Heavy Duty Entry Level Technician Course Hydraulics Created by: Mark D. Adair Hydraulics 4.8.2016 Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/.

Course Instructor Mark D. Adair Experience Hydraulics Course Instructor Mark D. Adair Experience Over 30 years working in the diesel technology field. Factory certified technician for Cummins, Caterpillar & Detroit Diesel Engines. Manager of numerous EPA and ARB engine test cells and emission laboratories. Participated in the development of the first SCR, DPF ,Bio Diesel fuel & Ethanol fuel technologies ever sold in USA. Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 2 2

Sign-In Sheet Restrooms Parking Passes Sign-In Sheet Participant Form Hydraulics Sign-In Sheet Restrooms Parking Passes Sign-In Sheet Participant Form Smoking Area Note: Put your name in your book Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/.

Introductions Name Title Type of Vehicles in Fleet Hydraulics Introductions Name Title Type of Vehicles in Fleet Experience with Diesel Engines Prior Diesel classes taken Military Experience Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/.

Hydraulics This module will focus on the Cummins ISL-G natural gas engine management systems. This system uses fly by wire Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/.

Hydraulics Disclaimer The material presented here is intended for instructional purposes only. Please be sure to follow manufacturer’s latest bulletins and procedures as the ultimate source. If its under warranty you must follow all Cummins procedures….. Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/.

Instructional Objectives Hydraulics Instructional Objectives By the end of this course the student will be able to: Indentify hydraulic system components and functions Knowledge of hydraulic system safety Knowledge of Transmission PTO and Hydraulic pumps Knowledge refuge truck hydraulic applications Inspecting and servicing of Hydraulics systems Tech Tip: Bring a USB Memory Drive to Level 2 to obtain bonus electronic handout materials. Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/.

Theory Hydraulics Hydraulics Hydraulic machines are machinery and tools that use liquid fluid power to do simple work.  Heavy equipment is a common example.  Hydraulic fluid from a reservoir to a hydraulic pump. The fluid is controlled directly or automatically by control valves.  The fluid is distributed through hoses and tubes. Hydraulic cylinders become pressurized according to the resistance present. Hydraulic machinery is operated by the use of hydraulics, where a liquid is the powering medium. Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 8

Theory Hydraulics Hydraulics Hydraulic machinery is operated by the use of hydraulics, where a liquid is the powering medium. Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 9

WARNING : FLAMMABLE Theory Hydraulics Hydraulics 10 Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 10

Hydraulic fluid safety Hydraulics Theory YOUTUBE Click on Hyperlink below Hydraulic fluid safety Video length 00:54 minutes Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 11

Theory Components Hydraulic reservoir Hydraulics 12   Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 12

Theory Components Hydraulic hoses Hydraulics 13   Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 13

Theory Hose safety YOUTUBE Click on Hyperlink below Hydraulics Theory YOUTUBE Click on Hyperlink below Hose safety Video length 1:08 minutes Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 14

Theory Components Hydraulic oil filter Hydraulics   Spin-On filter Sintered metal filter (element) Element filter installation Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 15

Theory Components Power take off (PTO) Hydraulics 16   Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 16

Theory Truck PTO'S YOUTUBE Click on Hyperlink below Hydraulics Theory YOUTUBE Click on Hyperlink below Truck PTO'S Video length 1:31 minutes Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 17

Theory Components Hydraulic pump Hydraulics 18 Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 18

Theory Components Hydraulic pump Hydraulics 19 Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 19

Theory Components Hydraulic control valves Hydraulics Manual controls Electronic controls Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 20

Theory Components Hydraulic control valves Hydraulics Manual controls/Electronic controls Electronic control solenoid Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 21

Theory Components Hydraulic control valves Hydraulics Electronic controls Electronic control solenoid Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 22

Theory Components Hydraulic cylinders Hydraulics 23 Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 23

Theory Components Hydraulic cylinders Hydraulics 24 Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 24

Hydraulic cylinders in action Hydraulics Theory YOUTUBE Click on Hyperlink below Hydraulic cylinders in action Video length 1:31 minutes Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 25

Refuge truck applications Hydraulics Theory YOUTUBE Click on Hyperlink below Refuge truck applications Video length 9:59 minutes Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 26

Theory Components Refuge truck Hydraulic cylinder applications Hydraulics Theory Components Refuge truck Hydraulic cylinder applications Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 27

Theory Components Refuge truck Hydraulic cylinder applications Hydraulics Theory Components Refuge truck Hydraulic cylinder applications Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 28

Theory Components Refuge truck Hydraulic cylinder applications Hydraulics Theory Components Refuge truck Hydraulic cylinder applications Except where otherwise noted, this work by Long Beach City College, a Department of Labor, TAACCCT funded project is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/. 29