321 hours for fall quarter

This week I worked on painting the air lines in the plant and did organised  in the shop.Lately it has been slow so i have been cleaning in the shop.I pored some concrete and replaced lights in the buidings.                                                                                                                                                       Total hours for the quarter are 321                   last week work and school hours total 40

Report all of your findings on your blog by the 11th (Sunday night) deadline.

This is all on the college black Dodge 4WD truck:

1. #2 below shows the FCA. What is it and what does it do?

It is a fuel control acuator.It controls fuel pressure in fuel rail"The Fuel Control Actuator (FCA) is an electronically controlled solenoid valve. The ECM controls the amount of fuel that enters the high-pressure pumping chambers by opening and closing the FCA based on a demanded fuel pressure."

2. Copy and paste the HP fuel “Warning” text from Alldata AND/or Cummins into your

blog. What is the pressure to be cautious of, in psi?Verify high pressure pump output volume (see high pressure pump info). You can also cap off all the injectors and see how quickly the rail pressure climbs. It takes about 4000 PSI rail pressure in order to start

3. Regarding the intake manifold air heater element: How many elements are on the

truck? How much current is needed to the operate the unit?
Two heavy-duty cables connect the 2 air heater elements to the 2 air heater relays. Each
of these cables will supply approximately 95 amps at 12 volts to an individual heating element
within the heater block assembly.

4. This unit is currently in a “cranks but no start” condition. What codes are present?

DTC P0148; high pressure common rail checksum, which is a deviation between the fuel pressure set point and the actual fuel pressure.

1. FCA, check for rust on the fuel control actuator, which could indicate other fuel system problems caused by water contamination.
2. Fuel pressure sensor
3. Lift pump or fuel supply issues, check fuel supply pressure and fuel filter condition.
4. Cascade over flow valve
5. Pressure limit valve
6. Injectors, excessive return, see injectors
7. High pressure pump (CP3)

DTC P0300 – P0306; injector misfire, all and 1 through 6

1. Low fuel supply pressure
2. Use scan tool to isolate each cylinder

DTC P0217; decreased engine performance due to a engine overheat condition

1. Check ECT sensor
2. Restricted air flow (caked dirt and bugs) through the intercooler and radiator.

DTC P0251; CP3 pump regulator control, ECM detects a discrepancy between PWM signal supplied to FCA and the PWM returned from FCA

1. Low or no fuel supply pressure (bad supply pump or plugged filter)
2. Fuel Control Actuator (FCA) bad, use the scan tool to verify rail pressure set point versus fuel pressure. Normal idle pressure is 6000 – 7000 PSI. If you have a fluctuation over 500 PSI this can cause a surge as well.

DTC P0336; crank position sensor (CKP) signal, CLP below calibrated value

1. Excessive cranking with a no start condition
2. CKP sensor
3. CKP wiring issue

No Start or Hard Start

1. No or low fuel supply to the high pressure pump (CP3)
2. Monitor rail pressure and see if you have over 4000 PSI during cranking, if not one or more injectors can cause a hard start, see injector section for further diagnostics. No smoke from the tailpipe after about 10 seconds of cranking means no fuel is getting into the cylinders.
3. Injector connector tube not seated in injector, bad tube or improper torque on nut.
4. Leaking fuel pressure limit valve, should not leak at idle or during cranking.
5. Verify high pressure pump output volume (see high pressure pump info). You can also cap off all the injectors and see how quickly the rail pressure climbs. It takes about 4000 PSI rail pressure in order to start.
6. Shorted fan clutch, unplug fan and try starting again.

Does this relate to the no start? (DO NOT REPAIR THE PROBLEM. DO NOT TELL

ANYONE OF YOUR FINDINGS)

5. With the Modis scan tool. Make the horn blow and wipers operate. What is this type

of control called?

motis

I worked on finding fault codes on the frieghtliner with Daniel and also worked on replaceing a tie rod on my Dakota truck the tie rod was worn due to wear from no lubrication.I bought one with the cert fitting torqued to spec and installed the wheel and torqued it to spec of 135 ft lbs .The rest of the week I spent working atWilliams doing a demo on some hydraulic lines and ajusting some air start valves on a clarktcv 12 engine with a Brandon the tech. we found rust to be the root cause and cleaned the valves and reset them and it worked fine I also worked on day 34, 35 sheets other than that I flushed a radiator coil for my sons truck seem that the gunk is is still coming out and seems to plug the heater core so that it will not heat up fixed that and also a bad light on my truck.                   I spent total 40 hours                                 Trying to keep busy all the time.

max force

Last week I learned how to check the compression ratio specs on the international.It was  all valuable info needed to predict and analyze piston wear and troubleshoot major problems.I also learned how   to check for fault codes .The testing must be done in sequence for it to work.I spent alot of my time concentrated on the max force program and hope to spend more this week .At Williams I worked on numerous jobs from helping to locate the 36 inch gas lines and staking the right of way, to working on taking out abandoned lines by purging hydraulic  oil out of them and cutting into pieces for recycling. total hours            40 hours worked

Diesel particulate filter link

http://www.fsxinc.com/site1/video/video.html  I was on the Navistar website and I came across this link to a great video I do recommend everyone to watch the cleaning process on a DPF.This week I mostly was navigating on the Navistar website it is a great library of information I found out all the manuels and researched my homework easily there.I learned that having the acsess to this site is greatest tool of all.Total hours for the week ending 10/27/2012 are 40

week ending 10/20/2012 40 hours

This week was a great learning experience I worked on the Cummings engine with Don and Stephanie and installed the injectors and tubing to the pump .I also installed the exhaust and fuel filter system and the water cooler and turbo.we have cleaned all the rust off of most of the coolant lines and brackets that hold other parts on the engine. My goal is to star the engine next month by the 12 of November and  hear it run and get it ready to deliver to the owner .Work at Williams was very interesting also we worked on the Clarke oil pressure issues and hopefully can get them fixed this week  total hours work and school 40

reporting on the lithal strike

The video teaches us that not all injuries are visible at first .Although a person may seem like he or she has had some minor injury, it could very well be a life threatening incident.The mechanic had an oil  injection injury, amputation could be needed if not attended  by a Doctor within the first six hours. All injuries  whether small or big need to be reported and looked at asap .Sometimes being a Mr tuff guy could kill you.The video teaches us the importance of reporting and making sure every accident is attended to properly and to take every injury serious because they could be lethal.The mechanic was lucky he only lost 2 fingers ,he could have lost alot more like his life .Be cautious and alert about safety and take injuries serious is what I learned from the video.

Pin Timing a Denso Pump on a Cummins

http://www.youtube.com/watch?v=KnUYMmjUams&feature=context-cha link to a  a great video on how to find timing on your fuel pump. Last week was a great week.Don and Stephanie and I worked on trying to put the c6 8.3 liter marine engine together It has been a good learning project I learned how to gap the valves and find true tdc as Cummings has on their site .Following their specs was simple just be careful not to to force the piston to hard against the valve when you spin the crank .you will feel the piston against the valve.You will have to fabricate a pointer so that it points onto the vibration damper so that you can make a mark for reference  when you find tdc after that spin counter clockwise until you feel the valve again remark it then divide that distance between the two marks and that is your true tdc  also when you find tdc don't forget to reset the number 1piston  gap to its specs. I learned the steps and set the timing on the engine so that i could install the NippoDenso pump which also needs to be timed to the book specs i included a l;ink to the video that was on the web  I thought he did a good job explaining the process so I used it hope you all watch it and use the Cummings web site to learn the steps it surely helped me.

 My hours in the shop and work are 50

International Automotive Technicians Network is powerful info

ship from south Africa we loaded turbines on to

!20 ton Crane at the port in Esberg Denmark  loading gear heads from a wind turbine Marks father Bjorne operates it .

 

Steam turbine has 520 k hp

 

Setting the load onto the ship

Raul next to 9-t  used to push coal into the hopper at Dong Energy

 

                                            This is a wind turbine erector ship at the port in Esjberg  Denmark

International Automotive Technicians Network .The more knowledge you have the better.I also enjoy reading  David Lieghton' s post of the Whatcom chief .David is one of the fortunate ones in our class .He has had the opportunity to work on different engines and is exposed to many scenarios where it takes allot of thought to be able to pull the engines out of very confined spaces.I guess I have been fortunate because at Williams there is definitely  space around the engines that is one of the reasons I have  decided to focus on stationary engines.Iam a big guy who probably would  not fit in the engine room of a sailboat like  the Aqavit where David worked on the Perkins engine last week.I really enjoy reading his post.Thanks for the great info David keep up the Good work. Last week I finished up installing the side doors to the compressors on number six engine while my co worker changed the oil filters on the Clark tcv 12 which has over a hundred of them .I worked on my electrical panel and auto schematics .I worked total class room and internship 40 hours

Electrical ( 40 hours class and intership )

Slowly but surely the electrical will sink in. Last week was a definite challenge as we worked on wiring the test boards .I must say it is critical to learn the diagram and symbols before you proceed to the board  .On the job at Williams last week I helped reassemble  the Clark compressors  we torqued up all the bolts holding the caps on the compressor and gear heads that attach to the rods and pistons of the compressors using the star pattern and required torque specs I also  started assembly of the tubing for monitoring the compression  in the compressors. and greased the valves in and around the  meter station.I have been very fortunate to have a great pair of journey man mechanics such as Brandon and Theason to teach me at Williams pipeline next week we will finish the job and go on to new and exciting challenges hope you all are having fun. have a great week.

dc motors

Direct-current motors transform electrical energy into mechanical energy. They drive devices such as hoists, fans, pumps, calendars, punch-presses, and cars. These devices may have a definite torque-speed characteristic (such as a pump or fan) or a highly variable one (such as a hoist or automobile). The torque-speed characteristic of the motor must be adapted to the type of the load it has to drive, and this requirement has given rise to three basic types of motors: 1. Shunt motors 2. Series motors 3. Compound motors Direct-current motors are seldom used in ordinary industrial applications because all electric utility systems furnish alternating current. However, for special applications such as in steel mills, mines, and electric trains, it is sometimes advantageous to transform the alternating current into direct current in order to use dc motors. The reason is that the torque-speed characteristics of dc motors can be varied over a wide range while retaining high efficiency. Today, this general statement can be challenged because the availability of sophisticated electronic drives has made it possible to use alternating current motors for variable speed applications. Nevertheless, there are millions of dc motors still in service and thousands more are being produced every year.

Compression rings

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Rod and rods that hold the piston

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Rod and piston assembly for a clark tcv12. We are Installing three back into the compressors they came out of after they were rebored. We have been working on them for about 2 months now .it has been a major project at Williams and I have learned alot about it bieng that I have been on it since the start we we finished installing the valves and unloaders today and will torque everything to spec tommorow .

This weeks hours 40 class and work at internship

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link to jobs in oil industry

http://www.rigzone.com

Class presentation Denmark

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Marine Fitters EUC VEST Esjberg Denmark

PRESENTLY we are at the EUC VEST IN ESBERG Denmark working with the Danish students IT has been a great experience for us .We had the opportunity to work with DONG ENERGY a national company which produces power and heating water for the Danes.ALSO GRUMSEN EQUIPMENT A/S While I was at DONG ENERGY I had the chance to go to the highest point in Denmark which is 240 meters above sea level and leave my name imprinted on the blocks, with the few others who were able to have the opportunity since it was built.We have also visited numerous other companys such as Semco, a world leader in the oil bussiness and have visited the port where windmills are bieng loaded on to cargo ships headed to other parts of the world , Our greatest experience is bieng able to live with a DANISH FAMILY AND LEARN THIER CULTURE AND BUILD A LIFE LONG RELATIONSHIP.THANK YOU TO ALL THE FAMIELIES WHO HOSTED US . Thanks to SCAN DESIGHN and the ASBTC student body at Bellingham TECHNICAL cOLLEEGE and EUC VEST in ESGBERG AND THE INSTRUCTERS who have made this experience possible. Thankyou very much sincerly RAUL Soto Ian Winters

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360 Hours Summer Quarter

Compressor was a 16" diameter will be a 18". Ingersell Rand came in Oklahoma to bore out and complete. I have been working with them and also working on a Ingersell Rand engine which had problems with the bearings and we had to tear out the compressor rod. We ran into trouble trying to find the right bearings for it because of the age of the engine (1966). I have also been working on the gas pipping system to prepare for Dunkin and Busch to paint. Also, I worked on the coolers for the Mars Turbins which had vibrations and squeling which we changed. Previously we had Solar come in and try to analyze more vibrations in a turbine. I helped them align the shafts. In my spare time my son and I are tearing apart a 1989 Ford Ranger. All in all this summer has flown by and been very educational. I owe so much to Williams for all they have invested in me and taught me. I possibly will be able to return to Williams after my trip to Denmark. Hope everyone is having a wonderful, learning and enjoyable summer. ~Soto

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This week I was working on a water pump that goes on a clark tcv12 gutted it and replaced with new shaft and bearings and i have been helping on alighnment of a turbine and currently working on tearing apart compressors. Hope you all are learning as much as I am.

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Searching root cause of vibration in the Mars 90 turbine

This week we worked on finding the root cause of the slight vibration on the turbine we had previosly boroscoped the compressor and did not find any visible damage so Williams brought in a Solar tech to try and find the cause we disassembled th line and found it to be a full day job with torque specs of 9500 ft pounds it takes some heavy duty impacts I have some pictures of the disasembly and assembly enjoyAlso have some pictures of the radiator that cools the turbine I was up on it cleaning the coils I used a man lift to get up on top and spray it with coil bright then washed it with water I also have been helping Ernie the welder at the Mount Vernon station on new piping install going in the Seatle area we have been cuting and fitting flanges on pipe and fabricating other pieces needed..

last Two photos are the upper and lower view of the coolant fan and coils of the cooler.for the turbine,

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Alex cooking best carne asada ever at diesel program graduation barbeque.Stefany cooked some delicous mexican rice and Jeff cooked up some of the best chili beans I have ever had.Thanks to everybody for helping and making it such a success hope you all have a great summer.

Fith wheel removal

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Lesson on removing and replacing the fith wheel simple process but you need a lift of sometype to get it off, not to complicated.

300 hrs shop time and computer research time spring quarter.

Total hours this spring quater were as follows 300 hrs shop time and computer research time .

Pilot bearing check

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The pilot bearing on the frieghtliner is good I checked it out for wear and it felt like it had been properly greased so there was no damage it was smooth and lubed when I reinstalled the clutch

Sheet 17 Air brakes

Iparticipated in a disassembly of one of the ZF loader axles.Stephanie and I took apart the smaller axle.We found that the planetery gears inside are held together by a ring and it was a challenge to reasembleble it but we did it. I did 14 brake jobs total on all the trucks in the shop it was quite the learning experience today i feel confident that I can use my skills to fix any truck brake by using my basic skills i learned on instalation and examination of brakes from Jeff.

24 Remove and replace deferential carrier assembly 15hrts

1. Remove and replace differential carrier assembly. (Optional) 2. Inspect and replace drive axle shafts. 3. Remove and replace wheel assembly; check rear wheel seal and axle flange gasket for leaks; perform needed action. 4. Identify causes of drive axle wheel bearing noise and check for damage; perform needed action. 5. Inspect and test drive axle temperature gauge and sending unit/sensor; determine needed action. 6. Clean, inspect, lubricate and replace wheel bearings; replace seals and wear rings; inspect and replace retaining hardware; adjust drive axle wheel bearings.

22 Inspection of clutch 15 hrs

Inspect and/or replace clutch brake assembly; inspect input shaft and bearing retainer; perform needed action. 2. Inspect and replace pilot bearing. 3. Inspect flywheel mounting area on crankshaft, rear main oil seal, and measure crankshaft end play; determine needed action. 4. Inspect flywheel, starter ring gear and measure flywheel face and pilot bore runout; determine needed action. 5. Inspect flywheel housing(s) to transmission housing/engine mating surface(s) and measure flywheel housing face and bore runout; determine needed action.

23 Removeing transmision 15 hrs

1. Remove and reinstall transmission. I worked on the frieghtliner transmission removal It was nice to have the option of the truck lift first I removed the drive line and set the lift under the tranny and tied it so it was secure.Then I took the bolts that hold the transmission on the engine.Follewed by a up down motion with the tranny lift so it would seperate from the block of the engine and slowly bring the tranny down.I think this process would be very difficult in th e field without a lift but certainly I can do it.I inspected the clutch wear and the tolerance with the dial indicayer to check for trueness and wear of the crank bearing andresults were within the .008 permited by the eaton. 2. Inspect and test function of reverse light, neutral start, and warning device circuits; determine needed action. 3. Inspect and test operation of automatic transmission electronic shift selectors, switches, displays and indicators, wiring harnesses. 4. Identify causes of driveshaft and universal joint noise and vibration problems; determine needed action. 5. Inspect, service, or replace driveshaft, slip joints, yokes, drive flanges, and universal I inspected the slip joints and yoke drive flanges for wear and loseness they all looked to be tight and secure fit and lubed. joints, driveshaft boots and seals, and retaining hardware; check phasing of all shafts. 6. Inspect driveshaft center support bearings and mounts; determine needed action.

21 Clutch problems 15hrs

1. Identify causes of clutch noise, binding, slippage, pulsation, vibration, grabbing, dragging, and chatter problems; determine needed action. 2. Inspect and adjust clutch linkage, cables, levers, brackets, bushings, pivots, springs, and clutch safety switch; check pedal height and travel; perform needed action. 3. Inspect, adjust, lubricate, or replace release (throw-out) bearing, sleeve, bushings, springs, housing, levers, release fork, fork pads, rollers, shafts, and seals. 4. Inspect, adjust, and replace two-plate clutch pressure plate, clutch discs, intermediate plate, and drive pins/lugs.

20 fith wheel 15hrs

1. R&R, disassemble at least one each 5th wheel in the shop, or document one off site. 2. Inspect, adjust, repair, or replace 5th wheel and inspect mountings.

19 Power steering system 15hrs

1. Perform power steering system pressure, temperature, and flow tests; determine needed action. 2. Inspect, adjust, repair, or replace integral type power steering gear(s) (single and/or dual) and mountings.

18 Alighnments and suspension 15hrs

Use the tools listed in the MD Alignment file to perform an alignment. (of course I will demonstrate multiple times if needed. 2. Consider where you might use these principles of alignment on other things that you may be called upon to do. I performed alighnments on the frieght liner and the international trucks I have the knowledge of measureing toe and adjusting by ay tie rod and camber by bending axle and also thrust by measuring distance between wheels and shimming where needed.

Tutorials on Tractor brakes install. 40 hours

Wheel take off

Takeing off the wheel hub assembly

Torque procedures

Evaluating the bearing for wear.

Installing the seal.

Learning brakes 35 hours study. class and shop time

Last week we learned to take off and install brake pads and seals,bushings,springs and slack adjusters  I also  learned  how to check s cams for wear and the tolerance on play permited by using a dial indicator. I have down loaded a video of my practice trials on brake work done on a kw t600  truck. 35 hours

Packard 6hrs

I really enjoyed the the open house at Packard.I took some pictures and will post soon.I learned how extensive the testing is and why they do build the best trucks in the world.I asked a lot of questions,and learned alot .Great expo.

Electrical sinking in after lots of practice 100 hrs

 Voltage is the force that moves Electrons  through a circuit and  is measured in volts using a voltmeter.

The flow of electrons is called electric current there are two types of electric current AC for alternating current and DC for direct current.

  Amperage describes the rate of current flow which is measured by an  amp meter.Low current flow creates  low heat and high current flow high heat Current capacity increases by wire size Bigger wire more current, smaller wire less current

.Resistance describes how much a component restricts current flow.The greater the resistance the less current flows the less resistance the greater the current flow and it  is measured in ohms,with an ohm meter.

Conductors  are most metals  example aluminum copper iron ,

Last week was definitely a brain warmer as I practiced the boards. I realized that it was starting to sink in and I was using the process of elimination. Electrical can be difficult but don't over think it.That's what Einstein said .

We worked on electrical for 8hrs

I learned to find short circuits

Spring Quarter

My reflection of electrical diagnosis, I must say I did have a brain surge today.

Winter Quarter Internship hours

January hours= 102
February hours=120
March hours=121.5
Total hours for Winter Quarter Diesel Internship program =343.5

Solar Mars 90 Turbine

3/12-3/17=39.5 hours

This is a Mars 90 tubine it has 13,000 horsepower.

Working on Scruber



Scrubber unit top pipe is a gas inlet. The  gas runs through filters  inside on left side of unit and cycles through to right side outlet. the two bottom boots are for extracting any liquid in the gas before it goes on into the turbine to be compressed and pushed on through the mainline.

This is the inside of a filter separator also known as  scrubber.  A scrubber is a filtration system that is used to filter all particles in the main gas line before it enters the compressor it has a total of 64 six foot filters. We replaced the filters and the oring on this unit.  



  The ring that holds the door to the scrubber is held together by 2 bolts and a safety pin that compress to tighten the door. There is a rubber oring to seal the gas from leaking out which is set in a grove which must be lubed with lubriplate to prevent from rolling it out when tightening the clam shell door.

Air respirator and fire retardant and chemical retardant protective gear is necessary to work on a scrubber..



Finishing up the Exhaust job

Total hours for last 2 weeks ending3/3/2012and3/10/2012 is
82 hours including computer research

View of top of engine block.

Last week I posted some pictures of the work done to the Clarke TCV 12  I learned alot about the engine after helping Brandon on the exhaust job. The project took us 8 days primarily because of the size of exhaust and all the coolant and gas lines needed to be taken out of the way  to get to the exhaust.On an engine this size everything needs to be handled with an overhead crane.We installed the new gaskets to the exhaust an also to the coolant and fuel lines and replaced some gaskets on one the engines compressors.I then went to help Teason (aka T-Bone ) on calibrating some of the pressure sensors on the 2000 hp Ingersol Rand engines he monitors Where he was teaching me how to calibrate the sensors which monitor pressures and temperatures on the engines all computerized and are also remotely monitored from the Utah main site.I also spent time learning how to adjust and replace  intake exhaust and fuel valves on the Ingersol Rand engine monitored by Ray he taught me how to set the valve lash on it I have added some more pictures and will post more during the week.

 . 

Manifold Gasket Replacement hours for the Month of Febuary are 120 hours

The two twenty inch pipes below connect to the exhaust on the engine. 



The picture below shows the exhaust.  Next to the exhaust is the coolant pipe. 


The picture below shows the 3 compressors tied into the engine.  Each compressor has an individual arm connected to the crankshaft. 



As you can see in the picture below the 6 ports of the exhaust.  Each exhaust tube weighs 8,500 lbs and has a 20" diameter.







Each one of these is a head on one side of the engine.  There is a total of 12 heads to the engine.



Below is a picture of the top of the engine block where the exhaust is placed.  Each hole is where we will be installing the new gaskets.The smaller holes you can see are for the coolant ports. 




To take off the exhaust was one entire day.