GLOBAL MANPOWER DEVELOPMENT

Instructor Led Training - Quick Start Guide

GMD Instructor Led Training is developed and delivered as a comprehensive package of training materials. This training
package consists of several Technical Instructor Modules (TIM’s) which are based on Standard Module Lists.

Technical Instructor Modules

Audience MEDIATOR: Dealer Instructors, Service Training Staff
END USER: Service Technicians, Shop Mechanics
Goal • Provide a complete instructional package that can be implemented with minimal instructor prep time
• Facilitate more flexible scheduling (4-8 hour classes)
General Function •P rovide instruction on a system (or segment of a system) that impacts a range of products; for example,
transmissions or implement systems.
• A complete course on a machine or engine may be made up of one or more TIMs.

Individual modules should be assembled as described below:

Instructor • TOC • Module Description • Preparation Checklist • Prerequisites • Lesson Plan • Objectives • Lab Instructions
Materials • Lab Exercises (w/ answers) • Case Study Instructions • Case Study • Post-Test Instructions
• Post Test (w/ answers)
Student Materials • Objectives • Lab Exercises • Case Study • Post Test

Slide / • Bulleted teaching points • Media Elements (photos, line art, 3D, video, tables, charts, graphs, etc.)
Text Reference

The illustrations below further visualize how the package of training materials are delivered as well as the components for each
module.

TRAINING PACKAGE STRUCTURE: MODULE COMPONENTS:

Table of Contents

Required
Description
Introduction /
Table of Contents Module Checklists
Custom
Training
Package Prerequisites
Module Module
Lesson Plans
Instructor

Module Module Objectives

Introduction /
Module Labs
Module Module Table of Contents
Student

Module Module
Custom
Training Case Study
Module Module Module Module
Package
Technical
Presentation Quizzes / Assessments
Based on Standardized Topic Lists
Slide / Text Reference

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GLOBAL MANPOWER DEVELOPMENT
Instructor Led Training - Quick Start Guide

TEXT / SLIDE REFERENCE

Recommended settings:
- Adobe Reader Version 8
- Screen Resolution at 1024x768

PLEASE AVOID USE OF 1280x1024 SCREEN RESOLUTION

To navigate this document, use the right keyboard arrow to advance to the next page, and the left keyboard arrow to go back one
page - OR - left click the mouse to advance forward, right click to go back one page.

Print Participant Pages To print a participant guide, click the “Print Participant Pages” button on the title page.

Print Instructor Pages To print an instructor guide, click the “Print Instructor Pages” button on the title page.

Following are the on-screen buttons and their functions:

Sets the document to ‘presentation mode’ on the monitor

Toggles the callouts ‘on’ and ‘off’ (for applicable pages)

Toggles the document to ‘instructor mode’

Toggles the document to ‘participant mode’

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Instructor Led Training - Quick Start Guide
Hydraulic Schematic Color Codes
Black - Mechanical Connection - Seal
Dark Gray - Cutaway Section
Light Gray - Surface Color
White - Atmosphere or Air (No Pressure)
Purple - Pneumatic Pressure
Yellow - Moving or Activated Components
Dark Yellow - (Restricted Usage) Identification of
Components within a Moving Group
Brown - Lubricating Oil
Green - Tank, Sump or Return Oil
Green / White Stripes -
Scavenge / Suction Oil or Hydraulic Void
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Red - High Pressure Oil
Red / White Stripes - 1st Pressure Reduction
Red Crosshatch - 2nd Reduction in Pressure
Pink - 3rd Reduction in Pressure
Red / Pink Stripes - Secondary Source Oil
Pressure
Orange - Pilot, Charge or Torque Converter Oil
Orange / White Stripes - Reduced Pilot,
Charge, or TC Oil Pressure
Orange Crosshatch - 2nd Reduction in Pilot,
Charge, or TC Oil Pressure
Blue - Trapped Oil
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COLOR (cont.)

Wire Function Color Codes - 2pt.

Red Wires with system voltage (Keystart switch off)

Dark Blue Wires with system voltage (Keystart switch on)

Blue Voltage Converter

Orange Starting Circuit

Black Ground Circuit (Must be attached to ground stud)

Pink Engine Control Circuit (Master)

Green Monitor Circuit (VIMS / CMS / EMS / Others)

Purple Front Engine Control Circuit

Brown Integrated Braking Control Circuit

Data Link Color Code - 2pt.

Dark Blue Global CAN A

Blue Global CAN B

Purple Local CAN

Red Cat Data Link

Orange Display Data Link

Pink ATA Data Link

Green Communication Link: Fiber Optic

Brown Available (Unused Wire)

Black Available (Unused Wire)

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Instructor Led Training - Quick Start Guide

COLOR (cont.)

AIR CONDITIONING Color Codes

Light Blue - Low Pressure Gas Pink - High Pressure Gas

Blue - Low Pressure Gas / Liquid Mix Medium Red - High Pressure Gas / Liquid Mix

Dark Blue - Low Pressure Liquid Red - High Pressure Liquid

Green - Water

TRANSMISSION COMPONENT Color Codes

Red - Input Brown - Carrier, Sun Gear, Planetary Gear

Blue - Output Dark Gray - Cutaway

Yellow - Bearings Light Gray - Surface

Green - Ring Gear

TRANSMISSION COMPONENT IDENTIFICATION Solenoid

Valves

Pump

Input
Shaft
Counter
Shaft

Output
Shaft

AWD
Shaft

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COLOR (cont.)

ENGINE Color Codes

Black - Seal Green - Coolant

Dark Gray - Cutaway Section Red - Oil

Light Gray - Surface Color Yellow - Fuel

Blue - Air Intake Orange - Exhaust

AIR INTAKE & EXHAUST COLOR CODES

Dark Blue - Lowest (coldest) Temperature Red - Highest (hottest) Temperature

Blue - Lower (colder) Temperature Medium Red - Higher (hotter) Temperature

Light Blue - Low (cold) Temperature Pink - High (hot) Temperature

Green - Water

COOLING Color CodeS

Dark Blue - Lowest (coldest) Temperature Red - Highest (hottest) Temperature

Blue - Lower (colder) Temperature Medium Red - Higher (hotter) Temperature

Light Blue - Low (cold) Temperature Pink - High (hot) Temperature

Green - Water

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AIR ACTUATED SYSTEMS COLOR CODES

Purple - High Pressure Purple Crosshatch - Lowest Pressure

Purple Stripe - Low Pressure White - No Pressure

FUEL SYSTEM COLOR CODES

Red - High Pressure Fuel Red Crosshatch - 2nd Pressure Reduction

Red Stripe - 1st Pressure Reduction Green - Tank/Return

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COLOR (cont.)

COLOR VALUES

COLOR RGB CMYK HTML

Yellow 255-255-0 0-0-100-0 FFFF00

Dark Yellow 204-204-0 12-10-96-1 CCCC00

Brown 153-102-0 23-64-98-8 996600

Orange 255-153-0 1-53-95-0 FF9900

Red 255-0-51 0-98-90-0 FF0033

Medium Red 255-102-153 1-77-19-0 FF6699

Pink 255-204-204 2-21-11-0 FFCCCC

Purple 204-153-255 49-57-0-0 CC99FF

Light Blue 204-255-255 23-0-12-0 CCFFFF

Blue 0-153-255 89-16-0-0 0099FF

Dark Blue 56-56-247 100-84-0-0 3333FF

Green 0-255-51 76-0-99-0 00FF33

White 255-255-255 0-0-0-0 FFFFFF

Light Gray 204-204-204 13-10-10-0 CCCCCC

Dark Gray 153-153-153 31-24-24-5 999999

Black 0-0-0 84-72-72-93 000000

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Instructor Led Training - Quick Start Guide

DRAWING CONVENTION

ENGINEERING CUTAWAYS
• All parts should be colored
• Components should be drawn so that they can be assembled and disassembled easily
• All cavities and slots should be cut out for coloring in hydraulic fluid (See example below)

ISO SYMBOLS

CHECK VALVES
• Drawn in the closed position regardless of flow (Instructor may shift check ball at his/her discretion)
• Check ball should be yellow

RESOLVERS
• Check ball should be yellow
• Check ball moves according to flow direction
• Must be enclosed by a light gray box around the group

BOLT HOLES IN THE BODY OF VALVE

• Color should be white

ELECTRICAL SWITCHES AND/OR COMPONENTS IN A NON-ELECTRO/HYDRAULIC SCHEMATIC

• Represented by light gray boxes
• No contact or wiring detail is drawn within the gray box denoting the switches
• Descriptions of the devices should be supported by text portion of the document only

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Instructor Led Training - Quick Start Guide

ISO SYMBOLS (cont.)

CYLINDER
• Piston should be gray when not activated
• Piston should be yellow when activated
• Piston should be moved up or down to indicate activation direction
• Instructor should be responsible for color changes

GENERAL CONFIGURATION SPECIAL CONFIGURATION

Normal Activated Steering Follow-up

ELECTRICAL COMPONENTS
• The entire electrical symbol should be one color
• Similar to hydraulic symbols, electrical symbols are normally colored gray
• If the instructor wishes to indicate activation, the entire symbol should be colored yellow

CORRECT INCORRECT

The terminals (circles) should

be the same color as the symbol

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COMMON INPUT & OUTPUT ICONS

Switch - Keystart Switch - Manual

Switch - Multiple / Master Switch - Non-Manual

Sensor - Speed Sensor - Pressure

Sensor - Temperature Sensor - Temperature

Switch - Position Switch - Position

(Auto / Manual / Circular) (Linear)

Switch - Level Solenoid

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Instructor Led Training - Quick Start Guide

COMMON INPUT & OUTPUT ICONS (cont.)

Relay Fuel Injector

Connector Indicator Lamp

Processor Joystick

ECM Instrument Panel

Messenger Advisor

Electric Motor Back-up Alarm

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