SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
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. Install correct tooling. 2. Measure fuel setting using continuity light or multimeter. 3. Adjust fuel setting. 4. Seal with governor seal group.
REFERENCE:
Service Manual Special Instructions – SEHS8436 Video Tape 42 – Hydraulic Air-Fuel Ratio Control Adjustment - JEGO9042 (¾ “) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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. Install correct tooling. 2. Measure fuel setting using continuity light or multimeter. 3. Adjust fuel setting. 4. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENT EMPLOYEE EVALUATION GUIDE
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 (¾”) Battery Service Manual - SEBD0625 Pages 29 - 32 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENT EMPLOYEE EVALUATION GUIDE
DEFINITION PERFORMANCE SKILL 6
TITLE: Retired
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENT EMPLOYEE EVALUATION GUIDE
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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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. Install correct tooling for fuel system being calibrated. 2. Measure timing dimension using depth micrometer. 3. Measure timing dimension using dial indicator. 4. Adjust timing dimension on one pump using either tool.
REFERENCE:
Service Manual Special Instructions - SEHS8980 Video Tape 88 – Fuel Injection Pump Recon. SEVV9088 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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. Make sure hardware is clean and lubricated. 2. Make correct initial torque. 3. Rotate hardware to correct final position. 4. Calculate torque using a torque wrench extension. 5. 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 (½”) Slide Rule Computer - SEHS7150 Special Instructions - SMHS7657 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 10
TITLE: Retired
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENT EMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 11
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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENT EMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 12
TITLE: Demonstrate Correct Liner Projection Measurement
EQUIPMENT REQUIRED: LIFT TRUCK HEAVY EQUIPMENT XN1P Gas Engine 1P5510 Tool Group 8T0501 Dial Indicator Engine 8T0502 Indicator Base T - Bar 8T0472 Liner Compressor Tool 8T0476 Cylinder Liner Clamp
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 Special Instructions - SMHS7727 Video Tape 43 – Cylinder Block Counterboring – JEGO9043 (¾”) Video Tape 47 – Cylinder Block Liner Seat Sleeving – JEGO9037 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 13
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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 14
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. 4. Record your findings on worksheet #14 and attach to this form.
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 15
TITLE: 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 (¾”) Video Tape 56 - Turbo Reconditioning 2 - JEGO9056 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 16
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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 17
TITLE: 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 (¾”) 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 ____________________ DATE__________
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 18
TITLE: 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 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 19
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 20
TITLE: Demonstrate Refacing Valves and Valve Seats
EQUIPMENT REQUIRED:
Valves Cylinder Head Valve Refacing Machine 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 Special Instructions - SMHS6998 Video Tape 55 - Knurling Valve Guides – LEVN9055 (½”) Video Tape 62 – Cylinder Head Reconditioning – JEGO9062 (¾”) Video Tape 63 – Valve Grinding – JEGO9063 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 21
TITLE: Demonstrate Checking Cylinder Head for Reusability
EQUIPMENT REQUIRED:
Cylinder Head Straight Edge Feeler Gauge Magna-Flux Group Liquid Dye Kit
PROCEDURE:
1. Clean head thoroughly. 2. Follow videotape instructions.
REFERENCE:
Service Manual Video Tape 62 - Cylinder Head Reconditioning JEGO9062 (¾”) Video Tape 63 – Valve Grinding JEGO9063 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 22
TITLE: Demonstrate Testing Load Sensing, Pressure Compensating Hydraulic System
EQUIPMENT REQUIRED:
Gauge Group Appropriate Machine
PROCEDURE:
1. Measure system maximum pressure. 2. Measure system margin pressure. 3. Measure system low pressure standby. 4. Record your findings on worksheet #16 and attach to this form.
REFERENCE:
Service Manual Video Tape 202 - Pressure Compensated Load Sensing Hydraulic System SEVN9202 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 23
TITLE: Demonstrate Measuring Fuel For Specific Gravity
EQUIPMENT REQUIRED:
1P7408 Thermo-Hydrometer – Range 29º- 41º API 5P2712 Thermo-Hydrometer – Range 39º- 51º 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENT EMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 24
TITLE: Demonstrate Testing Fuel Injection Nozzles
EQUIPMENT REQUIRED: 5P4150 Nozzle Tester Group Direct Injection Nozzle (Capsule Type) Direct Injection Nozzle (Pencil Style) Precombustion Chamber Nozzle 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 (¾”) Video Tape 167 – Fuel Nozzle Testing SEVV9167 (¾”) Special Instructions - SEHS7292, SEHS7350, SEHS7390 Lift Truck Video Tape 42 - Testing Perkins Nozzle SEVV7042 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 25
TITLE: Demonstrate Testing a Cooling System and Components.
EQUIPMENT REQUIRED:
9S8140 Pressurizing Pump Regulators Machine Heat Source Thermometer Conditioner test kit Coolant Tester 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 (½”) Lift Truck Video Tape 23 – Lift Truck Cooling Systems Troubleshooting SEVV7023 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 26
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 27
TITLE: Demonstrate Measuring Coolant for Freezing Point and Inhibitor Concentration
EQUIPMENT REQUIRED:
Coolant Samples 8T5296 Coolant Conditioner Kit 5P0957 Coolant Tester Commercial Anti-freeze Tester 5P9734 Coolant Syringe
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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 28
TITLE: Demonstrate Testing Glow Plugs
EQUIPMENT REQUIRED:
Glow plugs form Caterpillar engine or Lift Truck engine with glow plugs Electric test bench Digital Clamp on ammeter Digital Multimeter 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 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 29
TITLE: Retired
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 30
TITLE: 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: Special Instructions - SEHS6891 Special Instructions - SEHS8268 Battery Service Manual - SEBD0625 Electric Lift Truck T/S Series Part 1 Module 4 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 31
TITLE: Demonstrate Test a Lead Acid Battery
EQUIPMENT REQUIRED: Battery 5P9735 Battery Fluid Probe Digital Multimeter 5P0957 Coolant and Battery Tester Clamp on Ammeter 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:
Special Instructions – SEHS8268 Battery Service Manual – SEBD0625 Lift Truck Video Tape 25 – Lift Truck Battery Servicing SEVV7025 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITION PERFORMANCE SKILL 32
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 33
TITLE: 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 (¾”) Lift Truck Video Tape 9- Troubleshooting The 3-speed Power Shift Transmission SEVV7009 (¾”) Lift Truck Video Tape 52- Single Speed Power Shift Transmission Orientation, Test & Adjust SEVV7052 (¾”) Special Instructions - SEHS7807 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 34
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 35
TITLE: 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: Special Instructions - SEHS8429 Check the 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 36
TITLE: 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. 4. Record your findings on worksheet #20 and attach to this form.
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 37
TITLE: Demonstrate Bevel Gear/Pinion Adjustments
EQUIPMENT REQUIRED: Bevel Gear/Pinion Spring Gauge 8S2328 Dial Indicator 1P2390 Pinion Depth Gauge Lubriplate or suitable substitute 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 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 38
TITLE: 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 (¾”) Service Magazine - 11/4/85 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 39
TITLE: 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 (½”) Special Instructions - GMGO2591 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 40
TITLE: 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 CD’s or SIS Web
PROCEDURE:
1. Fill out report2. Follow directions found in reference material.3. Record your findings on worksheet #22 and attach to this form.
REFERENCE:
Guidelines to follow in Reporting SIMS Information (SEBD0809) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 41
TITLE: 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 Special Instructions - SMHS7185 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 42
TITLE: 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 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 43
TITLE: 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 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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 (½”) Wall Chart - SEWV1339 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 45
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 46
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 47
TITLE: Demonstrate Connection of a Hydraulic Flow Meter
EQUIPMENT REQUIRED:
Hydraulic Flow Meter Machine
PROCEDURE:
1. Connect correct tooling for machine being tested. 2. Perform systems test according to Service Manual. 3. Interpret results according to Service Manual guidelines. 4. Record your findings on worksheet # 23 and attach to this form.
REFERENCE:
Service Manual Special Instructions - SEHS7097-01 and SMHS7308-00 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 48
TITLE: 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 (½”) Video Tape 77 - Reconditioning Hydraulic Cylinders SEVV9077 (¾”) Special Instructions – SEHS7150 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 49
TITLE: 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
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 50
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 51
TITLE: 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 Magazine - 4/28/71 Service Manual - REGO0756 - Series "30" Pump Guidelines for Reusable Parts - SEBF8073 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 52
TITLE: 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
2. Record your findings on worksheet #24 and attachto this form.
REFERENCE: Appropriate Service Manual Special Instructions – SEHS7768 Video Tape 165 – 6V2150 Starting/Changing Analyzer Group SEVV9165 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 53
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 54
TITLE: 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. 2. Compare to welding standard for appearance quality.
REFERENCE:
Hobart Pocket Welding Guide Service Welding Guide - SEBD0512 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 55
TITLE: 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. 2. Compare to welding standard for appearance quality.
REFERENCE:
Hobart Pocket Welding Guide 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 56
TITLE: Demonstrate These Weld Positions: 1- Flat, 2- Horizontal, 3- Vertical, 4- Overhead
EQUIPMENT REQUIRED:
Welding Machine Electrodes Metal
PROCEDURE:
1. Demonstrate each weld position. 2. Compare to welding standard for appearance quality.
REFERENCE:
Service Welding Guide - SEBD0512 Hobart Pocket Welding Guide 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 57
TITLE: 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 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 58
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 59
TITLE: 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. Locate three (3) specifications for industrial engines.2. Locate three (3) specifications for vehicle engines.3. Locate three (3) specifications for power train.4. 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:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 60
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 61
TITLE: 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
Record your findings on worksheet # 21 and attach to this form.
REFERENCE:
Special Instructions - SEHS8417 Check Special Instructions for the latest update. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 62
TITLE: 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.3. Record your findings on worksheet #25 and attach to this form.
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 63
TITLE: 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)
Record your findings on worksheet # 21 and attach to this form.
REFERENCE: SEBD0547 - SIRS User Instructions 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 64
TITLE: 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.S.
S.I.R.S. T.I.B. FIND
P.S.P. S.M.C.S.
Record your findings on worksheet # 21 and attach to this form.
REFERENCE:
SEBD0547 SIRS User Instructions 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 65
TITLE: Demonstrate Proper Removal and Installation of Crankshaft Seal and Wear Ring.
EQUIPMENT REQUIRED:
Seal Removal and Installation Tools Engine
PROCEDURE:
1. Remove and install seal and wear sleeve according to Special Instructions. 2. Check surfaces for cleanliness. 3. Lightly lubricate seal. 4. Use caution to prevent seal damage. 5. Check alignment to prevent damage to seal.
REFERENCE:
Service Manual Video Tape 33 – SEVV9033 (¾”) Special Instructions - SMHS7100 and SMHS8301 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 67
TITLE: 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:
Special Instructions - SMHS7140 Video Tape 92 – How To Use Cooling System Diagnostic Tools Themistors SEVN9092 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 68
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 69
TITLE: 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:
Guideline for Reusable Parts - SEBF8006 and SEBF8014 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 70
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 71
TITLE: 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:
Special Instructions – SEHS7734 SR4 Generator 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 72
TITLE: Demonstrate Checking a Variable Resistor (Potentiometer)
EQUIPMENT REQUIRED:
Multimeter Variable Resistor
PROCEDURE:
1. Select proper scale2. Attach leads correctly.3. Disconnect any wires that may cause an incorrect reading.4. Determine values in ohms and test resistor for open and shorted circuit.
REFERENCE:
SR4 Generator Service Manual Special Instructions – SEHS7734 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 73
TITLE: Demonstrate Checking a Capacitor EQUIPMENT REQUIRED: Multimeter Capacitor PROCEDURE:
1. Select proper scale.2. Attach leads correctly.3. Reverse Polarity.4. Determine Condition of Capacitor
REFERENCE: Service Manual SR4 Generator Service Manual Special Instructions – SEHS7734 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 74
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 75
TITLE: 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: Service Welding Guide - SEBD0512 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 76
TITLE: Demonstrate the Operation and Servicing of the Glass Cleaning Machine
EQUIPMENT REQUIRED: Several Items for Cleaning Bead Cleaning Machine PROCEDURE: 1. Demonstrate precaution to follow when using different types of metals. 2. Steam clean greasy parts first. 3. Never put wet parts in cleaner. 4. Clean valves and change the cleaning media. REFERENCE: Guideline for Reusable Parts Fundamental Skills Development Guide - SEGV2505 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITION
PERFORMANCE SKILL 77 TITLE: Demonstrate Proper Use of Caterpillar Adhesives EQUIPMENT REQUIRED: 7M7260 Adhesive 5H2471 Adhesive 9S3262 Sealant Kit 5M2941 Epoxy Cement 5S1454 Sealing Compound 7F2770 Rubber Cement 4H5363 Permatex No. 1 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 78
TITLE: 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.
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 79
TITLE: 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 (¾”) Video Tape 47 – Cylinder Block Liner Seat Sleeving JEGO9047 (¾”) Video Tape 147 – D342 & D353 Spacer Plate Block Salvage SEVV9147 (¾”) Check S.I.R.S. and Find System 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENT EMPLOYEE EVALUATION GUIDE
DEFINITION PERFORMANCE SKILL 80
TITLE: Retired
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 81
TITLE: 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.
3. Record your findings on worksheet #12 and attach to this form. REFERENCE: Special Instructions - SEHS8149 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 82
TITLE: Retired
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 83
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 84
TITLE: 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 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 85
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 86
TITLE: Demonstrate Use of Bearing/Gear Puller Group.
EQUIPMENT REQUIRED: Shaft with Gear or Bearing 1P2321 or 1P2322 Puller
PROCEDURE: 1. Properly set up tooling. 2. Safely remove bearing or gear. 3. Safely remove a bearing cup. 4. Safely use the bearing heater. 5. Safely install a gear or bearing.
REFERENCE: Service Manual - SENR3193 Video Tape 44 – Working With Pullers SEVN9044 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 87
TITLE: 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 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 88
TITLE: Demonstrate Installation of Piston Assembly into a Cylinder EQUIPMENT REQUIRED: Piston with Rings, attached to Connecting Rod Ring Compressor Liner or Block PROCEDURE: 1. Correctly position rings on piston. 2. Properly lubricate piston. 3. Properly prepare rod and rod bolts to protect crankshaft. 4. Install piston assembly according to Service Manual procedure. REFERENCE: Service Manual Video Tape 138 - Piston Pin Bearing Removal and Installation SEVC9138 (¾”) Lift Truck Video Tape 46 - Continental Engine Rebuild SEVV7046 (¾”)
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 89
TITLE: 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: Service Manual - SENR2077 Video Tape 185 – Hydrostatic Loader Troubleshooting SEVN8185 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 90
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 91
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 92
TITLE: 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. 3. Record your findings on worksheet #26 and attach to this form. REFERENCE: Service Manual Video Tape 162 – Use of The 6V3100 Diesel Engine Timing Indicator SEVN9162 (½”) Special Instructions - SEHS7742 Service Magazine - 8/31/81 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 93
TITLE: Demonstrate Checking a Diode EQUIPMENT REQUIRED: Multimeter or VOM Diode Load Voltage Tester PROCEDURE:
1. Attach multimeter and record values in ohms in both directions2. Attach load tester and check for excessive leakage.3. Determine diodes condition.
REFERENCE: Service Manual Special Instruction – SEHS7734 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 94
TITLE: 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 Special Instructions - SEHS7734 Flight System Instructions 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 95
TITLE: 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. 3. Record your findings on worksheet #28 and attach to this form.
REFERENCE: Service Manual Video Tape 186 – Hydrostatic Loader Troubleshooting II - Analyzing the Data Sheet SENR4119 - SEVN9186 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 96
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 97
TITLE: 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 Special Instructions - SMHS7842 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 98
TITLE: 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 (½”) Video Tape 81 – Lifting A Vehicle With Hydraulic Jack Stands SEVN9081 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 99
TITLE: 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 (½”) Fundamental Skills Development Guide - SEGV2505 Special Instructions - GMGO0576 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 100
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 101
TITLE: Demonstrate Use of Dial Bore Gauge EQUIPMENT REQUIRED: Cylinder Liner 1P3537 Gauge Group PROCEDURE: 1. Check calibration of gauge. 2. Check for bore size. 3. Check for bore out-of-round. 4. Check for bore taper. REFERENCE: Service Manual Special Instructions - GMGO0981 Guideline for Reusable Parts - SEBF8049 *Transmission Rebuild Specialists should use 5P2170 Dial Bore Gauge Group. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 102
TITLE: 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 Special Instruction - SMHS6672 Video Tape 77 – Reconditioning Hydraulic Cylinders SEVV9077 (¾”) Rebuild Process Control Guidelines - Hydraulic Cylinders 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 103
TITLE: 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 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 ____________________ DATE__________.
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 104
TITLE: Demonstrate Use of Vibration Selector EQUIPMENT REQUIRED: Vibration Selector Generator set, truck or tractor PROCEDURE: 1. Measure amplitude as per Special Instructions. 2. Measure frequency as per Special Instructions. 3. Record results and compare to specification. 4. 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 105
TITLE: Retired
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 106
TITLE: 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 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 107
TITLE: Demonstrate Use of Bearing Puller
EQUIPMENT REQUIRED:
5F7343 Puller Shaft with bearing installed Push-Puller or T-bar and Hydraulic Press
PROCEDURE:
1. Follow safety rules.2. Check pullers for condition.3. Properly set up tool.
REFERENCE:
Video Tape 44 – Working With Pullers, Torque Wrenches, Multipliers SEVN9044 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 108
TITLE: Demonstrate Use of Bearing Cup Puller EQUIPMENT REQUIRED: Bearing Cup Puller Housing with bearing race installed. PROCEDURE:
1. Follow safety rules.2. Correctly, install puller.3. Remove cup.
REFERENCE: Video Tape 44 – Working With Pullers, Torque Wrenches, Multipliers SEVN9044 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 109
TITLE: 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 Video Tape 44 – Working With Pullers, Torque Wrenches, Multipliers SEVN9044 (½”) Fundamental Skill Development Guide - SEGV2505 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 110
TITLE: Retired
EQUIPMENT REQUIRED:
PROCEDURE:
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 111
TITLE: 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: Special Instructions - SMHS8391 Fundamental Skills Development Guide - SEGV2505 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 112
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 113
TITLE: 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. Drill pilot hole. 2. Show correct drill bit selection. 3. Exercise care in use of tap. 4. Use thread lubricant. 5. Follow safety precautions. 6. Install Threaded Insert and drive "Keys" with special tooling. REFERENCE: Fundamental Skills Development Guide Bars and Reconditioning Tools - SEGV2505 Special Instructions - SEHS8792 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 ____________________ DATE .
REVISED 20010
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 114
TITLE: Demonstrate Installation Of Threaded Insert. EQUIPMENT REQUIRED: Threaded Inserts Thread Tap Drill Motor and Bits Tool Guide PROCEDURE:
1. Drill out damaged threads.2. Countersink hole.3. Cut new threads.4. Screw insert in slightly below surface.5. Drive “kees” down with special tool.
REFERENCE: Special Instructions – SEHS8792 Fundamental Skills Development Guide – Bars and Reconditioning Tools – SEGV2505 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 115
TITLE: 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 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 116
TITLE: Demonstrate Use of Cylinder Liner Puller EQUIPMENT REQUIRED: 5P8665 Cylinder Liner Puller PROCEDURE: 1. Follow safety rules. 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 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 117
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 118
TITLE: 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. 2. Record your findings on worksheet #16 and attach to this form. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 119
TITLE: Demonstrate Use of Engine Handling Equipment. EQUIPMENT REQUIRED: 9S9060 Dual Hook Hoist 9S8500 Engine Stand Engine Block
PROCEDURE:
1. Install lifting eyes2. Use spreader bar.3. Follow safety procedures.4. 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 (¾”) Video Tape 58 - Roll-over Hoist JEGO9057 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 120
TITLE: Demonstrate Use of 5P6584 Timing Light EQUIPMENT REQUIRED: 5P6584 Timing Light PROCEDURE: 1. Attach battery leads to 12V source. 2. Attach secondary pickup lead on number 1 wire. 3. Aim light at timing marks found on flywheel. 4. Turn magneto or distributor to advance or retard timing - read just to
within specifications. REFERENCE: Service Manual Natural Gas Engine 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 121
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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 5P3600 Flow Meter 8S4627 Circuit Tester 6V3121 Multitach Hydrostatic Power Control Unit 8N5945 Adapter Assembly for 943 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. 5. Record your findings on worksheet #28 and attach to this form. REFERENCE: Service Manual - SENR3193 Video Tape 186 – Hydrostatic Loader Troubleshooting II – Analyzing the Date Sheet SENR4119 – SEVN9186 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 123
TITLE: Demonstrate Disassembly and Assembly of Steering Clutch EQUIPMENT REQUIRED: Steering Clutch (Oil or Dry) Steering Clutch Stand
PROCEDURE: 1. Disassemble and assemble steering clutch. 2. Measure and compare stack height. 3. Follow safety procedures outlined in Service Manual. 4. Check S.I.R.S for latest updated information
REFERENCE: Service Manual Video Tape 71- Rebuilding Oil-Type Steering Clutches SEVN9071 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 124
TITLE: 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 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 125
TITLE: 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 Special Instructions - SMHS6954 Video Tape 79 – Track Removal and Installation SEVN9079 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 126
TITLE: 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 Special Instructions - SMHS8348 Video Tape 79 - Track Removal and Installation SEVN9079 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 127
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 128
TITLE: 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 Check S.I.S. or S.I.R.S. and FIND for the latest updates
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)
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 129
TITLE: Demonstrate Cleaning Air Cleaner Element
EQUIPMENT REQUIRED: Dirty air cleaner element Air supply, hose and nozzle ( 30 psi Max.) Drop light. PROCEDURE:
1. Clean filter2. Check cleaner for holes.3. Check sealing ring.
REFERENCE: Service Manual Operation and Maintenance Guide 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 130
TITLE: 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 Special Instructions - SMHS9208 Lift Truck Video Tape 58 – C.A.V. Fuel Injection Pump Removal and Installation SEVV7058 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 131
TITLE: Demonstrate Final Drive Sprocket Bearing Adjustment
EQUIPMENT REQUIRED:
Conventional Track-Type Tractor 6V0082 Tool Group PROCEDURE: 1. Demonstrate bearing adjustment. REFERENCE: Service Manual Special Instruction - SMHS7583 Service Magazine – 10/20/80 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 132
TITLE: Demonstrate Testing Hydraulic System Main Relief and Pressure Limiter
EQUIPMENT REQUIRED:
D6H or D7H Track-Type Tractor 6V4161 Hydraulic Test Group Hand Tools PROCEDURE: 1. Follow step by step procedure outlined in the Service Manual. 2. Record your findings on worksheet #16 and attach to this form. REFERENCE: Appropriate 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 133
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 134
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 135
TITLE: 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 8S4627 Circuit Tester PROCEDURE:
1. Follow procedure outlined in the Service Manual or Special Instructions. REFERENCE:
Service Manual Special Instructions - SEHS8024 Video Tape 172 – Testing and Adjusting The New Scroll Fuel System SEVV9172 (¾”) Video Tape 182 – Testing and Adjusting The Hydraulic Fuel Ratio Control On “B” Series Engine SEVV9182 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 136
TITLE: Demonstrate Testing Hydraulic System Pilot Pressure
EQUIPMENT REQUIRED:
Machine with pilot operated hydraulic control valve. Examples: 225, 235, 245, E180, 963, 973, 992C, D11N 6V4161 Hydraulic Test Group Hand Tools
PROCEDURE:
1. Follow procedure outlined in the appropriate Service Manual. 2. Record your findings on worksheet #16 and attach to this form.
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 137
TITLE: 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 8S4627 Circuit Tester 6V2031 Rack Position Indicator PROCEDURE: 1. Follow Directions in service manual
REFERENCE: Service Manual Fuel Setting Chart Special Instruction – SEHS8024 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 138
TITLE: Retired EQUIPMENT REQUIRED: PROCEDURE: REFERENCE: 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 139
TITLE: 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) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 140
TITLE: Demonstrate Checking a Silicone Controlled Rectifier EQUIPMENT REQUIRED: Silicone Controlled Rectifier Digital Multimeter Test Light 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: SR4 Generator Service Manual Flight Systems Instructions Electric Lift Truck Troubleshooting Series Part 1 – Module 5
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 141
TITLE: Demonstrate Use of a Meggar
EQUIPMENT REQUIRED:
Electric Set Meggar PROCEDURE: 1. Prepare electric set. 2. Connect meggar. 3. Administer test. 4. Record readings.
REFERENCE:
SRCR Generator Service Manual SR4 Generator 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 142
TITLE: 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:
1. Install correct tooling. 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 Special Instructions - SEHS6663 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 143
TITLE: Demonstrate Testing Steering Relief Pressure
EQUIPMENT REQUIRED:
Wheel Loader Hydraulic Test Group Hand Tools PROCEDURE: 1. Follow procedure outlined in appropriate Service Manual. 2. Record your findings on worksheet #16 and attach to this form. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 144
TITLE: Demonstrate Testing Rod End Tilt Relief Valves
EQUIPMENT REQUIRED:
7M1293 Adapter 5S4648 Hose 4M5317 Bushing Wheel Loader 7S8714 Pressure Gauge
PROCEDURE: 1. Follow procedure outlined in appropriate Service Manual. 2. Record your findings on worksheet #16 and attach to this form. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 145
TITLE: 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. Check pressure. 2. Check signal pressure reading where staging occurs. 3. Check maximum system pressure. 4. Record your findings on worksheet #16 and attach to this form. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 146
TITLE: 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 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 147
TITLE: Demonstrate Testing Head End Relief Valves for Lift Cylinder
EQUIPMENT REQUIRED: 5P47 Blocking Cover 6V4143 Coupling 6V4161 Test Group 5P4816 Pressure Gauge 8S3033 Electric Hydraulic Pump 6V3081 Hose 943, 953, 963, or 973 Track Loader PROCEDURE:
1. Follow procedure outlined in the appropriate Service Manual. 2. Record your findings on worksheet #16 and attach to this form. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 148
TITLE: 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 Special Instructions - SMHS6988 Video Tape 76 - Testing Sleeve Metering Pumps with Fuel Injection Test Bench SEVV9076 (¾”) Video Tape 103 - V-Type Sleeve Metering Fuel Pump Calibration SEVV9103 (¾”) Video Tape 104 - In-Line Sleev3e Metering Fuel System Adjustment SEVV9104 (¾”) Video Tape 131 - Sleeve Metering Fuel System Reconditioning SEVV9131 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 149
TITLE: Demonstrate Pin Timing Camshafts on a 3500 Series Engine
EQUIPMENT REQUIRED:
9S9082 Engine Turning Tool 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
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 150
TITLE: 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 MODELDarr Equip. Co. ABC Construction 14GADDRESS ADDRESS SERIAL NUMBERP.O. Box 540788 6789 Tenth St. 96U06585Dallas, TX. 75354-0788 Dallas, TX. 75221 HOUR METER DEALER CODE CUSTOMER COMPLAINT 37E090 hydraulic line to wheel PARTDEL. DATE OF VEHICLE lean cylinder burst Gp. Name: Leaning February 14, 1985 Wheel LinesWORK ORDER CLOSING DATE Gp. Number: 8D8600 -March 17, 1990 Sims - 3252,5057,5102,HOURS TO REPAIR ENGINE MODEL 63126.5 Hours 3306 FAILED PARTTODAY'S DATE SERIAL NUMBER Name: Hose AssemblyMarch 19, 1990 8Z22888 Number: 9D5969WORK ORDER NUMBER RIPPER MODEL PARTS REPLACEDJ1234D 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 151
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 152
TITLE: 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 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 153
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 154
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 155
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 156
TITLE: 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. Bring oil in compartment to operating temperature 2. Take an oil sample by each sampling method. 3. Correctly, complete the sample labels. 4. Route samples to the Oil Lab. 5. Complete and turn in time card. REFERENCE:
Special Instructions - SEHS9043 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 157
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 158
TITLE: Demonstrate Evaluating Worn Transmission Plates and Discs
EQUIPMENT REQUIRED: Plates and Discs Guideline for Reusable Parts 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: Guideline for Reusable Parts - SEBF8031 Lift Truck Video Tape 8 - Troubleshooting The 2-Speed Power Shift Transmission SEVV7008 (¾”) Lift Truck Video Tape 9 - Troubleshooting The 3-speed power Shift Transmission SEVV7009 (¾”) Lift Truck Video Tape 52 - Single Speed Power Shift Transmission Orientation, Test & Adjust SEVV7052 (¾”) Lift Truck Video Tape 53 - single Speed Power Shift Transmission Disassembly & Assembly SEVV7053 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 159
TITLE: 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 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 ____________________ DATE .
.
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 160
TITLE: 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. 3. Record your findings on worksheet #15 and attach to this form. REFERENCE: Special Instructions - GMGO0981 Special Instructions - SMHS7220 Guideline for Reusable Parts - SEBF8049 and SEBF8068 Diagnosing Piston Ring and Liner Failure - FEG45132 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 161
TITLE: Demonstrate Evaluating Worn Main and Rod Bearings
EQUIPMENT REQUIRED:
Samples of Rod and Main Bearings PROCEDURE: 1. Compare samples to guidelines and determine reusability. REFERENCE: Guidelines for Reusable Parts - SEBF8009 Engine Bearings and Crankshafts - SEBD0531 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 162
TITLE: 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 6V87 Valve Stem Gauge 5P6518 Fixture Group 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 Special Instructions - SEHS7758 Guideline for Reusable Parts - SEBF8002 & SEBF8034 Video tape 62 - Cylinder Head Reconditioning JEGO9062 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 163
TITLE: Demonstrate Evaluating Worn Turbocharger Parts
EQUIPMENT REQUIRED:
Turbocharger Parts 5P6518 Fixture Group PROCEDURE:
1. Compare samples to guidelines and determine reusability. 2. Record your findings on Work Sheet #35 and attach to this form REFERENCE:
Guideline for Reusable Parts - SEBF8018 Analyzing Turbocharger Failure - FEG45138 Special Instruction - SMHS6998 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 164
TITLE: Demonstrate Use of Bearing Heater
EQUIPMENT REQUIRED: Bearing Heater
PROCEDURE:
1. Prepare item to be heated2. Adjust heater temperature control
CAUTION: DO NOT OVERHEAT! REFERENCE: Service Manual Fundamental Skills Development Guide – SEGV2505 –page 499 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 165
TITLE: Demonstrate PROFICIENCY in using the listed Tool Groups. EQUIPMENT REQUIRED: 8T5300 or 6V3100 Timing Indicator Machine 5P3600 Hydraulic Flow Meter 6V2100 Multitach Group 6V4060 Set Point Indicator 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 166
TITLE: 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: Special Instruction - SEHS8866 VR3 Voltage Regulator Supplement - SENR3473 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 167
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 168
TITLE: 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 Special Instructions - SEHS7918 Video Tape 178 - Use of The 6V4050 Transmission Shift Analyzer SEVN9178 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 169
TITLE: 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 Special Instructions - SMHS9208 L & M Guide 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 170
TITLE: Demonstrate Checking Engine Pressures on Cat or Other Engines
EQUIPMENT REQUIRED:
Engine 1U5470 or 6V9450 Engine Pressure Group PROCEDURE: 1. Check fuel system pressure according to Service Manual procedure. 2. Check Engine Boost 3. Check Engine Oil Pressure 4. State findings. REFERENCE: Service Manual Fuel Setting Micro Fiche 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 171
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 172
TITLE: Demonstrate Use of 6V146 LDC Analyzer
EQUIPMENT REQUIRED:
Lift Truck with LDC Panel 6V146 LDC Analyzer PROCEDURE:
1. Install correct tooling. 2. Conduct test according to Special Instruction procedure. 3. Analyze test results and make recommendations for corrections
if needed. REFERENCE: Service Manual Special Instructions - SEHS6633 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 173
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 174
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 175
TITLE: 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 doesn’t rotate, attempt to rotate entire assembly by hand. If it can be rotated, then rotator is defective. Mark for replacement.
REFERENCE: Video Tape 62 - Cylinder Head Reconditioning JEGO9062 (¾”) Guidelines for Reusable Parts – SEBF8002 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 176
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 177
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 178
TITLE: Demonstrate Removal and Installation of Camshaft Bearings and
Evaluate Camshaft for Reusability EQUIPMENT REQUIRED: Engine Block Micrometers Camshaft Camshaft Bearings 8S2241 Camshaft Bearing Group
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. 4. Record your findings on worksheet #29 and attach to this form.
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 179
TITLE: Demonstrate Differential Steering Diagnostic Instrument Test
EQUIPMENT REQUIRED: Tractor with Differential Steering 1U5796 Pressure Differential Gauge Group 6V7830 Tetragauge Group 8T0853 (0-60PSI) Gauge 6V3121 Multitach Group 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 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 180
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 181
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 182
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 183
TITLE: 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 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 184
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 185
TITLE: Demonstrate Determining Cause for Open Fuse or Circuit Breaker
EQUIPMENT REQUIRED: Digital Multimeter Machine PROCEDURE: 1. Explain "shorts," "opens," "intermittence, short to ground." 2. Find cause for open fuse. 3. Find cause for open circuit breaker. 4. Troubleshoot for short to ground. REFERENCE: Service Manual Service Magazine 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 186
TITLE: 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 obtained3. 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 (½”) Video tape 94 - How to Use the Cooling System Diagnostic Tools Air Flow Meter SEVN9094 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 187
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 188
TITLE: 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: Guideline for Reusable Parts 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 189
TITLE: Demonstrate Disassembly and Assembly of a Powershift Transmission
EQUIPMENT REQUIRED: Powershift Transmission Lifting Equipment Hand Tools PROCEDURE: 1. Follow procedure outlined in appropriate Service Manual. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 190
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 191
TITLE: Demonstrate Machining Sprocket Shaft Bore
EQUIPMENT REQUIRED: Final Drive Case Boring Bar
PROCEDURE: 1. Machine bore to accept fabricated sleeve. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 192
TITLE: Demonstrate Measuring Steering Clutch Thickness
EQUIPMENT REQUIRED: Steering Clutch Measuring Scale PROCEDURE: 1. Check clutch pack thickness. Compare with specification.
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 193
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 194
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 195
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 196
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 197
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 198
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 199
TITLE: 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. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 200
TITLE: 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) Service Manual - SENR2107 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 201
TITLE: 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: Special Instruction - SEHS8346 Special Instruction - SEHS8874 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 202
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 203
TITLE: Demonstrate Checking Excavator Swing Bearing Wear
EQUIPMENT REQUIRED: Excavator 8S2328 Dial Indicator Group
PROCEDURE: 1. Properly attach dial indicator. 2. Properly position machine. 3. Record dial indicator reading. 4. Follow procedure in Service Manual.
REFERENCE: Service Manual Service Magazine June 2, 1986 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 204
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 205
TITLE: 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: 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 206
TITLE: 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 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 207
TITLE: 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 (½”) Video Tape 155 - Geometric Tolerancing SEVV9155 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 208
TITLE: 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 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 209
TITLE: 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: Service Welding Guide - SEBD0512 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 210
TITLE: 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 Service Welding Guide - SEBD0512 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 211
TITLE: 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: Special Instruction - SEHS8712 Service Magazine July 20, 1987 "Additional Guidelines for Using the 8T2700 Blowby/Air flow Indicator Group Know Your Cooling System - SEBD0518 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 212
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 213
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 214
TITLE: 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: Special Instructions - SEHS6696 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 215
TITLE: 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 (½”) Special Instruction - SEHS8979 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 216
TITLE: 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 Special Instruction - SMHS8557 Service Magazine 8/12/85 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 217
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 218
TITLE: Demonstrate using the 8T1000 Electronic Position Indicator
EQUIPMENT REQUIRED: 8T1000 Electronic Position Indicator 6V4060 Set Point 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: Special Instruction - SEHS8623 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 219
TITLE: 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: Special Instruction - SEHS8382 LTTB 10/01/84 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 220
TITLE: 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: Special Instruction - SEHS8742 Special Instruction - SEHS8747 Special Instruction - SEHS8743 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 221
TITLE: Retired
EQUIPMENT REQUIRED: PROCEDURE: REFERENCE: 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 222
TITLE: Demonstrate Correct Assembly of Track Roller and Idler
EQUIPMENT REQUIRED: Rollers, idlers Seal Installer
Pressing equipment Plug Installer Dial Indicator Test Group Hand Tools Test Tooling Regulated Air PROCEDURE: 1. Follow Service Manual procedures to inspect and assemble components. 2. Test for Leaks REFERENCE: Service Manual Undercarriage Reconditioning Bulletin - SEBF8515 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 223
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 224
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 Undercarriage Reconditioning Bulletin MP-2 SEBF8506 Undercarriage Reconditioning Bulletin MP-3 SEBF8507 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 225
TITLE: Demonstrate Use of Curtis 1020 Power Prover
EQUIPMENT REQUIRED: Electric Lift Truck Curtis 1020 Power Prover PROCEDURE:
1. Install correct tooling.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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 226
TITLE: 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: Special Instruction - SEHS8579 Video Tape194 - Transmission Controls for the 631/637E Wheel Tractor- Scrapers SEVN9194 (½”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 227
TITLE: 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:
Special Instruction - SEHS8038 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 228
TITLE: 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: Service Manual - SENR3535 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 229
TITLE: 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: Service Manual - SENR3535 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 230
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 231
TITLE: Demonstrate Use of 6V2172 Test Terminal Board
EQUIPMENT REQUIRED: Electric Lift Truck with LDC Panel 6V2172 Test Terminal Board 6V3030 VOM
PROCEDURE: 1. Install correct tooling. 2. Check power integrity to logic, according to Technical Bulletin instructions. 3. Conduct test according to Service Manual procedure. 4. Analyze test results and make recommendations for corrections.
REFERENCE: Service Manual L.T. Technical Bulletin March 1982 - Troubleshooting the LDC System Special Instructions - SMHS6662 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 232
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 233
TITLE: 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 to Service Manual procedure.
2. Analyze test results and make recommendations for corrections, if needed.
REFERENCE: Service Manual Lift Truck Video Tape 6 - Perkins Fuel System SEVV7006 (¾”) Lift Truck Video Tape 7 - Perkins Fuel System SEVV7007 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 234
TITLE: Demonstrate Checking High Pressure Relief Valves on Hydrostatic
Transmission
EQUIPMENT REQUIRED: Hydrostatic Transmission Test Stand or Lift Truck with Hydrostatic Transmission
PROCEDURE: 1. Install correct tooling.
2. Properly demonstrate checking high pressure relief valves on hydrostatic transmission according to Service Manual procedure.
3. Adjust pressure if necessary.
REFERENCE: Service Manual - SENB8055 L.T. Video Tape 31 - Hydrostatic Transmission Testing and Adjusting SEVV7031 (¾”) L.T. Spec. Book - SENB8060 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 235
TITLE: 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: 1. Install correct tooling. 2. Properly check charge pump pressure relief valve according to Service
Manual procedure. 3. Adjust pressure if necessary. REFERENCE: Service Manual - SENB8055 L.T. Video Tape 31 - Hydrostatic Transmission Testing and Adjusting SEVV7031 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 236
TITLE: Demonstrate Checking and Adjusting Hydrostatic Transmission Low Pressure
Relief Valve
EQUIPMENT REQUIRED: Hydrostatic Transmission Test Stand or Lift Truck with Hydrostatic Transmission 0-600 Pressure Gauge Tachometer
PROCEDURE: 1. Install correct tooling.
2. Properly check low pressure relief valve according to Service Manual procedure.
3. Adjust pressure if necessary.
REFERENCE: Service Manual - SENB8055 L.T. Video Tape 31 - Hydrostatic Transmission Testing and Adjusting SEVV7031 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 237
TITLE: Demonstrate Checking Hydrostatic Transmission Servo Cylinder
Linkage Wear
EQUIPMENT REQUIRED: Hydrostatic Transmission
PROCEDURE: 1. Drain approximately one gallon of oil from transmission, if not already drained. 2. Mark (for assembly) and remove forward and reverse servo cylinder. 3. Check for excessive linkage wear, using reusability guidelines. 4. Make recommendation for reuse or replacement.
REFERENCE: Service Manual Guideline for Reusable Parts - SEBF8026 Hydrostatic Transmission Page 35 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 238
TITLE: Demonstrate Checking Hydrostatic Transmission Charge Pump Drive
EQUIPMENT REQUIRED: Hydrostatic Transmission 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 Guideline for Reusable Parts - SEBF8026 Hydrostatic Transmission 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 239
TITLE: 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 to Service Manual procedure.
REFERENCE: Service Manual Lift Truck Video Tape 4 - Rebuilding a Hydrostatic Transmission Disassembly. SEVV7004 (¾”) Lift Truck Video Tape 5 - Rebuilding a Hydrostatic Transmission Assembly SEVV7005 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 240
TITLE: 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 to Service Manual procedure.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 (¾”) L.T. Video Tape 5 - Rebuilding a Hydrostatic Transmission SEVV7005 (¾”) L.T. Video Tape 31 - Rebuilding a Hydrostatic Transmission SEVV7031 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 241
TITLE: Demonstrate Adjusting Hydrostatic Transmission Control Valve
EQUIPMENT REQUIRED: Hydrostatic Transmission
PROCEDURE:
1. Follow the procedure in the Service Manual for removing centering spring end plug.2. Adjust external linkage according to Service Manual.
REFERENCE: Service Manual - SENB8055 L.T. Video Tape 31 - Rebuilding a Hydrostatic Transmission SEVV7031 (¾”) Check the S.I.R.S. and FOND 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 ____________________ DATE .
.
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 242
TITLE: Demonstrate Use of 1135T Curtis Tester
EQUIPMENT REQUIRED: Lift Truck with Curtis Lift Interrupter 1135T Curtis Tester PROCEDURE:
1. Install correct tooling2. 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
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 243
TITLE: 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: 1. Install correct tooling. 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 244
TITLE: 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 (¾”) Lift Truck Video Tape 55 - IMPCO LP Conversion Kit Installation SEVV7055 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 245
TITLE: 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 (¾”)
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 246
TITLE: Demonstrate Checking Crankshaft for Reusability EQUIPMENT REQUIRED: Used Crankshaft Two 5P8637 Vee Blocks Micrometers Dial Indicator 6V6035 Hardness Tester
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.3. Record your findings on worksheet #15 and attach to this form.
REFERENCE: Service Manual Guideline for Reusable Parts – SEBF8039, SEBF8041 and SEBF8043 Engine Bearings and Crankshafts – SEBD0531 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 247
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 248
TITLE: 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 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 249
TITLE: Demonstrate Checking High and Low Idle Speed on a Diesel Engine
EQUIPMENT REQUIRED: Lift Truck with Diesel Engine 6V3121 Multitach Group
PROCEDURE:
1. Install correct tooling.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 (¾”) Special instructions – SEHS7807 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 250
TITLE: Demonstrate Checking Tilt Cylinder Alignment
EQUIPMENT REQUIRED: Lift Truck Tilt Indicator or Protractor PROCEDURE: 1. Check tilt cylinder alignment according to Service Manual procedure. 2. Make adjustments if necessary.
REFERENCE: Service Manual L.T. Video Tape 3 - Mast Testing and Adjusting SEVV7003 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 251
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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 252
TITLE: 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. Install correct tooling. 2. Conduct test according to Service Manual procedure. 3. Analyze test results and make recommendation for corrections if needed. 4. Record your findings on worksheet #20 and attach to this form. REFERENCE: Service Manual Lift Truck Video Tape 8 -Troubleshooting The 2 Speed Power Shift Transmission SEVV7008 (¾”) Lift Truck Video Tape 9 - Troubleshooting The 3-speed Power Shift Transmission SEVV7009 (¾”) Lift Truck Video Tape 52 - Single Speed Power Shift Transmission Orientation, Test & Adjusting SEVV7052 (¾”) Special Instructions - SEHS7807 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 253
TITLE: 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 Transmission SEVV7053 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 254
TITLE: 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 (¾”) Lift Truck Video Tape 2 - LP Gas Systems Operation and Adjustment SEVV7002 (¾”) Gas Industries - LP - Gas Carburetion Systems - CEBS0001 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 255
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 256
TITLE: Demonstrate Removing and Installing Solid Tire from Wheel Assembly
EQUIPMENT REQUIRED: Wheel Assembly Tire Tape Measure 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 257
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 258
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 259
TITLE: Demonstrate Checking Cylinder for Wear
EQUIPMENT REQUIRED: Engine Hydraulic Cylinder 1P3537 Gauge Group 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 Special Instructions - GMGO0981 Guideline for Reusable Parts - SEBF8068 Fundamental Skills Development Guide - SEGV2505 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 260
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 261
TITLE: 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 (¾”) L.T. Technical Bulletin May 7, 1980 Pages 2-4 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 262
TITLE: 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 Special Instructions - SMHS6637 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 263
TITLE: 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 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 264
TITLE: Demonstrate Removing and Installing Forks
EQUIPMENT REQUIRED:
Lift Truck With Forks
PROCEDURE:
Follow Procedure Outlined in the Service Manual
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 265
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 266
TITLE: Demonstrate Control Valve Card Adjustment
EQUIPMENT REQUIRED: M-Series D STD and SA PROCEDURE: 1. Follow Service Manual procedure. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 267
TITLE: 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 Service Welding Guide - SEBD0512 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENT EMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 268
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 269
TITLE: 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 (¾”) Lift Truck Video Tape 54 - Mechanical Brake Adjustment SEVV7054 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 270
TITLE: Demonstrate Installation of Valve Guide Liner.
EQUIPMENT REQUIRED: 1404 Engine Head 6V3107 Tool Kit PROCEDURE:
1. Install correct tooling2. Machine valve guide3. Install liner.
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 271
TITLE: 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 (¾”) Gas Industries - LP - Gas Carburetion Systems CEBS0001 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 272
TITLE: 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 Gas Industries - LP - Gas Carburetion Systems CEBS0001 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 273
TITLE: 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 Gas Industries - LP - Gas Carburetion Systems CEBS0001 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 274
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 275
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 276
TITLE: Demonstrate Breaker Point Ignition System Component Operation Checks
EQUIPMENT REQUIRED: Lift Truck with Breaker Point Ignition System 5P6585 Electrical System Analyzer Dwell Meter Insulated Pliers
PROCEDURE:
1. Properly demonstrate breaker point ignition component operation checks according to Service Manual procedure.2. Analyze results and make recommendation for correction if needed.
REFERENCE: Service Manual Lift Truck Video Tape 10 - Lift Truck Ignition System – Breaker Points SEVV7010 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 277
TITLE: Demonstrate Breakerless Induction Ignition Component Operation Checks
EQUIPMENT REQUIRED: Lift Truck with Breakerless Induction Ignition 5P6585 Electrical System Analyzer 6V3030 VOM or equivalent Insulated Pliers PROCEDURE:
1. Properly demonstrate breakerless induction ignition component operation checks according to Service Manual procedure.2. Analyze results and make recommendation for correction if needed.
REFERENCE: Service Manual Lift Truck Video Tape 11 - Lift Truck Ignition System SEVV7011 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 278
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 279
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 280
TITLE: Demonstrate Seating Brushes on an Electric Motor
EQUIPMENT REQUIRED: Electric Lift Truck Drive Motor Ruler Calculator 343337 Brush Seater Stone 6V2063 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 (¾”) Special Instructions - SMHS6589 and SMHS6605 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 281
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 282
TITLE: 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 to Service Manual procedure.2. Make any repairs if necessary.3. Follow all safety precautions.
REFERENCE: Service Manual L.E.D. Troubleshooting EMS Panel 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 283
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 284
TITLE: 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 to Service Manual procedure.2. Make adjustments if necessary.
REFERENCE: Service Manual Lift Truck Video Tape 31 - Hydrostatic Transmission Testing and Adjusting SEVV7031 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 285
TITLE: Demonstrate Neutral Adjustment of Servo Cylinders on Hydrostatic
Transmission
EQUIPMENT REQUIRED: Hydrostatic Transmission Test Stand or Lift Truck with Hydrostatic Transmission 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 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 286
TITLE: Demonstrate Checking Steering Axle Linkage Adjustment
EQUIPMENT REQUIRED: Lift Truck PROCEDURE:
1. Check steering axle stops and linkage according to Service Manual procedure.
2. Make adjustments if necessary. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 287
TITLE: 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 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 288
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 289
TITLE: 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: Special Instructions - SMHS6823 L.T. Video Tape 27 - Thermoplastic Hydraulic Hose for Lift Truck SEVV7027 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 290
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 291
TITLE: 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:
Special Instruction - SEHS9160 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 292
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 293
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 294
TITLE: 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. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 295
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 296
TITLE: Demonstrate Use of Lubrication and Maintenance Guide EQUIPMENT REQUIRED: Service Manual PROCEDURE:
1. Locate engine oil type and change recommendations.2. Locate transmission oil type and change recommendations.3. Locate procedure for removing and installing LP fuel tanks.4. Record your findings on worksheet #21 and attach to this form.
REFERENCE: Service Manual Lift Truck Video Tape 26 – How to Use Lift Truck Service Manual SEVV7026 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 297
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 298
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 299
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 300
TITLE: 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 Special Instructions - SEHS8420 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 301
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 302
TITLE: 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 Special Instructions - SMHS7531 LTTB March 1987 Page 2 - New Electrical Control Panel LTTB 84-03-01 Current Limit Button 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 303
TITLE: Demonstrate Hydrostatic Transmission Field Test
EQUIPMENT REQUIRED: Lift Truck Equipped with Hydrostatic Transmission PROCEDURE: 1. Follow procedure in Service Manual.
2. Analyze test results and make recommendation for further testing if necessary.
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 304
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 305
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 306
TITLE: Demonstrate Setting XD3P Oil Pump Drive Clearance
EQUIPMENT REQUIRED:
XD3P EngineFeeler GaugeTorque Wrench
PROCEDURE: 1. Follow procedure in Service Manual. 2. Make any adjustments if needed.
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 307
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 308
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 309
TITLE: 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: 1. Install correct tooling. 2. Check spool limiters according to Service Manual procedure. 3. Make adjustments if necessary. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 310
TITLE: Demonstrate Integral Breakerless Induction Ignition Component Operation Checks
EQUIPMENT REQUIRED: Lift Truck with 1404 Engine 5P6585 Electrical System Analyzer 6V3030 VOM or Equivalent PROCEDURE:
1. Properly demonstrate integral breakerless induction ignition component operation checks according to service manual procedure.
2. Analyze results and make recommendation for correction if needed. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 311
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 312
TITLE: 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 Special Instructions - SEHS8554 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 313
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 314
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 315
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 316
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 317
TITLE: Demonstrate Determining Surface Finishes
EQUIPMENT REQUIRED: Surface Comparator 6V6116 PROCEDURE: Use thumbnail. REFERENCE: Guidelines to Reusable Parts - SEBF8041 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 318
TITLE: Demonstrate Proficiency in Using Caterpillar Applied Failure Analysis
(Engine Components)
EQUIPMENT REQUIRED: 8S2257 Loupe Small Pick (Seal Pick) Microscope (Stereo Zoom) Small Magnet Bristle Brush and Fast Drying Solvent 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 319
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 320
TITLE: 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
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 321
TITLE: 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 Appropriate Gauges Digital Multimeter - 6V7800 Multitach - 6V2100 Set Point Indicator - 6V4060 Cable - 6V2198 Calculator (Battery Powered) 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 322
TITLE: 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 tankb. Waste antifreeze: Waste antifreeze tank or designated storage drum.c. Waste solvent: Safe-T-Klean vat drums.d. Waste caustic: Caustic tankse. 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
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 323
TITLE: 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. 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.
6. Deposit paint waste/spent cleaning liquids in liquid waste material containers.
REFERENCE: Service Manual Uniform Fire Code 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 324
TITLE: Demonstrate Use and Care of Respiratory Protection Equipment
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: 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 325
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 326
TITLE: 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: 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 327
TITLE: 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: 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 328
TITLE: 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: 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENT EMPLOYEE EVALUATION GUIDE
DEFINITION PERFORMANCE SKILL 329 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: 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 330
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 331
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 332
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 333
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 334
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 335
TITLE: Demonstrate Making Bevel Gear and Pinion Adjustments on T50D or V50D Transaxle EQUIPMENT REQUIRED: FT1923 Spanner Wrench Transaxle 8T3217 Gauge Block Hand Tools 8S2328 Dial Indicator Group PROCEDURE: 1. Follow the instructions in the service manual. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 336
TITLE: Demonstrate Calculating Rated Lifting Capacity with Crane in Different
Configurations
EQUIPMENT REQUIRED: Crane Load Rating Information
PROCEDURE: 1. Determine load, which can be supported in each quadrant.
2. 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 337
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 338
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 339
TITLE: Demonstrate Testing and Adjusting A Piston Pump and Relief Valve on
Transmission Test Stand
EQUIPMENT REQUIRED: Test Stand Piston Pump Relief Valve
PROCEDURE:
1. Demonstrate connecting components to transmission test stand.2. Perform necessary test and adjustments to assure component is operating
correctly. REFERENCE: Transmission Test Stand Manual 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 340
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 341
TITLE: 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: Special Instructions - SMHS7935 Video Tape 62 - Cylinder Head Reconditioning JEGO9062 (¾”) Video Tape 63 – Valve Grinding JEGO9063 (¾”) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 342
TITLE: Demonstrate Testing and Adjusting a 7 or 8-Speed Powershift
Transmission on the Test Stand
EQUIPMENT REQUIRED: Transmission Test Stand 7 or 8-Speed Powershift Transmission (not an ICM)
PROCEDURE: 1. Demonstrate connecting transmission to test stand.
2. Perform test and adjust to specifications as outlined in transmission test stand manual.
REFERENCE: Service Manual Transmission Test Stand 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 343
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 344
TITLE: Demonstrate Air Conditioning System Evacuation and Leak Detection.
EQUIPMENT REQUIRED:
Vacuum Pump Electronic Leak Detector
PROCEDURE:
1. Purge system.2. Evacuate system.3. Vapor change system4. Check for leaks.
REFERENCE: Service Manual Air Conditioning & Heating Service Manual – SENR3334 Electronic Leak Detector – SMHS8160 or SMHS7218 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITION PERFORMANCE SKILL 345
TITLE: 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 Air Conditioning & Heating Service Manual – SENR3334 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 346
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 347
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 348
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 349
TITLE: 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: 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 350
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 351
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 352
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITION
PERFORMANCE SKILL 353 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 354
TITLE: Demonstrate Proficiency in Conducting and Evaluating Cat’s 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 – SEHS80252. Cat Diesel Performance Analysis Report (PAR) LEDT6099
Super-Flow computer-controlled 1. Caterpillar PAR test compute program with instruction
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 355
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 356
TITLE: 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) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 357
TITLE: Demonstrate Testing and Adjusting ICM Powershift Transmission on a
Transmission Test Stand
EQUIPMENT REQUIRED: ICM Transmission Transmission Test Stand 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 358
TITLE: 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
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 359
TITLE: 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
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 360
TITLE: 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. 1-800-837-8872 Ext. 4060 USA or www.tpctraining.com
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 361
TITLE: Demonstrate Proficiency Using Ratios and Proportions EQUIPMENT REQUIRED: Pencil and Paper Calculator (optional) PROCEDURE: 1. Study material and take test. Score at least 80% REFERENCE: TPC Training Systems, Unit 103 “Using Mathematics in the Plant” Lesson Four. 1-800-837-8872 Ext. 4060 USA or www.tpctraining.com
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 362
TITLE: Demonstrate Proficiency Using Simple Geometric Principles
EQUIPMENT REQUIRED: Pencil and Paper Straight Edge Compass PROCEDURE: 1. Study material and take test. Score at least 80%
REFERENCE: TPC Training Systems, Unit 103 “Using Mathematics in the Plant,” Lesson Seven 1-800-837-8872 Ext. 4060 USA or www.tpctraining.com
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 363
TITLE: Demonstrate Proficiency Using Simple Algebra
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 eight. 1-800-837-8872 Ext. 4060 USA or www.tpctraining.com
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 364
TITLE: Demonstrate Proficiency Using Formulas
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 Nine. 1-800-837-8872 Ext. 4060 USA or www.tpctraining.com
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 365
TITLE: Demonstrate Proficiency by Completing Applied Electricity Course
EQUIPMENT REQUIRED: VCR Six video tapes PROCEDURE: 1. Watch video tapes. 2. Read Manual. 3. Work problems. 4. 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
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 366
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 367
TITLE: 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: Mobile Crane Manual, Construction Safety Association of Ontario For information out side of Darr www.csao.org
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 368
TITLE: 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: Mobile Crane Manual, Construction Safety Association of Ontario For information out side of Darr http://www.csao.org
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE 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
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 370
TITLE: 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
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 371
TITLE: 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
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 372
TITLE: 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
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 373
TITLE: Demonstrate Propeller Pitch Measurement
EQUIPMENT REQUIRED:
8T5322 Pitchometer or equivalentMarine Propeller, installed
PROCEDURE:
1. Follow special instructions, measure propeller pitch
REFERENCE:
Special Instructions - SEHS8643Check 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 374
TITLE: 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 Special Instructions SEHS8867 Special Instructions SEHS8884 Special Instructions SEHS7788 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 375
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 376
TITLE: 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. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 377
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 378
TITLE: 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:
1. Follow Procedure Outlined in the Service Manual
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 379
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 380
TITLE: 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 Special Instructions SEHS9120 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 381
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 382
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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 383
TITLE: 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 Fuel Setting Micro Fiche 6V2100 Multitach Group Exhaust Gas Analyzer
PROCEDURE:
1. Follow Procedures Outlined in the Service Manual and Special Instructions and Gas Engine Performance book.
REFERENCE:
Service Manual Special Instructions - SEHS8524 Special Instructions - SEHS7807 Fuel Setting Micro Fiche Gas Engine Performance - LEBQ2023 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 384
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 385
TITLE: Demonstrate Installing a Magneto and Setting the Timing on a Gas Engine
EQUIPMENT REQUIRED: Gas Engine 9S9082 Engine Turning Tool 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 Special Instructions - SEHS8580 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 386
TITLE: Successfully Complete a Supervision/Management Course at a Local
Community College
EQUIPMENT REQUIRED: None PROCEDURE: None REFERENCE: See Service Development Department For Details
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 387
TITLE: 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
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 388
TITLE: 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.
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 389
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 390
TITLE: 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 Special Instructions SEHS8876 Special Instructions SEHS8364 Service Manual Service Magazine 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITION PERFORMANCE SKILL 391
TITLE: 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 Check S.I.S. or S.I.R.S. and FIND for the latest updates
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 392
TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Electrical Systems Module Two: Applying Basic Electrical Concepts
EQUIPMENT REQUIRED:
Interactive Video Computer Video Disc Fundamentals of Electrical Systems
PROCEDURE:
1. Follow Computer On Screen Directions
REFERENCE:
Caterpillar Multimedia Products TEMV9002 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 393
TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Electrical Systems Module Three: Using Diagnostic Tools
EQUIPMENT REQUIRED:
Interactive Video Computer Video Disc Fundamentals of Electrical Systems
PROCEDURE:
1. Follow Computer On Screen Directions
REFERENCE:
Caterpillar Multimedia Products TEMV9002 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 394
TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Electrical Systems Module Four: Trouble Shooting Basics
EQUIPMENT REQUIRED:
Interactive Video Computer Video Disc Fundamentals of Electrical Systems
PROCEDURE:
1. Follow Computer On Screen Directions
REFERENCE:
Caterpillar Multimedia Products TEMV9002 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 395
TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Electrical Systems Module Five: The Caterpillar Lighting System
EQUIPMENT REQUIRED:
Interactive Video Computer Video Disc Fundamentals of Electrical Systems
PROCEDURE:
1. Follow Computer On Screen Directions
REFERENCE:
Caterpillar Multimedia Products TEMV9002 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 396
TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Electrical Systems Module Six: The Caterpillar Starting System
EQUIPMENT REQUIRED:
Interactive Video Computer Video Disc Fundamentals of Electrical Systems
PROCEDURE:
1. Follow Computer On Screen Directions
REFERENCE: Caterpillar Multimedia Products TEMV9002 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 397
TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Electrical Systems Module Seven: The Caterpillar Charging System
EQUIPMENT REQUIRED:
Interactive Video Computer Video Disc Fundamentals of Electrical Systems
PROCEDURE:
1. Follow Computer On Screen Directions
REFERENCE:
Caterpillar Multimedia Products TEMV9002 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 398
TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Mobile Hydraulics Module One: Course Introduction
EQUIPMENT REQUIRED:
Interactive Video Computer Video Disc Fundamentals of Mobile Hydraulics
PROCEDURE:
1. Follow Computer On Screen Directions
REFERENCE:
Caterpillar Multimedia Products TEMV9001 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 399
TITLE: Successfully Compete Interactive Video Self-Instruction Course, Fundamentals of Mobile Hydraulics Module two: basic Hydraulic Concepts
EQUIPMENT REQUIRED:
Interactive Video Computer Video disc fundamentals of Mobile Hydraulics
PROCEDURE:
Follow Computer On Screen Directions
REFERENCE:
Caterpillar Multimedia Products TEMV9001 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 400
TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Mobile Hydraulics Module Three: Components
EQUIPMENT REQUIRED:
Interactive Video Computer Video Disc Fundamentals of Mobile Hydraulics
PROCEDURE:
1. Follow Computer On Screen Directions
REFERENCE:
Caterpillar Multimedia Products TEMV9001 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 401
TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Mobile Hydraulics Module Four: Schematics
EQUIPMENT REQUIRED:
Interactive Video Computer Video Disc Fundamentals of Mobile Hydraulics
PROCEDURE:
1. Follow Computer On Screen Directions
REFERENCE:
Caterpillar Multimedia Products TEMV9001 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 402
TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Mobile Hydraulics Module Five: Systems
EQUIPMENT REQUIRED:
Interactive Video Computer Video Disc Fundamentals of Mobile Hydraulics
PROCEDURE:
1. Follow Computer On Screen Directions
REFERENCE:
Caterpillar Multimedia Products TEMV9001 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 403
TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Applied Failure Analysis Module One: Introduction
EQUIPMENT REQUIRED:
Interactive Video Computer Video Disc Fundamentals of Applied Failure Analysis
PROCEDURE:
1. Follow Computer On Screen Directions
REFERENCE:
Caterpillar Multimedia Products TEMV9005 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 404
TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Applied Failure Analysis Module Two: Fundamentals of Metallurgy
EQUIPMENT REQUIRED:
Interactive Video Computer Video Disc Fundamentals of Applied Failure Analysis
PROCEDURE:
1. Follow Computer On Screen Directions
REFERENCE:
Caterpillar Multimedia Products TEMV9005 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 405
TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Applied Failure Analysis Module Three: Analyzing Fractures
EQUIPMENT REQUIRED:
Interactive Video Computer Video Disc Fundamentals of Applied Failure Analysis
PROCEDURE:
1. Follow Computer On Screen Directions
REFERENCE:
Caterpillar Multimedia Products TEMV9005 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 406
TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Applied Failure Analysis Module Four: Analyzing Wear
EQUIPMENT REQUIRED:
Interactive Video Computer Video Disc Fundamentals of Applied Failure Analysis
PROCEDURE:
1. Follow Computer On Screen Directions
REFERENCE:
Caterpillar Multimedia Products TEMV9005 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 407
TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Applied Failure Analysis Module Five: Visual Examination
EQUIPMENT REQUIRED:
Interactive Video Computer Video Disc Fundamentals of Applied Failure Analysis
PROCEDURE:
1. Follow Computer On Screen Directions
REFERENCE:
Caterpillar Multimedia Products TEMV9005 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 408
TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Applied Failure Analysis Module Six: Managing Failure Analysis
EQUIPMENT REQUIRED:
Interactive Video Computer Video Disc Fundamentals of Applied Failure Analysis
PROCEDURE:
1. Follow Computer On Screen Directions
REFERENCE:
Caterpillar Multimedia Products TEMV9005 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 409
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 410
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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 411
TITLE: 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 Service Magazine 6-15-92 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 412
TITLE: 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:
1. Follow Procedure Outlined in the Service Manual
REFERENCE:
Service Manual Special Instructions - SEHS7807 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 413
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 414
TITLE: 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:
1. Follow Procedure Outlined in the Service Manual
REFERENCE:
Service Manual Service Magazine 10-4-93 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 415
TITLE: Demonstrate Checking Transmission Solenoids
EQUIPMENT REQUIRED:
TelehandlerVOM
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 Resistance’s between Solenoids.
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 416
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 Resistance’s between Solenoids.
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 417
TITLE: Demonstrate Checking Hydraulic System Pressures.
EQUIPMENT REQUIRED:
TelehandlerHydraulic Pressure Gages
PROCEDURE:
Following Service Manual Procedures, check the following:1. Standby Pressure2. Steering Relief Pressure3. Auxiliary Relief Pressure4. Implement Relief Pressure
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 418
TITLE: Demonstrate Checking Boom and Frame for Damage
EQUIPMENT REQUIRED:
TelehandlerProper lighting
PROCEDURE:
Follow Service Manual Procedure
REFERENCE:
Service Manual - Operation and Maintenance Guide. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 419
TITLE: Demonstrate Checking Boom Lowering and Retracting Without Hydraulic Power.
EQUIPMENT REQUIRED:
TelehandlerProper Lifting and Lowering Equipment to handle Boom Weight
PROCEDURE:
Follow Service Manual Procedure
REFERENCE:
Service Manual - Operation and Maintenance Guide. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 420
TITLE: Demonstrate Checking Boom Wear Pads.
EQUIPMENT REQUIRED:
TelehandlerFeeler Gages
PROCEDURE:
Follow Service Manual Procedure
REFERENCE:
Service Manual - Operation and Maintenance Guide. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 421
TITLE: Demonstrate Checking Boom Chain Tension / Adjustment
EQUIPMENT REQUIRED:
Telehandler
PROCEDURE:
Follow Service Manual Procedure
REFERENCE:
Service Manual - Operation and Maintenance Guide. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 422
TITLE: Demonstrate Setting and using the Three Different Steer Modes.
EQUIPMENT REQUIRED:
Telehandler
PROCEDURE:
Follow Service Manual Procedure
REFERENCE:
Service Manual - Operation and Maintenance Guide. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 423
TITLE: Demonstrate Operation of Differential Lock Control.
EQUIPMENT REQUIRED:
Telehandler
PROCEDURE:
Follow Service Manual Procedure
REFERENCE:
Service Manual - Operation and Maintenance Guide. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 424
TITLE: Demonstrate Purging Air From the Boom Extend / Retract Cylinder.
EQUIPMENT REQUIRED:
Telehandler
PROCEDURE:
Follow Service Manual Procedure
REFERENCE:
Service Manual - Operation and Maintenance Guide. 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 425
TITLE: Demonstrate Learning the Truck
EQUIPMENT REQUIRED:
Order Picker (NOR) Familyor
Reach (NRR) Family
PROCEDURE:
1. Follow Service Manual Procedure to Enter, Run, and Exit the Learn Program.
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 426
TITLE: Demonstrate a Voltage Test on the Power Supply Card in the Vehicle Manager.
EQUIPMENT REQUIRED:
Order Picker (NOR) Familyor
Reach (NRR) Family
PROCEDURE:
Follow Service Manual Procedure.
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 427
TITLE: Demonstrate Testing Q1.
EQUIPMENT REQUIRED:
Order Picker (NOR) Familyor
Reach (NRR) Family
VOM
PROCEDURE:
1. Follow Service Manual Procedure to test Q1.
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 428
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 429
TITLE: Demonstrate using Password to obtain the Truck Software (Firmware) Version.
EQUIPMENT REQUIRED:
Order Picker (NOR) Familyor
Reach (NRR) Family
PROCEDURE:
1. Follow Service Manual Procedure.
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 430
TITLE: Demonstrate obtaining Hour Meter readings and Distance Traveled.
EQUIPMENT REQUIRED:
Order Picker (NOR) Familyor
Reach (NRR) Family
PROCEDURE:
1. Follow Service Manual Procedure to obtain readings:1. (KH) - Key Hours2. (HD) - Hours on Deadman3. (HL) - Hours on Lift Motor4. (TM) - Travel Miles
Note: Early model trucks will not have all of the above options.
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 431
TITLE: Demonstrate Configuring the truck using Password and Superword.
EQUIPMENT REQUIRED:
Order Picker (NOR) Familyor
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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 432
TITLE: Demonstrate Configuring the Truck to Factory Default Setting Values.
EQUIPMENT REQUIRED:
Order Picker (NOR) Familyor
Reach (NRR) Family
PROCEDURE:
Follow Service Manual Procedure to:1. Enter the Configure Mode using Password.2. Note all Option Values3. Default truck to Factory Setting Option Values4. 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 433
TITLE: Demonstrate using the Maintenance Program
EQUIPMENT REQUIRED:
Order Picker (NOR) Familyor
Reach (NRR) Family
VOM9 & 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 Test2. 3 Input Test3. 3 Output Test
Note: a. Read and understand the entire procedure before doing each testb. 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 ManualCheck 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 434
TITLE: Demonstrate Initializing truck to Factory Default Parameters.
EQUIPMENT REQUIRED:
Order Picker (NOR) Family or Reach (NRR) FamilyMHA 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 ManualSENB8544-01 (or latest version) User's 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 435
TITLE: Demonstrate the use of LED Status Light
EQUIPMENT REQUIRED:
NPP40 or Pallet Jack with similar Controller.
PROCEDURE:
Follow Service Manual Procedure to:1. Raise and block truck so drive wheel is free to turn.2.. Raise controller cover and view Status LED3. 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 436
TITLE: Demonstrate using the 113-7132 Curtis 1207 Analyzer to Program the truck.
EQUIPMENT REQUIRED:
NPP40 or Pallet Jack with similar Controller.113-7132 Curtis 1207 Analyzer
PROCEDURE:
Follow Service Manual Procedure to:. 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 437
TITLE: Demonstrate using the 113-7132 Curtis 1207 Analyzer to Test the truck.
EQUIPMENT REQUIRED:
NPP40 or Pallet Jack with similar Controller.113-7132 Curtis 1207 Analyzer
PROCEDURE:
Follow Service Manual Procedure to:1. Raise and block truck so drive wheel is free to turn.
. 2. Install the Analyzer.3. Enter the Test Mode4. 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 438
TITLE: Demonstrate using the 113-7132 Curtis 1207 Analyzer to enter Diagnostics and Special Diagnostics Menu.
EQUIPMENT REQUIRED:
NPP40 or Pallet Jack with similar Controller.113-7132 Curtis 1207 Analyzer
PROCEDURE:
Follow Service Manual Procedure to:1. Raise and block truck so drive wheel is free to turn.
. 2. Install the Analyzer.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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 439
TITLE: Demonstrate using Programmable Setup Options.
EQUIPMENT REQUIRED:
EC15 - EC30EP13T - EP20TM40DDSA / P - MC60DSA / P W / 0R6713 Programmable Logic.
PROCEDURE:
Follow Service Manual Procedure to:1. Enter the Setup Option Program.2. Note all Option Values3. Default truck to Factory Setting Option Values4. 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 ManualSales Monitor CEKL0367 (for M50SA & P family of trucks)
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 440
TITLE: Demonstrate using the Diagnostic Program
EQUIPMENT REQUIRED:
Any Electric Lift Truck, (Caterpillar or MCF) with MicroCommand Panel
PROCEDURE:
Follow Service Manual Procedure to:1. Enter the Diagnostic Program2. Note all Faults, (if none exit the Program)3. If faults are found make proper repairs
Note: It’s 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 441
TITLE: Demonstrate using the History Folder Faults
EQUIPMENT REQUIRED:
EC15 - EC30EP13T - EP20TM40DDSA / P - MC60DSA / P W / 0R6713 Programmable Logic.
PROCEDURE:
Follow Service Manual Procedure to:1. Enter the Fault History Program.2. Note all Faults, (if none exit the Program)3. If faults are found make proper repairs
Note: It’s 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 ManualSales Monitor CEKL0367 (for M50SA & P family of trucks)
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 442
TITLE: Demonstrate Programming the Clock on a EC15 or EC30 Lift Truck
EQUIPMENT REQUIRED:
EC15 - EC30
PROCEDURE:
Follow Service Manual Procedure to: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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 443
TITLE: Demonstrate using Function Setup Procedures.
EQUIPMENT REQUIRED:
Any Electric Lift Truck W / EV100 LX, LXT, or ZX Panel97124-07400 EV100 LX Handset
PROCEDURE:
Follow Service Manual Procedure to:1. Enter the Function Setup Program2. Note all Function Values3. Check against Manufacturer recommended values.4. Make necessary changes and exit program
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 444
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 445
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 446
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 447
TITLE: Demonstrate Disassembly and Assembly of a Differential
EQUIPMENT REQUIRED:
DifferentialDial Indicator GroupHand 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 448
TITLE: Demonstrate Correct Disassembly and Assembly of a CountershaftTransmission
EQUIPMENT REQUIRED:
Countershaft TransmissionHand 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 449
TITLE: Demonstrate Setting Transmission Transfer Gear the Bearing Clearance
EQUIPMENT REQUIRED:
Transmission Transfer GearDial Indicator GroupHand Tools
PROCEDURE:
1. During Assemble of the Transmission Transfer Gear Group Correctly Set all Bearing Clearances.
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 450
TITLE: Demonstrate Disassembly and Assembly of an Integral Axle
EQUIPMENT REQUIRED:
Integral Type AxleDial IndicatorHand Tools
PROCEDURE:
1. Disassemble and Assemble Axle as Outlined in the Service Manual Correctly Make all Preload and Clearance Adjustments
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 451
TITLE: Demonstrate Bench Testing a Countershaft Transmission
EQUIPMENT REQUIRED:
Transmission Test BenchCountershaft TransmissionHand Tools
PROCEDURE:
1. Test and Adjust the Transmission as Outlined in the Service Manual Transmission Testing and Adjusting Section
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 452
TITLE: Demonstrate Use of the 9U7500 Transmission Analyzer
EQUIPMENT REQUIRED:
9U7500 Transmission AnalyzerMachine with ICM Transmissionor ICM Transmission on the Test Bench
PROCEDURE:
Following the Instructions Outlined in the 9U7500 TransmissionAnalyzer Operation Manual1. Connect Analyzer to the Transmission using the Correct Cables2. Test the Transmission Switch3. Test the Solenoids 4. Shift the Transmission
REFERENCE:
Service ManualTransmission Analyzer Operation Manual NEHS0644
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 453
TITLE: 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 454
TITLE: Demonstrate Proper Work Area Organization
EQUIPMENT REQUIRED:
None
PROCEDURE:
1. Organize work area as per instructions from a senior technician or supervisor
REFERENCE:
None 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 455
TITLE: Demonstrate Performing the Five Steps of Engine Troubleshooting
EQUIPMENT REQUIRED:
Truck Engine with Electronic ControlsApplicable Test Equipment
PROCEDURE:
Troubleshoot the Engine using the Five Step Diagnostic ProcessOutlined in the Service Manual1. Gather Information2. Verify Operational Problem3. Determine Probable Causes4. Narrow List of Causes5. Test Subsystems
REFERENCE:
Service ManualElectronic Troubleshooting SENR5582
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 456
TITLE: Instruct Junior Technicians in Work Area Organization Who Need Skill 454
EQUIPMENT REQUIRED:
None
PROCEDURE:
REFERENCE:
Skill # 454 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 457
TITLE: Demonstrate Removal And Installation Of A Tapered Roller Bearing
EQUIPMENT REQUIRED
Component With Tapered Roller Bearings Bearing Removal And Installation PullersBearing HeaterHand Tools
PROCEDURE:
1. Follow Procedure Outlined In The Service Manual
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 458
TITLE: Demonstrate Checking Track Adjuster for Leakage (Internal and External)
EQUIPMENT REQUIRED:
Roller Frame with track adjuster Hand Tools
PROCEDURE:
1. Follow Procedure Outlined In The Service Manual
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 459
TITLE: Demonstrate Evaluation of a Dozer Blade for Wear
EQUIPMENT REQUIRED:
Dozer Blade Hand Tools
PROCEDURE:
1. Follow Procedure Outlined In The Service Manual
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 460
TITLE: Demonstrate Evaluation of Loader Frame and Linkage for Wear
EQUIPMENT REQUIRED:
Loader Frame Hand Tools
PROCEDURE:
1. Follow Procedure Outlined In The Service Manual
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 461
TITLE: Demonstrate Boring Idler Bearings on High Sprocket Machines
EQUIPMENT REQUIRED:
Idler With New Bearings Boring Bar Hand Tools
PROCEDURE:
1. Follow Procedure Outlined In The Service Manual
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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:
1. Follow Procedure Outlined In The Service Manual
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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:
1. Follow Procedure Outlined In The Service Manual
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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:
Follow Procedure Outlined In The Service Manual
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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:
Follow Procedure Outlined In The Service Manual
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 467
TITLE: Demonstrate Properly Checking Roller Frame Alignment
EQUIPMENT REQUIRED:
Measuring Tools Hand Tools
PROCEDURE:
1. Follow Procedure Outlined In The Service Manual
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 468
TITLE: Demonstrate Proper Removal and Installation of a Recoil Spring on Low Sprocket Machine
EQUIPMENT REQUIRED:
Low Sprocket Machine Hand Tools
PROCEDURE:
1. Follow Procedure Outlined In The Service Manual (making sure to follow all safety precautions)
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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:
1. Follow Procedure Outlined In The Service Manual (Making sure to follow all prescribed safety precautions)
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 470
TITLE: 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:
1. Follow Procedure Outlined In The Service Manual (making sure to follow all safety precautions outlined)
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 471
TITLE: 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. 2. Follow Procedure Outlined In The Service Manual
REFERENCE:
SGV Service Manuel 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 472
TITLE: 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
Follow Procedure Outlined In The Service Manual
REFERENCE:
SGV Service ManuelGEM 8 Software Tools and Utilities Book
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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
Follow Procedure Outlined In The Service Manual
REFERENCE:LCS User Guide for SGV
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 474
TITLE: Demonstrate Test/Adjustment of Photo Electric Sensor
EQUIPMENT REQUIRED:
Volt Meter Hand Tools
PROCEDURE:
1. Test for Voltage and Visual Alignment Follow Procedure Outlined In The Service Manual
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 475
TITLE: 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
Follow Procedure Outlined In The Service Manual
REFERENCE:
Plant Wiring Schematic 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 476
TITLE: 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:
Caterpillar Multimedia Products TEMV9002 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 477
TITLE: Successfully Complete Interactive Computer Course, Fundamentals Of Mobile Hydraulics
EQUIPMENT REQUIRED:
Computer with Caterpillar Interactive Software Program, Fundamentals Of Mobile Hydraulics (TEMV9001)
PROCEDURE:
1. Follow Computer On Screen Directions And Complete The Entire Course
REFERENCE:
Caterpillar Multimedia Products TEMV9001 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 478
TITLE: Successfully Complete Interactive Computer Course, Fundamentals Of Applied Failure Analysis
EQUIPMENT REQUIRED:
Computer with Caterpillar Interactive Software Program, Fundamentals Of Applied Failure Analysis
PROCEDURE:
1. Follow Computer On Screen Directions And Complete The Entire Course
REFERENCE:
Caterpillar Multimedia Products TEMV9005 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 479
TITLE: Demonstrate Proper Use Of The Roto Alignment Tool
EQUIPMENT REQUIRED:
Roto Alignment Tool Hand Tools
PROCEDURE:
1. Follow Procedure Outlined In The Service Manual
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 480
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 ProceduresCheck 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 481
TITLE: 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) Follow Procedure Outlined In The Service Manual
REFERENCE: Service Manual - SENR5664 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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:
1. Follow Procedure Outlined In The Service Manual
REFERENCE:
Service Manual - SENR5664 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 483
TITLE: Demonstrate Performance Testing Heating System
EQUIPMENT REQUIRED:
Machine With Heating And Air Conditioning System Hand Tools
PROCEDURE:
1. Follow Procedure Outlined In The Service Manual
REFERENCE:
Service Manual - SENR5664 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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:
Follow Procedure Outlined In The Service Manual
REFERENCE:
Service Manual - SENR5664 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 485
TITLE: 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:
1. Follow Procedure Outlined In The Service Manual
REFERENCE:
Service Manual - RENR1976 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 486
TITLE: Demonstrate Timing New Components To An Automatic Temperature Control Air Conditioning Unit
EQUIPMENT REQUIRED:
Machine With Automatic Temperature Control Air Conditioning Hand Tools
PROCEDURE:
Follow Procedure Outlined In The Service Manual
REFERENCE:
Service Manual - RENR1976 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 487
TITLE: 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:
1. Follow Procedure Outlined In The Service Manual 2. Fill Out Worksheet #38 And Attach It To This Form
REFERENCE:
Service Manual - RENR1976 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 488
TITLE: Demonstrate “Quick-Check” Procedures For Expansion Valve Or Orifice Tube Air Conditioning
EQUIPMENT REQUIRED:
Machine With Air Conditioning HAND TOOLS
PROCEDURE:
1. Follow Procedure Outlined In The Service Manual
REFERENCE:
Service Manual - SENR5664 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 489
TITLE: Demonstrate Performance Testing An Air Conditioning System
EQUIPMENT REQUIRED:
Machine With Air Conditioning Thermometer Manifold Gauges Hand Tools
PROCEDURE:
1. Follow Procedure Outlined In The Service Manual record your findings on Worksheet 39 and attach to this form
REFERENCE:
Service Manual - SENR5664 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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:
1. Follow Procedure Outlined In The Service Manual
REFERENCE:
Service Manual - SENR5664 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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:
1. Follow Procedure Outlined In The Service Manual
REFERENCE:
Service Manual - SENR5664 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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 Recovery/Recycle Equipment Hand Tools
PROCEDURE:
1. Follow Procedure Outlined In The Service Manual
REFERENCE:
Service Manual - SENR5664 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 493
TITLE: Demonstrate Proper Use Of Air Conditioning Electronic Charging Scale
EQUIPMENT REQUIRED:
9U6507 Electronic Charging Scale Hand Tools
PROCEDURE:
1. Follow Procedure Outlined In The Service Manual
REFERENCE:
Service Manual - SENR5664 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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. Install Manifold Gauges, Apply Cold Source To TXV And Read Gauges. 2. Apply Heat Sources To TXV And Read Gauges 3. Follow Procedure Outlined In The Service Manual 4. Record Findings On Worksheet # 40 And Attach To This Form
REFERENCE:
Service Manual - SENR5664 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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:
1. Follow Procedure Outlined In The Service Manual
REFERENCE:
Service Manual - SENR5664 SEBU2580 (Service Training Meeting Guide)
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 497
TITLE: Demonstrate Leak Testing Air Conditioning System
EQUIPMENT REQUIRED:
Machine With Air Conditioning 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. Follow Procedure Outlined In The Service Manual
REFERENCE:
Service Manual - SENR5664 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 498
TITLE: Demonstrate Retrofitting An R-12 Air Conditioning System To R134a
EQUIPMENT REQUIRED:
Machine Equipped With An R-12 Air Conditioner Recovery/Recycle Equipment Hand Tools
PROCEDURE:
1. Follow Procedure Outlined In The Service Manual And Special Instructions
REFERENCE:
Special Instruction - SEHS9734 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 500
TITLE: Demonstrate Proper Installation Of Generator Protection Components
EQUIPMENT REQUIRED:
Generator; Protection Components
Hand Tools
PROCEDURE:
Follow Procedure Outlined In The Service Manual
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 501
TITLE: Demonstrate Installation of Generator AC Monitoring Components
EQUIPMENT REQUIRED:
Generator AC Monitoring Components Generator Hand Tools
PROCEDURE:
1. Follow Procedure Outlined In The Service Manual
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 502
TITLE: Demonstrate Modification Of Engine Generator Controls As Directed
EQUIPMENT REQUIRED:
Engine And Generator Set Hand Tools
PROCEDURE:
Follow Procedure Outlined In The Service Manual As Directed
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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:
Follow Procedure Outlined In The Service Manual
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 504
TITLE: Demonstrate Performing Tests Listed On 3500 Engine Installation Check List
EQUIPMENT REQUIRED:
3500 Engine Hand Tools
PROCEDURE:
Follow Procedure Outlined In The Service Manual
REFERENCE:
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 505
TITLE: Demonstrate Performing Generator/ Industrial Engine Load Test And Determine Compliance With Performance Standard
EQUIPMENT REQUIRED:
Engine Generator Set Hand Tools
PROCEDURE:
1. Follow Procedure Outlined In The Service Manual
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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:
Study material and take test, score at least 80%
REFERENCE:
Introduction to Compression Book # 1051WB Howell Training - Houston, Texas (800) 527-1851 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 507
TITLE: Successfully complete Programs in Learning Operating Techniques. Couplings, Gear Trains, and V-Belt Drives
EQUIPMENT REQUIRED:
Pencil and paper Booklet - American Petroleum Institute Programs In Learning Operating Techniques #1085WB “Couplings, Gear Trains and V-Belt Drives”
PROCEDURE:
Study material and take test, score at least 80%
REFERENCE:
Coupling, Gear Trains and V-Belt Drives Book #1085WB Howell Training - Houston, Texas (800) 527-1851 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 508
TITLE: Successfully complete Programs in Learning Operating Techniques. Centrifugal Compressors
EQUIPMENT REQUIRED:
Pencil and paper Booklet - American Petroleum Institute Programs In Learning Operating Techniques #1053WB “Centrifugal Compressors”
PROCEDURE:
Study material and take test, score at least 80%
REFERENCE:
Centrifugal Compressors Book #1053WB Howell Training - Houston, Texas (800) 527-1851 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 509
TITLE: Successfully complete Programs in Learning Operating Techniques. Positive Displacement Compressors
EQUIPMENT REQUIRED:
Pencil and paper Booklet - American Petroleum Institute Programs In Learning Operating Techniques #1052WB “Positive Displacement Compressors”
PROCEDURE:
Study material and take test, score at least 80%
REFERENCE:
Positive Displacement Compressors Book #1052WB Howell Training - Houston, Texas (800) 527-1851 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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. Record your findings on worksheet # 41 and attach to this form.
REFERENCE:
Service Manual Operation and Maintenance Manual for Caterpillar Gas Engine (Lubricant Recommendations SEBU6400) 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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 Special Instruction SEHS9156 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE SKILL 513
TITLE: Demonstrate Checking Engine/Compressor Soft Foot
EQUIPMENT REQUIRED:
Dial Indicator Group Mounting Feet Shims (As required by each Manufacture)
PROCEDURE:
Follow Procedure Outlined in the Appropriate Manufactures Service Manual.
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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
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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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 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 ____________________ DATE .
REVISED 2001
SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE
DEFINITIONPERFORMANCE 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 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 ____________________ DATE .
REVISED 2001
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