HEAVY MACHINERY

TECHNICAL ENGLISH
HANDBOOK

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UNIT ONE

PERSONAL PRONOUNS

GOALS:

 Use and meaning of personal pronouns

 Practice Greetings and farewells in the classroom or outside.

What is a personal pronoun?

A personal pronoun is a pronoun that is associated primarily with a particular person, in the
grammatical sense.

When discussing “person” in terms of the grammatical, the following rules apply:

 First person, as in “I”

 Second person, as in “you”
 Third person, as in “It, he, she”

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PRONOUNS

For example.

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Vocabulary of Heavy Machinery and Complementary Courses.

 Excavator / Digger :
 Dump truck :
 Crane truck :
 Wheel loader :
 Compactor roller :
 Motor Grader :
 Skid Steer Loader :
 Bulldozer :
 Backhoe Loader :
 Wheel Tractor - Scraper :
 Forklift :
 Mining Truck :
 Scooptram :
 Basic Mechanic :
 Electrical System :
 Welding :
 Hydraulic System :
 Technical english :
 Mixer :
 Farm Tractor :

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Activity / Hydraulic Excavator Internal and External Parts.

1. 12.
2. 13.
3. 14.
4. 15.
5. 16.
6. 17.
7. 18.
8. 19.
9. 20.
10. 21.
11. 22.

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GREETINGS AND FAREWELLS
GREETINGS:

Good morning : How are you? :

Good afternoon : How are you all? :
Good evening : Have a good day :
Hello : I´m glad to see you :
Hey : Long time no see :
How´s it going? : How have you been:

FAREWELLS:

Good bye : See you soon :

Goo night : See you then :
See you later : Take care :
See you tomorrow :

HOW TO CONGRATULATE SOMEONE?

Congratulations : Well done :

Very good : Good work :
Great : Congratulations for your ………
Excellent :

RESPONSES:

Good /Fine /Well : Very good :

Bad : Pretty good :

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So – so : Terrible :

POLITE WORDS:

Sir : No, thank you :

Yes : My pleasure :
Maybe / Perhaps : Please :
Welcome (to) : Gladly :
Come in! : Of course! :
Thank you / thanks : I´m sorry :
Thank you very much: Excuse me :
I´m very grateful : It´s okay :
You´re welcome : All right :

VOCABULARY OF PROFESSIONS.

1. Operator :
2. Mechanic :
3. Teacher :
4. Miss :
5. Carpenter :

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6. Instructor :
7. Inspector :
8. Chef :
9. Painter :
10. Nurse :
11. Artist :
12. Plumber :
13. Lawyer :
14. Paramedic :
15. Farmer :
16. Doctor :
17. Driver :
18. Dentist :
19. Engineer :
20. Maintainer :

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UNIT TWO
VERB TO BE

GOAL:

 Undertand the use of grammar in the sentences.

 Identify Diésel Engine Parts.
 Understand the working of Diésel Engine.

Use:

We use “TO BE” in present to talk about :

 To introduce yourself and other.

 To express nationality.
 To express age.
 To express occupations.
 To talk about physical characteristics, etc.

AFFIRMATIVE FORM.

 I AM I´M. :
 YOU ARE YOU´RE :
 HE IS HE´S :
 SHE IS SHE´S :
 IT IS IT´S :
 WE ARE WE´RE :
 YOU ARE YOU´RE :
 THEY ARE THEY´RE :

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NEGATIVE FORM.

 I AM NOT I´M NOT. :

 YOU ARE NOT YOU AREN´T :
 HE IS NOT HE ISN´T :
 SHE IS NOT SHE ISN´T :
 IT IS NOT IT ISN´T :
 WE ARE NOT WE AREN´T :
 YOU ARE NOT YOU AREN´T :
 THEY ARE NOT THEY AREN´T :

INTERROGATIVE FORM.

 AM I ? :
 ARE YOU ? :
 IS HE ? :
 IS SHE ? :
 IS IT ? :
 ARE WE ? :
 ARE YOU ? :
 ARE THEY ? :

Complete the sentences with affirmative form of verb To Be.

1. Mario..............................my best friend.

2. She.................................a french Singer.
3. My cat...........................Very fluffy.
4. I...................................A good student.
5. Maria and Efrain................................doctors.
6. I and Carlos...........................policemen.
7. They........................In the kitchen.
8. I................a heavy machinery operator.
9. He...........................20 years old.
10. Her excavator.......................in disrepair.

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11. Skid steer loader and Wheel loader..........................operational
12. It......................cold today.
13. You....................old.
14. I..................an engineer.

Put the sentences in the interrogative form of verb To Be.

1. Edward is a smart boy :

2. I am in my loader :
3. You are a good teacher :
4. It is cold today :
5. Betty is a beautiful operator :
6. They are ugly :
7. We are thin :

ACTIVITY / Complete the text using IS or ARE.

MY BEST FRÍEND OLGA

Olga …………. From Brazil. She...................20

years old. She …….. very communicative and has a
lot of friends. Two of her best friends
………….. David and Pauline. David................from
Portugal. He ………. 25 years old . Pauline…… a
very funny French girl. She ……….30 years old.
Olga and David …….. single, but pauline
……. Married to a heavy machinery operator.

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MOTORS

DEFINITION.

It is a set of perfectly synchronized components with each other, that it can be converted any type
of energy in mechanical energy.

Types of motors.
 Electric motor :
 Hydraulic motor :
 External combustión engine :
 Internal combustión engine, etc. :

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DIESEL ENGINE

DEFINITION.

Diésel engines, like gasolina powered engines, have a crankshaft, pistons, camshaft, etc.
In addition, four-stroke diesels require four piston strokes for
the complete combustión cycle, exactly like a gasolina engine.
The difference lies in how the fuel mixture is ignited. A diésel
engine does not rely on a conventional spark ignition to ignite
the fuel and produces a power stroke. This is known as a
compression – ignition engine.

No fuel enters the cylinder on the intake stroke, only air. Since
only air is present on the intake stroke, only air is compressed
on the compression stroke. At the end of the compression
stroke, fuel is sprayed into the combustión chamber and the
mixture ignites.

The fuel / air mixture ignites because of the very high temperaturas generated by the high
compression ratios used in diésel engines.

HISTORY OF THE DIESEL ENGINE.

Rudolf Christian Karl Diesel was born in Paris, France in 1858. He

was a German invertor and Mechanical
Enginner, famous for the invention of the Diesel
Engine.

His invention was adapted and improved and his

technology today is used for marine engines,
automobiles, electric power generators, factories,
trains, oil drilling equipment, and mining machines.

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DIESEL ENGINE PARTS.

THERE ARE TWO TYPES OF DIÉSEL ENGINE: ACCORDING TO THE INTERNAL

COMBUSTIÓN ENGINE.

FOUR STROKE DIESEL ENGINE.

The four strokes complete the engines cycle. As soon as one cycle is complete, the other
begins.

TWO STROKE ENGINE.

In a two stroke engine a cycle is completed in two strokes of a piston or one complete revolution
(360°) of a crankshaft.

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WORKING OF FOUR STROKE DIESEL ENGINE

1. Air intake.

During this stroke, intake valve will be opens and exhaust valve will be
closed to allowing the fresh charge of mixed fuel and air into the cylinder.
As the piston moves from Top Dead Center (TDC) to Bottom Dead Center
(BDC).

2. Compression Stroke.

As the piston moves from BDC to TDC, both valves are close and the air is
compressed about 23 times smaller than its original volumen. The
compressed air reaches a temperatura of about 1650°F., far above the
temperature needed to ignite diésel fuel.

3. Power or Combustión Stroke.

Both the valves are closed. When the piston reaches top of its stroke, the air temperatura
is at its máximum. The fuel is sprinkled by the Fuel Injector
and the Fuel mixture is ignited due to high temperatura and pressure
generated inside the cylinder and the piston is pushed to BDC by the
pressure (about 500 psi) of expanding gases.

Hence it is known as power. The power generated in this stroke is stored in the
flywheel for its furthur utilisation in the other strokes.

4. Exhaust Stroke.

In this stroke exhaust valve is opened and the piston reaches from BDC
to TDC the exhaust valve will open and burned gases are expelled out.

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ENGINE ORGANS

CYLINDER HEAD.

A cylinder head is usually located on the top of the engine block. It serves as a housing for
components such as the intake and exhaust valves, springs and lifters and the combustion
chamber.

The passages in the cylinder head

allow air and fuel to flow inside the
cylinder while permitting the
exhaust gases to flow out of it. The
cylinder head also channels the
coolant into the engine block,
thereby cooling down the engine
components. The cylinder head

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uses a gasket that aids in preventing water or oil from leaking into the combustion chambers

Parts of cylinder head.

 Exhaust Manifold. Intake Manifold.

 Exhaust valves.
 Intake valves.
 Cooling ducts.
 Valve guide.
 Camshaft.
 Rockers.
 Injectors housing.
 Valve spring, etc.

ENGINE BLOCK.

The engine block – also known as

a cylinder block- contains all of
the major components thet make
up the bottom end of a motor.
This is where the crankshaft
spins, and the piston move up and
down in the cylinder bores, fired
by the fuel combusting. On some
engine designs, it also holds the
camshaft.

Usually made from an aluminum alloy on modern cars, on older vehicles and trucks it was
commonly cast iron. Its metal construction gives it strength and the ability to

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transmit heat from the combustión processes to the integral cooling system in an efficient
manner.

Parts of Engine Block.

 Piston.
 Rings.
 Bearings
 Camshaft.
 Crankshaft.
 Bank.
 Wáter jacket.
 Oil ducts.
 Hosting other components

CRANKCASE.

A crankcase is the housing for the

crankshaft in a reciprocating internal
combustión engine. The enclosure forms
the largest cavity in the engine and is
located below the cylinders.

Also it stores the engine oil

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UNIT THREE
PRESENT SIMPLE

GOALs:
 Undertand the use of PRESENT SIMPLE in the sentences.
 Identify Main Engine Systems.
 Understand the working of Main Engine Systems.

Definition.

The simple present expresses an action in the present taking place regularly, never or several
times. It is also used for actions that take place one after another and for actions that are set by a
timetable or schedule. The simple present also expresses facts in the present.

Use it for..:

 Facts.
 Habitual actions.
 Things that don´t / won´t
change.
 Describing yourself.

Adverbs of frequency, like:

 Always :
 Usually :

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 Normally /generally :
 Often / frequently :
 Sometimes :
 Occasionally :
 Seldom :
 Rarely :
 Never :

Rules: in the third person singular (he/she/it).

 Most verbs take “S” in the third person singular.

 Verbs ending in SS, SH, CH, X and O take = “ES”.
 Verbs ending in a consonant + Y, drop the Y and take = “IES”.
 Verbs ending in a vowel + Y, take “S”.

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Activity

Tom ……………. (work) at a mining. He is a heavy machinery operator. He......................(start)

to work every day at 7:00 am. He.......................(finish) to work every day at

5: 00 pm. Tom ……….. (live) very close to the mining. He.........................(walk) to work every
day. His brother and sister also …………..(work) at the mining. But, they..............................(not
live) close to the mining. They ……… (drive) cars to work. They........................(start) to work
at 8:00 am. In the mining, Tom is nice. He …………….(help) all the workers and tells them what
to do.

He….............(like) his job. He is also very good at his job. Many customers like Tom, and
they..................(say) hello to him
when they ………….(come) to the
mining. Tom..........................(like)
to talk to the customers and make
them feel happy. Tom really
...........................(like) his job.

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MAIN ENGINE SYSTEMS

1. Engine Cooling System.

2. Engine Lubrication System.
3. Air Intake and Exhaust System.
4. Fuel Supply System.
5. Electrical system.

1. ENGINE COOLING SYSTEM.

Get the engine up to optimum

operating temperatura as
quickly as posible and
maintains it at that temperatura.

Controls the heat produced in

combustión chamber, so that
the engine parts are not
damaged and the oil does not
break down.

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Components of Engine Cooling System.

 Coolant reservoir.
 Radiator.
 Thermostat.
 Fan.
 Wáter pump.
 Heater core.
 Radiator cap.
 Radiator upper tank.
 Radiator lower tank.
 Hoses.

Working of Cooling.

2. ENGINE LUBRICATION SYSTEM

Lubricates all internal engine parts and external components.

Purpose of lubrcation system.

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 Lubricate.
 Seals.
 Cleans.
 Cools.
 Absorbs shock.
 Absorbs contaminants.

Components of Engine Lubrication System.

 Crankcase.
 Strainer.
 Oil pump.
 Oil filter.
 Pressure regulator.
 Oil galleries.
 Dipstick.
 Pressure indicator.
 Drain plug.

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AIR INTAKE AND EXHAUST SYSTEM.

Turbocharging an engine occurs when the engine´s own exhaust gases are forced through a
turbine (impeller) which rotates and is connected to a second impeller located in the fresh air
intake system. The
impeller in the fresh air intake system
compresses the fresh air. The compressed air
serves two functions:

It increases the engine´s available power by

increasing the máximum amount of air
(oxygen) that forced into each cylinder. This
allows more fuel to be injected and more
power to be produced by the engine.

To increase intake pressure. This

improves the scavenging of the exhaust gases out of the cylinder.

Components of Air Intake and exhaust system.

 Pre cleaner.
 Air filters.
 Air filter service indicator.
 Turbochargers.
 Intercooler. _
 Intake manifold.
 Intake valve
 Cylinders.
 Exhaust valve.
 Exhuast manifold.
 Catalyst.
 Silencer.

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 Exhaust pipe.

Activity, determine the following parts of the air intake and exhaust system.

FUEL SUPPLY SYSTEM.

The common rail diesel injection system was developed by Bosch. Common rail diesel engines
can be found in
many modern vehicles
including cars, vans, buses,
trucks,tractors and
earthmovers. The common rail
diesel fuel system is a
programmed electro-
mechanical system for control
of diesel fluid (fuel)

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pressure and flow. Diesel fuel injected and atomised in a fine spray to form an air fuel mixture
inside the engine combustion chambers must be delivered at the correct moment of the engine
cyle to allow efficient burning . There are several manufacturers of common rail diesel fuel
injection systems including Bosch , Delphi , Nippondenso , Siemens.

ADVANTAGES OF THE COMMON RAIL DIESEL SYSTEM.

 Higher performance through increased torque at low engine speed.

 Lower fuel consumption.
 Lower soot emissions – use of diésel particulate filter in exhaust system.
 Reduced noise.
 Closed loop feedback control.
 Programable characteristics enabling effective use of alternative biofuels.
 Electronic diagnostics.
 Diésel lambda control using exhaust gas recirculation to reduce NOx emission.

Components of Fuel Supply System.

 Fuel tank.
 Fuel wáter separator filter.
 Transfer pump.
 Low pressure fuel line.
 Main Filters
 High pressure pump.
 High pressure fuel lines.
 Injectors.
 Pressure sensor.
 Common rail.
 Pressure limiter.
 Electronic drive unit.
 Electronic control unit
 Fuel return line.

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COMMON RAIL

Activity, translate from English to Spanish.

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ELECTRICAL SYSTEM

a functional machine needs a running engine, and if the engine doesn´t crank, it doesn´t start. A
properly operating and reliable starting system is a must for keeping a machine productive. For
many years, diésel engines have mostly used electric motors to crank , them over to start the
combustión process. For some aplications, an air or hydraulic motor will créate the torque
needed to turn the engine over.

This chapter focuses on diesel engine starting

systems because at this time they are the
most popular type of engine used for heavy
equipment. However, there may be some
other types of engines used in the future such
as natural gas–powered engines.

Natural gas engines are used for many

stationary power applications, and many are
similar to diésel engines but with lower
compression ratios, different fuel system, and
a spark ignition system. Because of the lower
compression ratio, they will put a lower
demand on the starting system.

Safety First.

Some specific safety concerns related to diesel engine starting systems are as follows:

 Battery explosion risk

 Burns from high current flow through battery cables
 Strain injuries from lifting heavy starters and batteries (some are over 65 lb)
 Burns from battery electrolyte
 Fire hazards from sparks and hot wires
 Unexpected cranking or starting of engine

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 Injuries from sudden release of stored energy (electrical, hydraulic, air pressure)

Components of Electrical System.

 Ignition switch :
 Starter relay :
 Starter motor :
 Starter solenoid :
 Positive cable :
 Negative cable :
 Baterry :
 Fuses :
 Alternator :

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TRANSLATION FROM ENGLISH TO SPANISH.

JOHN DEERE 690E LC.

SAFETY.

Follow Safe Procedures.

Unsafe work practices are dangerous. Understand service procedure before

doing work; do not attempt shortcuts.

Prepare For Emergencies.

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher Handy.

Keep emergency numbers for doctors, ambulance service, hospital,

and fire department near your telephone.

Prevent Acid Burns.

Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well – ventilated área.

2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.

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If you spill acido n yourself

1. Flush your skin with wáter.

2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with wáter for 15 – 30 minutes. Get medical attention inmediately.

If acid is swallowed:

1. Do not induce vomiting.

2. Drink large amounts of wáter or milk, but do not exceed 2 L.
3. Get medical attention inmediately.

Handle Fluids Safety – Avoid Fires.

Handle fuel with care; it is highly flammable. Do not refuel

the machine while smoking or when near open flame or
sparks. Always stop engine before refueling machine. Fill fuel
tank outdoors.

Store flammable fluids away from fire hazards. Do not incinerate or

puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn spontaneusly.

Avoid High – Pressure Fluids.

Escaping fluid under pressure can penétrate the skin causing

serious injury.

Avoid the hazard by relieving pressure defore disconnecting

hydraulic or other lines. Tighten all connecting before
applying pressure.

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Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be
surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable medical source. Such information is available from
Deere / company medical department in Moline, Illinois, U. S. A.

Warn Others of Service Work.

Unexpected machine movement can cause serious injury.

Before performing any work on the machine, attach a “Do not

opérate” tag on the right control lever.

Support Machine Properly

Always lower the attachment or implement to the ground before you work on the machine. If you
must work on a lifted machine or attachment, securely support the machine or attachment. If left
in a raised position, hydraulically supported devices can settle or leak down.

Do not support the machine on cinder blocks, hollow tiles, or

props that may crumble under continuous load. Do not work under
a machine that is support solely by a Jack. Follow recommended
procedures in this manual.

When implements or attachments are used with a tractor, always

follow safaty precautions listed in the implement operator´s
manual.

Opérate only from Operator´s Seat.

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Avoid posible injury or machine damage. Do not start engine by shorting across starter terminals.

Never start engine while standing on ground. Start engine

only from operator´s seat.

Park Machine Safety.

Before working on the machine.

 Park machine on a level surface.

 Lower bucket to the ground.
 Turn auto-idle switch off.
 Run engine in light duty “L” mode withaout load for 2 minutes.
 Set power mode to low idle "I” and turn key switch to OFF to stop engine, remove key
from switch.
 Pull pilot control shut-off lever to locked position.
 Allow engine to cool.

Stay Clear of Moving Parts.

Entanglements in moving parts can cause serious injury.

To prevent acidents, use care when working around rotating parts.

Avoid Power Lines.

Serious injury or death can result from contact with

electric lines.

Never move any part of the machine or load closer to

electric line than 3 m plus twice the line insulator length.

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Use Handholds and Steps.

Falling is one of the major causes of personal injury.

When you get on and off the machine, always maintain a three point contact with the steps and
handrails and face the machine. Do not use any controls as handholds.

Never jump on or off the machine. Never mount or dismount a

moving machine.

Be careful of slippery conditions on platforms, steps,

and handrails when leaving the machine.

Keep Riders off Machine.

Only allow the operator on the machine. Keep riders off.

Riders on machine are subject to injury such as being struck by

foreign objects and being thrown off the machine. Riders also
obstruct the operator´s view resulting in the machine being
operated in an unsafe manner.

Move and Operate Machine Safety

Bystanders can be runo ver. Know the location of bystanders before moving, swinging, or
operating the machine.

Always keep the travel alarm in working condition. It warms people when the machine starts to
move.

Use a signal person when moving, swinging, or

operating the machine in congested áreas.
Coordinate hand signals defore starting the
machine.

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Wear Protective Clothing.

Wear close fitting clothing and safety equipment

appropriate to the job.

Operating equipment safety requires the full attention of

the operator. Do not wear radio or music headphones
while operating machine.

Protect against Flying Debris.

Guard against injury from flying pieces of metal or debris; wear goggles or
safety glasses.

Pretect against Noise.

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to

protect against objectionable or uncomfortable loud noises.

Service Machines Safety.

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you
work near machine tolos or moving parts. If these
ítems were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and

entanglement in moving parts.

Remove Paint Before Welding or Heating.

Avoid potentially toxic fumes and dust.

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Hazardous fumes can be generated when paint is heated by welding, soldering, or usin a torch.

Do all work outside or in a well ventilated área. Dispose of paint and solvent properly.

Remove paint before welding or heating:

 If you sand or grind paint, avoid breathing the dust. Wear

an approved respirator.
 If you use solvento or paint stripper, remove stripper with
soap and wáter before welding. Remove solvento or paint
stripper containers and other flammable material from
área. Allow fumes to disperse at least 15 minnutes before
welding or heating.

Work in a Clean Area.

Before starting a job, clean the work área. Remove objects that may be a safety hazard to the
mechanic or bystanders.

Use Tools Properly.

Use tolos appropriate to the work. Makeshift tolos, parts, and procedures can créate safety
hazards.

Use power tolos only to loosen threaded tolos and fasteners.

For loosening and tightening hardware, use the correct

size tolos. Do not use U.S. measurement tolos on metric
fasteners. Avoid bodily injury causes by slipping
wrenches.

Use only recommended replacement parts.

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Replace Safety Signs.

Replace missing or damaged safety signs. See the machine operator´s

manual for correct safety sign placement.

Live with Safety.

Before returning machine to customer, make sure machine is functioning

property, especially the safety system. Install all guards and shields.

THE END.

OPERADOR – INSTRUCTOR: CESAR LUIS AROCUTIPA A 39