Diesel Mechanics



Penn Foster’s Diesel Mechanic Apprenticeship

Course PF Course

Course Title Number Price Duration

Year 1:

Introduction to Truck Diesel Mechanics 055021 $75.00 10 hours

Diesel Engine Computer Systems 055006 $75.00 10 hours

Maintaining Diesel Engines 886M01 $275.00 55 hours

Truck Electrical Systems 886M02 $250.00 30 hours

Truck HVAC Systems 886M03 $175.00 10 hours

Tires, Suspension and Steering 886M04 $225.00 20 hours

Truck Brake Systems 886M05 $225.00 20 hours

Year 2:

Drivelines and Transmissions 886M06 $250.00 30 hours

Diesel Powered Vehicle Troubleshooting & Repair 886M07 $275.00 40 hours

Diesel Engine Computer Systems 055006 $75.00 10 hours

Mack Diesel Engine Mechanics: Introduction 00C1 $75.00 15 hours

Engine Disassembly (Mack) 00C2 $75.00 15 hours

Cylinder Block and Components, Part 1 (Mack) 00C3 $75.00 15 hours

Cylinder Block and Components, Part 2 (Mack) 00C4 $75.00 15 hours

Cylinder Block and Components, Part 3 (Mack) 00C5 $75.00 15 hours

Cylinder Head Assemblies and Valve Operating

Mechanisms (Mack) 00C6 $75.00 15 hours

Year 3:

Fuel Systems, Part 1 (Mack) 00C7 $75.00 15 hours

Fuel Systems, Part 2 (Mack) 00C8 $75.00 15 hours

Air Intake and Exhaust Systems (Mack) 00C9 $75.00 15 hours

Detroit Diesel Engine Mechanics: Introduction 00D1 $75.00 15 hours

Engine Disassembly (Detroit Diesel) 00D2 $75.00 15 hours

Cylinder Block and Components, Part 1 (Detroit

Diesel) 00D3 $75.00 15 hours

Cylinder Block and Components, Part 2 (Detroit

Diesel) 00D4 $75.00 15 hours

Cylinder Block and Components, Part 3 (Detroit

Diesel) 00D5 $75.00 15 hours

Cylinder Block and Components, Part 4 (Detroit

Diesel) 00D6 $75.00 15 hours

Cylinder Heads, Components, and Valve Operating

Mechanisms (Detroit Diesel) 00D7 $75.00 15 hours

Year 4:

Fuel Systems (Detroit Diesel) 00D8 $75.00 15 hours

Governors (Detroit Diesel) 00D9 $75.00 15 hours

Introduction to Caterpillar Diesel Engines 00E1 $75.00 15 hours

Introduction to Cummins Diesel Engines 00H1 $75.00 15 hours

Introduction to Engine Rebuilding (Cummins) 00H2 $75.00 15 hours

Rebuild Shop Practices, Part 1 (Cummins) 00H3 $75.00 15 hours

Rebuild Shop Practices, Part 2 (Cummins) 00H4 $75.00 15 hours

Engine Disassembly (Cummins) 00H5 $75.00 15 hours

Cylinder Block Group, Part 2 (Cummins) 00H7 $75.00 15 hours

Cummins PT Fuel System 00H9 $75.00 15 hours

Estimated Total Curriculum Duration: 625 hours (Yr 1 = 155 hrs; Yr 2 = 170 hrs; Yr 3 = 150 hrs; 150 hrs)

Number of Exams: 54

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055021

Introduction to Diesel Truck Mechanics

Duration: 10 hours (includes 1 test)

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:

• Name and describe the eight basic operating systems in a vehicle

• Describe the basic operation of a four-cycle diesel internal-combustion engine

• Define the terms horsepower, displacement, and compression ratio

• Discuss the employment possibilities that are available in the heavy-duty vehicle repair field

• List and discuss the steps needed to attain certification in the heavy-duty vehicle servicing field

Special Note:

• This updated course replaces 055002.

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055006

Diesel Engine Computer Systems

Duration: 10 hours (includes 1 test)

What Students Learn:

Preview:

Computers control many aspects of engine operation. Controlled systems range from more-obvious applications, such as fuel injection systems, to less likely ones, such as engine cooling fans. The precise nature of computer control systems is largely responsible for the increased fuel efficiency and reduced pollution emissions that characterize today’s engines. This course explains how engine-controlling computers interface with other engine systems. Since this interface occurs through the use of input and output devices, which are more-general terms used to describe sensors and actuators, much of this course identifies common devices, explains how they work, and then describes their specific role in one or more engine systems.

Objectives:

• Identify the functional components that make up an engine-controlling computer system and describe the role of each

• Explain the difference between analog and digital signals as they relate to an ECM system

• Describe the operating principles and common engine-control applications for various types of temperature, pressure, position, and speed sensors

• Describe the operating principles and common engine-control applications for various types of output devices including relays, solenoids, stepper motors, and piezo actuators

• Understand the operating principles of various ECM-controlled engine systems including the fuel injection, engine braking, emissions control, and fault indication systems

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886M01

Maintaining Diesel Engines

Duration: 55 hours (includes 11 tests)

What Students Learn:

Preview:

This courses focuses on the truck engine and its electronic fuel management systems. These systems are presented with a focus on the principles of operation to help technicians understand why and how components and systems function. 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:

Part 1 – Engine Maintenance Fundamentals:

Introduction to Truck Engine Operation: History of the diesel engine; differences in gasoline and diesel engines; powertrain components; engine classifications; power-related terms, such as bore, stroke, horsepower, and torque

Safe Shop Practices: Shop safety guidelines; fuel injector safety; fire types and extinguishers; handling hazardous materials; safe tool use

Part 2 – Truck Engines, Part 1:

Diesel Engine Fundamentals, Part 1: How to remove a vehicle’s engine; features of a cylinder block and cylinder liner; crankshaft and its purpose; purpose of the flywheel and vibration damper; piston, piston rings, and connecting rod functions; piston assembly installation into a cylinder block

Diesel Engine Fundamentals, Part 2: Cylinder head assembly parts; cylinder head disassembly; common problems with cylinder heads; cylinder head component inspection and service; installing and removing a camshaft; purpose of each valve train component and how they’re assembled

Part 3 – Truck Engines, Part 2:

Truck Engine Lubrication and Cooling Systems: The components of a lubrication system in a diesel engine and terminology related to lubrication systems; properly maintaining oil filters and recognizing low oil situations; naming different oil pressure indication systems; selecting appropriate oil for a diesel engine based on the American Petroleum Institute (API) classifications; cooling-system components and their functions in diesel engines; difference between air and liquid cooling systems; managing diesel engine cooling systems

Truck Engine Air Intake and Exhaust Systems: Intake and exhaust system components and their purpose; defining terms such as supercharging, scavenging, and other important concepts to the intake process; back pressure and how to route exhaust pipes to prevent harmful effects; roots blowers, turbochargers, the intake manifold, exhaust manifold, and charge-air heat exchangers as they relate to engine breathing; troubleshooting different components of the exhaust system; exhaust pyrometer and other common equipment in controlling engine emissions

Part 4 – Fuel Systems:

Introduction to Fuel Systems: Terminology common to diesel fuels; diesel fuel grades according to the standards of the American Society of Testing Materials (ASTM); fuel additives and alternative fuels; proper fuel storage, leakage, and foreign materials; fuel system’s major components; fuel gauge operations and types; fuel line types; replacing fuel line

Diesel Engine Injection Systems, Part 1: Fuel injection system types and components; terms related to fuel injection systems, including timing, injection, and rate control; locating nozzles, governors, and other essential components; removing and installing nozzle holders and nozzles; analyzing and diagnosing fuel injection system problems; inline fuel injection pumps; servicing inline fuel injection pumps, including bleeding air from the lines; performing diagnostic tests and timing procedures

Diesel Engine Injection Systems, Part 2: Distributor injection pump operation; removing and installing major components of distributor injection pumps; understanding how mechanical unit fuel injector systems deliver fuel to the engine’s cylinders; servicing major components of the unit injector fuel injection systems

Part 5 – Truck Electronics and Engine Controls:

Electricity and Diesel Engine Electrical Systems: Ohm’s law and other electrical concepts related to charging systems; battery operation and testing and servicing major electrical components; charging system function and components, including alternators and generators; maintaining a charging system; removing and installing an alternator; electrical starting system operation; performing starter system and no-loading tests; starting systems operations, including air-powered starting systems, hydraulic starting systems, and cold-weather starting aids

Electronic Engine Controls: Electronic engine control system components, including computer, sensors, and actuators; engine control computer operation; understanding engine control computers, personal computers, digital service equipment, and vehicle computer systems interfaces through the communication system; operating principles of high-pressure common-rail fuel injection systems; troubleshooting electronically controlled diesel engines

Textbook:

Diesel Technology

Special Note:

• This updated course replaces 086E12.

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886M02

Truck Electrical Systems

Duration: 30 hours (includes 3 tests)

What Students Learn:

Preview:

This course focuses on basic electrical topics, truck computer systems, and truck electrical systems, such as starting and charging systems and lighting and wiring.

Contents:

Truck Electrical Systems, Part 1: Electrical and electronic principles; making series and parallel circuit hookups to construct a circuit; magnetism and its usage in diesel engines; testing electric motors, solenoids, and relays; properly inspecting, cleaning, servicing, and testing battery systems; three primary battery types and the different types of terminal connections used in heavy-duty trucks; how a battery’s elements function to produce electrical power

Truck Electrical Systems, Part 2: Performing voltage-drop tests and other tests on starter systems, charging systems, and lighting systems; principles governing the operation of electric motors and generators; major charging-system components and their functions; cleaning, inspecting, repairing, and reassembling a starter motor; alternators; effect of wire size on electrical circuits; repairing damaged wiring; interpreting wiring diagrams

Truck Computer Systems: Computer system components and operation, including sensors and switches, testing computer systems, including sensors and switches; testing solenoids, relays, and electric motors; typical computer malfunctions and dash indicator lights meanings; using scanning tools and EOM diagnostic software to service computer systems

Textbook:

Truck and Trailer Systems

Special Note:

• This updated course replaces 086E07.

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886M03

Truck HVAC Systems

Duration: 10 hours (includes 1 test)

What Students Learn:

Preview:

This course focuses on truck heating, ventilation, and air-conditioning (HVAC) systems and auxiliary power units (APUs).

Contents:

HVAC Systems: AC components and AC refrigerants and oils; diagnosing, servicing, and repairing AC components; cabin heating system operation; air flow through the heater and AC systems; APUs and the service each type provides; installing and maintaining APUs

Textbook:

Truck and Trailer Systems

Special Note:

• This updated course replaces 086E11.

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886M04

Tires, Suspension, and Steering

Duration: 20 hours (includes 2 tests)

What Students Learn:

Preview:

This course deals with some of the systems and components that will most likely demand the bulk of technician repair efforts. Tires and suspension systems wear out during much shorter intervals than parts such as engines. The course also covers wheels, frames, and steering and trailer systems.

Contents:

Tires, Wheels, and Trailer Maintenance: How tires and wheels are fastened to a vehicle; servicing tire and wheel systems, including inspecting, repairing, and replacing faulty equipment; wheel bearings and adjustments; types of and replacing wheel seals; various types of fifth wheels; coupling and uncoupling fifth wheels; how trailer systems work; proper servicing of potential problems

Suspension and Steering Systems: Truck frame construction; performing frame inspections; identifying and correcting frame defects; operating principles of leaf and air-spring suspensions, including servicing, repairing, and replacing; steering linkage operation, including the steering column, steering gear, input shaft, and other essential parts; servicing and diagnosing kingpin and steer axle problems; steering gear and power steering system operation; aligning a truck

Textbook:

Truck and Trailer Systems

Special Note:

• This updated course replaces 086E08.

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886M05

Truck Brake Systems

Duration: 20 hours (includes 2 tests)

What Students Learn:

Preview:

This course focuses on truck brake systems, an important topic for just about any heavy-duty truck technician. The course covers different types of brake systems, their components, and how they work.

Contents:

Truck Brake Systems, Part 1: Hydraulic principles that allow a brake system to work; servicing and diagnosing hydraulic brake system components, including selecting proper brake fluids; power brake booster operation; diagnosing and servicing power brake boosters; basic air brake system operation, including air brake chambers, S-cam brakes, and slack adjusters; servicing and diagnosing both S-cam and air disc brake systems

Truck Brake Systems, Part 2: Air system theory; supply air system components and operation; primary and secondary air system components and operation, including testing and servicing; emergency/parking air system operation and servicing according to DOT guidelines; the differences between various types of air brake mechanical/foundation brake systems; ABS components; testing and diagnosing ABS systems; performing ABS and HABS computer system diagnosis; component testing with a digital voltohmmeter

Textbook:

Truck and Trailer Systems

Special Note:

• This updated course replaces 086E09.

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886M06

Drivelines and Transmissions

Duration: 30 hours (includes 3 tests)

What Students Learn:

Preview:

This course covers the driveline system, clutches, and drive axles before moving on to truck manual and automatic transmissions. You'll learn about the major components, operation, and general procedures for servicing these systems. The information is divided into three lessons; each lesson includes assignments that cover a specific area of truck-system technology.

Contents:

Drivelines, Clutches, and Axles: Driveline components and functions; Basic driveshaft testing and servicing; clutch terminology; testing, adjusting, and servicing clutches; drive-axle components and operation; repairing, replacing, servicing, and overhauling the drive axle; testing, servicing, overhauling and diagnosing inter-axle differential problems

Manual Transmissions: Manual transmission operation; major components in five- and six-speed manual transmissions; maintaining, diagnosing, servicing, and overhauling manual transmissions; servicing, repairing, and testing twin-countershaft transmissions, including both the main and auxiliary-transmission systems; automated manual transmission operation and servicing; computer-based testing

Automatic Transmissions: Automatic transmission operation and terminology; automatic transmission components, including planetary gear sets, the hydraulic valve, and torque-converter; general service procedures for automatic transmission components; inspecting and diagnosing problems with Allison automatic transmissions; removing and installing Allison 1000/2000/2400 series automatic transmissions

Textbook:

Truck and Trailer Systems

Special Note:

• This updated course replaces 086E10.

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886M07 (NEW)

Diesel Powered Vehicle Troubleshooting and Repair (40 hours)

Duration: 40 hours (includes 4 tests)

What Students Learn:

Preview:

This course covers preventative maintenance inspections (PMIs) on over-the-road vehicles and diesel engines. Proper maintenance inspections allow technicians to catch problems before they become bigger, more expensive issues. This course discusses the type of maintenance programs technicians may encounter, and the types of routine inspections technicians can carry out. This course also focuses on DOT inspection requirements and the characteristics of an effective preventative maintenance (PM) program.

Contents:

Review of Diesel Engine Topics: Diesel engine operating characteristics and terminology, including horsepower and pressure ratio; operating principles of a two- and four-cycle diesel engine; ratings applied to diesel fuel; likely causes of general engine malfunctions, including irregular starting characteristics and engine oil leaks

Troubleshooting and Repair: Troubleshooting and servicing diesel engine fuel-injection systems; electronic management systems; fault codes use and analysis in EMS systems; troubleshooting methods to diagnose cylinder head and valve problems; troubleshooting lubrication system problems in a typical diesel engine; troubleshooting diesel engine air cleaning systems and turbochargers

Review of Electrical, Starting, and Cooling Systems: Electrical terms and principles such as Ohm’s law; common electrical components, such as relays, fuses, switches, and semiconductor devices; testing and reconditioning diesel starters and alternators; basic components and properties of vehicle batteries and how they’re tested; diesel engine cooling system components and functions

PM, Inspection, and Troubleshooting: Maintenance programs, including schedules and types of inspections; performing DOT inspections; DOT out-of-service criteria; preventative maintenance programs and maintenance records; performing tests and checks for modern oil analysis; troubleshooting tests, troubleshooting charts, and service information; preparing diesel engines for long- and short-term storage

Textbook:

Troubleshooting and Repairing Diesel Engines

00C1

Mack Diesel Engine Mechanics: Introduction

Duration:

15 hours (includes 1 test)

Course Prerequisites:

In-Frame Overhaul, Part 2 (Diesel) (0A25)

What Students Learn:

Introduction to Mack Diesel Engines; Cylinder Block; Main Bearings; Crankshaft; Pistons and Connecting Rods; Camshaft and Bearings; Cylinder Head Assembly; Valve Operating Systems; Engine Model and Serial Number Identification.

00C2

Engine Disassembly (Mack)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Mack Diesel Engine Mechanics: Introduction (00C1)

What Students Learn:

Use of Equipment and Tools for Disassembly; Removing Electric Equipment; Cleaning the Engine Externally; Mounting Engine on Engine Stand; Step-by-Step Engine Disassembly; Engine Cleaning.

00C3

Cylinder Block and Components, Part 1 (Mack)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Engine Disassembly (Mack) (00C2)

What Students Learn:

Cylinder Block Functions and Requirements; Evaluating Cylinder Block Failures; Inspection; Block, Liners, Bores, Stud Holes, Main Bearing Caps, Main Bearing Bores; Cylinder; Block Rebuilding.

00C4

Cylinder Block and Components, Part 2 (Mack)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Cylinder Block and Components, Part 1 (Mack) (00C3)

What Students Learn:

Crankshaft; Functions and Requirements, Evaluating Crankshaft Failures, Inspection, Grinding; Main and Connecting Rod Bearings; Evaluating Failure, Misalignment, Inspection, Service; Camshaft; Camshaft Bearings.

00C5

Cylinder Block and Components, Part 3 (Mack)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Cylinder Block and Components, Part 2 (Mack) (00C4)

What Students Learn:

Connecting Rods; Pistons and Rings; Crankshaft Oil Seals; Flywheel and Ring Gear; Timing Gear Cover; Injection Pump Drive Assembly; Auxiliary Shaft Assembly; Tachometer Drive Assembly.

00C6

Cylinder Head Assemblies and Valve Operating Mechanisms (Mack)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Cylinder Block and Components, Part 3 (Mack) (00C5)

What Students Learn:

Cylinder Head Assembly; Functions and Requirements; Evaluating Failures, Cleaning, Inspection, and Testing, Rebuilding; Valve Operating Mechanism; Functions and Requirements; Evaluating Rocker Arm and Pushrod Failures; Disassembly, Cleaning, Inspection, Repair.

00C7

Fuel Systems, Part 1 (Mack)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Cylinder Head Assemblies and Valve Operating Mechanisms (Mack) (00C6)

What Students Learn:

A Brief Review of Diesel Fuel Properties; Diesel Fuel Specifications; Mack Diesel Engine Fuel System; Fuel Filters; Fuel in Pumps.

00C8

Fuel Systems, Part 2 (Mack)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Fuel Systems, Part 1 (Mack) (00C7)

What Students Learn:

American Bosch PSJ and PSM Fuel Injection Pumps: Description and Operation, Troubleshooting, Disassembly, Cleaning, Inspection, Assembly, Timing; American Bosch Nozzle Holders and Spray Nozzles: Description and Operation, Testing, Troubleshooting, Disassembly and Cleaning, Assembly and Testing.

00C9

Air Intake and Exhaust Systems (Mack)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Fuel Systems, Part 2 (Mack) (00C8)

What Students Learn:

Function of Air Intake System; Air Cleaner; Air Piping; Turbocharger; Special Checks of Air Intake Systems; Exhaust System Functions and Requirements; Evaluating Exhaust System Failures; Inspection and Service.

00D1

Detroit Diesel Engine Mechanics: Introduction

Duration:

15 hours (includes 1 test)

Course Prerequisites:

In-Frame Overhaul, Part 2 (Diesel) (0A25)

What Students Learn:

Introduction to the Detroit Diesel Engine; Principles of Operation; Description of Component Parts; Basic Engine Accessory Arrangements; Model Numbering Systems; General Engine Specifications.

00D2

Engine Disassembly (Detroit Diesel)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Detroit Diesel Engine Mechanics: Introduction (00D1)

What Students Learn:

Use of Equipment and Tools for Disassembly; Removing Electric Wiring and Components; Cleaning Engine; Removing: Exhaust Manifold, Cooling System Components, Lubrication System Units, Flywheel, Cylinder Head, Camshaft, Cylinder Liner, Piston and Connecting Rod Assemblies, and Crankshaft.

00D3

Cylinder Block and Components, Part 1 (Detroit Diesel)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Engine Disassembly (Detroit Diesel) (00D2)

What Students Learn:

Functions and Requirements of the Cylinder Block Cleaning; Evaluating Cylinder Block Failures; Inspection; Cracks; Flatness, Stud and Bolt Holes, Block Bores, Main Bearing Cap Fit; Water and Oil Passages.

00D4

Cylinder Block and Components, Part 2 (Detroit Diesel)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Cylinder Block and Components, Part 1 (Detroit Diesel) (00D3)

What Students Learn:

Resurfacing the Cylinder Block; Replacing Damaged or Broken Cylinder Head Studs; Increasing Size of Cylinder Block Bores; Honing Cylinder Block Bores; Replacing Camshaft and Balance Shaft Bushings; Evaluating Crankshaft Failures.

00D5

Cylinder Block and Components, Part 3 (Detroit Diesel)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Cylinder Block and Components, Part 2 (Detroit Diesel) (00D4)

What Students Learn:

Crankshaft Repair; Crankshaft Oil Seals; Main and Connecting Rod Bearings; Cylinder Liners; Pistons and Rings.

00D6

Cylinder Block and Components, Part 4 (Detroit Diesel)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Cylinder Block and Components, Part 3 (Detroit Diesel) (00D5)

What Students Learn:

Pistons and Rings; Connecting Rods; Flywheel; Crankshaft Vibration Damper; Crankshaft Pulley; Camshaft and Balance Shaft; Timing Gears; Accessory Drive.

00D7

Cylinder Heads, Components, and Valve Operating Mechanisms (Detroit Diesel)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Cylinder Block and Components, Part 4 (Detroit Diesel) (00D6)

What Students Learn:

Function of Cylinder Head and Components; Evaluating Cylinder Head and Failures; Cylinder Head Disassembly, Cleaning, Inspection, and Repair; Function of Valve and Injector Operating Mechanisms; Evaluating Valve and Injector Mechanism Failures; Value Mechanism Inspection and Repair.

00D8

Fuel Systems (Detroit Diesel)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Cylinder Heads, Components, and Valve Operating Mechanisms (Detroit Diesel) (00D7)

What Students Learn:

Diesel Fuel Oil Specifications; Fuel Strainers and Filters; Fuel Pump; Fuel Injectors; Troubleshooting Charts; Checking Injector Spray Tip Concentricity; Final Injector Testing.

00D9

Governors (Detroit Diesel)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Fuel Systems (Detroit Diesel) (00D8)

What Students Learn:

Mechanical Governors; Variable Speed, Limiting Speed; Hydraulic Governors; SG Governor, PSG Governor; Hydraulic Governor Drive.

00E1

Introduction to Caterpillar Diesel Engines

Duration:

15 hours (includes 1 test)

Course Prerequisites:

In-Frame Overhaul, Part 2 (Diesel) (0A25)

What Students Learn:

Caterpillar Engine Applications; Engine Models; Engine Performance Charts; Description of Engine Components; Fuel System; Air Inlet and Exhaust Systems; Lubricating System; Cooling System; Electrical System.

00H1

Introduction to Cummins Diesel Engines

Duration:

15 hours (includes 1 test)

Course Prerequisites:

In-Frame Overhaul, Part 2 (Diesel) (0A25)

What Students Learn:

Getting the Most Out of Block H; Cylinder Block Group; Cylinder Heads; Valve and Injector Operating Mechanisms; Fuel Systems; Lubricating Systems; Cooling Systems; Drive Units; Air Intake Systems; Exhaust Systems; Air Compressors; Electric System; Engine Mounting and Adaptations; Cummins Engine Identification.

00H2

Introduction to Engine Rebuilding (Cummins)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Introduction to Cummins Diesel Engines (00H1)

What Students Learn:

The Need for Engine Rebuilding; Engine Rebuilding versus Engine Repair; Inspection During Maintenance; Major Inspection; Unit Rebuilding; The Rebuild Shop: Layout; Work Flow, Cleanliness, Shop Equipment.

00H3

Rebuild Shop Practices, Part 1 (Cummins)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Introduction to Engine Rebuilding (Cummins) (00H2)

What Students Learn:

Pride of Workmanship; Parts Inspection with Precision Gauges; Magnetic Inspection; Pressing Tools and Operations Drilling; Reaming; Tapping; Grinding; Honing.

00H4

Rebuild Shop Practices, Part 2 (Cummins)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Rebuild Shop Practices, Part 1 (Cummins) (00H3)

What Students Learn:

Machine Boring versus Hand Reaming; Tobin-Arp Boring Machine; Hydro-Borer Boring Machine; Engine Lathe; Rebuild Test Equipment; Fuel Pump Test Stand; Injector Test Stand, Engine Dynamometer.

00H5

Engine Disassembly (Cummins)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Rebuild Shop Practices, Part 2 (Cummins) (00H4)

What Students Learn:

Use of Equipment and Tools for Disassembly; Disassembly Procedure: Removing Electric Wiring and Components, Turbocharger, Supercharger, Oil Cooler, Cooling System Components, Intake Manifold, Injectors, Cylinder Heads, Piston and Connecting Rod Assemblies, Cylinder Liners, Crankshaft and Main Bearings; Engine Cleaning.

00H7

Cylinder Block Group, Part 2 (Cummins)

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Cylinder Block Group, Part 1 (Cummins) (00H6)

What Students Learn:

Connecting Rods: Function, Inspection, Rebuilding; Camshaft: Function, Inspection, Rebuilding; Gear Train: Function, Inspection, Rebuilding; Gear Case Cover; Counterbalancer; Flywheel Gear Ring; Assembly of Cylinder Block Group.

00H9

Cummins PT Fuel System

Duration:

15 hours (includes 1 test)

Course Prerequisites:

Cylinder Heads, Cam Followers, Tappets, and Rocker Levers (Cummins) (00H8)

What Students Learn:

Fuel Pump: Functions and Requirements, Disassembly, Cleaning, Inspection, Rebuilding, Assembly, Testing; Injectors: Functions and Requirements, Evaluating Failures, Disassembly, Cleaning, Inspection, Repair, Assembly, Testing; Hydraulic Governors: Function, Disassembly, Cleaning, Inspection and Rebuilding, Assembly.

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