Improve Workforce Efficiency

Course #: 055002
Duration: 10 hours
What Students Learn: Preview
The modern vehicle powered by a diesel engine is a complex piece of technology, with its many components working together to safely and reliably haul freight, transport passengers, and serve the construction and farming industries. It takes highly trained, knowledgeable technicians to keep these high-tech vehicles in running order.
Objectives
When students complete this study unit, he and she will be able to:

Course #: 086E06
Duration: 100 hours
What Students Learn: Preview
The focus of this course is the truck engine and its hydromechanical and electronic fuel management systems, and electronically managed engines. These systems are presented with a focus on the principles of operation to help technicians understand why and how components and systems function. An overview of general procedures and specifications is presented.
Todays technician is expected to be computer literate. Computers are used to diagnose engine malfunctions, and to program customer and proprietary data to engine control modules (ECMs).
Due to the rapid increase in required noxious emission controls, the commercial highway diesel engine has evolved from hydromechanical management to electronic management. Electronically managed engines last longer, make vehicles easier to drive, require less maintenance, and produce much better fuel mileage.
This course covers engine and fuel management technology for the perspective of the technician in a modern truck service or fleet operation. The emphasis is on diagnosis followed by removal and replacement procedures. A technician capable of properly diagnosing vehicle systems must understand that systems from both the theoretical and practical perspective.
Contents: Diesel Engine Fundamentals: Introduction; Hand and Shop Tools, Precision Tools, and Units of Measurement; Personal and Safety Awareness; Engine Basics; History of the Heat Engine; Power; Engine Powertrain Components; Engine Feedback Assembly; Engine Housing Components; Engine Lubrication Systems; Diesel Engine Cooling Systems; Engine Breathing; Engine Retarders; Engine Removal, Disassembly, Cleaning, Inspection, and Reassembly Guidelines; Engine Run-In and Performance Testing.
Hydromechanical Diesel Fuel Injection Systems: Chemistry and Combustion; Diesel Fuel and Alternates; Fuel Subsystems; Overview of Hydromechanical Injection Principles and Objectives; Hydraulic Injector Nozzles; Port Helix Metering Injection Pumps; Detroit Diesel Mechanical Unit Injection Systems; Caterpillar Mechanical Unit Injection; Cummins PT; Governors; Engine and Fuel System Failure Analysis, Troubleshooting, and Diagnoses Strategies.
Computerized Truck and Bus Systems Management: Electricity and Electronics; Digital Computer; Networking and Communications in the Trucking Industry; Vehicle Computer Systems; Electronic Service Tools; Electrical Wiring, Connector, and Terminal Repair; Caterpillar PEEC; Mack Trucks V-MAC 1 and 2; Detroit Diesel Electronic Controls; Caterpillar ADEMS; Cummins CELECT and CELECT Plus; Bosch EUP on DDC Series S5 and V-MAC 3-E-Tech; Caterpillar / Navistar HEUI (Navistar 444E, Ford 7.3 liter, 466E, 530E, and Caterpillar 3126); Cummins HPI and Interact Series Engine Management; Emissions.

Course #: 086E07
Duration: 40 hours
What Students Learn: Preview
The technician of today must know the underlying theory of all systems, and be able to service and maintain those systems. They must also know how individual systems interact. This course series covers the mechanical and electrical systems of medium and heavy duty trucks.
Each Classroom Manual contains the principles of operation for each system and subsystem. It also discusses the design variations used by different manufacturers. This understanding is necessary to diagnose the complex truck systems.
All of the high priority skills, as identified by the National Institute for Automotive Service Excellence (ASE), are explained in the Shop Manual. It includes step by step instructions for diagnostic and repair procedures. This manual explains the reasons for performing the procedures and when that particular service is appropriate.

Contents
Classroom Manual: Safety; Basic Theories; Electrical Components; Wiring Systems and Diagrams; Batteries; Starting Systems; Charging Systems; Truck and Trailer Lighting Systems; Instrumentation and Warning Systems; Truck Electrical Accessories; Ignition Systems; Diesel Computer Systems.
Shop Manual: Safety; Electrical Diagnostic Tools; Basic Electrical Troubleshooting and Service; Wiring Repair Practices and Diagram Reading; Battery Diagnosis and Service; Starting System Diagnosis and Service; Charging System Testing and Service; Lighting Troubleshooting and Repairs; Instrument, Gauges, and Warning System Testing; Truck Electrical Accessories Diagnosis and Repairs; Ignition System Diagnosis and Service; Engine and Vehicle Computer Troubleshooting and Service.

Course #: 086E08
Duration: 40 hours
What Students Learn: Preview
The technician of today must know the underlying theory of all systems, and be able to service and maintain those systems. They must also know how individual systems interact. This course series covers the mechanical and electrical systems of medium and heavy duty trucks.
Each Classroom Manual contains the principles of operation for each system and subsystem. It also discusses the design variations used by different manufacturers. This understanding is necessary to diagnose the complex truck systems.
All of the high priority skills, as identified by the National Institute for Automotive Service Excellence (ASE), are explained in the Shop Manual. It includes step by step instructions for diagnostic and repair procedures. This manual explains the reasons for performing the procedures and when that particular service is appropriate.

Contents
Classroom Manual: Safety Practices; Basic Theories; Tires, Wheels, and Wheel Bearings; Steering Columns, Manual Steering Gears, and Steering Linkages; Power Steering Pumps and Power Steering Gears; Frames and Fifth Wheels; Suspension Systems; Air Suspension Systems; Wheel Alignment.
Shop Manual: Safety Practices; Tools and Shop Practices; Wheel, Tire, and Wheel Bearing Service; Steering Column, Manual Steering Gear, and Steering Linkage Diagnosis and Service; Power Steering Pump and Power Steering Gear Diagnosis and Service; Frame and Fifth Wheel Diagnosis and Service; Suspension System Diagnosis and Service; Air Suspension System Diagnosis and Service; Wheel Alignment Procedures.

Course #: 086E09
Duration: 30 hours
What Students Learn: Preview
The technician of today must know the underlying theory of all systems, and be able to service and maintain those systems. They must also know how individual systems interact. This course series covers the mechanical and electrical systems of medium and heavy duty trucks.
Each Classroom Manual contains the principles of operation for each system and subsystem. It also discusses the design variations used by different manufacturers. This understanding is necessary to diagnose the complex truck systems.
All of the high priority skills, as identified by the National Institute for Automotive Service Excellence (ASE), are explained in the Shop Manual. It includes step by step instructions for diagnostic and repair procedures. This manual explains the reasons for performing the procedures and when that particular service is appropriate.

Contents
Classroom Manual: Safety Practices; Basic Theories; Wheel Bearings; Hydraulic Brake Systems; Hydraulic Brake Mechanical Foundation Systems; Hydraulic Brake Power Assist Units; Hydraulic Parking Brake Systems; Air Brake Air Supply Systems; Air Brake Service Brake Systems; Park, Emergency, and Complete Air Brake Systems, Air Brake Mechanical Foundation Systems; Antilock Brake Systems; Collision Warning Systems, and Hydraulic and Electrical Retarder Systems.
Shop Manual: Safety Practices; Tools and Shop Practices; Wheel Bearing and Seal Service; Hydraulic Brake System Service; Hydraulic Brake Mechanical Foundation System Diagnosis and Service; Diagnosing and Servicing of Hydraulic Brake Power Assist Units; Hydraulic Brake Parking Brake Systems Diagnosis and Service; Air Brake Air Supply Systems Diagnosis and Service; Air Brake Service Brake System Diagnosis and Service; Park, Emergency, and Complete Air Brake Systems Diagnosis and Service; Air Brake Mechanical Foundation Brake System Diagnosis and Service; Antilock Brake System Diagnosis and Service; Collision Warning Systems, and Retarder System Diagnosis and Service.

Course #: 086E10
Duration: 40 hours
What Students Learn: Preview: Clutches and Standard Transmissions  Transmissions play a critical role in vehicles. A transmission transfers the engines power to a vehicles driveline and to other powered systems. Many vehicle repair technicians never see the inside of a transmission because specialized shops equipped with specific tooling usually overhaul transmissions. However, the technician must still be able to diagnose a range of transmission  related problems, including servicing the transmission, fluid replacement, filter cleaning, and linkage adjustment.
Objectives: Describe the operating principles of a clutch; Identify and describe the functions of clutch components; Troubleshoot clutch problems; Outline the procedure for removing, servicing; and replacing clutches; Describe how a manual transmission operates; Explain the function of each major component in a manual transmission; Identify shifting system types and their operating characteristics; Outline the procedure for maintaining and servicing manual transmissions; Troubleshoot a transmission and shift system to identify faults; List the tasks required to overhaul a manual transmission.

Preview: Automatic Transmissions - While automatic transmissions serve the same purpose as the manual transmissions you studied in Lesson 1, they do so with much less driver interaction. While a driver moves a shift lever to select the gear-meshing configuration of a manual transmission, an automatic transmission changes gear configuration on its own in response to engine load and rotational speed. As you might guess,
the added capabilities of an automatic transmission mean that it's also a much more complicated device than a manual transmission. In this lesson you'll learn how an automatic transmission operates as well as how its internal components are removed, serviced, and/or replaced.
Objectives: Describe the operating principles of a torque converter; Identify and describe the functions of torque-converter components; Troubleshoot torque converter problems; Outline the procedure for removing, servicing, and replacing torque converters; Describe how an automatic transmission operates and how it's shift points are controlled; Explain the function of each major subsystem of an automatic transmission; Describe how hydraulic retarders operate; Outline the procedure for maintaining and servicing automatic transmissions; Troubleshoot an automatic transmission to identify faults; List the tasks required to overhaul an automatic transmission.

Preview: Allison Transmissions - Allison is the primary manufacturer of electronically controlled automatic transmissions found in heavy duty vehicle applications. For this reason, your textbook focuses two chapters on two families of Allison automatic transmissions, the CEC and World models.
Objectives: Describe the operating principles of an Allison CEC transmission, including how electronic signals are converted into hydromechanical ones; Identify and describe the functions of Allison transmission components; Explain how an Allison World transmission operates, including the functions served by its electronic control system; Describe the design differences between Allison CEC and World transmission models; Troubleshoot problems with CEC and Allison World transmissions; Outline the procedure for removing, servicing, and replacing CEC and Allison World transmissions.

Preview: Drive Shafts and Axles  Transmission is described as being responsible for transferring engine power to the rest of the driveline. In this lesson youll study crirical components from the rest of the driveline; drive shafts and axle assemblies.
Objectives: Explain how driveshafts and other driveline components are connected; Outline the procedure for removing, servicing, and replacing drive shafts, universal joints, and other driveline components; Identify different types of drive axles, their operating characteristics, and the function served

Course #: 086E11
Duration: 10 hours
What Students Learn: Preview: Freight Hauling companies, and others that employ heavy-duty vehicle operators, work hard to find, hire, and train qualified drivers. One of the benefits that make it easier for these companies to retain their drivers is to provide them with comfortable, climate-controlled vehicles. Its the technicians job to ensure that the vehicles temperature-control systems (both air conditioning and heating) operate properly. Its also partially the responsibility of the technician to ensure that the company handles all refrigerants as dictated by state and federal law.
Objectives: Explain the regulatory system in place to control the handling of A/C system refrigerants and the technicians role in meeting system guidelines; Describe how an air-conditioning system operates; List general steps to be taken when troubleshooting A/C system complaints; Understand how a vehicles air ventilation system operates; Explain how the heat from engine coolant can be extracted and controlled to heat the vehicles operator compartment.