Construction Mechanic 1 And C: Naval Rate Training Manual .

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DOCUMENT RESUMEED 114 657TITLEINSTITUTIONCE 005 531Construction Mechanic 1 and C: Naval Rate TrainingManual and Nonresident Career Course.Naval Education and Training Command, Pensacola,Fla.REPORT NOPUB DATENOTEAVAILABLE FROMEDRS ; Photographs and portions of text willreproduce poorlySuperintendent of Documents, U.S. Government PrintingOffice, Washington, D.C. 20402 (Stock No.0502-LP-053-2260)MF- 0.76 HC- 12.05 Plus PostageAuto Mechanics; *Auto Mechanics (Occupation); CourseContent; Electrical Systems; Engines; *InstructionalMaterials; Job Training; *Manuals; Mechanics(Process) ; Military Training; Safety; *SupervisoryActivities; *Supervisory Training; TechnicalEducationNavyABSTRACTThe Rate Training Manual and Nonresident CareerCourse (PTM/NRCC) form a self-study package that enables ConstructionMechanics to fulfill the requirements for advancement to ConstructionMechanic First Class (CM1) or Chief Construction Mechanic (CMC).Chapter 1 provides information relevant to the duties andresponsibilities of a CM1 or CMC. Chapters 2-9 cover the followingtopics: supervision, public works transportation shops supervisor,battalion equipment company shops supervisor, engine overhaul,automotive electrical systems and equipment, diesel fuel systems,vehicle safety inspections, and power trains. Photographs anddiagrams illustrate the document. A subject index, a list of theminimum qualifications for advancement to Construction Mechanic FirstClass and Chief Petty Officer, and a 54-page course assignmentbooklet for the nonresident career course conclude the ts acquired by ERIC include many informal unpublished* materials not available from other sources. ERIC makes every effort ** to obtain the best copy available. Nevertheless, items of marginal ** reproducibility are often encountered and this affects the quality *** of the microfiche and hardcopy reproductions ERIC makes available** via the ERIC Document Reproduction Service (EDRS). EDRS is not* responsible for the quality of the original document. Reproductions *** supplied by EDRS are the best that can be made from the ******************************


PREFACEThe ultimate purpose of training Naval personnel is to produce acombatant Navy which can ensure victory at sea. A consequence ofthe quality of training given them is their superior state of readiness.Its result is a victorious Navy.This Rate Training Manual and Nonresident Career Course (RTM/NRCC) form a self-study package that will enable ambitious Construction Mechanics to help themselves fulfill the requirements of theirrating. Among these requirements are the abilities to maintain, repair,and overhaul automotive, materials-handling, and construction equipment;to supervisor assistants who locate, analyze, and correct malfunctiorisof the equipment, and who issue repair parts; to maintain records andprepare requisitions and reports; and to train assistants in repairprocedures and techniques.Designed for individual study and not formal classroom instruction,the RTM provides subject matter that relates directly to the occupationalqualifications of the Construction Mechanic rating. The NRCC providesthe usual way of satisfying the requirements for completing the RTM.The set of assignments in the NRCC includes learning objectives andsupporting items designed to lead students through the RTM. TheNRCC is designated a major revision, and retirement point credit willbe granted to Naval Reservists who complete (or retake) it successfully.This training manual and nonresident career course was preparedby the Naval Education and Training Program Development Center,Pensacola, Florida, for the Chief of Naval Education and Training.Technical assistance was provided by the Naval Facilities EngineeringCommand, the Naval Construction Training Center, Port Hueneme,California.; and the Naval Construction Training Center, Gulfport,Mississippi.Revised 1975Stock Ordering No.0502-LP-053-2260Published byNAVAL EDUCATION AND TRAINING SUPPORT COMMANDUNITED STATESGOVERNMENT PRINTING OFFICEWASHINGTON, D.C.: 19753

THE UNITED STATES NAVYGUARDIAN OF OUR COUNTRYThe United States Navy is responsible for maintaining control of the seaand is a ready force on watch at home and overseas, capable of strongaction to preserve the peace or of instant offensive action to win in war.It is upon the maintenance of this control that our country's gloriousfuture depends; the United States Navy exists to make it so.WE SERVE WITH HONORTradition, valor, and victory are the Navy's heritage from the past. Tothese may be added dedication, discipline, and vigilance as the watchwordsof the present and the future.At home or on distant stations we serve with pride, confident in the respectof our country, our shipmates, and our families.Our responsibilities sober us; our adversities strengthen us.Service to God and Country is our special privilege. We serve with honor.THE FUTURE OF THE NAVYThe Navy will always employ new weapons, new techniques, andgreater power to protect and defend the United States on the sea, underthe sea, and in the air.Now and in the future, control of the sea gives the United States hergreatest advantage for the maintenance of peace and for victory in war.Mobility, surprise, dispersal, and offensive power are the keynotes ofthe new Navy. The roots of the Navy lie in a strong belief in thefuture, in continued dedication to our tasks, and in reflection on ourheritage from the past.Never have our opportunities and our responsibilities been greater.ii

CONTENTSPageCHAPTER1. Duties and Responsibilities12. Supervision83. PW Transportation Shops Supervisor .284. Battalion Equipment Company Shops Supervisor375. Engine Overhaul576. Automotive Electrical Systems and Equipment837. Diesel Fuel Systems1038. Vehicle Safety Inspections127. .9. Power TrainsINDEXQualification for Advancement5148. . 174.179Nonresident Career Course follows Qualification for Advancementiii1

CREDITSThe illustrations listed below are included in this edition ofConstruction Mechanic 1 & C through the courtesy of the designatedsource. Permission to use these illustrations is gratefully acknowledged. Permission to reproduce illustrations and other materials inthis publication must be obtained from the source.SOURCEFIGURESBlack and Decker Manufacturing Company5-16Caterpillar Tractor Company7-12Clayton Manufacturing Company5-1Delco-Remy Company6-2, 6-3, 6-4, and6-21Detroit Diesel Engine Division5-28Fairbanks, Morse and Company5-29Ford Division, Ford Motor Company8-2General Motors Corporation5-12Sun Electric Corporation5-9iv

CHAPTER 1DUTIES AND RESPONSIBILITIESIfthe Navy, as a team, is to achieve itsultimate goal of "Victory at Sea," each memberof the team must be well trained and completelyinformed as to his duties and responsibilities.It is also essential that each member ensurethat he constantly keeps himself informed as toany new developments that affect his rating.In large measure, the extent of your contribution to the Navy depends upon your willing-ness and ability to accept increasing responsibilities as you advance. When you assumedthe duties of a CM3, you began to accept acertain amount of responsibility for the workof others. With each advancement, you acceptan increasing amount of responsibility in militaryThis training manual is designed to help youmeet the occupational qualifications for advancement to Construction Mechanic First Class andChief Construction Mechanic. Chapters 2 through9 of this training manual deal with the technicalsubject matter of the Construction Mechanicrating. The present chapter provides informationmatters as well as technical responsibilitiessibilities as a CM1 or CMC. It is stronglyrecommended that you study this chapter care-leadership are unique to your rating. The main-chapters that follow.Certain practical details that relate to yourresponsibilities for administration and supervision are discussed in other chapters of thistraining manual. At this point, let's considersome of the broader aspects of your increasingresponsibilities for military and technical lead-of the Construction Mechanic rating.that will help you in your duties and respon-You will find that your responsibilities formilitary leadership are the same as those ofa petty officer in other ratings, since everypetty officer is a leader as well as a technicalspecialist. Your responsibilities for technicalfully before beginning intensive study of thetenance and repair of automotive and constructionequipment is a job of vital importance.REWARDS AND RESPONSIBILITIESAdvancement brings both increased rewardsand increased responsibilities. The time to startlooking ahead and considering the rewards andthe responsibilities of advancement is rightnow, while you are preparing for advancementership.YOUR RESPONSIBILITIES WILL EXTENDBOTH UPWARD AND DOWNWARD. Both officersand enlisted personnel will expect youto translateto CM1 or CIVIC.the general orders given by officers into detailed, practical on-the-job language that can beunderstood and followed even by relatively in-By this time you have probably discoveredthat one of the most enduring rewards of advancement is the personal satisfaction you findin developing your skills and increasing yourknowledge. The Navy benefits by your advancement in that highly trainedpersonnelareessentialto the proper functioning of the Navy. With eachexperienced personnel. In dealing with yourjuniors, it is up to you to see that they performtheir work properly. At the same time, youmust be able to explain to officers any importantneeds or problems of the enlisted men.advancement you increase your value to the NavyYOU WILL HAVE REGULAR AND CONTINUING RESPONSIBILITIES FOR TRAINING. Evenin two ways; First, you become more valuableas a technical specialist; and second, you becomemore valuable as a supervisor, leader, andif you are lucky enough to have a highly skilledand well trained group of mechanics, you willinstructor.17

CONSTRUCTION MECHANIC 1 & Cstill find that training is necessary. For example,you will always be responsible for training lowerrated men to assume added responsibilities.Also, some of your best workers may be transferred and inexperienced or poorly trained personnel may be assigned to you. Or a particularjob may call for skills that none of yourpersonnel have acquired. These and similarproblems require you to be a training specialistwho can conduct formal and informal trainingprograms to qualify personnel to perform moreadvanced technical assignments and who can trainindividuals and groups in the effective executionof assigned tasks.written examinations for advancement. Althoughit is always important for you to use technicalterms correctly, it is particularly importantwhen you are dealing with lower rated men.Sloppiness in the use of technical terms is likelyto be very confusing to an inexperienced man.From time to time, inexperiencedmen under yoursupervision may ask you to explain the meaningof various terms used in the mechanic trade.Some of the terms which you may be askedto explain are listed and defined below; makesure you are familiar with the meaning of theseand other technical terms you may encounterin your work.YOU WILL HAVE INCREASING RESPONSI-BILITIES FOR WORKING WITH OTHERS. Asyou advance to CM1 and then to CbIC, you willfindat a great disadvantage when he takes thethat some of your plans and decisionsaffect a large number of persons. It becomesAdjust: Use precision measuring devices tomeasure clearances; make operational adjustments.increasingly important, therefore, to understandthe duties and responsibilities of others.Every petty officer in the Navy is a technicalEngine Overhaul (Minor); Perform cylinderhead and valve overhaul; remove oil pan, refitspecialist in his own field. Learn as much asyou can about the work of other ratings, andmain bearings, connecting rod bearings, andpiston rings as necessary; renew piston rings;hone cylinder walls or renew cylinder linersas required; reassemble and make necessaryplan your own work so that it will fit in with theoverall mission of the organization.AS YOUR RESPONSIBILITIES INCREASE,adjustment for operation.YOUR ABILITY TO COMMUNICATE CLEARLYEngine Overhaul (Major): Completely dis-AND EFFECTIVELY MUST ALSO INCREASE.The basic requirement for effective communi-assemble engine; recondition or replace all com-Use correct language in speaking and in writing.Remember that the basic purpose of all commu-required; reassemble, adjust,operation.ponent parts as required; rebore cylinders ifcation is a knowledge of your own language.nication is understanding. To lead, supervise,and train others, you must be able to speak andwrite in such a way that others can understandtest forEngine Tune-Up (Minor): Clean or renewspark plugs, renew ignition points and condenser,exactly what you mean.set ignition timing, set carburetor idle mixtureand idle speed; service carburetor air cleaners;clean or renew fuel bowl filter or screen.A second requirement for effective communication in the Navy is a sound knowledge of theNavy way of saying things. Some Navy termshave been standardized for the purpose of en-Engine Tune-Up (Major); Check engine transmission, clean or renew and adjust spark plugs;test battery, clean terminals; renew and adjustdistributor points and condenser, check distrib-suring efficient communication. When a situationcalls for the use of standard Navy terminology,use it.Still another requirement of effective communicationandutor cap and rotor; set ignition timing, testcoil; free-up manifold head control valve; tightenis precision in the use of technicalcylinder head and manifold bolts; adjust carburetor idle speed; inspect and tighten all hoseconnections; adjust an belt and solid valveterms. A command of the technical languageof the Mechanic rating will enable you to receiveand convey information accurately and to exchangeideas with others. A person who does not under-tappets.stand the precise meaning of terms used inconnection with the work of his own rating isat a disadvantage when he tries to read officialpublications relating to his work. He is alsoMinor Repair: Replacement of worn or brokenparts and adjustments required to restore equip-ment (or facilities) to its original capability,not requiring a high degree of technical skill.28

Chapter 1-DUTIES AND RESPONSIBILITIESOperators /Watchstanders Maintenance: Therequired inspection, service, lubrication, andadjustments performed by an operator/watchstander to keep power tools and equipment in asafe operable condition, in order to preventpersonnel injuries, mechanical malfunctions, andcurtailment of production or progress.Some changes will be called directly toyour attention, but others you will have to lookfor. Try to develop a special kind of alertnessfor new information. Keep up to date on allavailable sources of technical information. Andmake a continuing effort to keep up to dateon the subject of diesel and gasoline engines,Test: Use instruments or operate to identifyposSsible malfunction or failure; or determinecorrectness of completed repair work.automotive electrical systems, maintenance procedures, and so on, as well as changes ornew developments in tools or equipment relatedto your job.YOU WILL HAVE INCREASED RESPONSIBILITIES FOR KEEPING UP WITHNEWDEVEL-THE CONSTRUCTION MECHANICRATINGOPMENTS. Practically everything in the Navypolicies, procedures, equipment, publications,and systems is subject to change and develop-ment. As a CM1, and even more as a CMC,you must keep yourself informed about all changesand new developments that might affect yourrating or your work.There are several ways in which Navy trainingis changing. For instance, it is becoming moreindividualized because of the programmed instruction courses and audiovisual courses thatare being introduced. These courses enable atrainee to choose his medium of instruCtion(manuals, tapes, programmed instruction, TV)and to proceed at his own pace (called self-pacing). Other changes you will see taking placeIn Navy training affect the development of instructional materials. One change calls for theuse of job-related training materials. Theseare materials designed to teach trainees to dothe tasks that constitute a job. Another changeconcerns the application of techniques and procedures for instructional systems development.In other words, Navy training will be based onanalysis of job information and learning requirements from which tests, learning objectives,and training materials are developed.Then too, you will find that in many ratingsthere are plans to train men and women fromthe time they enter the Navy until they retire.Construction Mechanics schedule, oversee,and perform tasks involved in maintenance,repair, and overhaul of automotive, materialshandling, and construction equipment; assignand supervise activities of assistants who locate,analyze, and correct malfunctions in equipment,and issue repair parts; maintain records, preparerequisitions and reports; and train assistantsin repair procedures and techniques.Most of the billets for CM1 and CMC areallotted to mobile construction battalions, construction battalion units, and Public Works Departments. In a battalion, a CM1 or CMC usuallyserves as a supervisor of the equipment companyshops. In a Public Works Department, the CMmay serve as supervisor of the TransportationShops. Other billets for CMs include recruitingduty, recruit training, and Naval Reserve training.A limited number of particularly well qualifiedCMs are also given assignments to instruct inNavy schools; to assist in making up the servicewide advancement examinations; to assist in thepreparation of Rate Training Manuals (like thisone); to serve as a member of a SEABEEteam; and to perform other highly specializedduties where their technical knowledge can beutilized effectively for the needs of the service.REQUIREMENTS FOR ADVANCEMENTAccording to these plans, all training is putto use and overtraining is eliminated. The timedevoted to instruction in many, if not all, classA schools will be shortened; also, the numberIn general, to qualify for advancement youmust;1. Have a certain amount of time in rate.2. Complete the required military and occu-of other schools will be reduced. As a consequenceof shorter school terms and fewer schools, moretraining will take place onboard. This will resultin the development of training packages to assistpational training courses.3. Demonstrate the ability to perform all thePRACTICAL requirements for advancement bycompleting the "Record of Practical Factors,"the onboard trainers. Many of these are sureto be multimedia packages, that is, use moreNAVEDTRA 1414/1 CM.than one medium of instruction.3

CONSTRUCTION MECHANIC 1 & C4. Be recommended by your commanding ofSuch information is given in Construction Meficer.5. Demonstrate your KNOWLEDGE bypassing chanic 3 & 2, NAVPERS 10644-F.a written examination based on (a) the militaryThe occupational Construction it echanicrequirements for advancement and (b) the occuqualificationsthat were used as a guide in thepational qualifications for advancement.preparation of this training manual were thoseRemember that the requirements for advance- promulgated in the Manual of Qualifications forment may change from time to time. Check Advancements NAVPERS 18068-C.with your division officer or with your trainingSince your main purpose in studying thisofficer to be sure you have the most recenttrainingmanual is to meet the qualificationsrequirements when you are preparing for ad- for advancementto CM1 or CMC, it is importantvancement and when you are helping lower rated for you to obtainand study a set of the mostmen to prepare for advancement.recent Construction Mechanic qualifications.To prepare for advancement, you need to befamiliar with (1) the military requirements andthe occupational qualifications given in the Manualof Qualifications for Advancement, NAVPERS18068-C; (2) the Record of Practical Factors,NAVEDTRA 1414/1 CM; (3) appropriate RateTraining Manuals; and (4) any other materialthat may be required or recommended in thecurrent edition of Bibliography for Advancement Study, NAVEDTRA 10052. These materialsare discussed later in the section of this chapterthat deals with sources of information.SCOPE OF THIS TRAININGMANUALThis training manual includes informationthat is related to both the KNOWLEDGE FAC-TORS and the PRACTICAL FACTORS of thequalifications for advancement to CM1 and CMC.However, no training manual can take the placeof actual on-the-job experience for developingskill in the practical factors. The training manual can help you understand some of the whysand wherefores, but you must combine knowledge with practical experience before you candevelop the required skills. The "Record ofPractical Factors," NAVEDTRA 1414/1 CM,should be utilized in conjunction with this trainingmanual whenever possible.Before going on to the next chapter ofthis training manual, study the table of contentsand note the arrangement of information. Information can be organized and presented inmany different ways. You will find it helpfulto get an overall view of the organization of thistraining manual before you start to study it.Before studying any book, it is a good idea toknow the purpose and the scope of the book.Here are some things you should know aboutthis training manual:It is designed to give you informationon the occupational qualifications for advancementto CM1 and CMC.SOURCES OF INFORMATIONIt must be satisfactorily completed beforeyou can advance to CM1 or CMC, whether youare in the regular Navy or in the Naval Reserve.It is very important for you to have anextensive knowledge of the references to consultfor detailed, authoritative, up-to-date informa-tion on all subjects related to the militaryIt is NOT designed to give you informationon the military requirements for advancementto P01 or CPO. Rate Training Manuals that arespecially prepared to give information on therequirements and to the occupational qualifications of the Construction Mechanic rating.Some of the publications discussed here aresubject to change or revision from time to timesome at regular intervals, others as the needm i l i t a r y requirements are discussed in thesection of this chapter that deals with sourcesof information.arises. When using any publication that is subjectIt is NOT designed to give you information that is related primarily to the qualifications for advancement to CM3 and CM2.latest edition. When using any publication thatis kept current by means of changes, be sure youhave a copy in which all official changes havebeen change or revision, be sure you have the4

Chapter 1- DUTIES A ND RESPONSIBILITIES1. The quals are the MINIMUM requirementsfor advancement to each rate within each rating.Official publications and directives carryabbreviations and numbers which identify theIf you study more than the required minimum,you will of course have a great advantage whenyou take the written examination for advance-source of the doculient and its subject matter.An abbreviation designates the originator (forexample, NAVEDTRA. or NAVFAC), and thenumbers that follow indicate the subject matter.A letter following the numbers designates theedition.As a result of the establishment of the NavalEducation and Training Program DevelopmentCenter, new editions of rate training manuals,nonresident career courses, curricula, and othertraining publications formally designated withthe abbreviation NAVPERS are being designatedwith NAVEDTRA. The numbers and the editionment.2. Each qual has adesignatedpaygradeE-4,E-5, E-6, E-7, E-8, or E-9. You are respon-sible for meeting all quals specified for advancement to the pay grade to which you are seekingadvancement AND all quals specified for lowerpay grades.3. The written examinations for advancementto E-6 and above contain questions relatingto the practical factors and the knowledge factors of BOTH military /leadership requirementsand occupational qualifications. Personnel pre-designators remain unchanged. This trainingmanual, for instance, is NAVEDTRA 10645-E,which means that it is a publication of theNaval Education and Training Program Development Center.paring for advancement to E-4, or E-5 mustpass a separate military/leadership examinationprior to participation in the Navy-wide occupational examination. The military/leadershipIn this chapter and elsewhere in this text,training publications which carry the new abbreviation are so listed; those not yet changedare listed as NAVPERS numbers. Always makesure that you are using the latest edition ofany publication or directive.examinations for the E-4 and E-5 levels aregiven according to a schedule prescribed bythe commanding officer. Candidates are requiredto pass the applicable military/leader ship examination only once.NAVPERS AND NAVEDTRA PUBLICATIONSThe NAVPERS and NAVEDTRA publicationsdescribed here include some of which are absolutely essential for anyone seeking advancement and some which, although not essential,are extremely helpful.THE QUALS MANUAL.The Manual ofqualifications for Advancement, NA VP E RS18068-C, gives the minimum requirements forRECORD OF PRACTICAL FACTORS. Aspecial form known as the "Record of PracticalFactors," NAVEDTRA 1414/1 CM, is used torecord the satisfactory completion of the practicalfactors, both military and occupational, listedin the Quals Manual. Whenever a person demonstrates his ability to perform a practical factor,appropriate entries must be made in the DATEand INITIALS column. As a CM1 or CMC, youwill often be required to check the practicaladvancement to each rate within each rating. factor performance of lower rated men and toofficer.The Quals Manual lists the military require- report the results to your pratingsandtheallments which apply onal qualifications that are specific toactivity. Entries from the group records must,each rating.of course, be transferred to each individual'sThe Quals Manual is kept current by means Record of Practical Factors at appropriateof numbered changes. These changes are issued intervals.more frequently than most Rate Training Manualscan be revised; therefore, the training manualsAs changes are made periodically to the Qualscannot always reflect the latest qualifications 'LI. aanual new forms of NAVEDTRA 1414/1 arefor advancement. When preparing for advancement, you should always check the LATESTQuals Manual and the LATEST changes to besure that you know the current requirementsfor advancement.When studying the qualifications for advancement, remember these three things:provided when necessary. Extra space is allowedon the Record of Practical Factors for enteringadditional practical factors as they are publishedin changes to the Quals Manual. The Record ofPractical Factors also provides space for re-cording demonstrated proficiency in skills which11.are within the general scope of the rating but

CONSTRUCTION MECHANIC 1 & Cwhich are not identified as minimum qualifications for advancement. Keep this in mind whenyou are training and supervising lower ratedpersonnel. If a man demonstrates proficiency insome skill which is not listed in the Construction Mechanic quals but which falls within theRATE TRAINING MANUALS. Rate TrainingManuals are written for the purpose of helpingpersonnel prepare for assuming greater responsiblities and technical knowledge. In addition,the manuals are of great assistance in preparingforadvancement. Some manuals are general ingeneral scope of the rating, report this fact natureand are intended for use by more thanto the supervising officer so that an appropriate one rating;others (such as this one) areentry can be made.specific to a particular rating.The Record of Practical Factors should beRate Training Manuals are revised from timekept in each man's service record and should be to timeto bring them up to date. The revisionforwarded with the service record to the next of a RateTraining Manual is identified by aduty station. Each man should also keep a copy letter followingnumof the record for his own use. It is advisable ber. You can thetellNAVPERS/NAVEDTRAwhetheraRateTrainingfor each individual to review his service record, Manual is thelatest edition by checking theapproximately 15 days prior to any type of NAVPERS/NAVEDTRAnumber and the lettertransfer, to ensure that his practical factor following the number in themost recent editionsheet and other important papers have been of the List of Training Manualsand Correspondincluded in his record.ence Courses, NAVEDTRA 10061 (revised).NAVEDTRA 10052.Bibliography for Advancement Study, NAVEDTRA 10052, is a veryimportant publication for anyone preparing foradvancement. This publication lists required andrecommended Rate Training Manuals and otherreference material to be used by personnelworking for advancement. NAVEDTRA 10052is revised and issued once each year by theThere are three Rate Training Manuals thatare specially prepared to present informationon the military requirements for advancement.These manuals are:Basic Military Requirements, NAVPERS 10054(current e

Mechanic First Class (CM1) or Chief Construction Mechanic (CMC). Chapter 1. provides information relevant to the duties and responsibilities of a CM1 or CMC. Chapters 2-9 cover the following topics: supervision, public works transportation shops supervisor, batta

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