Improve Workforce Efficiency

Course #: 00A1
Duration: 10 hours
What Students Learn: What a Course in Diesel Mechanics Can Do for You; Getting the Most from Your Course; What is a Diesel Engine; Why is a Diesel Engine So Popular; How a Diesel Engine Operates; Basic Kinds of Diesel Engines; Horsepower.

Course #: 00A2
Duration: 10 hours
What Students Learn: Self Improvement; The Importance of Teamwork; What Your Job Does for You; What You Can Do for Your Job; Job Location; Order of Performance.

Course #: 00A3
Duration: 10 hours
Course Prerequisites: Work Habits and Practices, Part 1 (Diesel) (00A2);
What Students Learn: Work Practices; Safety; Importance of Cleanliness; Shop Records; The Value in Public Relations; The Value of Records in the Shop; Shop Communications; Self Improvement.

Course #: 0A14
Duration: 10 hours
Course Prerequisites: Work Habits and Practices, Part 2 (Diesel) (00A3);
What Students Learn: Using Tools Safely; Lifting Tools and Equipment; Cleaning Engines; Chassis Dynamometer; Power Tools; Hand Tools; List of Basic Tools.

Course #: 0A15
Duration: 10 hours
Course Prerequisites: Work Habits and Practices, Part 2 (Diesel) (00A3);
What Students Learn: Numbers and Symbols: Numbers and Position; Addition; Subtraction; Multiplication; Division; Fractions; Decimals; Practice Problems in Basic Arithmetic; Percentage and its Application; Equations and Formulas; Ratio and Proportion; Graphs; The Metric System of Measurement; Fundamental Ideas in Geometry.

Course #: 186011
Duration: 5 hours
What Students Learn:

Course #: 0A16
Duration: 10 hours
Course Prerequisites: Diesel Engine Parts, Part 2 (00A5);
What Students Learn: The Language of Drawing; Drawing Methods; Drawing Materials and Tools; Standard Drawing Practices; Kinds of Drawings; Blueprint Reading; Shop Photography.

Course #: 0A17
Duration: 10 hours
Course Prerequisites: Diesel Engine Parts, Part 2 (00A5);
What Students Learn: Simple Measurements; Precision Measuring Techniques; Feeler or Thickness Gauges; Radius Gauges; Telescoping Gauges; Small Bore Gauges; Micrometers; Dial Gauges; Pressure Gauges; Vacuum Gauges; Manometers; Pyrometers; Tachometers; Metric Conversion Table.

Course #: 0A18
Duration: 10 hours
Course Prerequisites: Diesel Engine Operations, Part 2 (0A12);
What Students Learn: Engine Specifications and Tolerances; Recommended Overhaul and Rebuild Procedures; Recommended Maintenance Procedures; Use of Specification and Tolerance Tables.

Course #: 00A4
Duration: 10 hours
What Students Learn: Engine Cylinder Blocks and Components; Cylinder Liners; Oil Pan; Timing Gears; Crankshaft; Main Bearings; Engine Balancer; Flywheel and Flywheel Housing; Camshaft and Bushings.

Course #: 00A5
Duration: 10 hours
Course Prerequisites: Diesel Engine Parts, Part 1 (00A4);
What Students Learn: Connecting Rods; Pistons and Piston Rings; Cylinder Heads and Components; Valves; Valve Seats and Guides; Cross Heads; Injector Operating Mechanisms.

Course #: 00A6
Duration: 10 hours
Course Prerequisites: Diesel Engine Parts, Part 2 (00A5);
What Students Learn: Diesel Fuel; Function of Fuel Systems; Description of Fuel Systems; Fuel Injection Pumps.

Course #: 00A7
Duration: 10 hours
Course Prerequisites: Fuel Systems, Part 1 (Diesel) (00A6);
What Students Learn: Combustion Chambers; Fuel Injectors and Spray Valves; Fuel Transfer Pumps; Fuel Filters; Fuel Tanks and Lines; Governors.

Course #: 00A8
Duration: 10 hours
Course Prerequisites: Diesel Engine Parts, Part 2 (00A5);
What Students Learn: The Function of a Lubricant; Essential Qualities of a Lubricating Oil; Lubricating Oil Properties; Processing Lubricating Oils; Lubricating Oil Classifications; Gear Lubricants; Greases; Typical Diesel Engine Lubricating Systems; Lubricating Oil Pumps; Filters and Strainers; Oil Coolers; Oil Lines and Bearing Lubrication; Piston Ring and Cylinder Lubrication.

Course #: 00A9
Duration: 10 hours
Course Prerequisites: Diesel Engine Parts, Part 2 (00A5);
What Students Learn: Function of the Cooling System; Radiator and Fan Cooling Systems; Heat Exchanger Cooling Systems; Keel Cooling Systems; Thermostats, Water Pumps, Corrosion Inhibitors; Antifreeze Solutions; Importance of Clean Air; Air Restriction; Air Cleaners; Air Piping; Turbochargers; Blowers and Superchargers; Heating; Intake Air; Exhaust Manifolds; Exhaust Piping; Mufflers; Spark Arresters.

Course #: 0A10
Duration: 10 hours
Course Prerequisites: Diesel Engine Parts, Part 2 (00A5);
What Students Learn: Electricity Defined; Magnets; Electric Circuits; Storage Batteries; DC Generators; AC Generators; Regulators; Cranking Motors; Wiring Diagrams; Air Cranking Systems; Hydraulic Starting Systems.

Course #: 0A11
Duration: 10 hours
Course Prerequisites: Electrical Systems (Basic Diesel Mechanics) (0A10);
What Students Learn: Need for Understanding Engine Operation; Pre-Starting Checks; Engine Starting Procedure; Engine Operation; Engine Warm-Up; Reading Instrument Panel Gauge; Engine Speed Control; Engine Shutdown.

Course #: 0A12
Duration: 10 hours
Course Prerequisites: Diesel Engine Operations, Part 1 (0A11);
What Students Learn: Engine Operation in Trucks; Proper Shifting Practices; High Altitude Operation; Downhill Operation; Cold Weather Operation; Hot Weather Operation; Factors Affecting Fuel Economy; Engine Operation in Other Mobile Equipment; Generator Set Operation.

Course #: 0A13
Duration: 10 hours
Course Prerequisites: Diesel Engine Parts, Part 2 (00A5);
What Students Learn: Metallurgy of Welding; Heat Treatment of Metals; Electric Arc Welding; Electric Arc Welding Procedures; The Carbon Arc; The Gas Shield Arc; Oxyacetylene Welding; Techniques Used in Welding; Soldering; High Brazing and Bronze Welding.

Course #: VB26XX
Duration: 0.95 hours
What Students Learn: The time to develop safety habits is before you begin to weld. While stressing the importance of safety to yourself and others in the shop, this program will alert students to, as well as teach them how to avoid, the hazards associated with welding.
Components: Operator and Fire Safety (VB2603); Personal Safety and Proper Attitude (VB2601); Safe Use of Equipment (VB2602); Cylinder Safety (VB2604);
Special Notes: This video series is available in a Spanish version.

Course #: 0A19
Duration: 10 hours
Course Prerequisites: Engine and Allied Equipment Service Manuals (Diesel) (0A18);
What Students Learn: Principles of Troubleshooting; Troubleshooting Procedure; Troubleshooting with a Chassis Dynamometer; Checking Compression Pressure; Fuel Flow; Restriction of Intake Air and Exhaust Back Pressure; Checking Causes of Vibration.

Course #: 0A20
Duration: 10 hours
Course Prerequisites: Troubleshooting Diesel Engines (0A19);
What Students Learn: Definition of Failure Analysis; Failure Analysis Procedure; Failure Analysis Charts: Cylinder Block, Camshaft and Camshaft Bearings, Crankshaft, Main and Connecting Rod Bearings, Pistons and Piston Rings, Gear Trains, Cylinder Heads and Cylinder Head Gaskets, Valves, Guides, Springs and Crossheads, Blowers and Superchargers, Turbochargers.

Course #: 0A21
Duration: 10 hours
Course Prerequisites: Failure Analysis (Diesel) (0A20);
What Students Learn: Advantages of Proper Maintenance; Inspecting Lubrication Systems; Servicing Lubrication Filters and Strainers; Servicing Oil Coolers; Inspecting Fuel System; Servicing Fuel Filters; Injection Pumps; Injectors and Nozzles; Engine Tune-Up.

Course #: 0A22
Duration: 10 hours
Course Prerequisites: Maintenance of Lubricating and Fuel Systems (Diesel) (0A21);
What Students Learn: Turbochargers; Superchargers and Blowers; Exhaust Systems; Cleaning the Cooling Systems; Servicing Cooling System Filters; Adjusting Fan Belts; Servicing Shutters; Antifreeze Solutions.

Course #: 0A23
Duration: 10 hours
Course Prerequisites: Maintenance of Air Intake, Exhaust, and Cooling Systems (Diesel) (0A22);
What Students Learn: Electrical System Problems; Battery Testing; Specific Gravity, Open Circuit Test, Load Test; Generator Testing; Alternator Testing; Regulator Testing; Starting Motor Testing; Battery Servicing; Generator Servicing, Alternator Servicing; Regulator Servicing; Starting Motor Service; Hydraulic Starting System; Air System; Starting System with Separate Gasoline Engine.

Course #: 0A24
Duration: 10 hours
Course Prerequisites: Maintenance of Electrical Systems (Diesel) (0A23);
What Students Learn: Symptoms Indicating a Need for In-Frame Overhaul; Transmission Removal; Clutch Removal; Disassembly of Engine; Inspection of Piston, Connecting Rod, and Cylinder Liner Assemblies; Inspection of Crankshaft, Main Bearings, and Connecting Rod Bearings; Inspection of Cylinder Block; Inspection of Cylinder Liners.

Course #: 0A25
Duration: 10 hours
Course Prerequisites: In-Frame Overhaul, Part 1 (Diesel) (0A24);
What Students Learn: Service of Cylinder Liner, Piston, and Connecting Rod Assemblies; Service of Cylinder Head Assemblies; Reassembly of Engine Following In-Frame Overhaul; Adjusting Injectors and Valves; Helpful Tips on Parts Replacement.

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 #: VB34XX
Duration: 1.15 hours
What Students Learn: The study of small engines is a fundamental building block on the road to understanding engine operation. A small engine generates and utilizes combustion energy in exactly the same way a larger engine does. By studying small engines, students will be able to focus on the operating principles of a less complicated system, and form a strong foundation toward the understanding of engine operation.
Components: Electronic Ignition System (VB3405); Basic Operation (VB3401); Basic Maintenance (VB3402); Disassembly of Engine (VB3403); Common Repair Procedures (VB3404); Assembly of Engine (VB3406);

Course #: VB48XX
Duration: 1.87 hours
What Students Learn: Knowing how to properly maintain the diesel engines found in today's vehicles is valuable information. This program details in a clear-cut,step-by-step manner the proper techniques and procedures for maintaining these motors. Each of the primary systems are fully covered and detailed.
Components: Lubricating System (VB4804); Fuel System (VB4801); Air System (VB4802); Cooling System (VB4803); Electrical System (VB4805);