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  Home >  Staff Directory  > Robert Bonner  > Syllabus: Diesel Engine Rebuild DS 101

                     Portland Community College  17705 NW Springville Rd, Portland, Or. 97229


 Engine Rebuild and Lab Procedures

Spring: 2015 March 30- June 12


CRN: 27075         12 Credits


Prerequisite       Math 20 or higher, Reading 80 or higher 


Instructor: Robert Bonner

Phone: Shop:   971-722-7210

Office: 971-722-7489


Office: RC Building 2-230


Class Hours: 05:00 PM-10:30 PM   Monday through Thursday.

                                    Rock Creek Campus. Bld 2/Room 117


Office Hours: 04:00-05:00 PM   Monday through Thursday, Friday by appointment


Text: Medium/Heavy Duty Truck Engines

Sean Bennett, 4th edition ______________________required

                                         Chapters: 1 - 15 Answer chapter questions

Introduction to bearings _______________________ required

Introduction to seals __________________________ required

Introduction to torque _________________________ required

Introduction to fasteners _______________________ required

Hoses Tubing and Couplings ___________________ required

                        Hand Tools _________________________________ required


Supplies Diesel Tool Kit ___________required by beginning of second week                                 

                                    Spiral Notebook _________________________ required

                                    Paint Pen  (any color) _____________________ required


                                    Lap Top or PC based Tablet  __ _______________ required


                                    Minimum requirements

                                         Operating System: Windows 7

                                         CPU speed: 1 Ghz

                                         RAM memory: 1 Gigabyte

                                         HDD storage: 16 Gigabyte

                                         Network adapter: Wireless

                                         Ports: 2 each USB 2.0 or greater

                                         Software: MS Word or compatible word processor



                                         Dell Inspiron 15

                                         Asus Transformer Book T100TA

                                         Microsoft Surface 2

Course content: Learn engine theory, engine components, and proper engine rebuild   


Introduced to basic engine electrical systems, shop tool use and

Maintenance and Identify how all of the internal systems of an       engine become a functional unit.

Cover Lift Truck safety and operation.

Students will maintain a daily portfolio and complete a project packet.  Continued On Next Page

                                    This is an outcome-based course utilizing a lecture/lab

format including videos, workbooks, demonstrations, lectures, written assignments and hands on learning. Professional practices such as safety, reliability, communication and work ethics are integral parts of this course.


                         DS 101 Course Content Guide



Attendance:               Daily attendance is required for this course, however missed

                                   time may be made up, with instructor’s approval.

           Three missed days equals grade lowered one letter. Two late arrivals    

                                    equals one missed day. Leaving early equals arriving late.



Note:                         All tobacco products are banned on all PCC property.

Sleeping in class, talking during lectures, coveralls on while    seated in the chairs, ear phones, hoodies, feet on tables and inappropriate language are also banned.



Note:                         Audio or visual recording of this class is prohibited without

                                   Instructor approval.



Note:                          Food will not be consumed in class room (Drinks ok)



Note:                          Safety Glasses, Coveralls and Work Type Shoes will be worn at 

                                   all times while in the Shop. They are also required in any other areas

                                   while work is being performed.


Note:                          All personal electronic devices will be turned off during class.

Except for instructor authorized learning tools.


Note: Work ethics include; safety, quality of workmanship, cleanliness,

punctuality, time management, and the ability to work with others.

Student may be asked to leave class because of safety violation.


Note: Student must with draw by the first Saturday (10:00 PM) of the term  ( April 4 ) on line via MY PCC, to be eligible for refund.


                                       Add/drop/withdraw deadlines for the term 


Note:      Instructional ADA statement

Students who experience disability-related barriers should contact Disability Services []. If students elect to use approved academic adjustments, they must provide in advance formal notification from Disability Services to the instructor.                              

 Note:               Letters of recommendations must be requested in writing from the


                         All email communication must be via “My PCC” email address.


Note:                          This syllabus may be amended at the Instructor’s discretion

Assignment/exam calendars, etc, may be changed in response to, but not limited to, institutional, weather, and other class problems


Student Rights and Responsibilities


It is the student’s responsibility to be familiar with the:


Portland Community College Student Rights and Responsibilities,


Code of Conduct














Academic Integrity Policy

Students are required to complete this course in accordance with the Student Rights and Responsibilities Handbook. Dishonest activities such as cheating on exams and submitting or copying work done by others will result in disciplinary actions including but not limited to receiving a failing grade. See the Academic Integrity Policy for further details


                                      Equal opportunity statement




                            Children on PCC Properties








PCC Grading Guidelines


Grading policy: Attendance 30%

Tests and quizzes 30%

Written assignments 30%

Work ethic 10%



Letter grade: A_____________ 90 through 100%

B _____________ 80 through   89%

C _____________ 70 through   79%

D _____________ 60 through   69%

F _____________    0 through 59%










Portland Community College Diesel Technology




This attendance policy is a department policy and is implemented into all Diesel Service Technology program classes.  The department instructors believe this to be important to provide consistency among the different classes and instructors.


Reliability is a growing concern of the local Diesel Technician employers. If technicians come late, leave early and consistently miss workdays, the most mechanically skilled are not productive and will not maintain an advancing career. This attendance policy simulates what is expected by our industry and will help in preparing students to enter the workforce as reliable employees.


1.  For each three days missed per six week module, the earned  

       module letter grade will be lowered by one letter.


2.  Late to class two times is equal to one missed day.


3.  Leaving early is equal to coming late and will count



Note:      When special circumstances arise, the instructor may allow the student to make up missed time after hours or by completing additional course-work on the student's own time. Examples of special circumstances may include but are not limited to family illnesses or death, jury duty and National Guard duty. If you foresee special circumstances arising, see your instructor before the days are missed to see if arrangements can be made to make up your time.








DATE: February 27, 2015

TO: Diesel Service Technology Students

FROM: Diesel Service Technology Faculty

RE: Break and Clean-up times

Diesel Service Technology day classes will break for lunch at 10:30 a.m.  The lunch break ends at 11:00 a.m.  Night class dinner break will be from 6:00 to 6:30 PM.

 All shop work must stop during this time unless your Instructor is present and you have Instructor permission.


Students are required to participate in daily clean-up which will begin at 12:15 p.m. Monday through Wednesday and 12:00 p.m. on Thursday.  A horn will blow at for each lunch break and at the start of each clean-up period.

Night class clean up and breaks will be at the instructor’s discretion.


If a student is to leave the classroom or lab area, for any reason, we ask that the student first inform the Instructor so the Instructor does not waste time trying to locate missing students.




























Diesel Service Technology

Portland Community College



Safety glasses are required in most of our local shops to minimize the chances of eye injuries and are required in the Diesel Service Technology Program.


Safety Glasses are on the student’s required tool list!!


The specifics of the policy are as follows:


1. Safety glasses must be OSHA approved.


2. Safety glasses are part of the students required tool list and are to be furnished by the students.


3. Students, Instructors and visitors are required to wear approved safety glasses while in the main lab area regardless of the work being done.


4. Visitor Safety glasses are available in the tool room.


5. Safety glasses are available for purchase in the bookstore.


6. It is the instructor’s discretion to require safety glasses in the classrooms.


7. Glass cleaner and tissues are available at the tool room window.


8. All Instructors are responsible for enforcing this policy.



















The staff at Portland Community College strongly recommends purchasing high quality

tools that have a lifetime guarantee. Students have an excellent opportunity to purchase

tools and tool storage at a substantial discount through many different vendors who

support the Diesel Program.


It is recommended that students contact a Diesel Service Technology Instructor for

guidance in the purchasing of the required tool set. Information on purchasing tools can

be obtained by calling the diesel shop at 971-722-7210.


This tool set is adequate to accomplish the work required of the students during class and it

will enable the students to accomplish the work required of them when they first are

employed. It should be understood that technicians must continue to build their tool

complement throughout their career.


It is understood that some pre-packaged vendor tool kits may vary from the Portland

Community College required tool list. If the vendor tool kit varies greatly for the PCC

required tool list, speak to an instructor to ensure that your purchase will provide you with

the needed tools to complete your classes

A current tool list is available upon request.

















Diesel Service Technology

Safety Clothes Policy


In order to better prepare students for the field of Diesel Service Technology and to better protect the Technicians in our shop, the Diesel Service Technology department has adopted the following policy.


• Safety glasses will be worn at all times in the main shop.  Safety glasses are up to the discretion of the instructors while working in the class rooms.


• Coveralls will be worn at all times while working in the shop.  Wearing coveralls in the class rooms is up to the discretion of the instructor.  Coveralls must be in good condition, free from holes, rips and tears.  New coveralls are available in the book store.


• Work shoes are required at all times while working in the shop.  These shoes must be 100% leather top and must be a work type non-slip in shoe. (steel toe recommended)





Note: These safety rules apply to everyone before, during and after class.





The rules and safety procedures listed below were designed to minimize safety hazards and maximize instructional time. If you do not understand any of the below listings, contact your instructor for further information.






1. Students are not allowed in the tool room without permission.


2. The lab telephone and the telephone in the resource center will only be used with instructor's permission on a lab related phone call or if there is a personal emergency.


3. The use of tobacco products is prohibited in all Diesel classrooms and lab areas as well

as inside the main shop.


4. Personal tools are required for each student if the student is to receive credit for the day.


5. Tools will be checked using established checkout procedure.

(See tool room attendant for checkout procedure.)


6. Students must check out a locker from the instructor if they are to put a personal lock on the locker.


7. Any outside projects must be authorized by an in-shop work repair sheet with the responsible instructor’s signature.




8. Think safety when working with equipment and components; protect your eyes and hands.


9. Support vehicle with proper jack stands and always use wheel blocks to secure vehicle.


10. Safety glasses must be worn at all times in the shop area.  You can purchase them in the 



11. Approved tinted goggles must be used whenever using the oxyacetylene torch.


12. Safety shields must be worn while grinding or using a wire wheel.


13. Unauthorized visitors will not be permitted in the shop.


14. Horseplay and throwing of tools, components or equipment will not be tolerated.


15. Approved eye protection must be worn when using any testing equipment, which involves high pressure.


16. Students are required to wear appropriate dress.  (Leather topped shoes; no tank tops, and no shorts, coveralls are required when working in the shop area and must be worn.)


17.       Inform an instructor of any potential safety hazards, be safety conscious.


18.        Do not wear watches, rings or loose clothing when working around equipment.


19.       Do not use mushroomed punches or chisels.


20.        Components placed in a vise must be secure before repairing component.  Soft jaws should 

             be used, to prevent damage to the components.


21. Do not use worn or low quality tools that may slip off bolts and nuts.  Replace worn bolts or  

              nuts that could cause a wrench or socket to slip.




22.. Do not weld, drill or modify the tabletops or lab area equipment in any way.


23. Make certain that the bench rest on a pedestal grinder is not more than 1/8th inch from

the grinding wheel.  Protective guards must be on the disc grinders.


24. Do not grind non-ferrous metals on the pedestal grinder.


25. The use of all power tools must be approved by the instructor.


26. Tools in need of repair must be reported to your instructor and to the tool room attendant.


27. Only students that have been instructed in the operation of the glass bead machine,

             pressure washer, and parts cleaner will be authorized to use the machine.  Instructor

             permission is required for use of the glass bead machine at any time.


28.         Report all electrical cords and air hoses that are in need of repair to the instructor and

             the tool room attendant.




29. Equipment in need of repair must be reported to your instructor and to the tool room    



30. Any mobile equipment must be tagged and disabled before repairs are performed.


31. Only students that have been instructed in the operation of the forklift will be authorized

to use the machine (see forklift safety rules).


32. When performing equipment tests, the area around the equipment should be roped off or


At any point during the testing if anyone enters or approaches the area, stop the test   



33. While performing test on equipment, there should always be one person seated at the controls and one person should be designated as the safety spotter.  The parking brakes should be set, stabilizers should be down, and students should be standing in the safe area in full view of the operator.




34. Students will clean their area daily and participate in shop clean up.


35. Garbage cans must be emptied when daily.


36. Floors will be kept clean and free from trip hazards.  Clean up oil spills as soon as they

               happen or are discovered.


37. Keep all walkways clear at all times.


38. Return fire extinguishers only if they are still charged and bring any that are low to

the tool room attendant.







Portland Community College Diesel Service Technology

Required Tool List Waiver


All students attending core program classes are required to have a complete set of tools each day of class (see required tool list).  Students will not receive credit for attending class each day in which the students do not have tools.

Students who do not have the funding to purchase tools or have another good reason for not having tools for class, must have this tool waiver completed by the instructor.  This waiver is only valid through the expiration date indicated on the waiver and will automatically expire at the end of each module.


Tools listed on the required tool list will not be checked out from the tool room to students who do not have a waiver.  The waivers will be kept in the tool room.


Students Name ________________________________________ Today’s Date ______________


Instructor ________________________________________ Course # ______________


Boxed area to be completed by instructor only.



Reason for waiver ________________________________________________________________









Student is authorized to check out the following tools from the tool room.   Attach syllabus or other class specific documentation if necessary.














Instructor Signature __________________________________ Expiration Date ______________







DS 101 Spring 2015.


I understand and agree to the grading criteria and to observe all safety and ethical expectations for this class,


Student signature: ___________________________________Date:___________________





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