video Tape 138 - Piston Pin Bearing Removal and Installation SEVC9138 ()
Lift Truck Video Tape 46 - Continental Engine Rebuild SEVV7046 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
89
Demonstrate Correct Internal Linkage Adjustment Procedure on a

Hydrostatic Power Control Unit (H.P.C.U.)
EQUIPMENT REQUIRED:
Hydrostatic Power Control Unit
6V2067 Underspeed Raising Tool Group
6V2155 Protractor Group
8S2328 Dial Indicator Group
6V2060 Synchronizing Adjustment Bar
6V3085 Fixture Group
PROCEDURE:
1. Follow EXACT PROCEDURE as outlined in the Service Manual.
REFERENCE:
Video Tape 185 Hydrostatic Loader Troubleshooting SEVN8185 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
90
Demonstrate Checking for Air Entry into Fuel System
EQUIPMENT REQUIRED:
Engine
2P8278 Tube
PROCEDURE:
1. Check according to procedure in Special Instructions.
REFERENCE:
Service Manual
Special Instructions - GMG00825 and SMHS9208
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
91
Demonstrate Proper Method of Filling Pivot Shaft Compartment on High

Drive Tractors
EQUIPMENT REQUIRED:
High drive tractor with floating pivot shaft
PROCEDURE:
1. Follow procedure outlined in Specification Section of Service Manual.
REFERENCE:
Service Manual
Maintenance Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
92
Demonstrate Using the 8T5300 or 6V3100 Fuel Injection Timing Indicator
EQUIPMENT REQUIRED:
8T5300 or 6V3100 Timing Indicator
Engine with timing advance
PROCEDURE:
1. Check for low idle timing.
2. Check for timing advance operation.
REFERENCE:
Service Manual
Video Tape 162 Use of The 6V3100 Diesel Engine Timing Indicator
SEVN9162 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
93
Demonstrate Checking a Diode
EQUIPMENT REQUIRED:
Multimeter or VOM
Diode
Load Voltage Tester
PROCEDURE:
1. Attach multimeter and record values in ohms in both directions
2. Attach load tester and check for excessive leakage.
3. Determine diodes condition.
REFERENCE:
Service Manual
Special Instruction SEHS7734
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
94
Demonstrate Checking an Ignition Coil
EQUIPMENT REQUIRED:
VOM
Coil
PROCEDURE:
1. Select proper ohms scale.
2. Isolate coil to insure correct reading.
3. Attach leads. Test coil for open or shorted circuit.
4. Determine if coil is within specifications.
REFERENCE:
Service Manual
Flight System Instructions
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
95
Demonstrate Making Pump Isolation Test on H.P.C.U.
EQUIPMENT REQUIRED:
Track Type Loader with H.P.C.U.
6V4161 Hydraulic Test Group
6V4156 Transmission Test
Hand Tools
PROCEDURE:
1. Install blocker plates in track motor lines.
2. Performance test H.P.C.U. as outlined in Service Manual.
REFERENCE:
Service Manual
Video Tape 186 Hydrostatic Loader Troubleshooting II - Analyzing the Data
Sheet SENR4119 - SEVN9186 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
96
Demonstrate Pressure Testing Backhoe Loader Transmission
EQUIPMENT REQUIRED:
Caterpillar Backhoe Loader Transmission
6V4160 Transmission Test Group or Test Bench
Hand Tools
PROCEDURE:
1. Follow procedure outlined in Service Manual.
2. Record following pressures on Work Sheet #2 and attach to this form.
A. Pump pressure
B. Converter Inlet Pressure
C. Converter Outlet Pressure
D. Lubrication Pressure
E. Forward Drive Pressure
F. Reverse Drive Pressure
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
97
Demonstrate Use of 5P6590 Wiring Harness Tester
EQUIPMENT REQUIRED:
Tandem Engine Scraper
5P6590 Wiring Harness Test Group
PROCEDURE:
1. Follow step-by-step instructions.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
98
Demonstrate Proper Machine Blocking Methods
EQUIPMENT REQUIRED:
Machine
Blocking Stands and/or Cribbing
Jacks or Lifting Equipment
PROCEDURE:
1. Use safety procedures as shown in videotapes or Service Manual.
REFERENCE:
Service Manual
Video Tape 79 Track Removal And Installation SEVN9079 ()
Video Tape 81 Lifting A Vehicle With Hydraulic Jack Stands SEVN9081 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
99
Demonstrate Proper Component Lifting and Blocking methods
EQUIPMENT REQUIRED:
Undercarriage component or
Engine or
Transmission
Lifting Equipment
Chains and/or Slings
PROCEDURE:
1. Show correct procedure for lifting a component and moving to
another location.
2. Show correct procedure for blocking an engine, transmission or
undercarriage.
3. Install engine on engine stand (Engine Rebuild only)
REFERENCE:
Service Manual
Video Tape 57 - Hoists, Cables and Slings SEVN9057 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
100
Demonstrate Use of the 1P5564 Cylinder Leakage Test Group
EQUIPMENT REQUIRED:
Engine
1P5564 Cylinder Leakage Test Group
Hand Tools
PROCEDURE:
1. Follow procedure outlined in the Service Manual and Special Instruction.
REFERENCE:
Service Manual
Special Instruction - GMGO0694
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
101
Demonstrate Use of Dial Bore Gauge
EQUIPMENT REQUIRED:
Cylinder Liner
1P3537 Gauge Group
PROCEDURE:
1.
2.
3.
4.
Check calibration of gauge.

Check for bore size.
Check for bore out-of-round.
Check for bore taper.
REFERENCE:
Service Manual
*Transmission Rebuild Specialists should use 5P2170
Dial Bore Gauge Group.
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
102
Demonstrate Disassembly and Assembly and honing of a Hydraulic

Cylinder
EQUIPMENT REQUIRED:
Hydraulic Cylinder
1P1784 Disassemble and Assemble Stand
Cylinder Honing Stand and Hones.
PROCEDURE:
1. Disassemble and assemble cylinder according to
procedures in Service Manual or Special Instruction.
2. Hone Cylinder according to Rebuild Process Control guidelines.
REFERENCE:
Service Manual
Video Tape 77 Reconditioning Hydraulic Cylinders SEVV9077 ()
Rebuild Process Control Guidelines - Hydraulic Cylinders
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
103
Demonstrate Use of 6N0087 Valve Stem Gauge
EQUIPMENT REQUIRED:
Several Engine Valves
6V0087 Gauge Group
PROCEDURE:
1. Measure dimensions according to procedure in Guidelines for Reusable
Parts.
REFERENCE:
Guideline for Reusable Parts SEBF8002 and SEBF8034
Instruction Card SEHS7758
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE__________.
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
104
Demonstrate Use of Vibration Selector
EQUIPMENT REQUIRED:
Vibration Selector
Generator set, truck or tractor
PROCEDURE:
1.
2.
3.
4.
Measure amplitude as per Special Instructions.

Measure frequency as per Special Instructions.
Record results and compare to specification.
Record your findings on worksheet #27 and attach
to this form.
REFERENCE:
Operation Manual for Vibration Selector
Special Instructions - SEHS7914 Troubleshooting Engine
Vibration in Vehicular Equipment
Special Instructions - SEHS7654 Alignment - General
Instructions
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
105
Retired
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
106
Demonstrate Use of Push-Puller
EQUIPMENT REQUIRED:
8B7548 Push-Puller
PROCEDURE:
1. Follow safety rules.
2. Properly set up tool to remove either a hear or bearing.
REFERENCE:
Video Tape 44 Working With Pullers, Torque Wrenches, Multipliers
SEVN9044 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
107
Demonstrate Use of Bearing Puller
EQUIPMENT REQUIRED:
5F7343 Puller
Shaft with bearing installed
Push-Puller or T-bar and Hydraulic Press
PROCEDURE:
2. Check pullers for condition.
3. Properly set up tool.
REFERENCE:
SEVN9044 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
108
Demonstrate Use of Bearing Cup Puller
EQUIPMENT REQUIRED:
Bearing Cup Puller
Housing with bearing race installed.
PROCEDURE:
2. Correctly, install puller.
3. Remove cup.
REFERENCE:
SEVN9044 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
109
Demonstrate Use of Seal Removal Tools
EQUIPMENT REQUIRED:
1P3075 Seal Puller Group
5P1720 Seal Pick
PROCEDURE:
1. Use lip type seal puller according to Service Manual.
REFERENCE:
Service Manual
SEVN9044 ()
Fundamental Skill Development Guide - SEGV2505
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
110
Retired
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
111
Demonstrate Use of Stud Remover
EQUIPMENT REQUIRED:
Stud Remover Group
8S1378 Stud Remover Group - 1/4" thru 5/8"
2P5535 Stud Remover Group - 3/4" thru 7/8" - 1"
5P0250 Stud Remover Group - Larger
PROCEDURE:
1. Follow instructions outlined in Special Instructions.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
112
Demonstrate Removing Broken Bolts Using Cutting Torch and Easy-Out
EQUIPMENT REQUIRED:
1B9925 Easy-Out Remover or Equivalent
Broken off stud
Drill motor and bits
Cutting Torch (Undercarriage Rebuild Technicians and Welders only)
PROCEDURE:
1. Follow safety procedures.
2. Properly select drill bit size in relation to stud being removed.
3. Properly light, adjust and cut with torch
REFERENCE:
Fundamental Skills Development Guide - Bars and
Reconditioning Tools - SEGV2505
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
113
Demonstrate Use of Thread Taps and Dies and Installation of a

Threaded Insert.
EQUIPMENT REQUIRED:
1P3000 Rethreading Die Group
1P3020 Machine Screw Tap Group
1P3070 Tap Group
1P3050 Tap Group
Tap Group
Drill Press
Rethread Dies
Bar Stock
Threaded Inserts
PROCEDURE:
1.
2.
3.
4.
5.
6.
Drill pilot hole.

Show correct drill bit selection.
Exercise care in use of tap.
Use thread lubricant.
Follow safety precautions.
Install Threaded Insert and drive "Keys" with
special tooling.
REFERENCE:
Fundamental Skills Development Guide Bars and
Reconditioning Tools - SEGV2505
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 20010
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
114
Demonstrate Installation Of Threaded Insert.
EQUIPMENT REQUIRED:
Threaded Inserts
Drill Motor and Bits
Thread Tap
Tool Guide
PROCEDURE:
1.
2.
3.
4.
5.
Drill out damaged threads.

Countersink hole.
Cut new threads.
Screw insert in slightly below surface.
Drive kees down with special tool.
REFERENCE:
Fundamental Skills Development Guide Bars and Reconditioning Tools
SEGV2505
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
115
Demonstrate Measuring and Adjusting Fuel Setting on a 3500

Series Engine
EQUIPMENT REQUIRED:
6V3139 Tool Group
3500 Engine
PROCEDURE:
1. Check fuel setting.
2. Follow procedure outlined in Service Manual under
"Fuel System Testing and Adjusting".
REFERENCE:
3500 Service Manual
Video Tape 168 3500 Series Engine Unit Injector Synchronization
And Adjustments SEVV9168 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
116
Demonstrate Use of Cylinder Liner Puller
EQUIPMENT REQUIRED:
5P8665 Cylinder Liner Puller
PROCEDURE:
2. Inspect tools for correct installation.
3. Pull liner.
REFERENCE:
Service Manual
Video Tape 138 Piston Pin Bearing Removal & Installation and
Cylinder Liner Puller Tool SEVC9138 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
117
Demonstrate Honing a Cylinder Liner
EQUIPMENT REQUIRED:
Flex-Hone
Drill Motor
PROCEDURE:
1. Follow guidelines in Special Instructions.
REFERENCE:
Service Manual
Special Instructions SMHS7220
Service Magazine 2/5/73 and 7/4/77
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
118
Demonstrate Testing Hydraulic System Main Relief Pressure on a Loader
EQUIPMENT REQUIRED:
Wheel Loader
Hydraulic Test Group
Hand Tools
PROCEDURE:
1. Follow procedure outlined in the appropriate
Service Manual.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
119
Demonstrate Use of Engine Handling Equipment.
EQUIPMENT REQUIRED:
9S9060 Dual Hook Hoist
9S8500 Engine Stand
Engine Block
PROCEDURE:
1.
2.
3.
4.
Install lifting eyes

Use spreader bar.
Follow safety procedures.
Move material from one area to another.
REFERENCE:
Fundamental Skills Development Guide Lift and Block Section SEGV2505
Special Instructions GEGO0576
Video Tape 57 - Hoists, Cables, Slings JEGO9057 ()
Video Tape 58 - Roll-over Hoist JEGO9057 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
120
Demonstrate Use of 5P6584 Timing Light
EQUIPMENT REQUIRED:
5P6584 Timing Light
PROCEDURE:
1.
2.
3.
4.
Attach battery leads to 12V source.

Attach secondary pickup lead on number 1 wire.
Aim light at timing marks found on flywheel.
Turn magneto or distributor to advance or retard timing - read just to
within specifications.
REFERENCE:
Service Manual
Natural Gas Engine Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
121
Demonstrate Pin Timing Fuel System to Engine
EQUIPMENT REQUIRED:
3208 Engine
3306 Engine
3406 Engine
5P4203 Sleeve Metering Fuel System Field Service Tool Group
PROCEDURE:
1. Time fuel system to engine.
2. Use the procedure in the Testing and Adjusting section of Service Manual.
REFERENCE:
3406 Service Manual
3208 Service Manual
3306 Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
122
TITLE: Demonstrate Performance Test of Hydrostatic Power Control Unit

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

6V3121 Multitach
PROCEDURE:
1. Install 6V3015 Test Group, 5P3600 Flow Meter, and 6V3121 Multitach
Group.
2. Move "U" tube to "test" position and test brakes.
3. Run performance test and record information on "Troubleshooting Data
Sheet."
4. Compare information of actual results to expected results.
REFERENCE:
Video Tape 186 Hydrostatic Loader Troubleshooting II Analyzing the Date
Sheet SENR4119 SEVN9186 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
123
Demonstrate Disassembly and Assembly of Steering Clutch
EQUIPMENT REQUIRED:
Steering Clutch (Oil or Dry)
Steering Clutch Stand
PROCEDURE:
1.
2.
3.
4.
Disassemble and assemble steering clutch.

Measure and compare stack height.
Follow safety procedures outlined in Service Manual.
Check S.I.R.S for latest updated information
REFERENCE:
Service Manual
Video Tape 71- Rebuilding Oil-Type Steering Clutches SEVN9071 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
124
Demonstrate Checking and Adjusting Rack Synchronization and Injector

Plunger Timing on a 3500 Series Engine
EQUIPMENT REQUIRED:
6V3139 Tool Group
9S9082 Engine Turning Tool
3500 Engine
PROCEDURE:
1. Check injector synchronization.
2. Check injector plunger timing.
3. Follow procedure outlined in Service Manual under "Fuel System
Testing and Adjusting".
REFERENCE:
3500 Service Manual
Video Tape 168 Rack Synchronization and Injector Plunger Timing on
3500 Series Engines JEGO9168 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
125
Demonstrate Removal and Installation of a Track Group

(Master Pin Type)
EQUIPMENT REQUIRED:
Track-Type Tractor
Track Tools
5P2380 Track Tool Arrangement
PROCEDURE:
1. Insure correct lubrication (pre-lube) of all parts prior to assembly.
2. Use all safety precautions when using hydraulic press.
REFERENCE:
Service Manual
Video Tape 79 Track Removal and Installation SEVN9079 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
126
Demonstrate Removal and Installation of a Track Group

(Split Master Link Type)
EQUIPMENT REQUIRED:
Track-Type Tractor
Track Tools
PROCEDURE:
1. Insure correct lubrication (pre-lube) of all parts prior to assembly.
2. Use all safety precautions.
REFERENCE:
Service Manual
Video Tape 79 - Track Removal and Installation SEVN9079 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
127
Demonstrate Disassembly and Assembly of Piston Pump
EQUIPMENT REQUIRED:
Piston Pump or Motor
Piston Pump or Motor Tooling
PROCEDURE:
1. Follow Procedure Outlined in the Service Manual
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
128
Demonstrate Recovery, Recycling, and Recharging an Air Conditioner

with R-12 or R134a Refrigerant
EQUIPMENT REQUIRED:
Machine equipped with air conditioner
Refrigerant R-12 orR134a
Recovery and Recycling equipment.
Leak Detection equipment
A/C Certification
PROCEDURE:
1. Follow all safety rules.
2. Attach low pressure and high pressure lines.
3. Recover and Recycle refrigerant from air conditioner
4. Charge air conditioner and leak test.
5. Performance test Air Conditioner, Expansion valve and Orifice tube type.
REFERENCE:
Service Manual
Video tape, IMACA Proper use of refrigerant Recovery and recycling Equipment.
Robinair 1770 Enviro-Charge
Note: Completion Of This Skill Requires That The Technician Be Certified For The
Servicing Of Motor Vehicle Air Conditioners. (For Information On Obtaining Certification,
Contact Technical Services At 972-721-2097 Darr Technician only)
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
129
Demonstrate Cleaning Air Cleaner Element
EQUIPMENT REQUIRED:
Dirty air cleaner element
Air supply, hose and nozzle ( 30 psi Max.)
Drop light.
PROCEDURE:
1. Clean filter
2. Check cleaner for holes.
3. Check sealing ring.
REFERENCE:
Service Manual
Operation and Maintenance Guide
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
130
Demonstrate Bleeding Air from Distributor Type Fuel Injection System
EQUIPMENT REQUIRED:
Perkins Engine
PROCEDURE:
1. Follow procedure outlined in the Service Manual.
REFERENCE:
Service Manual
Lift Truck Video Tape 58 C.A.V. Fuel Injection Pump Removal
and Installation SEVV7058 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
131
Demonstrate Final Drive Sprocket Bearing Adjustment
EQUIPMENT REQUIRED:
Conventional Track-Type Tractor
6V0082 Tool Group
PROCEDURE:
1. Demonstrate bearing adjustment.
REFERENCE:
Service Manual
Service Magazine 10/20/80
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
132
Demonstrate Testing Hydraulic System Main Relief and Pressure Limiter
EQUIPMENT REQUIRED:
D6H or D7H Track-Type Tractor
Hand Tools
PROCEDURE:
1. Follow step by step procedure outlined in the Service Manual.
REFERENCE:
Appropriate Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
133
Demonstrate Adjusting Voltage Level on an Electric Set
EQUIPMENT REQUIRED:
Electric Set
Electric Load
Tach or Frequency Meter
PROCEDURE:
1. Remove the access panel on the left side of the generator.
Loosen the locknuts on the voltage adjustment controls. Turn
voltage droop control fully counterclockwise.
2. Start engine. Increase engine speed to nameplate rating.
3. Adjust voltage level control to give nameplate rated voltage. Put
normal load on the generator. Let generator warn up to normal
temperature for operation.
4. Remove the load from the generator. Adjust the voltage level
control if necessary. Put a normal load on the generator. Check
generator voltage. If the voltage stays at nameplate rating,
regulator gain control is adjusted correctly. Tighten all locknuts.
5. If generator VOLTAGE INCREASES, turn the regulator gain
control a small amount counterclockwise. If generator VOLTAGE
DECREASES, turn regulator gain control a small amount
clockwise. Remove the load. Adjust voltage level control if
necessary.
6. Put a normal load on the generator. If the voltage does not stay
at nameplate rating see Step 5. If it does, tighten all locknuts
and install access panel.
REFERENCE:
Service Manual
Operation and Maintenance Guide
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
134
Demonstrate Timing Fuel Injection Pump to Perkins Engine
EQUIPMENT REQUIRED:
Perkins Engine
6V2189 or 9U6188 Timing Fixture
5P4721 Tube Assembly
5P4150 Nozzle Tester
PROCEDURE:
1. Follow procedure outlined in Service Manual.
REFERENCE:
Service Manual
Service Letter # 5 June 1984
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
135
Demonstrate Measuring and Adjusting Fuel Setting and Hydraulic Air

Fuel Ratio Valve on a 3406B or C Engine
EQUIPMENT REQUIRED:
3406B or 3406C Engine with New Scroll Fuel System
6V6070 Tool Group
PROCEDURE:
1. Follow procedure outlined in the Service Manual or Special Instructions.
REFERENCE:
Service Manual
Video Tape 172 Testing and Adjusting The New Scroll Fuel System
SEVV9172 ()
Video Tape 182 Testing and Adjusting The Hydraulic Fuel Ratio Control
On B Series Engine SEVV9182 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
136
Demonstrate Testing Hydraulic System Pilot Pressure
EQUIPMENT REQUIRED:
Machine with pilot operated hydraulic control
valve. Examples: 225, 235, 245, E180, 963, 973,
992C, D11N
Hand Tools
PROCEDURE:
1. Follow procedure outlined in the appropriate Service Manual.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
REVISED 2001
____________________
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
137
Demonstrate Measuring and Adjusting Fuel Setting on a 3300 Series Engine

with New Scroll Fuel System
EQUIPMENT REQUIRED:
3304 or 3306 Engine with New Scroll Fuel System
6V2106 Tool Group
6V3075 Dial Indicator
6V2031 Rack Position Indicator
PROCEDURE:
1. Follow Directions in service manual
REFERENCE:
Service Manual
Fuel Setting Chart
Check S.I.S. or S.I.R. S. and FIND for the latest updates
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
138
Retired
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
139
Demonstrate Checking SR4 Voltage Regulator
EQUIPMENT REQUIRED:
SR4 Voltage Regulator
Multimeter
SPST spring loaded to OFF switch
Frequency Meter
PROCEDURE:
1. Test each component with Multimeter as outlined in the Service Manual
REFERENCE:
Service Manual
Regulator Module (Al) Test Chart (3N1480)
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
140
Demonstrate Checking a Silicone Controlled Rectifier
EQUIPMENT REQUIRED:
Silicone Controlled Rectifier
Test Light
Digital Multimeter
Load Voltage Tester
PROCEDURE:
1. Using test light, follow Service Manual procedure to check S.C.R. operation.
2. Following Service Manual procedure using digital multimeter to check S.C.R.
for correct ohms indications.
3. With load voltage tester, check S.C.R. for leakage.
REFERENCE:
Flight Systems Instructions
Electric Lift Truck Troubleshooting Series Part 1 Module 5
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
141
Demonstrate Use of a Meggar
EQUIPMENT REQUIRED:
Electric Set
Meggar
PROCEDURE:
1.
2.
3.
4.
Prepare electric set.

Connect meggar.
Administer test.
Record readings.
REFERENCE:
SRCR Generator Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
142
Demonstrate Use of 6V4042 Wiring Harness Tester Group
EQUIPMENT REQUIRED:
Lift Truck with EV-1 or L.D.C. Panel
6V4042 Wiring Harness Tester Group
VOM
PROCEDURE:
2. Perform resistance test. Disconnect the battery and discharge the
capacitor or capacitors.
3. Test harness according to Special Instruction procedure.
4. Analyze test results and make recommendation for correction if needed.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
143
Demonstrate Testing Steering Relief Pressure
EQUIPMENT REQUIRED:
Wheel Loader
Hydraulic Test Group
Hand Tools
PROCEDURE:
1. Follow procedure outlined in appropriate Service Manual.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
144
Demonstrate Testing Rod End Tilt Relief Valves
EQUIPMENT REQUIRED:
7M1293 Adapter
5S4648 Hose
4M5317 Bushing
Wheel Loader
7S8714 Pressure Gauge
PROCEDURE:
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
145
Demonstrate Checking Pressure Staging on an Early G-Series

Hydraulic Pump
EQUIPMENT REQUIRED:
Early G-Series Motor Grader (Excluding 120G)
Pressure Gauge (0-5000 PSI)
PROCEDURE:
1.
2.
3.
4.
Check pressure.
Check signal pressure reading where staging occurs.
Check maximum system pressure.
Record your findings on worksheet #16 and attach to this form.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
146
Demonstrate Determining Engine Set point RPM
EQUIPMENT REQUIRED:
Multimter
6V4060 Set Point Indicator
PROCEDURE:
1. Follow procedure in service manual.
REFERENCE:
Service Manual
Special Instructions SEHS7931 How to Use the Set Point Indicator
Video Tape 174 Proper Governor Adjustment Using the 6V4060 Set
Point Indicator SEVN9174 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
147
Demonstrate Testing Head End Relief Valves for Lift Cylinder
EQUIPMENT REQUIRED:
5P47 Blocking Cover
6V4161 Test Group
8S3033 Electric Hydraulic Pump
943, 953, 963, or 973 Track Loader
6V4143 Coupling
5P4816 Pressure Gauge
6V3081 Hose
PROCEDURE:
1. Follow procedure outlined in the appropriate Service Manual.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
148
Demonstrate Internal Adjustments to Sleeve Metering Fuel System
EQUIPMENT REQUIRED:
3208 Sleeve Metering Fuel System
3P2200 Tool Group
Fuel Setting Charts
PROCEDURE:
1. Adjust cross bar.
2. Adjust sleeves of system.
REFERENCE:
Service Manual
Video Tape 76 - Testing Sleeve Metering Pumps with Fuel Injection Test
Bench SEVV9076 ()
Video Tape 103 - V-Type Sleeve Metering Fuel Pump Calibration
SEVV9103 ()
Video Tape 104 - In-Line Sleev3e Metering Fuel System Adjustment
SEVV9104 ()
Video Tape 131 - Sleeve Metering Fuel System Reconditioning
SEVV9131 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
149
Demonstrate Pin Timing Camshafts on a 3500 Series Engine
EQUIPMENT REQUIRED:
9N9991 Timing Pin
3500 Engine
PROCEDURE:
1. Check engine camshaft timing.
2. Follow procedure outlined in Service Manual under "Engine Timing Check".
REFERENCE:
3500 Service Manual
Video Tape 184 Check S.I.S. or S.I.R.S. and FIND for the latest updates
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
150
Demonstrate Proficiency in Completing a S.I.M.S., and Service Report
EQUIPMENT REQUIRED:
None
PROCEDURE:
Complete S.I.M.S. and Service Report using a real situation of the
below listed information. Attach worksheet # 22 to this form.
DEALER INFORMATION
CUSTOMER INFORMATION
FAILURE INFORMATION
DEALER
CUSTOMER NAME
VEHICLE MODEL
Darr Equip. Co.
ABC Construction
14G
ADDRESS
ADDRESS
SERIAL NUMBER
P.O. Box 540788
6789 Tenth St.
96U06585
Dallas, TX. 75354-0788
Dallas, TX. 75221
HOUR METER
DEALER CODE
CUSTOMER COMPLAINT
37
E090
hydraulic line to wheel
PART
DEL. DATE OF VEHICLE
lean cylinder burst
Gp. Name: Leaning
February 14, 1985
Wheel Lines
WORK ORDER CLOSING DATE
Gp. Number: 8D8600 March 17, 1990
Sims - 3252,5057,5102,
HOURS TO REPAIR
ENGINE MODEL
6312
6.5 Hours
3306
FAILED PART
TODAY'S DATE
SERIAL NUMBER
Name: Hose Assembly
March 19, 1990
8Z22888
Number: 9D5969
WORK ORDER NUMBER
RIPPER MODEL
PARTS REPLACED
J1234D
14
Qty. Number Description
SERIAL NUMBER
1 5P0178 Hose
39V0546
1 8S6417 Coupling A.
2 4S5414 Sleeve
1 1P9919 Coupling A.
DESCRIPTION OF REPAIR
Replaced hose assembly
REFERENCE: Reporting S.I.M.S. Information - SEBD0809

_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
151
Demonstrate Adjusting Air Compressor Governor
EQUIPMENT REQUIRED:
Machine with Air Brakes
PROCEDURE:
1. Adjust according to Service Manual procedure.
2. State air pressure specification.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
152
Demonstrate Performing Cycle Times Test on a Machine Hydraulic

System.
EQUIPMENT REQUIRED:
Machine
Stop Watch
PROCEDURE:
1. Perform cycle times test according to Service Manual.
REFERENCE:
Service Manual
Video Tape 156 -Hydraulic Excavator Tests SEVN9156 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
153
Demonstrate Performing Cycle Times Test on G-Series Motor Grader
EQUIPMENT REQUIRED:
G-Series Motor Grader
Stop Watch
PROCEDURE:
1. Perform cycle times test according to service manual.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
154
Demonstrate Performing Case Drain Test on Piston Pump
EQUIPMENT REQUIRED:
Any machine with a piston pump and case drain
Stop Watch
PROCEDURE:
1. Perform case drain test according to Service Manual.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
155
Demonstrate Checking and Adjusting Pump Signal Pressures on

an Excavator
EQUIPMENT REQUIRED:
Excavator
Gauges
PROCEDURE:
1. Perform task according to Service Manual.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
156
Demonstrate Obtaining Proper Oil Sample using the Vacuum Extraction,

Oil Valve Probe, and Drained Oil methods.
EQUIPMENT REQUIRED:
1. Compartment to be sampled
2. Sample bottles and shop labels
3. Vacuum gun and tubing
PROCEDURE:
1.
2.
3.
4.
5.
Bring oil in compartment to operating temperature

Take an oil sample by each sampling method.
Correctly, complete the sample labels.
Route samples to the Oil Lab.
Complete and turn in time card.
REFERENCE:
How to take a good Oil sample - PHEP6001
How to fill out an Oil sample Label - Oil Lab Procedures
Taking a sample from the drain plug - Oil Lab Procedures
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
157
Demonstrate Relining Brake Shoe
EQUIPMENT REQUIRED:
Brake Shoe
Lining
Rivet Machine
Drill Motor and Bit
PROCEDURE:
1. Demonstrate removal of old lining, cleaning of
brake shoe and inspection of shoe.
2. Install new lining.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
158
Demonstrate Evaluating Worn Transmission Plates and Discs
EQUIPMENT REQUIRED:
Plates and Discs
PROCEDURE:
1. Compare samples to guidelines and determine
reusability.
2. Discs - Demonstrate knowledge of more common wear areas.
3. Plates - Demonstrate several ways to check for warp and uneven wear.
REFERENCE:
Lift Truck Video Tape 8 - Troubleshooting The 2-Speed Power Shift
Lift Truck Video Tape 9 - Troubleshooting The 3-speed power Shift
Lift Truck Video Tape 52 - Single Speed Power Shift Transmission
Orientation, Test & Adjust SEVV7052 ()
Lift Truck Video Tape 53 - single Speed Power Shift Transmission
Disassembly & Assembly SEVV7053 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
159
Demonstrate Evaluating Sealed and Lubricated Tracks
EQUIPMENT REQUIRED:
Sample of S.A.L.T. components
Guidelines for Reusable Parts
PROCEDURE:
1. Compare samples to guidelines and determine reuse.
REFERENCE:
Guidelines for Reusable Parts SEBF8022
_____________________
__________________________________________________(Signature & Emp #)
____________________
.
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
160
Demonstrate Evaluating Worn Pistons, Rings and Liners and Demonstrate

Honing a Cylinder Liner.
EQUIPMENT REQUIRED:
Samples of Pistons, Rings and Liners or Cylinders
5P3519 or 5P4812 Ring Groove Gauge
1P3537 Dial Bore Gauge
Flex Hone and Drill Motor
PROCEDURE:
1. Compare samples to guidelines and determine reusability.
2. Follow guidelines and Special Instructions for honing liners.
REFERENCE:
Diagnosing Piston Ring and Liner Failure - FEG45132
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
161
Demonstrate Evaluating Worn Main and Rod Bearings
EQUIPMENT REQUIRED:
Samples of Rod and Main Bearings
PROCEDURE:
REFERENCE:
Guidelines for Reusable Parts - SEBF8009
Engine Bearings and Crankshafts - SEBD0531
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
162
Demonstrate Evaluating Worn Valves, Valve Springs, and Checking

Valve Rotators for Correct Operation.
EQUIPMENT REQUIRED:
Cylinder head with valve rotators
Samples of Valves and Valve Springs
8S2263 Spring Tester
5P6518 Fixture Group
6V87 Valve Stem Gauge

Tri-Square
PROCEDURE:
1. Before disassembly - mark valve and strike lightly with a soft hammer
6 or 8 times. Valve should rotate.
2. Compare valve samples to guidelines and determine reusability.
3. Measure dimensions according to procedure in guidelines for Reusable Parts
REFERENCE:
Service Manual
Special Instructions - SMHS6998 and GMGO2591
Guideline for Reusable Parts - SEBF8002 & SEBF8034
Video tape 62 - Cylinder Head Reconditioning JEGO9062 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
163
Demonstrate Evaluating Worn Turbocharger Parts
EQUIPMENT REQUIRED:
Turbocharger Parts
5P6518 Fixture Group
PROCEDURE:
2. Record your findings on Work Sheet #35 and attach to this form
REFERENCE:
Analyzing Turbocharger Failure - FEG45138
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
164
Demonstrate Use of Bearing Heater
EQUIPMENT REQUIRED:
Bearing Heater
PROCEDURE:
1. Prepare item to be heated
2. Adjust heater temperature control
CAUTION: DO NOT OVERHEAT!
REFERENCE:
Service Manual
Fundamental Skills Development Guide SEGV2505 page 499
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
165
Demonstrate PROFICIENCY in using the listed Tool Groups.
EQUIPMENT REQUIRED:
8T5300 or 6V3100 Timing Indicator
5P3600 Hydraulic Flow Meter
Machine
5P4150 Nozzle Tester
PROCEDURE:
1. Measure engine timing curve using the 6v3100 or 8T5300 Timing Indicator
and record your findings on worksheet # 26. Perform a hydraulic pump
efficiency test using the 5P3600 Hydraulic Flow Meter.
2. Measure engine set point using the 6V4060 Set Point Indicator.
3. Test a set of injector nozzles using the 5P4150 Nozzle Tester and record your
findings on the worksheet #18.
4. Attach worksheets to this form.
REFERENCE:
Timing Indicator SI SEHS8580 Set Point Indicator SI SEHS7931
Nozzle Tester SI SEHS7292
Multitach SI SEHS7807
Hydraulic Flow Meter SI SEHS7097
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
166
Demonstrate Setting Voltage Level and Voltage Gain on Working VR3

Voltage Regulator
EQUIPMENT REQUIRED:
SR-4 Generator with VR3 Regulator
PROCEDURE:
1. Follow procedures in Special Instruction.
REFERENCE:
VR3 Voltage Regulator Supplement - SENR3473
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
167
Demonstrate Installation of Brake Lining On Brake Band
EQUIPMENT REQUIRED:
Brake Lining Machine
Brake Band and Replacement Lining
PROCEDURE:
1. Demonstrate installation of lining according to Special Instructions.
REFERENCE:
Special Instructions - FEO12609
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
168
Demonstrate Testing Rotary Transmission Switches Using 6V4050 Shift

Analyzer
EQUIPMENT REQUIRED:
Scraper or Truck with electronic transmission control
PROCEDURE:
1. Test rotary switch according to Service Manual procedure.
REFERENCE:
Service Manual
Video Tape 178 - Use of The 6V4050 Transmission Shift Analyzer
SEVN9178 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
169
Demonstrate Bleeding Air from Fuel Injection System
EQUIPMENT REQUIRED:
Engine
PROCEDURE:
1. Eliminate air from fuel system according to Service Manual procedure.
REFERENCE:
Service Manual
L & M Guide
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
170
Demonstrate Checking Engine Pressures on Cat or Other Engines
EQUIPMENT REQUIRED:
Engine
1U5470 or 6V9450 Engine Pressure Group
PROCEDURE:
1.
2.
3.
4.
Check fuel system pressure according to Service Manual procedure.

Check Engine Boost
Check Engine Oil Pressure
State findings.
REFERENCE:
Service Manual
Fuel Setting Micro Fiche
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
171
Demonstrate Checking Engine Oil Pressure
EQUIPMENT REQUIRED:
Engine
Pressure Gauge
PROCEDURE:
1. Check engine oil pressure according to service manual procedure. Be sure
to take pressure at correct location.
REFERENCE:
Service Manual
OT Fuel Fiche
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
172
Demonstrate Use of 6V146 LDC Analyzer
EQUIPMENT REQUIRED:
Lift Truck with LDC Panel
6V146 LDC Analyzer
PROCEDURE:
2. Conduct test according to Special Instruction procedure.
3. Analyze test results and make recommendations for corrections
if needed.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
173
Demonstrate Checking Aftercooler for Operation
EQUIPMENT REQUIRED:
Engine with aftercooler
9S9102 Thermistor Thermometer or 1U8865 Infrared
Thermometer Group
PROCEDURE:
1. Determine air temperature before and after Aftercooler.
2. Determine Air Flow before and after the Aftercooler
REFERENCE:
Special Instructions - SEHS8149 and SMHS7140
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
174
Demonstrate Testing Cooling System Voltage Potential
EQUIPMENT REQUIRED:
Digital Multimeter
Running Engine
PROCEDURE:
1. Place one probe of meter in coolant at radiator fill neck. Attach other
probe to negative battery terminal.
2. Record voltage potential with the key start switch in the "off" position,
with the engine cranking, and with the engine running and all electrical
accessories turned "on".
REFERENCE:
Service Magazine
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
175
Demonstrate Checking Valve Rotators for Correct Operation.
EQUIPMENT REQUIRED:
Cylinder Head Group with valve rotators.
PROCEDURE:
1. Before disassembly mark valve and chamber strike lightly with soft
hammer 6 or 8 times. Valve should rotate. If it doesnt rotate, attempt to
rotate entire assembly by hand. If it can be rotated, then rotator is
defective. Mark for replacement.
REFERENCE:
Guidelines for Reusable Parts SEBF8002
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
176
Demonstrate Operational Check of Engine Brakesaver
EQUIPMENT REQUIRED:
Engine Equipped With Brakesaver
PROCEDURE:
1. Perform Operational Check According To Service Manual.
2. State Results Of Operation Check.
3. Check 1. Pull-Down R.P.M. Check
2. Klunk Check (Check For Free Movement Of The Valve Spool)
3. Control Valve Diaphragm Using Air Pressure.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
177
Demonstrate Exothermic Cutting
EQUIPMENT REQUIRED:
8T7792 Mini Cutting Torch or Bronco Gun
PROCEDURE:
1. Pierce a bolt or track pin lengthwise using a mini cutting torch.
REFERENCE:
8T7792 Mini Torch Operating Instructions - SEHS8923
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
178
Demonstrate Removal and Installation of Camshaft Bearings and

Evaluate Camshaft for Reusability
EQUIPMENT REQUIRED:
Engine Block
Camshaft
Camshaft Bearings
8S2241 Camshaft Bearing Group
Micrometers
PROCEDURE:
1. Remove old camshaft bearings using tooling and recommended
procedure outlined in Service Manual and Engine News.
2. Install bearings using tooling and recommended procedures in Service
Manual and Engine News.
3. Measure journal O.D. and Bearing I.D. and calculate the clearance.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
179
Demonstrate Differential Steering Diagnostic Instrument Test
EQUIPMENT REQUIRED:
Tractor with Differential Steering
1U5796 Pressure Differential Gauge Group
6V7830 Tetragauge Group
8T0853 (0-60PSI) Gauge
Hand wrenches - including metric hex
8T0861 Gauge
PROCEDURE:
1. Follow instructions to determine conditions of hydraulic valves,
pump and motor.
REFERENCE:
Service Manual - Systems Operation Testing & Adjusting SENR3414
Video Tape 286 - Differential Steer How It Works TEVC1286 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
180
Demonstrate Installation of Fuel Injection Valve into Pre-Combustion

Chamber
EQUIPMENT REQUIRED:
Cylinder Head Group
Torque Wrench
PROCEDURE:
1. Install nozzle properly on body.
2. Install assembly in chamber.
3. Properly torque retaining nut.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
181
Demonstrate Checking Electric Shutoff Solenoid
EQUIPMENT REQUIRED:
Engine with Electric Shutoff Solenoid
PROCEDURE:
1. Measure voltage drop across solenoid.
2. Measure amp draw.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
182
Demonstrate Differential Steering and Operation Tests without

Instrumentation
EQUIPMENT REQUIRED:
Track Type Tractor With Differential Steering
Tape Measure
PROCEDURE:
1. Following the Service Manual, check linkage adjustments.
2. With engine at Max RPM, implements raised and in hold, shift to 1st
forward and full steer left. Record diameter.
3. Repeat for right turn, record diameter.
4. Repeat above test but with dozer held in full raise. Record.
5. Analyze results.
REFERENCE:
Service Manual - Systems Operation Testing & Adjusting SENR3414
Video Tape 286 Differential Steer-How It Works TEVC1286
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
183
Demonstrate Troubleshooting the Electronic Traction Aid
EQUIPMENT REQUIRED:
Machine equipped with electronic traction aid
PROCEDURE:
1. Follow procedure in Service Manual.
REFERENCE:
Service Manual
Video Tape 187 -Introduction to Automatic Electronic Traction Aid
SEVN9187 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
184
Demonstrate Disassembly and Assembly and Evaluation of a Transmission

Oil Pump
EQUIPMENT REQUIRED:
Powershift Transmission Pump
Hand Tools
PROCEDURE:
1. Follow instructions outlined in appropriate Service Manual.
REFERENCE:
Service Manual
Diagnosing Pump Failures - FEG45137
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
185
Demonstrate Determining Cause for Open Fuse or Circuit Breaker
EQUIPMENT REQUIRED:
Digital Multimeter
Machine
PROCEDURE:
1.
2.
3.
4.
Explain "shorts," "opens," "intermittence, short to ground."

Find cause for open fuse.
Find cause for open circuit breaker.
Troubleshoot for short to ground.
REFERENCE:
Service Manual
Service Magazine
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
186
Demonstrate Checking Radiator Cap (Automotive Type)
EQUIPMENT REQUIRED:
Radiator Cap
9S8140 Pressure Pump or equivalent
PROCEDURE:
1. Attach pressurizing group to radiator cap.
2. Specify reading obtained
3. Compare with specifications and determine if cap is serviceable.
REFERENCE:
Service Manual
Know Your Cooling System SEBD0518
Video Tape 96 - How to Use the Cooling System Diagnostic Tools
Pressurizing Pump SEVN9096 ()
Video tape 94 - How to Use the Cooling System Diagnostic Tools
Air Flow Meter SEVN9094 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
187
Demonstrate Disassembly and Assembly of a Powershift Transmission

Hydraulic Control
EQUIPMENT REQUIRED:
Powershift Transmission Hydraulic Control
Hand Tools
PROCEDURE:
1. Follow instructions outlined in appropriate Service Manual.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
188
Demonstrate Evaluation of Worn Torque Converter Parts
EQUIPMENT REQUIRED:
Service Manual
PROCEDURE:
1. Compare examples to reusable guidelines.
2. Demonstrate procedure for checking stator to turbine clearance.
3. Demonstrate checking stator in impeller clearance.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
189
Demonstrate Disassembly and Assembly of a Powershift Transmission
EQUIPMENT REQUIRED:
Powershift Transmission
Lifting Equipment
Hand Tools
PROCEDURE:
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
190
Demonstrate Checking and Adjusting Transmission, Steering, Brake

Linkage and Evaluate for Wear.
EQUIPMENT REQUIRED:
Track-Type Tractor with Pedal Steering
PROCEDURE:
1. Check and adjust linkage according to Service Manual.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
191
Demonstrate Machining Sprocket Shaft Bore
EQUIPMENT REQUIRED:
Final Drive Case
Boring Bar
PROCEDURE:
1. Machine bore to accept fabricated sleeve.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
192
Demonstrate Measuring Steering Clutch Thickness
EQUIPMENT REQUIRED:
Steering Clutch
Measuring Scale
PROCEDURE:
1. Check clutch pack thickness. Compare with specification.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
193
Demonstrate Checking Steering Clutch Control Valve (Booster) Pressure

and for Correct Operation
EQUIPMENT REQUIRED:
Machine (Track-Type Tractor)
5P6225 Transmission Test Group
PROCEDURE:
1. Check steering booster for operation according to Service Manual
procedure.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
194
Demonstrate Steering Clutch Linkage Adjustment (Pedal Steer)
EQUIPMENT REQUIRED:
Machine
PROCEDURE:
1. Adjust linkage according to service manual procedure.
2. Check proper sequence.
3. Check dimensions for accuracy.
REFERENCE:
Service manual Testing and Adjusting Section
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
195
Demonstrate Brake Adjustment, including linkage.

(Track -Type Tractor or Track -Type Loader)
EQUIPMENT REQUIRED:
Machine
Track Type Tractor or Loader
PROCEDURE:
1. Adjust brakes and brake linkage according to service manual procedure.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
196
Demonstrate Black Light Leak Detection Group and Additives
EQUIPMENT REQUIRED:
1U5566 Black Light Leak Detection Group
Running Engine
PROCEDURE:
1. Add recommended quantity additive to system.
2. Use black light to observe leaks or fluid transfers.
REFERENCE:
Instructions in kit.
Special Magazine
Shop Product Guide
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
197
Demonstrate Installation of Sprocket Rim or Sprocket Adapter
EQUIPMENT REQUIRED:
Replacement Sprocket Rim or Adapter
Worn Sprocket
PROCEDURE:
1. Install replacement rim according to Special Instructions.
REFERENCE:
Special Instruction - SEHS7750, SEHS7751,and SEHS7274
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
198
Demonstrate Metal Identification
EQUIPMENT REQUIRED:
Grinder
Various Metal Samples
Magnet
PROCEDURE:
1. Identify metal composition using the following methods:
A. Appearance Test
B. Magnetic Test
C. Chisel Test
D. Flame Test
E. Spark Test
REFERENCE:
Metal Identification and Welding of Steel - copy
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
199
Demonstrate 1U5803 Deutsch Connector Repair Kit
EQUIPMENT REQUIRED:
Deutch connectors, used on PEEC . EUI or HEUI engines
1U5803 Deutsch Connector Repair Kit
PROCEDURE:
Using special tools, disassemble and assemble
Deutsch connectors used on PEEC, EUI or HEUI engines.
REFERENCE:
Tool Guide
Directions on lid of kit.
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
200
Demonstrate Disassembly and Assembly of a Rotochamber
EQUIPMENT REQUIRED:
8B7551 Bearing Puller Attachment
8B7548 Puller Assembly
PROCEDURE:
1. Follow procedures given in Service Manual SENR2107
disassembly and assembly.
REFERENCE:
Service Manual - SENR7621 (631D and 637 Tractors)
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
201
Demonstrate Measuring Rate of Fuel Consumption with 6V7925 Fuel

Rate Indicator Group or 1U5450 Fuel Flow Monitor System Group
EQUIPMENT REQUIRED:
6V7925 Fuel Rate Indicator Group or 1U5450
Fuel Flow Monitor
Running Engine
PROCEDURE:
1. Measure rate of fuel consumption of Caterpillar Diesel Engine.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
202
Demonstrate Checking Articulation Joint Wear
EQUIPMENT REQUIRED:
Hydraulic Jack
Bearing Cup Puller Attachment
"T" Bar Tooling Group
PROCEDURE:
1. Disassemble articulated joint of main frame and determine wear.
2. Compute shims needed to compensate for wear.
REFERENCE:
Service Manuals - 920, 930, 980, 988 and 992
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
203
Demonstrate Checking Excavator Swing Bearing Wear
EQUIPMENT REQUIRED:
Excavator
PROCEDURE:
1.
2.
3.
4.
Properly attach dial indicator.

Properly position machine.
Record dial indicator reading.
Follow procedure in Service Manual.
REFERENCE:
Service Manual
Service Magazine June 2, 1986
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
204
Demonstrate Tilting Modular Cab
EQUIPMENT REQUIRED:
Vehicle equipped with Rops or Modular Cab.
PROCEDURE:
1. Follow step by step procedure in Special Instruction.
REFERENCE:
Special Instructions SMSH7420 and SEHS6897
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
205
Demonstrate Use of Air Arc Equipment
EQUIPMENT REQUIRED:
"Jet-Arc" Gun or Equivalent
Electrodes
Air Supply
NOTE: "Arcair" and "Jetair" are synonymous terms.
PROCEDURE:
1. Using a regular "DC" welder on reverse polarity, remove an old weld
or prepare a joint for welding.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
206
Demonstrate Proper Use of Cutting Torch
EQUIPMENT REQUIRED:
OXY-Acetylene Set Up
Cutting Torch
Various Size Cutting Tips
Scrap Steel of Various Thickness
PROCEDURE:
1. Accurately cut a section of metal plate straight and at an angle.
REFERENCE:
Video Tape 50 & 51 - Gas Welding Equipment, Gas Cutting Torch
and Tip Care SEVN9050 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
207
Demonstrate Reading Blueprint, Laying Out and Building Example

from Blueprint
EQUIPMENT REQUIRED:
Electric Welder
OXY - Acetylene Welding Equipment
Blueprint from Tool Guide for Fabricated Tools (FT)
PROCEDURE:
1. From furnished blueprints, read, cut out and weld a fabricated tool.
2. This fabricated tool should be placed in the tool room for use.
REFERENCE:
Caterpillar Tool Guide - (Contains blueprints for many special "FT" tools)
Video Tape 154 - Reading Caterpillar Prints SEVN9154 ()
Video Tape 155 - Geometric Tolerancing SEVV9155 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
208
Demonstrate Use of Automatic Gas Cutting Machine
EQUIPMENT REQUIRED:
Automatic Metal Cutting Machine
"C" Kater
PROCEDURE:
1. Set up "C" Kater for metal cut.
2. Adjust flame to correct intensity for metal being cut.
3. Correctly adjust "C" Kater travel speed for clean cut.
REFERENCE:
Video Tape 50 & 51 - Gas Welding Equipment, Gas Cutting Torch
and Tip Care SEVN9050 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
209
Demonstrate Gas Welding, Using Steel and Brass Rod
EQUIPMENT REQUIRED:
OXY-Acetylene Set Up
Assortment of Steel Welding Rods
Assortment of Brass Welding Rods
PROCEDURE:
1. Demonstrate using both steel and brass welding techniques.
REFERENCE
:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
210
Demonstrate Scarifying or Gouging with Acetylene and Oxygen Torch
EQUIPMENT REQUIRED:
OXY - Acetylene Set-Up
"Scarifying" or Gouging Tips
PROCEDURE:
1. Demonstrate removal of an old weld or preparation of a cracked joint for
welding repair.
REFERENCE:
Welding, Cutting & Heating Guide - Victor 2A1/77
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
211
Demonstrate 8T2700 Blowby/Air Flow Indicator Group
EQUIPMENT REQUIRED:
8T2700 Blowby/Air Flow Indicator Group
Running Engine
PROCEDURE:
1. Following the Special Instructions, evaluate engine blowby. Compare to
value given in chart.
2. Measure air flow through radiator as described in Special Instructions. Record
results on worksheet #12 and attach to this form.
REFERENCE:
Service Magazine July 20, 1987 "Additional Guidelines for Using the 8T2700
Blowby/Air flow Indicator Group
Know Your Cooling System - SEBD0518
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
212
Demonstrate "MIG" Wire Feed Welding
EQUIPMENT REQUIRED:
"MIG" Welding Machine
PROCEDURE:
1. Demonstrate use of "MIG" welding machine correctly adjusting output
voltage and wire feed speed to suit material to be welded.
REFERENCE:
Hobart Pocket Welding Guide - Pages 124, 125 and 126
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
213
Demonstrate Use of 9S7370 or 6V7830 Tetragauge
EQUIPMENT REQUIRED:
9S7370 or 6V7830 Tetragauge
PROCEDURE:
1. Make proper connection of tetragauge.
2. Record pump pressure, relief pressure.
REFERENCE:
Service Manual
Special Instructions - GMG00449
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
214
Demonstrate Use of 6V4820 Adapter Group
EQUIPMENT REQUIRED:
Lift Truck with EV-1 Panel
6V4820 Adapter Group
PROCEDURE:
1. Install correct tooling - WARNING: Lift the front wheels of the lift truck
and put wood blocks safely under the frame so the drive wheels are free
to turn. Disconnect the battery and discharge 1 C capacitor.
2. Conduct test according to Special Instruction procedure.
3. Analyze test results and make recommendations for corrections if needed.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
215
Demonstrate Pressure Differential Gauge Group
EQUIPMENT REQUIRED:
1U5796 Pressure Differential Gauge Group
Machine with Load Sensing, Pressure Compensated
Hydraulic System
PROCEDURE:
1. Connect gauge group to fittings provided to measure differential pressure
(Delta P).
REFERENCE:
Service Manual
Service Magazine May 25, 1987 - page 7
Video Tape 202 Pressure Compensated/Load Sensing Hydraulic System
SEVN9202 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
216
Demonstrate Evaluating and Filling Lubricated Track Joint with Portable

Equipment
EQUIPMENT REQUIRED:
8T3115 Portable Track Lubricator
Sealed and Lubricated Track
PROCEDURE:
1. Follow Special Instructions. Attach tool.
Evaluate and fill joint.
REFERENCE:
Service Manual
Service Magazine 8/12/85
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
217
Demonstrate Transducer to Minimize Oil Loss During Hydraulic System

Repair
EQUIPMENT REQUIRED:
5P0306 Transducer
PROCEDURE:
1. Replace hydraulic tank oil fill cap with modified cap adapted to accept
5P0306 transducer.
2. Follow instructions in Tool Guide.
3. Apply vacuum to top of hydraulic tank.
4. Disconnect pump inlet to replace pump.
REFERENCE:
Service Magazine 10/12/73 page 11
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
218
Demonstrate using the 8T1000 Electronic Position Indicator
EQUIPMENT REQUIRED:
8T1000 Electronic Position Indicator
Running Engine
PROCEDURE:
1. Follow Special Instructions.
2. Connect the electronic position indicator to fuel rack of live engine.
3. Start engine and read rack position at engine set point RPM.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
219
Demonstrate 6V9130 Temperature Adapter Group and 8T5334 Surface

Temperature Probe
EQUIPMENT REQUIRED:
6V9130 Temperature Adapter Group
8T5334 Surface Probe
6V770 or 6V7800 Digital Multimeter
PROCEDURE:
1. Attach 6V9130 temperature adapter to multimeter.
2. Following Special Instructions, read temperatures of engine block, radiator
top tank, radiator bottom tank.
REFERENCE:
LTTB 10/01/84
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
220
Demonstrate Electronic Control Analyzer Programmer (ECAP) or Digital

Diagnostic Tool Group (DDT).
EQUIPMENT REQUIRED:
8T8697 Electronic Control Analyzer Programmer or
8T5282 Digital Diagnostic Tool
PROCEDURE:
1. Following Special Instructions, measure engine readings and make
adjustments.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
221
Retired
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
222
Demonstrate Correct Assembly of Track Roller and Idler
EQUIPMENT REQUIRED:
Rollers, idlers
Pressing equipment
Dial Indicator Test Group
Test Tooling
Seal Installer
Plug Installer
Hand Tools
Regulated Air
PROCEDURE:
1. Follow Service Manual procedures to inspect and assemble components.
2. Test for Leaks
REFERENCE:
Service Manual
Undercarriage Reconditioning Bulletin - SEBF8515
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
223
Demonstrate Checking Rebuilt Rollers/Idlers for Oil Leaks.
EQUIPMENT REQUIRED:
Rollers or Idler
Testing Tool
Shop Air with Pressure Regulator
PROCEDURE:
1. Follow service manual procedures to check for leaks.
REFERENCE:
Service Manual
Undercarriage Reconditioning Bulletin SEBF8515
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
TITLE:
Demonstrate Automatic Submerged Arc Welding
EQUIPMENT REQUIRED:
Automatic Welding Equipment
PROCEDURE:
1. Follow procedures in the Undercarriage Reconditioning Guide.
REFERENCE:
Undercarriage Reconditioning Bulletin MP-1 SEBF8505
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
225
Demonstrate Use of Curtis 1020 Power Prover
EQUIPMENT REQUIRED:
Electric Lift Truck
Curtis 1020 Power Prover
PROCEDURE:
2. Conduct test according to Curtis 1020 Power Prover Instructions.
3. Analyze test results and make recommendations for corrections if needed.
REFERENCE:
Service Manual
Curtis 1020 Power Prover Instruction Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
226
Demonstrate Pulse Generator Group
EQUIPMENT REQUIRED:
8T5200 Pulse Generator
Electronic Control System Requiring Speed Sensor Input
9W6370 Electronic Speed Switch Adapter
PROCEDURE:
1. Simulate speed signal to electronic control.
CAUTION: Remove axles from unit PRIOR TO TEST,
(if used on Electronic Shift Control.)
REFERENCE:
Video Tape194 - Transmission Controls for the 631/637E Wheel TractorScrapers SEVN9194 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
227
Demonstrate Repair of VE Series Electrical Connectors
EQUIPMENT REQUIRED:
6V4810 or 8T5319 Tool Group
PROCEDURE:
1. Follow procedures in Special Instructions to remove and install wires in
connector.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
228
Demonstrate Programming the ECM of the Electronic Modular Control

Panel (SR4 Generator Mounted)
EQUIPMENT REQUIRED:
SR4 Generator equipped with the Electronic Modular Control Panel
PROCEDURE:
1. Refer to the Shop Manual, and adjust the following set points:
A. Overspeed
B. Crank termination speed
C. High coolant temperature shutdown
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
229
Demonstrate Programming the AC Meter Module (ACM) of the Electronic

Modular Control Panel (SR4 Generator Mounted)
EQUIPMENT REQUIRED:
SR4 Generator equipped with the Electronic Modular Control Panel
PROCEDURE:
1. Following the Shop Manual procedures, program the ACM for voltmeter
range and current transformer (CT) ratios.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
230
Demonstrate Troubleshooting the Electronic Neutral/Start Control
EQUIPMENT REQUIRED:
Multimeter
Machine equipped with the Electronic Neutral/Start Control
EXAMPLES:
"E" Series Scraper, 768C, 772B, 776B, 769C, 773B,
777B, 785, 789
PROCEDURE:
1. Test and troubleshoot control.
REFERENCE:
Electronic Neutral/Start Control - SENR3889
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
231
Demonstrate Use of 6V2172 Test Terminal Board
EQUIPMENT REQUIRED:
Electric Lift Truck with LDC Panel
6V2172 Test Terminal Board
6V3030 VOM
PROCEDURE:
1.
2.
3.
4.

Check power integrity to logic, according to Technical Bulletin instructions.
Conduct test according to Service Manual procedure.
Analyze test results and make recommendations for corrections.
REFERENCE:
Service Manual
L.T. Technical Bulletin March 1982 - Troubleshooting the LDC System
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
232
Demonstrate Proper Use of Recommended Tool List
EQUIPMENT REQUIRED:
Tool Guide
Tool Listing Fiche
Microfiche Reader
PROCEDURE:
1. Find tools required to repair current as well as older machines.
REFERENCE:
Service Manual
Tool Guide - Recommended Tool List Section
Tool Listing Fiche - NBFG9000
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
233
Demonstrate Testing Cold Start Heater
EQUIPMENT REQUIRED:
Lift Truck with Perkins Diesel Engine
Voltmeter
Amp Gauge
Air Regulator Valve
PROCEDURE:
1. Check cold start heater for leakage, voltage, and current draw according
2. Analyze test results and make recommendations for corrections, if needed.
REFERENCE:
Service Manual
Lift Truck Video Tape 6 - Perkins Fuel System SEVV7006 ()
Lift Truck Video Tape 7 - Perkins Fuel System SEVV7007 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
234
Demonstrate Checking High Pressure Relief Valves on Hydrostatic

Transmission
EQUIPMENT REQUIRED:
Hydrostatic Transmission Test Stand or Lift Truck with Hydrostatic Transmission
PROCEDURE:
1.
2.
3.

Properly demonstrate checking high pressure relief valves on hydrostatic
transmission according to Service Manual procedure.
Adjust pressure if necessary.
REFERENCE:
Service Manual - SENB8055
L.T. Video Tape 31 - Hydrostatic Transmission Testing
and Adjusting SEVV7031 ()
L.T. Spec. Book - SENB8060
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
235
Demonstrate Checking and Adjusting Hydrostatic Transmission Charge

Pump Pressure Relief Valve
EQUIPMENT REQUIRED:
Hydrostatic Transmission Test Stand or Lift Truck with Hydrostatic
Transmission
0-600 Pressure Gauge
Tachometer
PROCEDURE:
2. Properly check charge pump pressure relief valve according to Service
Manual procedure.
3. Adjust pressure if necessary.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
236
Demonstrate Checking and Adjusting Hydrostatic Transmission Low Pressure

Relief Valve
EQUIPMENT REQUIRED:
0-600 Pressure Gauge
Tachometer
PROCEDURE:
2. Properly check low pressure relief valve according to Service Manual
procedure.
3. Adjust pressure if necessary.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
237
Demonstrate Checking Hydrostatic Transmission Servo Cylinder

Linkage Wear
EQUIPMENT REQUIRED:
PROCEDURE:
1.
2.
3.
4.
Drain approximately one gallon of oil from transmission, if not already drained.
Mark (for assembly) and remove forward and reverse servo cylinder.
Check for excessive linkage wear, using reusability guidelines.
Make recommendation for reuse or replacement.
REFERENCE:
Service Manual
Hydrostatic Transmission Page 35
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
238
Demonstrate Checking Hydrostatic Transmission Charge Pump Drive
EQUIPMENT REQUIRED:
Mirror (small one)
PROCEDURE:
1. Drain approximately two quarts of oil from transmission, if not already drained.
2. Remove charge pump and check for worn tang or broken shaft on charge
pump.
3. Check tang slot shaft wear using mirror and adequate lighting.
4. Remove coil wire, insert screwdriver on tang slot and turn engine several
revolutions, keeping slight amount of pressure on screwdriver.
5. Analyze test results and make recommendation for corrections if needed.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
239
Demonstrate Disassembly and Assembly of Hydrostatic Transmission High

Pressure Relief Valve
EQUIPMENT REQUIRED:
Hydrostatic Transmission High Pressure Relief Valve
PROCEDURE:
1. Properly identify early or late style of relief valve.
2. Properly disassemble and assemble high pressure relief valve according
REFERENCE:
Service Manual
Lift Truck Video Tape 4 - Rebuilding a Hydrostatic Transmission Disassembly.
SEVV7004 ()
Lift Truck Video Tape 5 - Rebuilding a Hydrostatic Transmission Assembly
SEVV7005 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
240
Demonstrate Disassembly and Assembly of the Hydrostatic Transmission

Manifold Metering Valve
EQUIPMENT REQUIRED:
Hydrostatic Transmission Manifold Metering Valve
PROCEDURE:
1. Properly disassemble and assemble manifold metering valve according
2. Determine if valve is reusable.
Note: Use correct procedure when installing metering shaft seal.
REFERENCE:
Service Manual
L.T. Video Tape 4 - Rebuilding a Hydrostatic Transmission SEVV7004 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
241
Demonstrate Adjusting Hydrostatic Transmission Control Valve
EQUIPMENT REQUIRED:
PROCEDURE:
1. Follow the procedure in the Service Manual for removing centering
spring end plug.
2. Adjust external linkage according to Service Manual.
REFERENCE:
Check the S.I.R.S. and FOND for the latest updates
_____________________
__________________________________________________(Signature & Emp #)
____________________
.
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
242
Demonstrate Use of 1135T Curtis Tester
EQUIPMENT REQUIRED:
Lift Truck with Curtis Lift Interrupter
1135T Curtis Tester
PROCEDURE:
2. Conduct test according to service manual procedure.
3. Analyze test results and make recommendations and or adjust for
corrections if needed.
REFERENCE:
Service Manual
Check the S.I.R.S. and FIND for the latest dates
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
243
Demonstrate Using a Peak Reading Diode Block for Checking Electric

Lift Truck Transformer
EQUIPMENT REQUIRED:
Electric Lift Truck
Transformer
Digital Multimeter
Peak Reading Diode Block or Flight Sys. Tester
PROCEDURE:
2. Conduct test according to Service Manual procedure.
3. Analyze test results and make recommendation for corrections if needed.
REFERENCE:
Service Manual
Flight Sys. Instructions
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
244
Demonstrate Governor and Carburetor Adjustment on Cat 1404 Gasoline

Engine
EQUIPMENT REQUIRED:
Lift Truck with Cat 1404 Gasoline Engine
5P6585 Electrical System Analyzer
PROCEDURE:
1. Properly adjust Governor and Carburetor according to Service Manual
procedure.
REFERENCE:
Service Manual
Lift Truck Video Tape 48 - Gasoline Carburetors and Governor Adjustments
SEVV7048 ()
Lift Truck Video Tape 55 - IMPCO LP Conversion Kit Installation SEVV7055 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
245
Demonstrate Proper Timing of Engine Gear Train
EQUIPMENT REQUIRED:
Engine
PROCEDURE:
1. Demonstrate timing of valve camshaft (and fuel system camshaft if
applicable) to crankshaft.
REFERENCE:
Service Manual
L.T. Video Tape 46 - Continental Engine Rebuild SEVV7046 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
246
Demonstrate Checking Crankshaft for Reusability
EQUIPMENT REQUIRED:
Used Crankshaft
Micrometers
6V6035 Hardness Tester
Two 5P8637 Vee Blocks

Dial Indicator
PROCEDURE:
1. Check for journal wear. Check for journal taper and out-of-round. Check for
surface profile. Check for surface finish. Check for visible cracks. Check for
crankshaft straightness. Check for crankshaft hardness.
2. Compare readings with specifications found in service manual.
REFERENCE:
Service Manual
Guideline for Reusable Parts SEBF8039, SEBF8041 and SEBF8043
Engine Bearings and Crankshafts SEBD0531
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
247
Demonstrate Checking Vacuum on Vacuum Operated Brakes
EQUIPMENT REQUIRED:
Lift Truck with Vacuum Operated Brakes
9S7370 Tetragauge
5P6582 Vacuum Pressure Gauge
PROCEDURE:
1. Properly demonstrate vacuum test according to Service Manual procedures.
2. Analyze results and make recommendations for corrections if needed.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
248
Demonstrate Installation of Fuel Injection Valve on 3208 Engine
EQUIPMENT REQUIRED:
Cylinder Head Group
Torque Wrench
PROCEDURE:
1. Reseal injection valve according to Service Manual procedures.
2. Install injection valve properly.
3. Properly torque retaining capscrew.
REFERENCE:
Service Manual
Video Tape 29 - Servicing the Pencil-Type Nozzle JEGO9029 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
249
Demonstrate Checking High and Low Idle Speed on a Diesel Engine
EQUIPMENT REQUIRED:
Lift Truck with Diesel Engine
PROCEDURE:
2. Check high and low idle speeds according to service manual procedure.
3. Make adjustments if necessary.
REFERENCE:
Service Manual
Lift Truck Video Tape 7 Perkins Fuel Systems SEVV7007 ()
Special instructions SEHS7807
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
250
Demonstrate Checking Tilt Cylinder Alignment
EQUIPMENT REQUIRED:
Lift Truck
Tilt Indicator or Protractor
PROCEDURE:
1. Check tilt cylinder alignment according to Service Manual procedure.
REFERENCE:
Service Manual
L.T. Video Tape 3 - Mast Testing and Adjusting SEVV7003 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
TITLE:
Demonstrate Adjusting Clutch Linkage
EQUIPMENT REQUIRED:
Lift Truck with Mechanical Transmission
PROCEDURE:
1. Make clutch pedal adjustment according to Service Manual procedure.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
252
Demonstrate Checking Pressures on Transmission
EQUIPMENT REQUIRED:
Lift Truck with Powershift Type Transmission
Six 0-300 PSI Gauges
5P6585 Electrical Analyzer or Tachometer if Gasoline or L.P. Powered
6V3121 Multitach Group if Diesel Powered
PROCEDURE:
1.
2.
3.
4.

Conduct test according to Service Manual procedure.
Analyze test results and make recommendation for corrections if needed.
REFERENCE:
Service Manual
Lift Truck Video Tape 8 -Troubleshooting The 2 Speed Power Shift Transmission
SEVV7008 ()
Lift Truck Video Tape 9 - Troubleshooting The 3-speed Power Shift Transmission
SEVV7009 ()
Lift Truck Video Tape 52 - Single Speed Power Shift Transmission Orientation,
Test & Adjusting SEVV7052 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
253
Demonstrate Disassembly and Assembly of Powershift Transmission

Control Valve
EQUIPMENT REQUIRED:
Control Valve
8S2263 Spring Tester
PROCEDURE:
1. Properly disassemble and assemble control valve according to Service
Manual procedure.
2. Inspect springs and spool valves and make recommendations for reusability.
3. Keep work area clean.
REFERENCE:
Service Manual
Lift Truck Video Tape 53 Single Speed Powershift
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
254
Demonstrate Adjusting LP Gas Carburetor
EQUIPMENT REQUIRED:
Lift Truck with LP Gas System
5P6585 Electrical Analyzer
0-30 PSI Gauge
PROCEDURE:
1. Check for LP gas leaks.
2. Adjust carburetor.
3. Follow guidelines in Service Manual.
REFERENCE:
Service Manual
Lift Truck Video Tape 1 - LP Gas Systems Components SEVV7001 ()
Lift Truck Video Tape 2 - LP Gas Systems Operation and Adjustment
SEVV7002 ()
Gas Industries - LP - Gas Carburetion Systems - CEBS0001
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
255
Demonstrate Adjusting Wheel Bearing Preload
EQUIPMENT REQUIRED:
Lift Truck
Torque Wrench
Wheel Bearing Grease Packer
PROCEDURE:
1. Properly pack wheel bearings with grease.
2. Properly adjust wheel bearing preload according to Service Manual.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
256
Demonstrate Removing and Installing Solid Tire from Wheel Assembly
EQUIPMENT REQUIRED:
Wheel Assembly
Tape Measure
Tire
Tire Press
PROCEDURE:
1. Properly press old tire from wheel assembly.
2. Use correct push plate and install new tire.
3. Make sure all items are straight and aligned correctly. Stop pressing if
a bind occurs, realign and continue to press.
REFERENCE:
Chicago Industrial Tire Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
257
Demonstrate Removal and Installation of Drive Wheels
EQUIPMENT REQUIRED:
2 - 5P3045 Jack Stand
1 - 5P4194 Wheel and Hub Dolly Lift Truck
PROCEDURE:
1. Properly block lift truck.
2. Properly remove and install drive wheels.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
258
Demonstrate Checking Park Brake Adjustment
EQUIPMENT REQUIRED:
Electric Lift Truck
PROCEDURE:
1. Check park brake adjustment according to service manual procedure.
2. Make necessary adjustments.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
259
Demonstrate Checking Cylinder for Wear
EQUIPMENT REQUIRED:
Engine
1P3537 Gauge Group
Hydraulic Cylinder
Inside Micrometer Set
PROCEDURE:
1. Check inside diameter and compare to specifications.
2. Check for out-of-roundness.
3. Make recommendation for reusability.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
260
Demonstrate Removal and Installation of Steering Axle Assembly
EQUIPMENT REQUIRED:
2 - FT1222 Wheel Stand
2 - 5P6215 Stand Group Lift Truck
PROCEDURE:
1. Properly block lift truck.
2. Remove and install steer axle assembly.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
261
Demonstrate Use of 6V3050 Gauge Set
EQUIPMENT REQUIRED:
Lift Truck with Roller Type Mast
6V3050 Gauge Set
6V3051 Adapter
PROCEDURE:
1. Properly demonstrate removal, check for proper shimming, and installation
of mast channels or carriage.
REFERENCE:
Service Manual
Lift Truck Video Tape 3 -Mast Testing and Adjusting SEVV7003 ()
L.T. Technical Bulletin May 7, 1980 Pages 2-4
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
262
Demonstrate Checking Lift Chain for Wear
EQUIPMENT REQUIRED:
Lift Truck
6V28 Chain Wear Gauge
PROCEDURE:
1. Check lift chain wear according to Service Manual procedure.
2. Make recommendation for reusability.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
263
Demonstrate Checking Lift Chain Adjustment
EQUIPMENT REQUIRED:
Lift Truck
PROCEDURE:
1. Check lift chain tension according to Service Manual procedure.
Make adjustments if necessary.
2. Check carriage height, adjust if necessary.
REFERENCE:
Service Manual
Lift Truck Video Tape 3 - Mast Testing and Adjusting SEVV7003 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
264
Demonstrate Removing and Installing Forks
EQUIPMENT REQUIRED:
Lift Truck With Forks
PROCEDURE:
Follow Procedure Outlined in the Service Manual
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
265
Demonstrate Removal and Installation of Counterweight
EQUIPMENT REQUIRED:
Lift Truck
Lift Truck with Adequate Capacity to Lift Counterweight or Overhead Crane
Lifting Eyes
Chains or Slings
PROCEDURE:
1. Remove or install counterweight.
2. Secure chain or sling to lift truck to keep counterweight from sliding off forks.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
266
Demonstrate Control Valve Card Adjustment
EQUIPMENT REQUIRED:
M-Series D STD and SA
PROCEDURE:
1. Follow Service Manual procedure.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
267
Demonstrate Straightening and Aligning a Beam by Heating
EQUIPMENT REQUIRED:
Bent Beam
OXY - Acetylene Torch Group
PROCEDURE:
1. Straighten and align beam by using heat only.
2. Follow all safety precautions.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
268
Demonstrate Checking Fuel System Supply Pressure
EQUIPMENT REQUIRED:
Gas or Diesel Engine
Pressure Gauge
PROCEDURE:
1. Check fuel system pressure according to Service Manual procedure.
2. State findings.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
269
Demonstrate Bleeding Air from Brake Fluid System
EQUIPMENT REQUIRED:
Lift Truck
PROCEDURE:
1. Check brake pedal adjustment.
2. Bleed air from system according to Service Manual procedure.
3. Adjust brake shoes if necessary.
REFERENCE:
Service Manual
Lift Truck Video Tape 40 - Troubleshooting Air Brakes SEVV7040 ()
Lift Truck Video Tape 54 - Mechanical Brake Adjustment SEVV7054 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
270
Demonstrate Installation of Valve Guide Liner.
EQUIPMENT REQUIRED:
1404 Engine Head
6V3107 Tool Kit
PROCEDURE:
2. Machine valve guide
3. Install liner.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
271
Demonstrate Changing LP Gas Tank
EQUIPMENT REQUIRED:
Lift Truck with LP Gas
PROCEDURE:
1. Change LP gas tank on lift truck according to Service Manual procedure.
REFERENCE
:
Service Manual
Lift Truck Video Tape 1 - LP Gas System Components SEVV7001 ()
Gas Industries - LP - Gas Carburetion Systems CEBS0001
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
272
Demonstrate Disassembly and Assembly of Impco LP Gas Converter
EQUIPMENT REQUIRED:
Impco LP Gas Converter
9S8138 Pressure Gauge
PROCEDURE:
1. Properly disassemble and assemble Impco converter according to
Service Manual procedure.
2. Test converter after assembly.
REFERENCE:
Service Manual
L.T. Video Tape 41 - Rebuild Impco Converter
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
273
Demonstrate Checking LP Gas Fuelock Valve
EQUIPMENT REQUIRED:
Electric Fuelock Valve
Vacuum Fuelock Valve
PROCEDURE:
1. Check electric Fuelock valve according to Service Manual procedure.
2. Check vacuum Fuelock valve according to Service Manual procedure.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
274
Demonstrate Checking Synchromesh Transmission Shifting Linkage
EQUIPMENT REQUIRED:
Lift Truck with Synchromesh Transmission
PROCEDURE:
1. Demonstrate properly checking synchromesh
transmission linkage according to Service
Manual procedure.
2. Adjust if necessary.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
275
Demonstrate Checking Oil Clutch Pressure
EQUIPMENT REQUIRED:
Lift Truck with oil clutch
9S8138 Pressure Gauge (0-30 PSI)
PROCEDURE:
1. Demonstrate properly checking oil clutch pressure according to
Service Manual procedure.
2. Analyze results and make recommendation for correction if needed.
REFERENCE:
Service Manual
Lift Truck Video Tape 17T - Oil Clutch Transmission
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
276
Demonstrate Breaker Point Ignition System Component Operation Checks
EQUIPMENT REQUIRED:
Lift Truck with Breaker Point Ignition System
Dwell Meter
Insulated Pliers
PROCEDURE:
1. Properly demonstrate breaker point ignition component operation checks
according to Service Manual procedure.
REFERENCE:
Service Manual
Lift Truck Video Tape 10 - Lift Truck Ignition System Breaker Points
SEVV7010 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
277
Demonstrate Breakerless Induction Ignition Component Operation Checks
EQUIPMENT REQUIRED:
Lift Truck with Breakerless Induction Ignition
6V3030 VOM or equivalent
Insulated Pliers
PROCEDURE:
1. Properly demonstrate breakerless induction ignition component operation
checks according to Service Manual procedure.
REFERENCE:
Service Manual
Lift Truck Video Tape 11 - Lift Truck Ignition System SEVV7011 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
278
Demonstrate Use of 5P6583 Compression Gauge
EQUIPMENT REQUIRED:
Lift Truck with LP or Gasoline Engine
5P6583 Compression Gauge
PROCEDURE:
1. Demonstrate a cylinder compression check according to Service Manual
procedure.
2. Analyze test results and make recommendations for correction if needed.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
279
Demonstrate Use of 19943 Hydraulic Hose Fitting Tool Kit
EQUIPMENT REQUIRED:
19943 Hydraulic Hose Fitting Tool Kit
Swivel Fitting
Hose (Size to Fit Swivel Fitting)
PROCEDURE:
1. Demonstrate properly making a hydraulic hose.
REFERENCE:
Service Manual
Installation Instructions for Reusable Fittings - Cascade - 5210
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
280
Demonstrate Seating Brushes on an Electric Motor
EQUIPMENT REQUIRED:
Electric Lift Truck Drive Motor
Calculator
6V2063 Brush Seater Stone
Ruler
343337 Brush Seater Stone
PROCEDURE:
1. Seat brushes according to Special Instruction procedure.
WARNING: When seating drive motor brushes, lift the front wheels of
the lift truck, and put wood blocks safely under the frame so the drive
wheels are free to turn.
2. Demonstrate projecting brush life.
REFERENCE:
Service Manual
Lift Truck Video Tape 51 - Brush Seating and Electric Motor P.M. SEVV7051 ()
Special Instructions - SMHS6589 and SMHS6605
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
281
Demonstrate Air Removal from Full Free or Full Free Triple Lift Cylinder
EQUIPMENT REQUIRED:
Lift Truck with Full Free or Full Free Triple Lift Cylinder
PROCEDURE:
1. Properly remove air from lift cylinder according to service manual
procedure.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
282
Demonstrate Checking the Pump or Drive Motor Overtemperature

Protection Circuits on L.D.C. or M and F Series D-SA Lift Truck
EQUIPMENT REQUIRED:
Lift Truck with L.D.C. Panel or M or F
Series D-SA Lift Truck
PROCEDURE:
1. Check the pump and drive overtemperature protection circuits according
2. Make any repairs if necessary.
3. Follow all safety precautions.
REFERENCE:
Service Manual
L.E.D. Troubleshooting EMS Panel
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
283
Demonstrate Use of 5P5263 Seal Installation Tool Group
EQUIPMENT REQUIRED:
5P5263 Seal Installation Tool Group
Hydraulic Cylinder with Teflon Seals on Piston
PROCEDURE:
1. Disassemble hydraulic cylinder.
2. Install seals according to Lift Truck Technical Bulletin procedure.
3. Assemble hydraulic cylinder.
REFERENCE:
Service Manual
Tool Guide
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
284
Demonstrate Checking Neutral Adjustment on Hydrostatic Transmission

Metering Valve Linkage
EQUIPMENT REQUIRED:
Hydrostatic Transmission Test Stand or lift truck with Hydrostatic Transmission
PROCEDURE:
1. Properly check neutral adjustment of the metering valve linkage according
REFERENCE:
Service Manual
Lift Truck Video Tape 31 - Hydrostatic Transmission Testing and Adjusting
SEVV7031 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
285
Demonstrate Neutral Adjustment of Servo Cylinders on Hydrostatic

Transmission
EQUIPMENT REQUIRED:
1P7389 Servo Cylinder Adjustment Tool
0-600 PSI Gauge
PROCEDURE:
1. Install correct pressure gauge.
2. Properly adjust servo control valve and servo cylinders according to
the Service Manual procedure under Neutral Adjustments.
REFERENCE:
Service Manual
Lift Truck Video Tape 31 - Hydrostatic Transmission Testing and Adjusting
SEVV7031 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
286
Demonstrate Checking Steering Axle Linkage Adjustment
EQUIPMENT REQUIRED:
Lift Truck
PROCEDURE:
1. Check steering axle stops and linkage according to Service Manual
procedure.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
287
Demonstrate Adjusting Gasoline Carburetor
EQUIPMENT REQUIRED:
Lift Truck Equipped with Gasoline Carburetor
5P6585 Electrical System
PROCEDURE:
1. Demonstrate adjusting gasoline carburetor according to Service
Manual procedure.
REFERENCE:
Service Manual
Lift Truck Video Tape 48 - Gasoline Carburetors and Governor
Adjustments SEVV7048 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
288
Demonstrate Voltage Test on Logics
EQUIPMENT REQUIRED:
Lift Truck with G.E., Sevcon, or TMC panel
VOM
Adequate Personnel
PROCEDURE:
1. Install correct tooling. WARNING: Lift the front of the lift truck, and put
wood blocks safely under the frame so the drive wheels are free to turn.
Disconnect the battery and discharge capacitor.
2. Conduct test according to Service Manual or STMG procedure.
3. Analyze test results and make recommendations for correction if needed.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
289
Demonstrate Use of 5P4800 Swagging Tools for Thermoplastic

Hydraulic Hose
EQUIPMENT REQUIRED:
5P4800 Swagging Tool Group
Thermoplastic Hose
Coupling
PROCEDURE:
1. Properly demonstrate making thermoplastic hose assembly according
to Special Instructions procedure.
REFERENCE:
L.T. Video Tape 27 - Thermoplastic Hydraulic Hose for Lift Truck
SEVV7027 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
290
Demonstrate Checking Adjustment of Accelerator Box Used with G.E. Panels
EQUIPMENT REQUIRED:
Lift Truck with G.E. panel
VOM (Analog type easier)
PROCEDURE:
1. Properly check accelerator potentiometer according to service manual
procedure. WARNING Disconnect the battery and discharge IC capacitor.
2. Check accelerator box for proper operation of accelerator switch, !A switch,
and potentiometer (especially after removing, repairing, and installing
accelerator potentiometer box.)
3. Adjust accelerator linkage if necessary.
REFERENCE:
Service manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
291
Demonstrate Use of the 4C5084 Filter Cutter Tool
EQUIPMENT REQUIRED:
4C5084 Filter Cutter Tool
Used Filters (spin on type)
PROCEDURE:
Using the Filter Cutter Tool Cut Open the Filter and Examine Filter
Media for Debris
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
292
Demonstrate Wheel Angle Sensor Operation
EQUIPMENT REQUIRED:
F25 or F35 Lift Truck
PROCEDURE:
1. Raise drive wheels off floor so wheels are free to turn.
2. Drive lift truck as described in Service Manual.
3. Note any differences.
REFERENCE:
Service Manual
Monitor - CEKL0209
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
293
Demonstrate Checking a Zener Diode
EQUIPMENT REQUIRED:
Zener Diode
Load Voltage Tester
VOM
PROCEDURE:
1. Attach multimeter and record values in ohms in both directions.
2. Attach load tester and check for correct amount of leakage through zener.
3. Determine zener diode condition.
REFERENCE:
Service Manual (M30B thru M100B)
Flight system tester instructions
LTTB March 1982
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
294
Demonstrate Checking an NPN Power Transistor
EQUIPMENT REQUIRED:
NPN Transistor
Load Voltage Tester
VOM
Test Light
PROCEDURE:
1. Follow service manual procedure to check T.R.N. for shorted or open
circuits.
2. Use test light to verify correct T.R.N. operation.
3. Attach load voltage tester to T.R.N. to check for excessive leakage.
REFERENCE:
Service Manual
Flight system tester instructions.
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
295
Demonstrate Checking Surface Temperatures
EQUIPMENT REQUIRED:
Lift Truck
8T2844 Recorder Group
PROCEDURE:
1. Attach appropriate temperature range recorders to several lift truck
components.
2. Operate truck until it reaches operating temperature.
3. Check temperature recorders to verify that they are monitoring component
surface temperature.
REFERENCE:
LTTB - 85-02-01 Page 2
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
296
Demonstrate Use of Lubrication and Maintenance Guide
EQUIPMENT REQUIRED:
Service Manual
PROCEDURE:
1.
2.
3.
4.
Locate engine oil type and change recommendations.

Locate transmission oil type and change recommendations.
Locate procedure for removing and installing LP fuel tanks.
REFERENCE:
Service Manual
Lift Truck Video Tape 26 How to Use Lift Truck Service Manual
SEVV7026 ()
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
297
Demonstrate Adjusting Velocity Governor
EQUIPMENT REQUIRED:
Lift Truck - with XNIP liter gas engine
PROCEDURE:
1. Follow Service Manual procedure. Make all three adjustments to governor.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
298
Demonstrate Piston to Liner and Piston to Piston Pin Matching
EQUIPMENT REQUIRED:
2.0 liter engine parts
PROCEDURE:
1. Follow Service Manual procedure using charts provided to match
piston pin to piston and cylinder liner to piston.
REFERENCE
Service Manual
Parts Book
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
299
Demonstrate Parking Brake Adjustment on T-V 50D Lift Truck
EQUIPMENT REQUIRED:
Lift Truck
PROCEDURE:
1. Follow service manual procedure.
2. Make any needed adjustments.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
300
Demonstrate Using 8T900 Clamp-on Ammeter
EQUIPMENT REQUIRED:
8T900 Ammeter
6V3030 VOM
Lift Truck
PROCEDURE:
1. Attach ammeter to circuit being tested. Zero meter.
2. Operate circuit. Observe amp reading.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
301
Demonstrate Driver Board Test on a T.M.C. Panel
EQUIPMENT REQUIRED:
F30, M-F Series D STD or SA
VOM
PROCEDURE:
1. Follow Service Manual procedure for driver board that is being tested.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
302
Demonstrate Logics Potentiometer Adjustments
EQUIPMENT REQUIRED:
Any Caterpillar Electric Lift Truck
VOM
Ammeter
Current Limit Button
PROCEDURE:
1. Install correct tooling. WARNING: Lift the front wheels of the lift truck,
use wood blocks under mast so the drive wheels are free to turn.
2. Conduct all logics potentiometer adjustments according to Service Manual
procedure for lift truck being tested.
REFERENCE:
Service Manual
LTTB March 1987 Page 2 - New Electrical Control Panel
LTTB 84-03-01 Current Limit Button
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
303
Demonstrate Hydrostatic Transmission Field Test
EQUIPMENT REQUIRED:
Lift Truck Equipped with Hydrostatic Transmission
PROCEDURE:
2. Analyze test results and make recommendation for further testing if
necessary.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
304
Demonstrate Installing Timing Chain and Tightener on an XD3P Engine
EQUIPMENT REQUIRED:
XD3P Engine
PROCEDURE:
1. Install timing chain and idler gear assembly as written in Service Manual.
2. Install timing chain, tensioner and adjust as needed.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
305
Demonstrate Checking and Adjusting Inching Pedal Adjustment
EQUIPMENT REQUIRED:
T-V50D Lift Truck
PROCEDURE:
1. Follow Service Manual procedure.
2. Make any needed adjustments.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
306
Demonstrate Setting XD3P Oil Pump Drive Clearance
EQUIPMENT REQUIRED:
XD3P Engine
Feeler Gauge
Torque Wrench
PROCEDURE:
2. Make any adjustments if needed.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
307
Demonstrate Self and Run Time Diagnostics
EQUIPMENT REQUIRED:
F30, M50D STD or M50DSA
7/16 Wrench
PROCEDURE:
1. For self diagnostics follow Service Manual procedure.
2. Run diagnostics. Occurs during normal lift truck operation.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
308
Demonstrate Instrument Panel Test
EQUIPMENT REQUIRED:
Lift Truck Equipped with 918566 or 908131 instrument panel
FT1830 Test Harness
PROCEDURE:
1. Test 918566 instrument panels with FT1830 test harness.
2. Test 908131 instrument panels, follow procedure in service manual.
REFERENCE:
Service Manual
LTTB December, 1984
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
309
Demonstrate Proper Adjustments of Spool Limiters
EQUIPMENT REQUIRED:
Late Model M20 - MC30 Lift Truck
5P969 Ammeter Group or 5P300 Electrical Tester
0-3,000 PSI Gauge or Tetragauge
PROCEDURE:
2. Check spool limiters according to Service Manual procedure.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
310
Demonstrate Integral Breakerless Induction Ignition Component Operation

Checks
EQUIPMENT REQUIRED:
Lift Truck with 1404 Engine
6V3030 VOM or Equivalent
PROCEDURE:
1. Properly demonstrate integral breakerless induction ignition component
operation checks according to service manual procedure.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
311
Demonstrate Analyzing Engine Vibration
EQUIPMENT REQUIRED:
Vibration selector
Engine with vibration
PROCEDURE:
1. Demonstrate the order of a vibration.
2. Demonstrate cause of vibration.
REFERENCE:
Operation Manual for vibration selector
Special Instruction - SEHS7914 - Troubleshooting Engine Vibration in Vehicular
Equipment
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
312
Demonstrate Removal and Installation of Cylinder Pack
EQUIPMENT REQUIRED:
8T0812 or 6V9448
1U6317 Bridge
1U6319 Socket
PROCEDURE:
1. Remove and install cylinder liner, piston, and rod assembly in engine.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
313
Demonstrate Checking Electrical Relay Operation
EQUIPMENT REQUIRED:
Digital Multimeter
Machine with Relay
PROCEDURE:
1. Follow procedure in reference and check relay.
REFERENCE:
L.T. Technical Bulletin - Aug. 1988
Service Magazine - Aug. 29, 1988
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
314
Demonstrate Testing the Starter on the Engine
EQUIPMENT REQUIRED:
Digital Multimeter
8T0900 Clamp-on Ammeter
PROCEDURE:
1. Follow procedure in Service Magazine.
REFERENCE:
Service Magazine - May 28, 1990
Engine News - June 1990
Special Instructions - SEHS8420 and SEHS7734
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
315
Demonstrate Testing Alternator/Generator Output on the Engine
EQUIPMENT REQUIRED:
Digital Multimeter
8T0900 AC/DC Clamp-on Ammeter
PROCEDURE:
1. Follow procedure in Service Magazine.
REFERENCE:
Service Magazine Video Tape - Testing the Alternator - SEVC1592
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
316
Demonstrate Engine Alignment with Driven Equipment
EQUIPMENT REQUIRED:
Engine
Generator, pump, etc.
PROCEDURE:
Follow Procedure Outlined In the Special Instructions and Service Manual
REFERENCE:
Service Manual
Special Instructions - SEHS7654, SEHS7073 and SEHS7456
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
317
Demonstrate Determining Surface Finishes
EQUIPMENT REQUIRED:
Surface Comparator 6V6116
PROCEDURE:
Use thumbnail.
REFERENCE:
Guidelines to Reusable Parts - SEBF8041
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
318
Demonstrate Proficiency in Using Caterpillar Applied Failure Analysis

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

Small Magnet
Failed Engine Components
PROCEDURE:
1. Follow the eight steps of Applied Failure Analysis
REFERENCE:
Applied Failure Analysis Course (Engine) Course Notes
Applied Failure Analysis Reference Books - SEBV0544, SEBV0554, SEBV0567
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
319
Demonstrate Proficiency in Using Caterpillar Applied Failure Analysis

(Drive and Hydraulic Components)
EQUIPMENT REQUIRED:
8S2257 Loupe
Small Pick (Seal Pick)
Microscope (Stereo Zoom)
Small Magnet
Bristle Brush and Fast Drying Solvent
Failed Hydraulic and Drive-train Components
PROCEDURE:
1. Follow the eight steps of Applied Failure Analysis as outlined in
the Applied Failure Analysis Course.
REFERENCE:
Applied Failure Analysis Course Notes (Drive and Hydraulic Components.
Applied Failure Analysis Books - SEBV0545, SEBV0547, SEBV0549,
SEBV0552, SEBV0554, SEBV0561, SEBV0662, SEBV0563, SEBV0565,
SEBV0567
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
320
Demonstrate Proficiency in Conducting a Machine Condition Appraisal Report

(Certified Rebuild)
EQUIPMENT REQUIRED:
Filter Cutter
Extension Magnet
CTB Kit and Handbook
Hand Tools
Oil Sample Kit
Parts Book
Borescope Inspection Group 6V7000
Product Update Record
Update and Service Magazine References
Replacement Filters for Power Train, Engine and Hydraulics
PROCEDURE:
1. Follow the certified rebuild appraisal procedure guide.
REFERENCE:
Track -Type Tractor PEEP5212
Track-Type Tractor D8L, D9L and D10 PEEP6209
Wheel Type Loaders PEEP7221
Off Highway Truck & Tractors PEE7229
Motor Grader PEEP8201
Wheel Tractor Scraper PEEP9211
Track Type Loaders PEEP7201
S.I.S. or S.I.R.S. and FIND for the latest updates
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
321
Demonstrate Proficiency in Performance Evaluation of "E" Series Excavator

(Advance Variable Flow Hydraulics, Microcomputer Controls and Machine
Specs)
EQUIPMENT REQUIRED:
Portable Hydraulic Tester - 1U9551
Photo Pickup - 6V3136
Digital Multimeter - 6V7800
Set Point Indicator - 6V4060
Calculator (Battery Powered)
Appropriate Gauges
Multitach - 6V2100
Cable - 6V2198
PROCEDURE:
1. Follow procedure outline in the appropriate
Excavator Adjustment and Performance Test.
REFERENCE:
Service Manual
Updates and Service Magazine Reference
Product Update Record
Excavator Performance Handbook - SEBF8292-02
"E" Series Excavator Course
Caterpillar Performance Handbook - SEBD0330
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
322
Demonstrate Proper Hazardous Waste Handling and Storage

Methods
EQUIPMENT REQUIRED:
none
PROCEDURE:
1.
Correctly describe the main types of chemical waste originating from Darr
locations. (Waste oil, waste antifreeze, waste solvent, waste caustic,
contaminated water, contaminated fuel).
2.
Describe the correct locations for storage for each waste stream.
a. Waste oil: Waste oil storage tank
b. Waste antifreeze: Waste antifreeze tank or designated storage drum.
c. Waste solvent: Safe-T-Klean vat drums.
d. Waste caustic: Caustic tanks
e. Contaminated water: Through grease sump in steam cleaning area.
f. Contaminated fuel: In designated waste fuel storage drum
3.
Describe the location of each of the storage areas.
4.
Demonstrate knowledge of correct method for storing waste liquids
in each area.
5.
Explain reasons for keeping waste streams separate.
6.
Describe procedures for chemical spill containment.
a. Control: Eliminate the source of the spill, if possible.
b. Contain: Use oil-sorb, "kitty litter", booms or dikes.
c. Communicate: Notify supervisor and proper authorities if needed.
d. Cordon: Keep others out of the spill area.
e. Clean: Remove spill & containment materials to proper receptacle (drum,
dumpster, etc.).
7.
Describe locations of spill containment/clean-up equipment & supplies.
REFERENCE:
Service Manual

_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
323
Demonstrate Handling and Storage of Flammable Painting Related Materials
EQUIPMENT REQUIRED:
UL-approved flammable material storage locker
Assorted cans of open paint (1 gallon)
Assorted cans of thinner, reducer (1 quart)
Assorted oily or solvent contaminated rags
Transistor radio or other electrical appliance
PROCEDURE:
1.
2.
3.
4.
5.
6.
6.
Observe "No Smoking" regulations in paint area, remove radio/appliance

from work area.
Properly close all paint cans.
Properly close all other flammable material containers.
Store all paint and flammable containers in storage lockers.
Close and secure locker door.
Place oily/solvent rags in approved fire-retardant container.
Deposit paint waste/spent cleaning liquids in liquid waste material
containers.
REFERENCE:
Service Manual
Uniform Fire Code
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
324
Demonstrate Use and Care of Respiratory Protection Equipment
EQUIPMENT REQUIRED:
Half-face respirator (3M/North or equivalent) Vapor cartridges and retainer
assemblies
PROCEDURE:
1.
2.
3.
Proper fit and seal check.

a.
Install cartridges with retainers properly.
b.
Properly place respirator on face.
c.
Adjust head and neck straps to snugness.
d.
Place palms of hands over both cartridges.
e.
Inhale sharply - no air should get past face seal of mask or through
exhaust valve.
f.
Place heel of hand on exhaust valve.
g.
Exhale sharply - no air should pass through or around cartridges. Air may
"burp" past face seal.
h.
Mask is now properly fitted and sealed.
Cleaning and care of respirator.
a.
Remove mask and remove cartridges and retainers.
b.
Inspect interior gasket of cartridges for wear or breaks in gasket.
c.
Check for presence of rubber diaphragms in both cartridge airways.
Inspect for wear/tear.
d.
Unsnap exhaust valve retainer cap.
e.
Inspect exhaust diaphragm for wear/tear.
f.
With cartridges removed, wash interior of respirator with warm soapy
water while checking face seal for tears. Area inside face seal should be
thoroughly cleaned as well.
g.
Dry interior of respirator with clean dry cloth.
h.
Store respirator in airtight container or bag.
Replacement of filter cartridges.
a.
Anytime seal gasket is worn or torn, or
b.
Anytime the odor of paint or hazardous material can be smelled while the
respirator is properly being worn, or
c.
Every 30 days, whichever comes first.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
325
Demonstrate Fire Safety
EQUIPMENT REQUIRED:
Two properly mounted and inspected A-B-C 10 lb. fire extinguishers
PROCEDURE:
ALL TECHNICIANS:
1.
Correctly identify exits from areas.
2.
Correctly identify areas of flammable storage (this will include products as
well as waste liquids).
3.
Demonstrate location and simulated use of fire extinguishers as identified
on extinguisher use label.
4.
Identify types of fires on which extinguishers may be used.
5.
Identify situations in which an extinguisher should be used and those in
which it should not.
6.
Identify proper storage areas for oily/solvent soaked rags.
PAINTERS ONLY:
1.
Describe what is meant by "explosion-proof fixture". Describe the types of
equipment found in paint areas which are explosion proof, and those which
are not and are prohibited.
2.
Identify ways to protect extinguishers and sprinkler heads from paint
overspray.
REFERENCE:
Safety Manual (Darr Equipment Co. Technicians Safety and Environmental
Handbook Section 6 page 44-46)
Uniform Fire Code
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
326
Demonstrate Proper Preparation of Surfaces for Painting
EQUIPMENT REQUIRED:
Spray Gun
Piece of Painted Metal
Piece of Unpainted Metal
PROCEDURE:
1. Prepare painted surface for final painting.
2. Prepare unpainted metal for final painting.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
327
Demonstrate Proper Cleaning of Painting Equipment
EQUIPMENT REQUIRED:
Spray Gun
Wrenches
Cleaner
PROCEDURE:
1. Disassembly and assembly of spray gun.
2. Demonstrate proper method of cleaning spray gun components.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
328
Demonstrate Correctly Mixing of Paint for Spraying
EQUIPMENT REQUIRED:
Shaker
Paint
Thinner
PROCEDURE:
1. Demonstrate mixing paint and thinner for best spray pattern and
paint coverage.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
TITLE:
Demonstrate Correct Painting Technique to Get Best Results
EQUIPMENT REQUIRED:
Painting Equipment
Machine
PROCEDURE:
1. Demonstrate painting a machine with least amount over
spray and runs.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
330
Demonstrate Testing an Electric Lift Truck Drive Motor with Motor Installed
in the Truck
EQUIPMENT REQUIRED:
Electric Lift Truck
Hand Tools
Battery Charger
PROCEDURE:
1. Using the wiring diagram from the Service Manual, by pass the SCR
control and run test the drive motor using the battery charger.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
331
Demonstrate Bench Testing an Electric Lift Truck Drive Motor
EQUIPMENT REQUIRED:
Drive Motor
Hand Tools
Battery Charger
Cables
PROCEDURE:
1. Using the wiring diagram from the Service Manual, connect cables to
motor, run test motor using the battery cables.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
332
Demonstrate Adjusting the SCR Control Functions Using The General Electric
LX Handset
EQUIPMENT REQUIRED:
General Electric LX Handset
General Electric EV100/200LX SCR control.
PROCEDURE:
1. Follow the instruction in the General Electric LX Handset instructions, and
program the EX100/200LX card functions.
REFERENCE:
Service Manual
General Electric LX Handset instructions
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
333
Demonstrate Monitoring Systems Fault Codes Using the General Electric LX

Handset
EQUIPMENT REQUIRED:
General Electric LX Handset
General Electric Ev100/200LX SCR control
PROCEDURE:
1. Follow the instructions in the General Electric LX handset instructions.
REFERENCE:
Service Manual
General Electric LX handset instructions
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
334
Demonstrate Checking Pressures on Transaxle
EQUIPMENT REQUIRED:
T50D or V50D Lift Truck
6V7835 Transmission Test Group
PROCEDURE:
1. Follow the instructions in the service manual and record your findings on
worksheet # 30 and attach to this form.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
335
Demonstrate Making Bevel Gear and Pinion Adjustments on T50D or V50D

Transaxle
EQUIPMENT REQUIRED:
FT1923 Spanner Wrench
8T3217 Gauge Block
Transaxle
Hand Tools
PROCEDURE:
1. Follow the instructions in the service manual.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
336
Demonstrate Calculating Rated Lifting Capacity with Crane in Different

Configurations
EQUIPMENT REQUIRED:
Crane Load Rating Information
PROCEDURE:
1.
2.
Determine load, which can be supported in each quadrant.

Calculate load capacity relative to boom length, boom radius, use
of out riggers.
REFERENCE:
Crane Manufactures Load Rating Information
Mobile Crane Manual, Construction Safety Association of Ontario www.csao.org
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
337
Demonstrate Hoist Hand Signals
EQUIPMENT REQUIRED:
None
PROCEDURE:
1. Demonstrate least 15 hand signals relative to crane operation.
REFERENCE
:
Mobile Crane Manual, Construction Safety Association of Ontario
http://www.csao.org
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
338
Demonstrate Wire Rope Inspection
EQUIPMENT REQUIRED:
Wire Rope with Various Defects
PROCEDURE:
1.
Inspect wire rope for:

a.
Broken wires.
b.
Worn or abraded wires.
c.
Reduction in rope diameter.
d.
Rope stretch.
e.
Corrosion.
f.
Insufficient lubrication.
g.
Crushed, flattened or jammed strands
h.
High stranding and unlaying.
i.
Bird caging.
j.
Kinks.
k.
Bulges in rope.
l.
Gaps or excessive clearance between strands.
m.
Core protrusion.
n.
Heat damage, torch burns, and electric Arc strokes.
o.
Corroded, cracked, bent, worn and improperly applied end
connections.
REFERENCE:
Mobile Crane Manual, Construction Safety Association of Ontario www.csao.org
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
339
Demonstrate Testing and Adjusting A Piston Pump and Relief Valve on

Transmission Test Stand
EQUIPMENT REQUIRED:
Test Stand
Piston Pump
Relief Valve
PROCEDURE:
1.
2.
Demonstrate connecting components to transmission test stand.

Perform necessary test and adjustments to assure component is operating
correctly.
REFERENCE:
Transmission Test Stand Manual
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
340
Demonstrate Reconditioning of Hydraulic Control Valves and Tank
EQUIPMENT REQUIRED:
Hydraulic Control Valve
Pilot Control Valve
PROCEDURE:
1. Disassemble and assemble valve according to procedure in Service Manual.
2. Evaluate parts for reusability.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
341
Demonstrate Removal and Installation of Valve Guides and Valve Seat Inserts
EQUIPMENT REQUIRED:
Cylinder head stand
Valve seat cutting tool
Valve guide press stand
Cylinder head
PROCEDURE:
1. Press out and install valve guide.
2. Remove and install valve seat.
3. Cut head for valve seat installation.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
342
Demonstrate Testing and Adjusting a 7 or 8-Speed Powershift

Transmission on the Test Stand
EQUIPMENT REQUIRED:
7 or 8-Speed Powershift Transmission (not an ICM)
PROCEDURE:
1.
2.
Demonstrate connecting transmission to test stand.

Perform test and adjust to specifications as outlined in transmission
test stand manual.
REFERENCE:
Service Manual
Transmission Test Stand Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
343
Demonstrate Servicing Orifice Tube in Air Conditioning System
EQUIPMENT REQUIRED:
Machine with orifice tube system
PROCEDURE:
1. Connect gauges.
2. Determine system performance. Add R-12 if necessary.
3. Replace orifice tube.
REFERENCE:
Service Manual
Air Conditioning & Heating Service Manual SENR3334
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
344
Demonstrate Air Conditioning System Evacuation and Leak Detection.
EQUIPMENT REQUIRED:
Vacuum Pump
Electronic Leak Detector
PROCEDURE:
1.
2.
3.
4.
Purge system.
Evacuate system.
Vapor change system
Check for leaks.
REFERENCE:
Service Manual
Electronic Leak Detector SMHS8160 or SMHS7218
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
345
Demonstrate Replacing Air Conditioner Receiver Drier without Discharging Air

Conditioning System.
EQUIPMENT REQUIRED:
Machine with quick disconnects on receiver drier.
PROCEDURE:
1. Following service manual directions, pump R-12 from old receiver drier to
new receiver drier and attach now unit.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
346
Demonstrate Measuring Cushion Hitch Bearing Clearances
EQUIPMENT REQUIRED:
Dial Indicator or Electronic Position Indicator
Magnetic Base
Tractor Scraper with Cushion Hitch
PROCEDURE:
1. Measure and record clearances at the following locations.
a. Front pin in bottom H-link on either side.
b. Rear pin in top H-link on either side.
c. Vertical pin bores for top and bottom pins.
d. Front and rear horizontal hitch pins.
2. Record your findings on work sheet # 31 and attach it to this form.
REFERENCE:
Service Magazine
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
347
Demonstrate Judging Weld Quality Visually
EQUIPMENT REQUIRED:
Defect weld samples.
Weld Comparison Replica
PROCEDURE:
1. Identify weld defects type and label them.
2. Determine if a weld sample is or is not acceptable.
REFERENCE:
Caterpillar Educational Products
4052 Participant Wookbook
4053 Weld Example Set (30 Pcs.)
4054 Weld Comparison Replica
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
348
Demonstrate Failure Analysis of Failed Welds
EQUIPMENT REQUIRED:
Failed welds
Models
Visual Aids (photographs)
PROCEDURE:
1. Determine cause of failure and report.
REFERENCE:
Metals Handbook Volume 11, American Society for Metals
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
349
Demonstrate Welding Aluminum by Stick Welding and Oxy-Acetylene
EQUIPMENT REQUIRED:
Arc Welding Machine
Oxy-Acetylene Torch
Aluminum Welding Rods
PROCEDURE:
1. Weld aluminum using both gas welding and arch welding techniques.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
350
Demonstrate Salvage Weld Procedure for Cast Iron Cylinder Blocks
EQUIPMENT REQUIRED:
Standard Welding Equipment
PROCEDURE:
1. Prepare and weld a fractured cast iron cylinder block or similar
component, following procedures in reference material.
REFERENCE:
Salvage Weld Procedure for Cast Iron Cylinder Blocks SEHS8919
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
351
Demonstrate Proficiency Using a Bore Scope
EQUIPMENT REQUIRED:
Bore Scope
Diesel Engine
PROCEDURE:
1. Remove fuel injection nozzle.
2. Inspect cylinder walls, valves etc., without disassembling engine.
REFERENCE:
Operating Manual - NEHS0504
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
352
Demonstrate Checking Camber on a Caterpillar Motor Grader
EQUIPMENT REQUIRED:
Motor Grader
Plumb Bob
Ruler
PROCEDURE:
1. Follow the procedures listed in the Service Magazine.
REFERENCE:
Service Manual
Service Magazine June 25, 1990
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
TITLE:
Demonstrate Proficiency in Using Engine Dynamometer
EQUIPMENT REQUIRED:
Engine
Engine Dynamometer
PROCEDURE:
1. Hook up engine.
2. Run engine using Caterpillar guidelines for dynamometer testing.
3. Record your findings on work sheet # 32 and attach to this form.
REFERENCE:
Special Instructions - GEGO1024 and SEHS7461
OT Fuel Specifications Microfiche - SEHS7357
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
354
Demonstrate Proficiency in Conducting and Evaluating Cats Diesel

Performance Analysis Report (Par Test)
EQUIPMENT REQUIRED:
Truck equipped with a Caterpillar Diesel Engine
Truck chassis Dynamometer
Hewlett-Packard model HP- 41 series calculator system or Super-Flow Unit
with Personal computer-control.
Personal Safety Equipment (Safety glass, ear plugs, and safety shoes)
PROCEDURE:
1. Install truck on chassis dynamometer using proper safety procedures and
equipment
2. Perform performance analysis test (PAR) in accordance with Caterpillar
recommended procedures, either manual or computer-controlled chassis
dynamometer.
3. Record you finding on PAR test and attach to this form.
REFERENCE:
OT Fuel Specifications
Hewlett-Packard series calculator system
1. Special instruction SEHS8025
2. Cat Diesel Performance Analysis Report (PAR) LEDT6099
Super-Flow computer-controlled
1. Caterpillar PAR test compute program with instruction
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
355
Demonstrate 7X1200 EUI Timing Adapter Group on 3176 Engine
EQUIPMENT REQUIRED:
8T8697 Electronic Control Analyzer Programmer (ECAP)
7X1200 EUI Timing Adapter Group
PROCEDURE:
1. Following instructions in Service Manual, calibrate electronic injection timing.
REFERENCE:
3176 Service Manual
Special Instruction - SEHS8824 and SEHS8742
Operating Manual for 7X2000 SPM - NEHS0518
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
356
Demonstrate Measuring and Adjusting Fuel Setting, Injector Timing and

Injector Synchronization on 1.1 Liter Engine
EQUIPMENT REQUIRED:
1U6680 Governor and Fuel System Adjusting
Tool Group
PROCEDURE:
1. Follow the steps in the "Systems Operation Testing and Adjusting"
section of the Shop Manual to make these adjustments.
REFERENCE:
Service Manual
OT Fuel Specifications Microfiche
Video Tape 574 1.1 Fuel System Orientation (LEVN1574)
Video Tape 575 1.1 Fuel System Orientation (LEVN1575)
Video Tape 577 1.1 Fuel Timing and Specification (LEVN1577)
Video Tape 578 1.1 Fuel Setting (LEVN1578)
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
357
Demonstrate Testing and Adjusting ICM Powershift Transmission on a

EQUIPMENT REQUIRED:
ICM Transmission
1U7446 Transmission Shift Analyzer Group
PROCEDURE:
1. Determine if transmission will shift correctly.
2. Measure and analyze pressures.
3. Make appropriate adjustments.
REFERENCE:
Service Manual
Service Instruction - SEHS7918
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
358
Demonstrate Proficiency Using Whole Numbers
EQUIPMENT REQUIRED:
Pencil and paper
PROCEDURE:
Study material and take test, score at least 80%
REFERENCE:
TPC Training System, Unit 103 "Using Mathematics in the Plant, "Lesson One".
Order 1-800-837-8872 Ext. 4060 USA or www.tpctraining.com
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
359
Demonstrate Proficiency Using Common Fractions
EQUIPMENT REQUIRED:
Pencil and paper
PROCEDURE:
1. Study material and take test. Score at least 80%
REFERENCE:
TPC Training System, Unit 103 "Using Mathematics in the Plant, "Lesson Two".
1-800-837-8872 Ext. 4060 USA or www.tpctraining.com
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
360
Demonstrate Proficiency Using Decimal Fractions
EQUIPMENT REQUIRED:
Pencil and paper
PROCEDURE:
1. Study material and take test. Score at least 80%.
REFERENCE:
TPC Training System, Unit 103 "Using Mathematics in the Plant," Lesson Three.
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
361
Demonstrate Proficiency Using Ratios and Proportions
EQUIPMENT REQUIRED:
Pencil and Paper
Calculator (optional)
PROCEDURE:
REFERENCE:
TPC Training Systems, Unit 103 Using Mathematics in the Plant Lesson Four.
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
362
Demonstrate Proficiency Using Simple Geometric Principles
EQUIPMENT REQUIRED:
Pencil and Paper
Straight Edge
Compass
PROCEDURE:
REFERENCE:
TPC Training Systems, Unit 103 Using Mathematics in the Plant, Lesson Seven
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
363
Demonstrate Proficiency Using Simple Algebra
EQUIPMENT REQUIRED:
Pencil and Paper
PROCEDURE:
REFERENCE:
TPC Training System, Unit 103 Using Mathematics in the Plant, Lesson eight.
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
364
Demonstrate Proficiency Using Formulas
EQUIPMENT REQUIRED:
Pencil and paper
PROCEDURE:
REFERENCE:
TPC Training System, Unit 103 "Using Mathematics in the Plant," Lesson Nine.
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
365
Demonstrate Proficiency by Completing Applied Electricity Course
EQUIPMENT REQUIRED:
VCR
Six video tapes
PROCEDURE:
1.
2.
3.
4.
Watch video tapes.

Read Manual.
Work problems.
Take test. Must score 90% or better.
REFERENCE:
A Study Guide to Applied Electricity - Tel-Train
(Out side of Darr) www.Telatrain.com or 1-800-251-6018 USA
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
366
Instruct Visual Inspection of Welds to Those Technicians Who Need Skill #347.
EQUIPMENT REQUIRED:
Defective Weld Samples
Weld Comparison Replica
PROCEDURE:
1. Instruct types of weld defects, causes of these defects, and how to
correct or avoid.
REFERENCE:
Caterpillar Education Products
4051 Instructor Guide
4052 Participant Work Book
4053 Weld Example Set (32 pcs.)
4054 Weld Comparison Replica
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
367
Instruct Hoist Hand Signals to Those Technicians Who Need Skill #337.
EQUIPMENT REQUIRED:
Visual aids
PROCEDURE:
1. Instruct Technicians who need skill #337 the proper communication
procedures between crane operator and assisting personnel.
REFERENCE:
For information out side of Darr www.csao.org
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
368
Instruct Wire Rope Inspection to Those Technicians Who Need Skill #338.
EQUIPMENT REQUIRED:
Wire rope with different defects
PROCEDURE:
1. Instruct other Technicians who need Skill #338 the proper inspection
of wire rope or cable.
REFERENCE:
For information out side of Darr http://www.csao.org
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
369
TITLE: Instruct Fire Safety to Those Technicians Who Need Skill #325
EQUIPMENT REQUIRED:
Two properly mounted and inspected A-B-C 10 lb. Fire Extinguishers
PROCEDURE:
1. Describe what is meant by "explosion-proof fixture". Describe the types of
equipment found in paint areas which are explosion proof and those which
are and are not prohibited.
2. Correctly identify exits from any work area.
3. Correctly identify areas of flammable storage (this will include products as
well as waste liquids).
4. Demonstrate location and simulated use of fire extinguishers as identified on
extinguisher use label.
5. Identify types of fires on which extinguishers may be used. (on label of
extinguisher)
4. Identify situations in which an extinguisher should or should not be used. (only
In incipient (beginning) stage of fire
7. Identify proper storage areas for oily/solvent soaked rags.
8. Identify ways to protect extinguishers and sprinkler heads for paint overspray.
9. Properly explain how to summon emergency fire response to work area.
10. Indicate proper storage areas and locations for flammable materials in work
area (paint cabinets, acetylene, LP-gas, etc.)
11.
Correctly identify no smoking areas in work place. Explain why these
areas are
designated as no smoking areas.
REFERENCE:
Safety Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
370
Instruct Use and Care of Respiratory Protection Equipment to Those

Technicians Who Need Skill #324.
EQUIPMENT REQUIRED:
Half-face respirator (3M/North or equivalent)
Vapor cartridges and retainer assemblies
PROCEDURE:
1. Proper fit and seal check.
a. Install cartridges with retainers properly.
b. Properly place respirator on face.
c. Adjust head and neck straps to snugness.
d. Place palms of hands over both cartridges.
e. Inhale sharply - no air should get past face seal of mask or through exhaust
valve.
f. Place heel of hand on exhaust valve.
g. Exhale sharply - no air should pass through or around cartridges. Air may
"burp" past face seal.
h. Mask is now properly fitted and sealed.
2. Cleaning and care of respirator.
a. Remove mask and remove cartridges and retainers.
b. Inspect interior gasket of cartridges for wear or breaks in gasket.
c. Check for presence of rubber diaphragms in both cartridge airways. Inspect
for wear/tear.
d. Unsnap exhaust valve retainer cap.
e. Inspect exhaust diaphragm for wear/tear.
f. With cartridges removed, wash interior of respirator with warm soapy water
while checking face seal for tears. Area inside face seal should be
thoroughly cleaned as well.
g. Dry interior of respirator with clean dry cloth.
h. Store respirator in airtight container or bag.
3. Replacement of filter cartridges.
a. Anytime seal gasket is worn or torn, or
b. Anytime the odor of paint or hazardous material can be smelled while the
respirator is properly being worn, or
c. Every 30 days, whichever comes first.
REFERENCE:
Safety Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
371
Instruct Handling and Storage of Flammable Painting Related Materials

to Those Technicians Who Need Skill #323.
EQUIPMENT REQUIRED:
UL-approved flammable material storage locker
Assorted cans of open paint
Assorted cans of thinner, reducer
Assorted oily or solvent contaminated rags
Transistor radio or other electrical appliance
PROCEDURE:
1. Observe "No Smoking" regulations in paint area, remove radio/appliance
from work area.
2. Properly close all paint cans.
3. Properly close all other flammable material containers.
4. Store all paint and flammable containers in storage lockers.
5. Close and secure locker door.
6. Place oily/solvent rags in approved fire-retardant container.
7. Deposit paint waste/spent cleaning liquids in liquid waste material containers.
REFERENCE:
Safety Manual
Uniform Fire Code
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
372
Instruct Proper Hazardous Waste Handling and Storage Methods to Those

Technicians Who Need Skill #322.
EQUIPMENT REQUIRED:
none
PROCEDURE:
1. Correctly describe the main types of chemical waste originating from Darr
locations. (Waste oil, waste antifreeze, waste solvent, waste caustic,
contaminated water, contaminated fuel).
2. Describe the correct locations for storage for each waste stream.
a. Waste oil: Waste oil storage tank
b. Waste antifreeze: Waste antifreeze tank or designated storage drum.
c. Waste paint in designated paint storage drums.
d. Waste caustic: Caustic tanks
e. Contaminated water: Through grease sump in steam cleaning area.
f. Contaminated fuel: In designated waste fuel storage drum
3. Describe the location of each of the storage areas.
4. Demonstrate knowledge of correct method for storing waste liquids in each
area.
5. Explain reasons for keeping waste streams separate.
6. Describe procedures for chemical spill containment.
a. Control: Eliminate the source of the spill, if possible.
b. Contain: Use oil-sorb, "kitty litter", booms or dikes.
c. Communicate: Notify supervisor and proper authorities if needed.
d. Cordon: Keep others out of the spill area.
e. Clean: Remove spill & containment materials to proper receptacle (drum,
dumpster, etc.).
7. Describe locations of spill containment/clean-up equipment & supplies.
REFERENCE:
Safety Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
373
Demonstrate Propeller Pitch Measurement
EQUIPMENT REQUIRED:
8T5322 Pitchometer or equivalent
Marine Propeller, installed
PROCEDURE:
1. Follow special instructions, measure propeller pitch
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
374
Demonstrate Testing Unit Injector
EQUIPMENT REQUIRED:
Unit Injector for 1.1 L, 1.7 L, or 3500 Engine
1U6661 Unit Injector Tester or
6V4022 Injector Tester
PROCEDURE:
1. Select the proper holders and adapters and test Unit Injector according to
instructions.
2. Record your findings on work sheet #18 and attach it to this form
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
375
Demonstrate Proper Adjustment of a Pull Type Clutch and Clutch Brake
EQUIPMENT REQUIRED:
Truck with a Pull Type Clutch
Pull Type Clutch Adjusting Tool
Hand Tools
PROCEDURE:
1. Adjust the Clutch Linkage and Clutch Brake according to Manufactures
Specifications
2. Adjust the Clutch according to Manufactures Specifications.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
376
Demonstrate Tilting Truck Cab to the 90 degree Breakover Position
EQUIPMENT REQUIRED:
Cabover Truck
Hand Tools
Safety Brackets
PROCEDURE:
1. Tilt Cab for Engine Removal following the instructions outlined in the Trucks
Service Manual
2. Make Sure All Safety Precautions are Followed
REFERENCE:
Service Manual for the Truck being used.
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
377
Demonstrate Making Jake Brake Adjustments
EQUIPMENT REQUIRED:
Engine Equipped with Jake Brake
Hand tools
Feeler gauge
9S9082 engine turning tool
PROCEDURE:
1. Follow procedure outlined in the service manual.
REFERENCE:
Service manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
378
Demonstrate Removal, Installation and Calibration of all Electronic Sensors

on P.E.E.C Engine
EQUIPMENT REQUIRED:
P.E.E.C. Engine
Hand Tools
PROCEDURE:
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
379
Demonstrate Making Unit Injector Height Adjustment on 3406E Engine
EQUIPMENT REQUIRED:
3406E Engine
Hand Tools
9U7227 Injector Height Gauge
PROCEDURE:
1.
Follow Procedure Outlined in the Service Manual
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
380
Demonstrate Removal and Installation of Injection Sleeves on 1.1 L or 1.7 L

Engines, using the 4C4462 Tool Group
EQUIPMENT REQUIRED:
1.1 L or 1.7 L Engine
Hand Tools
4C4462 Tool Group
PROCEDURE:
1. Remove and Install Injector Sleeve Following the Procedure Outlined in the
Special Instructions and Service Manual
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
381
Demonstrate Removing and Installing Injector Sleeves on 3406E using the

9U6891 Tool Group
EQUIPMENT REQUIRED:
3406E Engine
9U6891 Tool Group
PROCEDURE:
1. Remove and Install Injector Sleeves Following the Procedure Outlined in the
Service Manual
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
TITLE:
Demonstrate Using the 4C6761 Component Tester (Handyman Flight

Systems Component Tester)
EQUIPMENT REQUIRED:
Electrical Components:
1. Diode
2. Silicone Controlled Rectifier (SCR)
3. Zener Diode
4. Capacitor
PROCEDURE:
1. Follow the Procedure Outlined in the Handyman Operators Manual
REFERENCE:
Handyman Model 269 Operators Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
383
Demonstrate 3500 Gas Engine Set Up, including, "A" Regulator, Governor
Linkage, Carburetor and Waste Gate adjustment.
EQUIPMENT REQUIRED:
3500 Gas Engine
Protractor
6V9450 Engine Pressure Group
8T5160 Regulator Adjusting Tool Kit
Water Manometer
Exhaust Gas Analyzer
PROCEDURE:
1. Follow Procedures Outlined in the Service Manual and Special Instructions
and Gas Engine Performance book.
REFERENCE:
Service Manual
Gas Engine Performance - LEBQ2023
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
384
Demonstrate Testing Fuel Supply System using the FT1996 Low Fuel
Pressure Test Kit
EQUIPMENT REQUIRED:
Truck with 3300 or 3400 Engine
Hand Tools
FT1996 Low Fuel Pressure Test Kit
PROCEDURE:
1. Test Fuel Supply System as Outlined in the Truck Performance diagnostic
Guide and Record your findings on Work Sheet #34 and attach to this form
REFERENCE:
Truck Engine Performance Diagnostic Guide SEBD0808
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
385
Demonstrate Installing a Magneto and Setting the Timing on a Gas Engine
EQUIPMENT REQUIRED:
Gas Engine
5P6584 Timing Light or
6V3100 or 8T5300 Timing Indicator
6V9060 Spark Timing Adapter Group
PROCEDURE:
1. Install the Magneto and check the Engine Timing as outlined in the Service
Manual.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
386
Successfully Complete a Supervision/Management Course at a Local

Community College
EQUIPMENT REQUIRED:
None
PROCEDURE:
None
REFERENCE:
See Service Development Department For Details
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
387
Instruct, Observe and Certify at Least 10 Skills for Junior Technicians
EQUIPMENT REQUIRED:
None
PROCEDURE:
Follow Procedures and Instructions Outlined in the Employee Evaluation Guide
REFERENCE:
Employee Evaluation Guide
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
388
Demonstrate Opening and Closing a Work Order
EQUIPMENT REQUIRED:
Company Computer Terminal
PROCEDURE:
1. Follow Procedure Outlined in the Caterpillar Dealer Information Systems
(C.D.I.S.) Manual
REFERENCE:
Caterpillar Dealer Information Systems (C.D.I.S.) Manual.
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
389
Demonstrate Rolling Tracks For Transportation
EQUIPMENT REQUIRED:
Track Coiling Clamps
Grove Crane or equivalent
PROCEDURE:
1. Follow the procedure outline in the Undercarriage Rebuild Guide
REFERENCE:
Undercarriage Rebuild Guide bulletin MP 13 SEBF8557
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
390
Demonstrate the Proper Installation of a Duo-Cone Seal
EQUIPMENT REQUIRED:
Hand Tools
Duo-Cone Installation Tools
Machine with Duo-Cone Seals
PROCEDURE:
1. Follow the Procedure Outlined in the Service Manual and Special Instructions.
REFERENCE:
Tool Chart SEHS8484
Service Manual
Service Magazine
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
391
Successfully Complete Interactive Video Self-Instruction Course,

Fundamentals of Electrical Systems Module One: Course Introduction
EQUIPMENT REQUIRED:
Interactive Video Computer
Video Disc Fundamentals of Electrical Systems
PROCEDURE:
1. Follow Computer On Screen Directions
REFERENCE:
Caterpillar Multimedia Products TEMV9002
have studied the listed material and have demonstrated the skill listed on this sheet.
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
392
Successfully Complete Interactive Video Self-Instruction Course, Fundamentals

of Electrical Systems Module Two: Applying Basic Electrical Concepts
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
393

of Electrical Systems Module Three: Using Diagnostic Tools
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
394

of Electrical Systems Module Four: Trouble Shooting Basics
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
395

of Electrical Systems Module Five: The Caterpillar Lighting System
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
396

of Electrical Systems Module Six: The Caterpillar Starting System
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE
:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
397

of Electrical Systems Module Seven: The Caterpillar Charging System
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
398

of Mobile Hydraulics Module One: Course Introduction
EQUIPMENT REQUIRED:
Video Disc Fundamentals of Mobile Hydraulics
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
399
Successfully Compete Interactive Video Self-Instruction Course, Fundamentals

of Mobile Hydraulics Module two: basic Hydraulic Concepts
EQUIPMENT REQUIRED:
Video disc fundamentals of Mobile Hydraulics
PROCEDURE:
Follow Computer On Screen Directions
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
400

of Mobile Hydraulics Module Three: Components
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
401

of Mobile Hydraulics Module Four: Schematics
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
402

of Mobile Hydraulics Module Five: Systems
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
403

of Applied Failure Analysis Module One: Introduction
EQUIPMENT REQUIRED:
Video Disc Fundamentals of Applied Failure Analysis
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
404

of Applied Failure Analysis Module Two: Fundamentals of Metallurgy
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
405

of Applied Failure Analysis Module Three: Analyzing Fractures
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
406

of Applied Failure Analysis Module Four: Analyzing Wear
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
407

of Applied Failure Analysis Module Five: Visual Examination
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
408

of Applied Failure Analysis Module Six: Managing Failure Analysis
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
409
Demonstrate Proper Adjustment of a P.T.O. Clutch on a RR250 or SS250.
EQUIPMENT REQUIRED:
RR250 or SS250
Spring Scale
Hand Tools
PROCEDURE:
1. Follow Procedure Outlined in the Service Manual and Service Magazine
REFERENCE:
Service Manual
Service Magazine 9-12-88
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
TITLE:
Demonstrate Testing, Adjusting and Trouble Shooting Load Control (Feet Per
Minute Control) on RR/SS or Compactor
EQUIPMENT REQUIRED:
Machine With Load Controller (Feet Per Minute Control)
Pulse Generator
Digital Multimeter
Multitach
Hand Tools
PROCEDURE:
1. Follow the Procedure Outlined in the Service Manual and Service Magazine.
REFERENCE:
Service Manual
Service Magazine - 2-26-90
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
411
Demonstrate Checking and Adjusting Frequency of Vibration on Vibratory

Compactor
EQUIPMENT REQUIRED:
Vibratory Compactor
773904 Tach or
8C1869 Tach
6V2100 Multitach
PROCEDURE:
1. Follow the Procedure Outlined in the Service Manual
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
412
Demonstrate Checking and Adjusting Vibration/Propulsion Pump Charge

Pressure
EQUIPMENT REQUIRED:
Vibratory Compactor
6V3121 Multitach
1U8865 Infrared Thermometer
0-300 psi Gauge
0-580 psi Gauge
PROCEDURE:
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
413
Demonstrate Testing and Adjusting the Main Relief Valve Pressure on Two
Pump Vibratory Compactor
EQUIPMENT REQUIRED:
Vibratory Compactor
Two 0-9000 psi Gauges
4C4892 ORFS Fitting Group
PROCEDURE:
1. Follow the Procedure Outlined in the Service Manual
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
414
Demonstrate Setup, Testing, Adjusting and Calibration of Automatic

Grade/Depth Control on Paving Products.
EQUIPMENT REQUIRED:
Paving Equipment With Grade/Depth Control
Hand Tools
PROCEDURE:
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
415
Demonstrate Checking Transmission Solenoids
EQUIPMENT REQUIRED:
Telehandler
VOM
PROCEDURE:
1. Locate and expose Solenoid Bank.
2. Without starting engine , turn Key Switch to the ON Position.
3. Test each Solenoid for Voltage in Neutral, all Forward Speeds, and all
Reverse Speeds.
4. Turn Key Switch Off, and properly test each Solenoid Coil's resistance.
5. Note differences in Voltages and Resistances between Solenoids.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
TITLE:
Demonstrate Checking Hydraulic System Solenoids.
EQUIPMENT REQUIRED:
Telehandler
VOM
PROCEDURE:
1. Locate all Hydraulic Solenoids and name the Function it controls.
2. Without starting engine, turn Key Switch to the ON Position.
3. Using each Solenoids corresponding switch activate and Test each Solenoid
for Voltage.
4. Turn Key Switch Off, and properly test each Solenoid Coil's resistance.
5. Note differences in Voltages and Resistances between Solenoids.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
TITLE:
Demonstrate Checking Hydraulic System Pressures.
EQUIPMENT REQUIRED:
Telehandler
Hydraulic Pressure Gages
PROCEDURE:
Following Service Manual Procedures, check the following:
1. Standby Pressure
2. Steering Relief Pressure
3. Auxiliary Relief Pressure
4. Implement Relief Pressure
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
418
Demonstrate Checking Boom and Frame for Damage
EQUIPMENT REQUIRED:
Telehandler
Proper lighting
PROCEDURE:
Follow Service Manual Procedure
REFERENCE:
Service Manual - Operation and Maintenance Guide.
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
TITLE:
Demonstrate Checking Boom Lowering and Retracting Without Hydraulic

Power.
EQUIPMENT REQUIRED:
Telehandler
Proper Lifting and Lowering Equipment to handle Boom Weight
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
420
Demonstrate Checking Boom Wear Pads.
EQUIPMENT REQUIRED:
Telehandler
Feeler Gages
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
TITLE:
Demonstrate Checking Boom Chain Tension / Adjustment
EQUIPMENT REQUIRED:
Telehandler
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
TITLE:
Demonstrate Setting and using the Three Different Steer Modes.
EQUIPMENT REQUIRED:
Telehandler
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
423
Demonstrate Operation of Differential Lock Control.
EQUIPMENT REQUIRED:
Telehandler
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
424
Demonstrate Purging Air From the Boom Extend / Retract Cylinder.
EQUIPMENT REQUIRED:
Telehandler
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
TITLE:
Demonstrate Learning the Truck
EQUIPMENT REQUIRED:
Order Picker (NOR) Family
or
Reach (NRR) Family
PROCEDURE:
1. Follow Service Manual Procedure to Enter, Run, and Exit the Learn
Program.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
TITLE:
Demonstrate a Voltage Test on the Power Supply Card in the Vehicle

Manager.
EQUIPMENT REQUIRED:
or
Reach (NRR) Family
PROCEDURE:
Follow Service Manual Procedure.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
427
Demonstrate Testing Q1.
EQUIPMENT REQUIRED:
or
Reach (NRR) Family
VOM
PROCEDURE:
1. Follow Service Manual Procedure to test Q1.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
428
Demonstrate Testing TM1 / TM2.
EQUIPMENT REQUIRED:
Reach (NRR) Family
PROCEDURE:
Follow Service Manual Procedure to test TM1 / TM2 on Field Wiring Board.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
429
Demonstrate using Password to obtain the Truck Software (Firmware)

Version.
EQUIPMENT REQUIRED:
or
Reach (NRR) Family
PROCEDURE:
1. Follow Service Manual Procedure.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
430
Demonstrate obtaining Hour Meter readings and Distance Traveled.
EQUIPMENT REQUIRED:
or
Reach (NRR) Family
PROCEDURE:
1. Follow Service Manual Procedure to obtain readings:
1. (KH) - Key Hours
2. (HD) - Hours on Deadman
3. (HL) - Hours on Lift Motor
4. (TM) - Travel Miles
Note: Early model trucks will not have all of the above options.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
TITLE:
Demonstrate Configuring the truck using Password and Superword.
EQUIPMENT REQUIRED:
or
Reach (NRR) Family
PROCEDURE:
Follow Service Manual Procedure to:
1. Enter the Configure Mode using Password and note all Menu
Options.
2. Enter the Configure Mode using Superword and note all Menu
Options.
3. Note the differences between the two Menus and exit the Program.
Note: Do not change any Option Values unless you are actually Configuring the
Truck or note the values before changing them to re-set back to original
values.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
432
Demonstrate Configuring the Truck to Factory Default Setting Values.
EQUIPMENT REQUIRED:
or
Reach (NRR) Family
PROCEDURE:
1. Enter the Configure Mode using Password.
2. Note all Option Values
3. Default truck to Factory Setting Option Values
4. Note all Option Setting Values again, if different than original
change to original Values (unless you are configuring the truck
differently) and exit the program.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
433
Demonstrate using the Maintenance Program
EQUIPMENT REQUIRED:
or
Reach (NRR) Family
VOM
9 & 25 Position Pin Adapters, (obtain from MHA)
26-266 & 26-1945 Gender Changers, (obtain from Radio Shack)
Proper Terminals
PROCEDURE:
Follow Service Manual Procedures to enter into the Maintenance Program
and do:
1. 3 Analog Test
2. 3 Input Test
3. 3 Output Test
Note: a. Read and understand the entire procedure before doing each test
b. Choose test that are different in nature, (for instance in the Reach Truck Test
O00, O01, O02, and O03 test contactors. Choose only one and than choose
one of eight Solenoid Test, etc.)
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
434
Demonstrate Initializing truck to Factory Default Parameters.
EQUIPMENT REQUIRED:
Order Picker (NOR) Family or Reach (NRR) Family
MHA Hand Set or Laptop with proper Software Program.
PROCEDURE:
Follow SENB8544-01 (or latest version) User's Manual procedure to
resetting the Vehicle Manager to Factory Default Parameters.
Note: This same Equipment and Similar Procedures are used to add or
delete some Options. MHA must be contacted to obtain
authorization number called a Pass Key. Once the hardware for the
option is installed, this Configuration Program must be executed for
the truck accept or delete the option.
REFERENCE:
Service Manual
SENB8544-01 (or latest version) User's Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
435
Demonstrate the use of LED Status Light
EQUIPMENT REQUIRED:
NPP40 or Pallet Jack with similar Controller.
PROCEDURE:
1. Raise and block truck so drive wheel is free to turn.
2.. Raise controller cover and view Status LED
3. Simulate and SRO Condition.
Note: DO NOT PLUG (ELECTRICAL BRAKING & REVERSING) THE
TRUCK DRIVE WHEEL UP IN THE AIR. Damage to the controller
or drive motor may occur. Use the mechanical brakes to slow down
and stop the drive wheel.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
436
Demonstrate using the 113-7132 Curtis 1207 Analyzer to Program the

truck.
EQUIPMENT REQUIRED:
113-7132 Curtis 1207 Analyzer
PROCEDURE:
.

1. Install the Analyzer.
2. Drive the truck forward and reverse.
3. Enter the Program Mode and note the Quick Start Option Value.
4. Change it to its minimum Value and drive the truck forward and reverse.
5. Change it to its Maximum Value and drive the truck forward and reverse.
(truck TAKE OFF SPEED will be faster, make sure you have enough room
to perform this test properly)
6. Note the difference and change it back to its original Value.
Note: Look at other options, note there value if you change it, and set it back to
Its original value, unless you are configuring the truck differently.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
437
Demonstrate using the 113-7132 Curtis 1207 Analyzer to Test the truck.
EQUIPMENT REQUIRED:
PROCEDURE:

3. Enter the Test Mode
4. Look at all Test Options. Operate the truck while viewing test results.
Note: DO NOT PLUG (ELECTRICAL BRAKING & REVERSING) THE TRUCK
DRIVE WHEEL UP IN THE AIR. Damage to the controller or drive motor
May occur. Use the mechanical brakes to slow down and stop the drive
wheel.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
438
Demonstrate using the 113-7132 Curtis 1207 Analyzer to enter Diagnostics

and Special Diagnostics Menu.
EQUIPMENT REQUIRED:
PROCEDURE:

3. Enter the Test Diagnostic mode, ( This is not a menu as such, but simply a
list of possible messages you may see displayed when the programmer is
operating in either Program or Test Mode), note any faults and exit program.
Note: DO NOT PLUG (ELECTRICAL BRAKING & REVERSING) THE TRUCK
DRIVE WHEEL UP IN THE AIR. Damage to the controller or drive motor
May occur. Use the mechanical brakes to slow down and stop the drive
wheel.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
439
Demonstrate using Programmable Setup Options.
EQUIPMENT REQUIRED:
EC15 - EC30
EP13T - EP20T
M40DDSA / P - MC60DSA / P W / 0R6713 Programmable Logic.
PROCEDURE:
1. Enter the Setup Option Program.
2. Note all Option Values
3. Default truck to Factory Setting Option Values
4. Note all Option Setting Values again, if different than original change to
original Values (unless you are configuring the truck differently) and
exit the program. After finishing put the Run, Diagnostic (Setup) Switch
back to Run.
Note: If using the EC15 - EC30 W / MicroCommand II Panel, make sure to
to access all three option groups.
REFERENCE:
Service Manual
Sales Monitor CEKL0367 (for M50SA & P family of trucks)
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
440
Demonstrate using the Diagnostic Program
EQUIPMENT REQUIRED:
Any Electric Lift Truck, (Caterpillar or MCF) with MicroCommand Panel
PROCEDURE:
1. Enter the Diagnostic Program
2. Note all Faults, (if none exit the Program)
3. If faults are found make proper repairs
Note: Its a good Idea to record the Fault Codes and Hrs. (if applicable)
in the Service Report before erasing the Fault Codes and Hrs.
After finishing put the Run, Diagnostic (Setup) Switch back to Run.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
441
Demonstrate using the History Folder Faults
EQUIPMENT REQUIRED:
EC15 - EC30
EP13T - EP20T
M40DDSA / P - MC60DSA / P W / 0R6713 Programmable Logic.
PROCEDURE:
1. Enter the Fault History Program.
2. Note all Faults, (if none exit the Program)
3. If faults are found make proper repairs
Note: Its a good Idea to record the Fault Codes and Hrs. (if applicable)
in the Service Report before erasing the Fault Codes and Hrs.
After finishing put the Run, Diagnostic (Setup) Switch back to Run.
REFERENCE:
Service Manual
Sales Monitor CEKL0367 (for M50SA & P family of trucks)
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
442
Demonstrate Programming the Clock on a EC15 or EC30 Lift Truck
EQUIPMENT REQUIRED:
EC15 - EC30
PROCEDURE:
1. Enter the Program.
2. Change time using the 24 hour clock instead of the 12 hour clock.
3. Using the 24 hour clock, change the time back to correct time, and back to
12 hour clock, (if the truck is programmed for the 24 hour clock leave it
at the 24 hour clock).
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
443
Demonstrate using Function Setup Procedures.
EQUIPMENT REQUIRED:
Any Electric Lift Truck W / EV100 LX, LXT, or ZX Panel
97124-07400 EV100 LX Handset
PROCEDURE:
1. Enter the Function Setup Program
2. Note all Function Values
3. Check against Manufacturer recommended values.
4. Make necessary changes and exit program
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
444
Demonstrate Down Loaning Faults on a Machine using the Scroll and Clear
Switches
EQUIPMENT REQUIRED:
Machine With an Electronic Control
4C8195 Caterpillar Service Tool
PROCEDURE:
1. Using the Service and Set Switches on the machine ,or Caterpillar Service
tool 4C8195 enter the fault code mode and scroll through and record the
fault codes
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
445
Demonstrate Bench Testing a Hydraulic Cylinder
EQUIPMENT REQUIRED:
Hydraulic Cylinder
Test Bench
PROCEDURE:
1. Properly Mount Cylinder to Test Bench, Test Cylinder for Internal and
External Leakage
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
446
Demonstrate Disassembly and Assembly of a Planetary Final

Drive
EQUIPMENT REQUIRED:
Planetary Final Drive
Lifting Equipment
PROCEDURE:
1. Follow Procedure Outlined in the Applicable Service Manual
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
447
Demonstrate Disassembly and Assembly of a Differential
EQUIPMENT REQUIRED:
Differential
Dial Indicator Group
Hand Tools
PROCEDURE:
1. Using the Procedure Outlined in the Service Manual Correctly
Disassemble and Assemble a Differential Making All Preload
and Bearing Adjustments. Correctly Set Pinion Depth, Gear
Backlash and Tooth Pattern
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
448
Demonstrate Correct Disassembly and Assembly of a Countershaft

Transmission
EQUIPMENT REQUIRED:
Countershaft Transmission
Hand Tools
PROCEDURE:
1. Using the Procedure Outlined in the Service Manual
Correctly Disassemble and Assemble the Transmission making
All Bearing Prelaod and Clearance Adjustments
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
449
Demonstrate Setting Transmission Transfer Gear the Bearing

Clearance
EQUIPMENT REQUIRED:
Transmission Transfer Gear
Hand Tools
PROCEDURE:
1. During Assemble of the Transmission Transfer Gear Group
Correctly Set all Bearing Clearances.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
450
Demonstrate Disassembly and Assembly of an Integral Axle
EQUIPMENT REQUIRED:
Integral Type Axle
Dial Indicator
Hand Tools
PROCEDURE:
1. Disassemble and Assemble Axle as Outlined in the Service Manual
Correctly Make all Preload and Clearance Adjustments
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
451
Demonstrate Bench Testing a Countershaft Transmission
EQUIPMENT REQUIRED:
Transmission Test Bench
Countershaft Transmission
Hand Tools
PROCEDURE:
1. Test and Adjust the Transmission as Outlined in the Service Manual
Transmission Testing and Adjusting Section
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
452
Demonstrate Use of the 9U7500 Transmission Analyzer
EQUIPMENT REQUIRED:
9U7500 Transmission Analyzer
Machine with ICM Transmission
or ICM Transmission on the Test Bench
PROCEDURE:
Following the Instructions Outlined in the 9U7500 Transmission
Analyzer Operation Manual
1. Connect Analyzer to the Transmission using the Correct Cables
2. Test the Transmission Switch
3. Test the Solenoids
4. Shift the Transmission
REFERENCE:
Service Manual
Transmission Analyzer Operation Manual NEHS0644
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
453
Demonstrate Checking Phase Rotation of a Generator Set to

Utility Power
EQUIPMENT REQUIRED:
Generator Set Connected to Utility Power
Phase Rotation Meter
Safety Equipment
PROCEDURE:
1. Follow Instructions Outlined in the Service Manual
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
454
Demonstrate Proper Work Area Organization
EQUIPMENT REQUIRED:
None
PROCEDURE:
1. Organize work area as per instructions from a senior technician
or supervisor
REFERENCE:
None
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
455
Demonstrate Performing the Five Steps of Engine Troubleshooting
EQUIPMENT REQUIRED:
Truck Engine with Electronic Controls
Applicable Test Equipment
PROCEDURE:
Troubleshoot the Engine using the Five Step Diagnostic Process
Outlined in the Service Manual
1. Gather Information
2. Verify Operational Problem
3. Determine Probable Causes
4. Narrow List of Causes
5. Test Subsystems
REFERENCE:
Service Manual
Electronic Troubleshooting SENR5582
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
456
Instruct Junior Technicians in Work Area Organization Who Need

Skill 454
EQUIPMENT REQUIRED:
None
PROCEDURE:
REFERENCE:
Skill # 454
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
457
Demonstrate Removal And Installation Of A Tapered Roller Bearing
EQUIPMENT REQUIRED
Component With Tapered Roller Bearings Bearing Removal And Installation
Pullers
Bearing Heater
Hand Tools
PROCEDURE:
1. Follow Procedure Outlined In The Service Manual
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
458
Demonstrate Checking Track Adjuster for Leakage (Internal and

External)
EQUIPMENT REQUIRED:
Roller Frame with track adjuster
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
459
Demonstrate Evaluation of a Dozer Blade for Wear
EQUIPMENT REQUIRED:
Dozer Blade
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
460
TITLE: Demonstrate Evaluation of Loader Frame and Linkage for Wear
EQUIPMENT REQUIRED:
Loader Frame
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
461
TITLE: Demonstrate Boring Idler Bearings on High Sprocket Machines
EQUIPMENT REQUIRED:
Idler With New Bearings
Boring Bar
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
462
TITLE: Demonstrate Evaluation of Pivot Shaft for Leakage and Wear
EQUIPMENT REQUIRED:
Large Track Type Tractor With Pivot Shaft
Lifting and Blocking Equipment
Dial Indiactors
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
463
TITLE: Demonstrate Field Repair Procedure for a Dry Joint on S.A.L.T. Track
EQUIPMENT REQUIRED:
Machine with S.A.L.T. track
Portable track Press
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
464
TITLE: Demonstrate Proper Lubrication of a Pivot Shaft
EQUIPMENT REQUIRED:
Large track type tractor with a Pivot Shaft
Hand Tools
PROCEDURE:
Follow Procedure Outlined In The Service Manual
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
465
TITLE: Demonstrate Proper Pivot Shaft Seal Installation
EQUIPMENT REQUIRED:
High drive Track Type Tractor With Pivot Shaft
Seal Installation Tooling
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
466
TITLE: Demonstrate Evaluation of Equalizer Bar For Wear
EQUIPMENT REQUIRED:
Equalizer Bar or
Track Type Tractor With Equalizer Bar
Measuring Tools
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
467
Demonstrate Properly Checking Roller Frame Alignment
EQUIPMENT REQUIRED:
Measuring Tools
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
468
TITLE: Demonstrate Proper Removal and Installation of a Recoil Spring on Low

Sprocket Machine
EQUIPMENT REQUIRED:
Low Sprocket Machine
Hand Tools
PROCEDURE:
(making sure to follow all safety precautions)
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
469
TITLE: Demonstrate Proper Removal and Installation of Recoil Spring on High

Sprocket Machine
EQUIPMENT REQUIRED:
Track Type Tractor With High Drive
Hand Tools
PROCEDURE:
(Making sure to follow all prescribed safety precautions)
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
470
Demonstrate Proper Disassembly and Assembly of Low Sprocket Recoil

Spring
EQUIPMENT REQUIRED:
Recoil Spring Assembly From A Low Sprocket Machine
Recoil Spring Press
Hand Tools
PROCEDURE:
(making sure to follow all safety precautions outlined)
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
471
Demonstrate Manuel Operation of a SGV (Self Guided Vehicle)
EQUIPMENT REQUIRED:
SGV Truck With Pendant Controller
Hand Tools
PROCEDURE:
1. Install Pendant and Basic Maneuver Vehicle.
REFERENCE:
SGV Service Manuel
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
472
Demonstrate SGC Basic Computer Skills With Lap Top Computer
EQUIPMENT REQUIRED:
P.C. with Windows
GEM 80 Software
Hand Tools
PROCEDURE:
1. Access GEM 80 Program
2. Download file to SGV
3. K-400 Procedure
REFERENCE:
SGV Service Manuel
GEM 8 Software Tools and Utilities Book
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
473
TITLE: Demonstrate Land Base Computer Skill Test
EQUIPMENT REQUIRED:
SGV Land Base Computer
Hand Tools
PROCEDURE:
1. Download Target Files to SGV
2. Look at Location Control
3. Look at Alarm History Files
REFERENCE:
LCS User Guide for SGV
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
474
TITLE: Demonstrate Test/Adjustment of Photo Electric Sensor
EQUIPMENT REQUIRED:
Volt Meter
Hand Tools
PROCEDURE:
1. Test for Voltage and Visual Alignment
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
475
Demonstrate I/O Panel wiring on Landbase Computer for SGV
EQUIPMENT REQUIRED:
Prints of System Wiring
Hand Tools
PROCEDURE:
1. Trace Wires from Battery Charger to Panel
REFERENCE:
Plant Wiring Schematic
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
476
Successfully Complete Interactive Computer Course,

Fundamentals Of Electrical Systems
EQUIPMENT REQUIRED:
Computer with Caterpillar Interactive Software Program,
Fundamentals Of Electrical Systems (TEMV9002)
PROCEDURE:
1. Follow Computer On Screen Directions And Complete The Entire
Course
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
477
TITLE: Successfully Complete Interactive Computer Course,

Fundamentals Of Mobile Hydraulics
EQUIPMENT REQUIRED:
Fundamentals Of Mobile Hydraulics (TEMV9001)
PROCEDURE:
Course
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
478
TITLE: Successfully Complete Interactive Computer Course,

Fundamentals Of Applied Failure Analysis
EQUIPMENT REQUIRED:
Fundamentals Of Applied Failure Analysis
PROCEDURE:
Course
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
479
TITLE: Demonstrate Proper Use Of The Roto Alignment Tool
EQUIPMENT REQUIRED:
Roto Alignment Tool
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
TITLE:
Demonstrate Use of S.I.S. (Service Information System)
EQUIPMENT REQUIRED:.
Computer that has S.I.S. installed
PROCEDURE:
Write your answer at the end of each question.
1. Find the torque for the bolt that holds the crankshaft hub and the damper
on a D7H serial number 82Z12987.
2. Find the description for a 3P5715 located in the final drive of a D7F serial
number 93N01175.
3. Find the part number for the tip at the end of the ripper shank for a D7H
serial number 4AB05501.
4. Find the tooling necessary to remove and install the valve seat inserts in a
D7H 79Z04001.
5. Find the new replacement part number for the 1115152 powertrain oil
hose on a D5M S/N 6AS425 listed in Service Letter May 31,1999.
6. Find the new part number for the sprocket segments on a D7H serial
number 4AB05501.
7. Find the part number for the Extreme Service cab door striker listed in
Special Instruction on a D11N, S/N 74Z.
8. Find the nominal low idle speed for an engine in a D7H serial number
79Z05636 equipped with an engine serial number 08Z75146.
REFERENCE:
REBW0005- S.I.S. (Service Information System) User Procedures
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
481
Demonstrate Identifying Air Conditioning System Type
EQUIPMENT REQUIRED:
Air condition equipped equipment.
PROCEDURE:
EXAMINE AIR CONDITIONING SYSTEM, LOOKING AT THE SERVICE
FITTINGS AND IDENTIFICATION PLATES AND DETERMINE TYPE OF
REFRIGERANT USED (R-12, R134a)
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
482
TITLE: Demonstrate Testing An Adjustable And None Adjustable Thermostatic

Switch
EQUIPMENT REQUIRED:
Machine With Air Conditioning
Multimeter
Heat Source
Cold Source
Thermometer
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
483
TITLE: Demonstrate Performance Testing Heating System
EQUIPMENT REQUIRED:
Machine With Heating And Air Conditioning System
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
484
TITLE: Demonstrate Flushing An Air Conditioning System That Has Had A

Component Failure
EQUIPMENT REQUIRED:
Recovery & Recycle Cart
R134a Refrigerant Supply
153-8538 Flushing Solvent
Flushing Tool
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
485
Demonstrate Down Loading Faults And Error Codes On An Automatic

Temperature Control Air Conditioning Unit
EQUIPMENT REQUIRED:
Machine With Automatic Temperature Control Air Conditioning
Hand Tools
PROCEDURE:
REFERENCE:
Service Manual - RENR1976
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
486
Demonstrate Timing New Components To An Automatic Temperature

Control Air Conditioning Unit
EQUIPMENT REQUIRED:
Machine With Automatic Temperature Control Air Conditioning
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
487
Demonstrate Reading Component Parameters On An Automatic

Temperature Control Air Conditioning Unit
EQUIPMENT REQUIRED:
Machine With An Automatic Temperature Control Air Conditioning Unit
Hand Tools
PROCEDURE:
2. Fill Out Worksheet #38 And Attach It To This Form
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
488
Demonstrate Quick-Check Procedures For Expansion Valve Or Orifice

Tube Air Conditioning
EQUIPMENT REQUIRED:
HAND TOOLS
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
489
TITLE: Demonstrate Performance Testing An Air Conditioning System
EQUIPMENT REQUIRED:
Thermometer
Manifold Gauges
Hand Tools
PROCEDURE:
record your findings on Worksheet 39 and attach to this form
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
490
TITLE: Demonstrate Proper Method Of Finding Restrictions In An Air Conditioning

System
EQUIPMENT REQUIRED:
Machine With Air Conditioning System
Manifold Gauges
Thermometer
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
491
TITLE: Demonstrate Checking The Oil Level In An Air Conditioning Compressor
EQUIPMENT REQUIRED:
Machine With An Air Conditioning System
Recovery/Recycle Equipment
Measuring Container
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
492
TITLE: Demonstrate Proper Removal And Installation Of An Air Conditioning

System Orifice Tube
EQUIPMENT REQUIRED:
Machine With Orifice Tube Type Air Conditioning System
1U9890 Orifice Tube Extraction And Installation Tool
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
493
TITLE: Demonstrate Proper Use Of Air Conditioning Electronic Charging Scale
EQUIPMENT REQUIRED:
9U6507 Electronic Charging Scale
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
494
TITLE: Demonstrate Proper Method Of Checking Cab Sealing
EQUIPMENT REQUIRED:
Machine With Air Conditioning And/or Heating
4C5623 Smoke Candles
Hand Tools
PROCEDURE:
1. Place Candle On A Non Flammable Disposable Material In The Center Of
The Cab Floor. Follow Procedure Outlined In The Service Manual
REFERENCE:
Tool Guide
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
495
TITLE: Demonstrate Proper Method Of Testing A Thermostatic Expansion

Valve With The Valve Installed On The Machine
EQUIPMENT REQUIRED:
Machine With Thermostatic Expansion Valve Type Air Conditioning
Manifold Gauges
9U6070 Heat Gun (Or Source Of Alternate Heat)
Ice Or Alternate Source Of Cold (Do Not Use Refrigerant)
Hand Tools
PROCEDURE:
1.
2.
3.
4.
Install Manifold Gauges, Apply Cold Source To TXV And Read Gauges.
Apply Heat Sources To TXV And Read Gauges
Record Findings On Worksheet # 40 And Attach To This Form
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
496
TITLE: Demonstrate Checking And Setting Clutch Clearance (Dry Plate)

On Standan Compressor
EQUIPMENT REQUIRED:
Standan Compressor
Feeler Gauges
T Puller
Hand Tools
PROCEDURE:
REFERENCE:
SEBU2580 (Service Training Meeting Guide)
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
TITLE:
497
Demonstrate Leak Testing Air Conditioning System
EQUIPMENT REQUIRED:
4C2964 Electronic Leak Detector (Or Equivalent)
Air Conditioning Dye
Soap Solution in Squirt Bottle
Hand Tools
PROCEDURE:
1. Leak Test Air Conditioning System Using The Different Methods Of Detection.
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
498
TITLE: Demonstrate Retrofitting An R-12 Air Conditioning System To R134a
EQUIPMENT REQUIRED:
Machine Equipped With An R-12 Air Conditioner
Hand Tools
PROCEDURE:
1. Follow Procedure Outlined In The Service Manual And Special Instructions
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
499
TITLE: Demonstrate Use of Electronic Technician (ET) on a Unit with Electronic Control
EQUIPMENT REQUIRED:
Lap Top Computer with ET Installed
Unit With an Electronic Control That Required ET
Communication adapter with cables.
Hand Tools
PROCEDURE:
1. Connect Computer with ET Using Communication Adapter with Appropriate cables
to Unit According to Service Manual
2. View the Active and Logged Codes With Caterpillar ET (Electronic Technician)
Follow Procedure Outlined In the Service Manual
3. Attach A Paper Copy of the Active Codes, or Logged Codes, or Configuration of
Unit with the this Skill Sheet.
REFERENCE:
Training Package inside ET software (Must have ET open before you can
Access Training Package)
Book on Introduction to Microsoft Windows operating System
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
500
TITLE: Demonstrate Proper Installation Of Generator Protection Components
EQUIPMENT REQUIRED:
;
Generator
Protection Components
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
501
TITLE: Demonstrate Installation of Generator AC Monitoring Components
EQUIPMENT REQUIRED:
Generator AC Monitoring Components
Generator
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
502
TITLE: Demonstrate Modification Of Engine Generator Controls As Directed
EQUIPMENT REQUIRED:
Engine And Generator Set
Hand Tools
PROCEDURE:
As Directed
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
503
TITLE: Demonstrate Performance Of A Cooling System Audit
EQUIPMENT REQUIRED:
Engine With A Radiator Type Cooling System
Cooling System Audit Equipment
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
504
TITLE: Demonstrate Performing Tests Listed On 3500 Engine Installation

Check List
EQUIPMENT REQUIRED:
3500 Engine
Hand Tools
PROCEDURE:
REFERENCE:
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
505
TITLE: Demonstrate Performing Generator/ Industrial Engine Load Test And

Determine Compliance With Performance Standard
EQUIPMENT REQUIRED:
Engine Generator Set
Hand Tools
PROCEDURE:
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
506
TITLE: Successfully complete Programs in Learning Operating Techniques.

An Introduction to Compression
EQUIPMENT REQUIRED:
Pencil and paper
Booklet - American Petroleum Institute Programs In Learning Operating
Techniques #1051WB An Introduction to Compression
PROCEDURE:
REFERENCE:
Introduction to Compression Book # 1051WB
Howell Training - Houston, Texas (800) 527-1851
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
507

Couplings, Gear Trains, and V-Belt Drives
EQUIPMENT REQUIRED:
Pencil and paper
Techniques #1085WB Couplings, Gear Trains and V-Belt Drives
PROCEDURE:
REFERENCE:
Coupling, Gear Trains and V-Belt Drives Book #1085WB
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
508

Centrifugal Compressors
EQUIPMENT REQUIRED:
Pencil and paper
Techniques #1053WB Centrifugal Compressors
PROCEDURE:
REFERENCE:
Centrifugal Compressors Book #1053WB
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
509

Positive Displacement Compressors
EQUIPMENT REQUIRED:
Pencil and paper
Techniques #1052WB Positive Displacement Compressors
PROCEDURE:
REFERENCE:
Positive Displacement Compressors Book #1052WB
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
510
TITLE: Demonstrate Proper Preventative Maintenance and Inspection of a Gas

Compression Unit
EQUIPMENT REQUIRED:
Gas Compression Unit
PROCEDURE:
1. Follow procedure outlined in the appropriate service manual.
REFERENCE:
Service Manual
Operation and Maintenance Manual for Caterpillar Gas Engine
(Lubricant Recommendations SEBU6400)
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
511
TITLE: Demonstrate Use of the 7X1400 Gas Engine Digital Diagnostic Tool (DDT)
Group
EQUIPMENT REQUIRED:
Electronic Controlled Gas Engine
7X1400 Gas Engine Digital Diagnostic Tool
PROCEDURE:
Follow procedure outlined in the appropriate service manual.
REFERENCE:
Service Manual
Operating Manual SEHS9122
Operating Manual SEHS8806
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
512
TITLE: Demonstrate Use of the 4C5850 Stud Tensioner Tool Group
EQUIPMENT REQUIRED:
4C5850 Stud Tensioner Tool Group
3S6224 Electric Hydraulic Pump
8T0820 Hydraulic Pressure Gauge
8T3035 Hydraulic Line
PROCEDURE:
Follow procedure outlined in the appropriate 3600 series service manual.
REFERENCE:
3600 Series Engine Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
513
TITLE: Demonstrate Checking Engine/Compressor Soft Foot
EQUIPMENT REQUIRED:
Mounting Feet Shims (As required by each Manufacture)
PROCEDURE:
Follow Procedure Outlined in the Appropriate Manufactures Service Manual.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
514
TITLE: Demonstrate Proper Starting and Stopping of a Gas Compressor Package
EQUIPMENT REQUIRED:
In-service Gas Compression Package
PROCEDURE:
Follow Procedure in American Institute Programs in Learning Operating
Techniques #1052WB Positive Displacement Compressors Section 3
REFERENCE:
Positive Displacement Compressors Book #1052WB
(Howell Training - Houston, Texas (800) 527-1851)
Check the S.I.R.S. and FIND for latest updates
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
515
TITLE: Demonstrate Proper Checking Method for Crosshead Clearance
EQUIPMENT REQUIRED:
12 inch Long Feeler Gauges
PROCEDURE:
1. Follow Procedure Outlined in the Appropriate Manufactures Service Manual.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
516
TITLE: Demonstrate Proper Checking Method for Rod Run Out.
EQUIPMENT REQUIRED:
Two Dial Indicator Groups
PROCEDURE:
1. Follow Procedure Outlined in the Appropriate Manufactures Service Manual to
ensure Rod Run Out is within Manufacturers Specifications.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE
SERVICE DEPARTMENT
DEFINITION
PERFORMANCE SKILL
517
TITLE: Demonstrate Purging Gas From Unit
EQUIPMENT REQUIRED:
In-service Gas Compression Package.
PROCEDURE:
1. Follow Procedure Outlined in the Appropriate Manufactures Service Manual.
REFERENCE:
Service Manual
_____________________
__________________________________________________(Signature & Emp #)
____________________
REVISED 2001
DATE

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SERVICE DEPARTMENT

EMPLOYEE EVALUATION GUIDE

Demonstrate Measuring and Adjusting Fuel Rack Setting on Forged Body

Install correct tooling.

Demonstrate Measuring and Adjusting Fuel Setting (Sleeve Metering

Install correct tooling.

Demonstrate Measuring Engine speed and Set Point with 6V3121

Demonstrate Proper Use of Electric Lift Truck Battery Charger

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

Demonstrate Measuring Timing Dimension (Compact Fuel System)

Install correct tooling for fuel system being calibrated.

Demonstrate Torque procedure using Torque Wrench, Torque Multiplier,

Make sure hardware is clean and lubricated.

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

Demonstrate Use of the 6V7070 or 6V7800 Digital Multimeter, using the

Demonstrate Correct Liner Projection Measurement

Demonstrate Measuring Piston Ring Land Wear

Demonstrate Measuring Clearance of Rod and Main Bearings and

Demonstrate Measuring Turbocharger Shaft Straightness

Demonstrate Checking Air Intake System for Leaks at Joints

Demonstrate on Engine Adjustment of Hydraulic Air Fuel Ratio Control on New

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

Demonstrate Correct Valve Lash and Jake Brake Adjustment

Demonstrate Refacing Valves and Valve Seats

Demonstrate Checking Cylinder Head for Reusability

Demonstrate Testing Load Sensing, Pressure Compensating

Measure system maximum pressure.

Demonstrate Measuring Fuel For Specific Gravity

Demonstrate Testing Fuel Injection Nozzles

Direct Injection Nozzle (Capsule Type)

Sequence PC Nozzle: (NOT REQUIRED FOR TRUCK ENG.SPEC.)

Demonstrate Testing a Cooling System and Components.

Demonstrate Testing Water Temperature Regulators

Demonstrate Measuring Coolant for Freezing Point and Inhibitor Concentration

8T5296 Coolant Conditioner Kit

Demonstrate Testing Glow Plugs

Lift Truck engine with glow plugs

Demonstrate Proper Use of Battery Charger, and testing a Lead

Demonstrate Test a Lead Acid Battery

5P9735 Battery Fluid Probe

Demonstrate Use of Battery Jumper Cables

Demonstrate Measuring Stall Speed of Torque Converter/Divider

Demonstrate Testing Steering and Brake Pressure on a High Drive Tractor

Demonstrate Use of the 8T0450 Thread Identification Kit

Demonstrate Checking Pressures of Transmission System

Demonstrate Bevel Gear/Pinion Adjustments

Demonstrate Evaluation of Duo-Cone Seal Groups

Demonstrate Measuring Steering Clutch Springs

Demonstrate Proper Completion of S.I.M.S. (Service Information

Demonstrate Adjusting Motor Grader Circle Drawbar

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

Demonstrate Proper Disassembly and Assembly of Sealed and Lubricated

TITLE: Demonstrate Proper Disassembly and Assembly of Sealed and Lubricated

Demonstrate Shoe Brake Adjustment

Demonstrate Charging Nitrogen Accumulator

Demonstrate Connection of a Hydraulic Flow Meter

Connect correct tooling for machine being tested.

Demonstrate Use of Torque Multiplier

Demonstrate Four Step Hydraulic Cylinder Drift Rate Test

Demonstrate Evaluating Worn Vane Pumps

Demonstrate Evaluating Worn Gear Pumps

Demonstrate Use of the 6V2150 Starting and Charging System