Automotive Service Technician Level 1
Contents
1. Apprenticeship Manitoba Automotive Service Technician Unit Level Duration Overview A5 Information Retrieval and Introduction to Scan Tools One 14 hours Theory 3 hours Practical 11 hours This unit of instruction is designed to teach the Automotive Service Technician apprentice how to use current technology in searching and locating information essential to servicing and repairing vehicles Objectives and Content 1 Interpret vehicle identification numbers VIN and manufacturers labels a VIN manufacturers label information e Make e Model e Year e Place of manufacture e Type of engine Type of fuel e Type of emission control VIN Interpret service manuals and service bulletins a 2205 Access service related information from automated information retrieval systems a Sequential layout operation Diagrams Flow charts Schematics Tool specifications Selecting test equipment and replacement parts Information resources available e CD ROM e Fax back retrieval system On line system update Procedure for operating microfiche Procedure for operating computerized information service systems e Mitchell On demand e All Data Percent of Unit Mark 10 10 40 17 Rev March 2011 d e On line updates Procedure for accessing on line manufacturer assistance and on line assistance 4 Describe scan tool fundamentals and how to use them a2. Principles of digital computers e Analogue and digital signals e Digital computers e Analogue to digital converters e Data storage Overall purpose and concept of scan tools e Trouble codes retrieved e Identification of stored DTCs e Clearing of DTCs e Performing output control tests e Reading of serial data Data link connectors DLCs e Location and purpose Scan tool usage e Monitoring of data streams e Access to freeze frame data e Obtaining stored DTCs e Clearance of stored DTCs e Bi directional functions e Snapshot data recording 40 Rev March 2011 Apprenticeshi PP Manito Ha Automotive Service Technician Unit B1 Engine Fundamentals Level One Duration 45 hours Theory 45 hours Practical 0 hours Overview This unit of instruction is designed to provide the Automotive Service Technician apprentice with the knowledge of engine construction and principles of operation Percent of Objectives and Content Unit Mark 1 Explain engine principles 20 a Internal combustion principles e Internal combustion engine Burning inside engine Combustion requirements e Combustion by products Ideal CO2 H20 Actual CO NOX e Engine purpose b Major engine components e Cylinder head e Valves e Valve spring e Piston e Piston pin e Cylinder e Connecting rod e Crankshaft e Block e Camshaft Cam lobe e Valve lifter e Camshaft gear e Crankshaft gear e Valve guide c Engine terminol
3. 5 Rev March 2011 Describe series and parallel circuits s used on automobiles a Series circuit characteristics e Voltage e Current e Resistance Total resistance Rr of a series circuit Current flow in a series circuit d Voltage drop e Calculation in series circuit e Electrical problems terms and their effects on a series circuit e Open circuit e Short circuit e Ground circuit f Parallel circuit characteristics Voltage e Current e Resistance g Total resistance Rr of a parallel circuit h Total current and branch current flow e Calculation i Branch voltage drops j Electrical problems terms and their effects on a series circuit e Open circuit e Short circuit e Ground circuit oo k Series and parallel circuit characteristics Total resistance Rr of a series and parallel circuits m Current flow and individual branch amperages n Calculation voltage drop in series and parallel circuits Describe electrical components a Resistors e Limit current flow e Protect electrical parts e Protect electrical circuits b Resistor types e Fixed resistor e Ballast resistor e Tapped resistor e Variable resistors e Rheostat e Potentiometer three wire resistor c Switches e Toggle e Single pole single throw e Single throw double pole e Double throw double pole e Normally closed e Push pull e Rotary e Thermal 44 8 8 Rev March 2011 e Pressure e Mercury d Types and use
4. A4 Computer Applications One 11 hours Theory 2 hours Practical 9 hours This unit of instruction is designed to provide the Automotive Service Technician apprentice with basic computer and internet skills to support trade related research and communications tasks Objectives and Content 1 Describe basic computer components and their functions TATT sao ao TD poOoP 3 Input devices Output devices CPU Hard drive RAM ROM Auxiliary drives A B C etc Keyboard Monitor Mouse Printer types impact and non impact Parallel port Series port Care and handling of diskettes and CD ROM Aspects of Windows software DOS vs Windows Perform basic word processing operations in a word processing package a b C Application programs Common commands File management tasks Describe internet system components a b c The World Wide Web File servers Network addresses Percent of Unit Mark 7 13 24 Rev March 2011 d URL addresses e Bookmarks f Search engines Perform internet searches utilizing various search engines a Accessing search engines via URL addresses b Using key words c Filtering results Use email to send and receive messages with available email software Public domain email services Email addresses Sending email Replying to email inquiries Email attachments text graphics Email website links 2295p 32 24 Rev March 2011
5. Automotive Service Technician Level 1 Rev March 2011 Apprenticeshi PP Manito Ha Automotive Service Technician Unit A1 Safety and WHMIS Level One Duration 16 hours Theory 16 hours Practical 0 hours Overview This unit of instruction is designed to provide the Automotive Service Technician apprentice with the knowledge and understanding of safety related procedures and WHMIS along with related government policies and standards Apprentices will also acquire basic first aid and CPR skills through the successful completion of a recognized certificate program Note No percentage weightings are prescribed for the First Aid and CPR content and objectives 3 7 inclusive Assessment of the objectives and content related to First Aid and CPR is based on the successful completion of a recognized First Aid and CPR Certificate Program Percent of Objectives and Content Unit Mark 1 Safety WHMIS and Government Standards 50 a WHMIS legislation and regulations e History of WHMIS e WHMIS components Evaluation of material Determination of health risks Monitoring of health hazards Control measures Prevention plans Workplace record maintenance e Components of the Health Hazard Regulation Labelling Material Safety Data Sheets Worker training and instruction e Duties and responsibilities of suppliers employers and employees b WHMIS classes and symbols e Class A e Class B e Class C e Class F e Product
6. Compression stroke ring twist Power stroke full face contact with cylinder wall Exhaust stroke ring twist Oil control ring construction Three piece oil control ring One piece Expander devices Location of fit bottom of the ring groove Force ring against cylinder Connecting rod construction Alloy steel Drop forged then machined l beam construction Aluminum and special aluminum Finishing operations Boring bearing hole Honed Splitting of lower end Possible drilling oil hole Rifle drilling Oil spit hole Lubrication of piston pin cylinder and opposite cylinder Construction and operation of intake and exhaust valve train mechanism Valve lifters Hydraulic could be roller type Solid Solid adjustable Hydraulic valve lifter operation Valve close position Valve open position Metering valve Push rod construction Hollow Solid Rocker arms Shaft and stud Shaft and ball stud Cam followers Rocker arm construction 24 Rev March 2011 Individual Shaft mounted Roller arms Materials re valve construction Alloy steel case hardened Head shape designs Poppet valves Rigid head Elastic head design Valve terminology Head Face Stem Keeper or lock groove Margin Sodium cooled valves Purpose Concerns with sodium Safety issues with valve stems Close coil spring construction Dampen out vibration Prevents valve float Damper spring
7. Suitable driver Proper depth Seal sleeves and bullets e Seal failure analysis lip and O ring Worn Twisted Flattened Cut Swollen Dirty 4 Describe and use shop equipment a Primary shop tools and equipment e Safety stands e Jacks e Frame hoist e Chassis hoist e Drill press e Hydraulic press e Shop creepers e Air compressor e Brake pressure bleeder e Parts washer e Pressure washer e Hot tank e Air tools e Grinders e Sand blaster e Engine cranes e Engine slings Safety considerations e Equipment capacity e Safety stands jack stands proper distance and location e Jacks e Frame hoist e Chassis hoist e Drill press e Hydraulic press e Shop creepers e Air compressor e Brake pressure bleeder e Parts washer e Pressure washer e Hot tank e Air tools 19 Rev March 2011 Grinders Sand blaster Engine cranes Engine slings Creepers Maintenance of hoist and lifting equipment Hoist capacity Use of service manual Safe work practices Daily visual inspection Damaged or loose mounts bolts Worn or damaged arms Hydraulic oil leakage Locks for damage Hydraulic controls Electrical conductors switches and controls Hoist and lifting equipment raising techniques Capacity Location Balance Use of hoist pads Air compressor maintenance procedures Belt tension Draining Inspection Lubrication Water traps Filters Oilers Rev March 2011 Apprentic
8. and use tap to remove shell Gasket construction materials and application Purpose Gasket materials Steel Aluminum Copper Asbestos Cork Rubber synthetic Paper Felt Liquid silicone Gasket selection criteria Temperature Type of fluid to be confined Smoothness of the mating surfaces Fastener tension Pressure of confined fluid Material of mating parts Localized unit loading fire ring coating beads flange neoprene Adverse forces Heat and cold Pressure Erosion Corrosion Moisture Gasket installation techniques Avoidance of reuse Checking of mating surface Proper fit Use of sealant types and uses Holding of gasket during assembly Straightening of stamped parts Proper torque sequence Gasket failure Checking of fastener torque Visible signs uneven pressure burning corrosion cracks voids Checking of mating surface warpage and burrs Seal construction and installation Purpose Confinement of fluids Stopping of foreign materials Separation of two different fluids Static and dynamic seals Material construction and use Lip seal three part construction single and double lip O ring seal Two piece oil seal engine rear main bearing 9 Rev March 2011 Graphite impregnated asbestos Synthetic rubber e Oil seal removal Depth Removal techniques Not reusable Potential damage to seal bore e Oil seal installation Proper coating
9. ethylene glycol Anti boil protection ethylene glycol Lubrication protection of water pump seal ethylene glycol Anti scale protection Acidity protection Anti foam protection Corrosion protection d Cooling system service External leaks Pressure testing method Black light and dye Hot or cold leak Internal leaks Pump gauge method Leaking cylinder bank Chemical method Other internal leak tests Service procedures for cooling system parts Safety precautions Servicing radiator leaks Radiator cap check using testing equipment Improper radiator cap vacuum valve operation Cooling system flush methods pressure reverse Precautions when flushing radiators Replacement of water pump Testing procedure for thermostat Cooling system hose deterioration signs Antifreeze change intervals Diagnosis of belt problems Belt types V belts serpentine Belt installation procedures Block heater servicing testing and replacement 28 Rev March 2011 Apprenticeship Manitoba Automotive Service Technician Unit Level Duration Overview C1 Basic Brake Systems One 40 hours Theory 26 hours Practical 14 hours This unit of instruction is designed to provide the Automotive Service Technician apprentice with the knowledge to understand brake system components and operation The unit will also provide the apprentice with the basic skills to repair braking systems Objectives and
10. methods e Multiple ply e Able to exceed 8000 psi 55 160 kPa e Avoidance of sharp or double bends and twisting e Allowance of slack for connections e Flats or flange shapes on mounting brackets e Clips to secure in place Fittings 31 10 Rev March 2011 e Connectors e Unions e Elbows e T fittings e Junction or distribution block e ISO e Metric Brake line flares e Double e Flare angles Brake fluids and their limitations e Disc brake fluid e Conventional glycol based e Silicone based Brake fluid characteristics e Even viscosity throughout temperature range e High boiling point e Hydroscopic and non hydroscopic e Use as lubricant e No corrosion of metal parts No deterioration of rubber parts Brake fluid precautions e No mixing of different brake fluids e Avoidance skin contact e Avoidance of paint e Lids on containers e Effect of contaminated fluid Brake fluid purpose e Transmission of motion e Transmission of force Flushing and changing brake fluid e Moisture accumulation e Rust and corrosion e Change in boiling temperature e Change in freezing temperature Disc brakes bleeding e Blocked open e Spring like hold open tool e Removal of pressure differential warning light switch terminal and plunger ABS systems precautions Describe drum brakes Brake drum construction e Brake drum functions e Frictional area e Heat dissipation Brake drum checks e Over size e Out of
11. to size Holes drilled oil coolant threads etc Bearing caps Lining of bored caps e Crankshaft finishing lathe operations Drilling of oil holes Filleting of radius Correction of diameter Grinding Polishing e Crankshaft parts Throw Main journal Connecting rod journal Flywheel flange Web Fillet radius Crank cheek Balance hole Counterweight Snout e Crankshaft throw arrangements Purpose 4 cylinder 6 cylinder 8 cylinder Throw arrangements vs firing order e Camshafts construction methods Cast Forged e Camshaft lobe parts Base circle Ramp Lobe Nose Heel Cam lobe lift e Cam shape differences Rotation of lifter Even wear pattern Drive fuel pump e Graduated camshaft journal diameter Installation Damage prevention of bearings e Camshaft drive Gear chain belt e Camshaft location advantages and disadvantages e Operation of valve mechanism Less weight Less valve float at high speeds Construction of cylinder heads combustion chambers as well as intake and exhaust systems e Cylinder head construction e Finishing operation Deck surface finishing operation 22 Rev March 2011 Holes drilled for oil bolt holes push rods etc Cooling nozzle and deflectors installed e Integral vs removable guides e Induction hardening of seats e Coolant distribution tube e Combustion chamber shapes Hemisperical Bearings e Friction bearings Split Full round e Materials used in construct
12. 4 17 17 Rev March 2011 e Pulsation damper principle and operation Electrical fuel pump e Impeller rotor type e Pulsating bellows type e Diaphragm e Plunger e Demand style fuel pumps Operation Purpose of inertia switch Fuel filters e In tank e In carburetor filter e Pleated paper e Screen e Stone or ceramic filter sintered bronze e In line filters Fuel system problems e Low fuel pump pressure e High fuel pump pressure e Fuel pump leaks fuel e Fuel pump leaks oil e Fuel pump noise Precautions in the replacement of fuel filters e Use of drain pan e Direction of flow and leaks in fuel line connections e Proper start of nuts threads Describe exhaust systems a b oa0 Manifolds Mufflers and resonators e Reverse Through flow e Heat rise valve and operation Butterfly valve Thermostatic spring operated Vacuum operated Catalytic converters Pipes supports clamps Oxygen sensors Exhaust problems Service exhaust system components a roaoop Tools Alignment Sealers Removal and replacement procedures Torquing of bolts to defined specifications System checks for leaks and or restrictions Safety precautions carbon monoxide Describe air intake systems a Intake system concepts 55 17 22 10 Rev March 2011 Principles Control Design Intercoolers Volumetric efficiency Comparison of manifold vacuum to ported vacuum Intake system comp
13. Content 1 Explain operation and service of master and wheel cylinders a Pascal s Principle e P F A e Area of piston calculation e Cylinder volume e Calculation of unknown quantities e Calculation of piston distance movement e Small vs large cylinders Levers e First class e Second class e Third class e Mechanical Advantage Load or Resistance Effort or MA R E Liquid under confinement Transmission of pressure e Increase in force e Decrease in force e Transmission of motion Simple hydraulic system e Reservoir e Piston and ramp Handle e Piston e Two check valves e Liquid e Check valve springs Simple vehicle hydraulic braking system 29 Percent of Unit Mark 13 Rev March 2011 e Foot pedal with linkage e Master cylinder e Master cylinder piston e Steel lines e Four 4 wheel cylinders e Distribution block e Brake fluid Small vs large cylinders e Pressure required e Force required Master cylinders e Conventional Single piston e Tandem Dual e Quick take up Single piston master cylinder e Residual check valve e Return spring e Piston e Primary cup e Secondary cup e Stop ring e Push rod e Dust boot e Breather port Compensating port Operation of single piston master cylinders e Release position e Brakes applied e Brakes release start and end Tandem dual master cylinder e Residual check valve e Primary spring e Primary pisto
14. Valve rotators Positive with ball and spring Release type Valve spring retainers Construction of the timing cover oil pan valve cover seals and gasket Timing cover oil pan and valve covers Stamped steel Cast aluminum Head gasket Localized unit loading Thin steel copper and asbestos Fire rings Head gasket types Embossed steel shim gasket Metal clad sandwich gasket Soft seal surface composition gasket steel core encapsulated Seals One piece Two piece Wick type Flywheel and harmonic balancers Flywheel purpose Reduction of power impulses Mounting for clutch Gear for starter operation Flywheel construction Machined steel Bolted to crankshaft Smooth surface to provide a friction surface Hole in center for pilot bearing Starter ring gear welded or interference fit to flywheel Flex plates Harmonic balancer purpose Absorption of torsional vibration Timed to size of engine Marks for timing of engine Harmonic balancer construction 25 Rev March 2011 Rubber plugs Spring loaded friction disc Fluid filled h Engine mounts and bell housing Construction of the bell housing Aluminum Cast iron Integral with and separated from transmission housing Bolted to engine block Alignment of bell housing to engine block Dowel pin Shims Engine mount Rubber pads Three point suspension Shock absorbers Location Liquid filled mount 4 Describe engi
15. ater Lighting adjustment shutting down and disassembly procedures e Adjustment of pressures e Ignition procedure Types of flames oxidizing carbonizing and neutral e Shut down procedure e Disassembly e Storage Perform welding brazing and cutting procedures a Fusion welding e Welding tip identification selection maintenance and size e Filler rod identification selection and size Heat and cutting damage to surrounding material Mild steel plate welding e Pressure settings and flame adjustments e Tip angle e Technique e Starting the weld e Welding results e Slow weld 12 64 Rev March 2011 e Fast weld e Dirty tip e Running bead with out a filler rod e Running bead with a filler rod e Welding joints Cutting torch and cutting process Cutting attachments connections control lever e Cutting tips orifices e Setting pressures e Flame lighting and adjusting e Extinguishing the flame e Starting the cut e Cutting technique e Tip angle e Cutting results e Slow cut e Fast cut e Dirty tip e Safety issues with concrete floors Perform braze welding using oxy acetylene equipment e Braze welding e Flame e Temperature e Brazing process e Angle e Technique e Starting the weld e Welding results e Slow weld e Fast weld e Dirty tip Rev March 2011 Apprenticeship Manitoba Automotive Service Technician Unit Level Duration Overview
16. due to parasitic draw Battery removal and installation e Cable removal e Battery mounting e Cleaning and repairing terminals and cables e Proper polarity connections and multiple battery set up e Cleaning of battery Special safety precautions e Acid to water e Wearing of safety glasses e Medical attention after contact with electrolyte Describe factors that will affect the service life of a battery a 9aoo Improper electrolyte level Poor mounting loose battery causing vibration Overcharging Cycling discharging and charging Undercharging sulfation 41 24 20 4 8 12 Rev March 2011 Apprenticeshi PP Manito Ha Automotive Service Technician Unit E2 Electrical Fundamentals Circuits and Test Equipment Level One Duration 48 hours Theory 24 hours Practical 24 hours Overview This unit of instruction is designed to provide the Automotive Service Technician apprentice with a working knowledge of fundamental electrical theory along with key electronic components essential to diagnose and repair an automobile s overall electrical system Objectives and Content 1 Describe electrical fundamentals a Safety practices and procedures b Electron theory e Matter e Element e Atom e Compound e Molecule e Proton e Neutron e Electron e Chemical reaction e Conductor e Insulator e Semi conductor Positive charge e Negative charge e Neutral charge e Permeability
17. e Adjustable channel lock e Needle nose e Locking vise grip Diagonal cutting e Snap ring Punches e Center e Starting e Pin punch e Aligning e Drift straight shank brass Cutting tools e Chisel rivet buster diamond round nose cape cape cold flat Rev March 2011 Taps taper plug bottoming machine screw e Dies e Hacksaw e Jab saw e Twist drills e Files e Reamers e Countersinks General shop tools e Stud removers e Tubing tools flaring tool e Gear and bearing pullers e Thread file thread chaser e Impact wrenches e Ratchet wrench e Vice e Battery strap e Drill press e Hydraulic press e Battery service tool e Cooling system service tools e Grinders e Drills e Air chisel e Die grinders 3 Describe fasteners and sealing devices 10 a Effects of electric current on the human body Bolt e Stud e Machine screw e Wing nut e Prevailing torque e Speed nut e Self locking nuts e Palnut e Cap screw e Castle nut e Plain hex nut e Set screw e Sheet metal e Pop rivet e Cotter pin e Key e Roll pin e Snap rings internal and external e Locking devices Split lock Tooth lock Locking nuts soft collar slotted and pinched distorted threaded palnut Lock plate Safety wire 7 Rev March 2011 Principles and precautions in selecting bolts and screws Bolt and screw terminology e Pitch e Minor diameter e Major diameter e Thread
18. e Inductance e Insulators e Holes c Sources of electricity and Electromotive Force EMF e Chemical e Magnetic e Heat e Light Percent of Unit Mark 5 Rev March 2011 e Piezo crystals e Static electricity e Vehicle EMF sources Practical electrical concepts e Water system operation vs electricity e Electromotive force vs water pressure Current flow vs water flow e Resistance vs water tap e Electron movement vs current flow e Electron and current flow and current flow theories e Conductor failures occur e Insulators Danger of damage from static electricity Describe magnetism and inductance om FTereaooD Inductance Magnetic field Permeability Retentivity Natural magnet Electromagnet construction Electron flow and magnetism The right hand rule Use of electromagnets on vehicles Conversion of energy by magnetism e Electrical energy into mechanical energy e Mechanical energy into electrical energy e Electrical energy into other forms Self induction Mutual induction Examples of induction self induction and mutual induction e Ignition coil e Alternator e Starter Describe OHM s Law a Key concepts e Volt Ohm e Amp e Waitt Units and symbols conversion between units e mega M e kilo k e milli m e micro p OHMS Law formula E I R OHMS Law calculations voltage amperage and resistance Calculation of electrical power W E l 43 5
19. er conductor diameter Metric size cross sectional area mm Wire colour code Solid colour Stripe Spiral stripe Hashmark Marker band Cutting and stripping of wires Wire protection devices Tubing Retainer Tie strap Sleeve Clip Boot Clip 47 Rev March 2011 e Vinyl plastic electrical tape e Wiring harness e Soldering of wires and terminals e Use of rosin core e Tinning e Connector types eye tab spade hook butt mid line splice spade secondary e Crimp type connector and tool e Proper wire repair e Proper removal of terminal ends from connectors Describe and use test equipment 42 Meters digital analog Moving coil Measure of current Meter shunt Voltmeter Load effects of a voltmeter Ohmmeters Multimeters Digital meters DMM Voltmeter Ohmmeter Applications ammeters Meter ranges Meter hookup Test lights Steps in reading voltage Circuit and testing problems e Short open and grounds e Diagnostic trouble shooting procedures e Testing procedures and equipment ATT searoao oD 2p 9533 48 Rev March 2011 Apprenticeshi PP Manito Ha Automotive Service Technician Unit F1 Chassis Lubrication and Inspection Level One Duration 23 hours Theory 18 hours Practical 5 hours Overview This unit of instruction is designed to provide the Automotive Service Technician apprentice with the theoretical and hands on skills required to diagnose and repair problem
20. ergency flashers e Fuses and circuit breakers e Fusible links e Dome lights e Dash lights e Glove compartment lights e Courtesy lights e Illuminated entry e Trailer lights e Roof lights e Fog lights e Light sensor e Electronic controller e Relay h Test equipment e Aiming of headlights e Inspection regulations e Aiming equipment e Aiming procedures e Replacement procedures i Lighting systems repair procedures e Meters and test lights Trim component removal e Special tools e Service manual j Lighting system problem diagnosis e Wiring diagrams e Wire and terminal connection k Electrical components in service manuals 7 Describe and apply wiring diagrams 22 a Repair manuals and troubleshooting charts e Common abbreviations 46 Rev March 2011 e Service manual illustrations section e Diagnosis charts flow chart troubleshooting fishbone component location Reference section Role of wiring diagrams Common automotive electrical symbols Electrical road map Wire connections Component locations Battery Capacitor condenser Coil solenoid or winding Connections Non connections Diode Fuse Ground Lamp Relay Resistor Rheostat Solenoid magnetic switch Switch Transistor PNP Transistor NPN Zener diode Variable resistor Fixed resistor Junction block Wiring splices Wires and terminals Wire types and sizes Solid and stranded Number vs size American Wire Gauge System Numb
21. eship Manitoba Automotive Service Technician Unit Level Duration Overview A3 Welding One 14 hours Theory 3 hours Practical 11 hours This unit of instruction is designed to provide the Automotive Service Technician apprentice with the knowledge understanding and skills related to welding techniques and equipment Objectives and Content 1 Identify the components of oxy acetylene equipment a Demonstrate procedure for setting up oxy acetylene unit a b omoa Tanks e Oxygen e Acetylene Pressure regulators e Oxygen Acetylene Gauges line pressure and tank pressure e Oxygen Acetylene Manual valves Torch tips Torches cutting and welding Hoses e Oxygen Acetylene Fittings e Oxygen Acetylene Cylinder handling storage and transport Tanks e Oxygen e Acetylene Pressure regulators e Oxygen e Acetylene Percent of Unit Mark 12 12 Rev March 2011 Describe principles for using welding and cutting equipment a Gauges e Oxygen e Acetylene Tips Torches cutting and welding Hoses e Oxygen e Acetylene Fittings e Oxygen e Acetylene e Construction e Identification Safety precautions e Eye protection Boots e Gloves e Face shield e Fire extinguisher e Ventilation equipment Portable units e Bottles e Safety caps e Valves e Regulators e Hoses e Torch e Gas flow e Leaks via soapy w
22. g position relative to grinder Fire control equipment and fire prevention procedures Fire extinguisher classification Fire blankets Fire classifications A B C amp D Fire extinguisher appropriate to fire class Pressurized water Class A fires Soda acid Class A fires Rev March 2011 Carbon dioxide CO2 Class B and C Dry chemical Class B C and D Foam Class A and B e Potential fire hazards e Location of fire fighting equipment e Fire exits and observations e Evacuation procedures e Fire warning procedures 2 Describe government policies procedures guidelines and standards 50 a Work related accident reporting procedure of Workers Compensation Board WCB e The Workers Compensation Act e WCB claim procedures e Written report supervisor e Examples accident report forms b Legislation and regulations that govern workplace safety and health e Workplace Safety and Health Act e Garage keepers Act e Information access regarding potential hazards in the workplace e Worker participation workplace safety conditions e Right of refusal in dangerous working conditions e Key definitions safety and health laws Shall May Duty Power Act Regulation Code Health Safety Welfare Discriminatory Action c Material Safety Data Sheets MSDS e Material Safety Data Sheets Definition Location Purpose e Inter
23. hanical efficiency Relationship between Indicated Horsepower IHP and Brake Horse Power BHP Calculation of mechanical efficiency d Engine horsepower and torque e Engine s work production ability e Indicated horsepower Definition Calculation e Brake horsepower BHP Measure Relationship of BHP to speed Measurement Gross vs net BHP e Frictional horsepower FHP Measurement Calculation e Graphing BHP torque and FHP curves e Relationship between IHP BHP and FHP IHP BHP FHP e Use of chassis dynamometer e Normal and abnormal combustion e Pre ignition and causes Over heated engine Glowing piece of carbon Spark plugs overheating Sharp valve edge Glowing exhaust valve e Detonation and causes Ignition timing advanced Engine temperature too high Carbon build raising of compression ratio Low octane fuel Stuck exhaust heat control Removal of excessive block or head metal increase of compression or truing of warped head or block surface No EGR flow e Stages of normal combustion Nucleus Hatching out Propagation Explain engine construction 25 a Cylinder block construction e Construction methods Drop forging Casting e Drop forging advantages e Block materials High grade cast iron 21 Rev March 2011 Cast or die cast aluminum alloy e Casting and die casting processes Oil sands cores Use of core box e Finishing of operations to block after casting Cylinders bored and finished
24. ing e Removing burrs e Proper use of flaring tool e Proper flare full contact e Improper flare Uneven Cocked Split Flare Shoulder Narrow contact e Square with centerline e Correct size Bleeding brakes e Use of shop manual e Manual e Pressure e Vacuum 37 35 Rev March 2011 e Series connected cylinders e Parallel connected cylinders Measurement of brake drum e Drum micrometer e As indicated by manufacturers specifications Machining of brake drum Use of safety goggles e Grinding e Lathing e Turning of drums in pairs e Minimal removal of metal e Light cut fed slow e Need for damper Service and adjustment procedures for drum brake assemblies e Brake shoe removal e Installation of brake shoes e Installation of all other parts e Adjustment of brakes e Use of shop manual Removal and reinstallation of brake disc assembly e Use of shop manual e Piston e Piston seal e Dust boot e Inner pad wear limit e Outer pad wear limit e Caliper assembly e Bushings Inspection of disc brake rotor e Lateral run out e Heavy scoring e Parallelism e Minimum thickness Demonstration of disc brake rotor machining e Machine set up e Speed of cut e Depth of cut e Need for damper e Use of safety goggles e Use of shop manual Disc brake caliper disassembly repair and assembly e Removal of piston boot e Careful use of compressed air to remove piston e Honing cylinder bore e Insta
25. inventory Manitoba WHIMS regulations c Appropriate work habits and related safety issues e Safety boots Eye protection e Face protection e Hearing protection Head protection 1 Rev March 2011 Masks Lifting techniques Location of safety equipment Long hair Jewelry Loose shirt and sleeves Oil soaked clothing Neck ties Horseplay Garage housekeeping work habits and procedures Disposal of flammable liquids Dangers of exhaust fumes ventilation Electrical hazards Drainage and rotating devices Safety shields and guards Rag and waste disposal Air lines and fittings Interior and fender covers Cluttered workplace hazards Liquid spill hazards In shop driving precautions Tool and equipment maintenance Personal grooming Safety rules for using hand drills and hand grinders Goggles Materials secured Loose clothing sleeves and ties hazards Water hazards Condition of tool cords Power tool hazards explosive vapors Unplugged when using drill chuck Properly grounded power equipment CSA approved Safety rules for bench grinder and wire wheels Use of goggles on worksite Tight clean and true abrasive stones Grinder at full RPM before using Tool rest close to wheel Vise grip pliers for small objects Use of leather gloves for heavy grinding Dangers of revolving grinding wheel Importance of grinding wheel guard Hazard grinding near explosive vapors New stones appropriate to grinders RPM Standin
26. ion Steel back Copper alloy lining Barrier plate Tin lead alloy over plate Pure tin flash plate e Construction of bearings Steel back Copper alloy lining Barrier plate Tin lead alloy over plate Pure tin flash plate e Bearing terms Crush Spread Clearance Thrust flange e Precision insert bearings Conformability Corrosion resistance Embedability Performance fatigue resistance Score resistance Piston and rod assembly e Materials Aluminum Tin plated Cast iron e Piston terminology Head Lands Oil ring drain hole Oil ring groove Skirt Compression rings grooves Pin hole Pin boss e Piston design and construction Cam ground e Piston construction features Heat dams location Thrust struts diagonal horizontal vertical Steel struts and inserts Cam ground Head shapes e Piston major and minor thrust side e Attaching pistons to connecting rods Fully floating 23 Rev March 2011 Piston pin locked to rod Piston pin locked to piston Piston pin construction Hollowed Case hardened Construction of rings Cast iron with coating of chrome Molybdenum graphite and phosphate Compression ring joints Butt Lap Bevel Ring shapes cross sectional Tapered face Counter bored barrel faced Outer grooved scraper type bevel Plain rectangular Inner grooved bevel Center grooved Action of counter bored taper faced or grooved ring Intake stroke ring twist
27. ion Tire rotation Purpose 4 5 wheel bias 4 5 wheel radial b Wheel balancing Wheel balancers Dynamic balancers on car off car Static balancers bubble Compare static to dynamic wheel imbalance Wheel balancing procedures Tire pressure check Tool manufacturers procedures Safety and verification procedures for wheel weight types c Radial force variation 52 Rev March 2011 Apprenticeshi PP Manito Ha Automotive Service Technician Unit H1 Fuel System Components and Exhaust Systems Level One Duration 18 hours Theory 14 hours Practical 4 hours Overview This unit of instruction is designed to show the Automotive Service Technician apprentice how to identify describe service and repair fuel tanks fuel lines fuel filters fuel pumps pressure regulators air intake systems and exhaust systems Percent of Objectives and Content Unit Mark 1 Describe fuel types 17 a List types of fuels e Gasoline e Diesel e Alternate fuels LP natural gas e Safety considerations b Relative heat produced by various fuels e Gasoline e Diesel e Alternate fuels c Advantages and disadvantages of various fuels e Diesel e Alternate fuels d Performance characteristics of gasoline e Anti knock quality and octane rating e Volatility and its effects e Gasoline additives e Anti icing or de icer Metal deactivators and rust inhibitors e Gum or oxidation inhibitors Detergents e Ethanol e Me
28. ion fluid level Temperature Level ground Engine running Gear shifter position Manual transmission Fluid level Seal leaks Transfer case Fluid level Seal leaks Rear axle Fluid level Seal leaks b General inspection of suspension steering and drive axle Inspection procedures for tires Proper inflation Evidence of improper front end alignment imbalance and physical damage Inspection procedures for suspension and wheel bearings Over loading and sagging of suspension chassis height Tire shake test for worn wheel bearings Ball joint looseness Shock absorbers struts and attaching parts Shocks or struts proper action or leakage Inspection procedures for steering system Steering gear mountings Steering linkage looseness and binding Inspection procedure for driveline Boots and clamps Seals for leaks oil wetness around shaft Cardan joints Hanger bearing and bracket assembly Signs of rubbing 3 Describe tire construction and classification a Wheel construction Types of wheels Drop center steel disc Drop center cast or forged aluminum Offset width diameter etc Directional wheels 50 34 16 Rev March 2011 Parts and purpose of wheel sections Mounting holes Spider center section Drop center section Bead area Rim Safety ridges b Tire construction Tire function Types of tire materials Rubber Fabric casting plies rayon nylon polye
29. isadvantages b Types of hybrid powertrain designs e Series e Parallel e Series parallel c Levels of hybrid vehicles e Mild hybrid e Medium hybrid e Full hybrid 2 Describe hybrid vehicle safety hazards Properly tag out the vehicle Fire hazards Electrocution hazards Electrolyte hazards Use of hybrid identification markers Working environment e Dry floor e With a partner oap 3 Describe tools for hybrid vehicle safety a Personal protective equipment e High voltage gloves e Testing high voltage gloves e Safety glasses 57 Percent of Unit Mark 20 50 10 Rev March 2011 Oy Bes e Insulated steel toed boots High voltage multimeters and leads Cat III Warning pylons Insulated tools Engine crane for battery removal Hook or gaff for electrocution Describe differences with high voltage batteries a Safety precautions for working on high voltage battery e Personal protective equipment e One hand rule Different types of hybrid batteries e Lead acid batteries in series e Nickel metal hydride e Lithium ion Safety procedures e Different disconnect procedures e Verify voltage 58 20 Rev March 2011
30. ke applied seal stretches e Brake released seal relaxed e Self adjusting feature f Disc brake pistons e Steel e Aluminum e Fiberglass reinforced Phenolic piston resin g Pad knockback e Excessive rotor run out e Loose wheel bearings Describe brake valves and parking brakes a Valve types e Metering valve e Proportioning valve Pressure differential valve Brake metering valve e Brake released e Light brake pedal application e Heavy brake pedal application d Brake proportioning valve e Brake released e Light brake pedal application e Heavy brake pedal application e Pressure differential switch e When working e During system failure f Brake light switches e Hydraulic 35 6 Rev March 2011 e Mechanical g Parking brakes e Rear brake shoe type e Drive line type e Disc brake type h Rear wheel parking brake e Parking brake apply pedal e Parking brake assembly e Equalizer e Parking brake front cable e Parking brake conduit e Strut rod e Parking brake cable left of right rear Describe brake booster operation a Hydroboost and vacuum operation e Hydraulic e Vacuum b Vacuum booster installations e Linkage e Integral e Multiplier c Power booster e Vacuum suspended e Atmospheric suspended air suspended d Power booster unit components e Front shell e Rear shell e Power piston diaphragm e Support plate e Reaction retainer e Power piston insert e Reaction lever e Reaction spring e Air va
31. length e Screw length e Threads per inch e Head size e Root e Crest e Flank e Size e UNC UNF e NPT e Metric Hardware descriptions e E g 3 13 UNC 2A 10 32 2 Imperial head grade marking length thread pitch nominal diameter e Metric head property class length thread pitch nominal diameter e UNC and UNF threads Removing and installing fasteners e Torque principles Elasticity Elastic limit Yield Torque to yield bolts Hooke s Law Tensile strength Residual tension Torque Tension Distortion Compression Cold flow High pressure lubricant e Torque charts imperial and metric Standard bolt and nut torque specifications Metric bolt and nut torque specifications Standard nut and bolt strength marking Metric nut and bolt strength marking Need for lubricating all head bolts e Use of torque wrench Types Choosing a torque wrench Effects of adapter use Torque wrench calibration Recommended torque sequence e Precautions for bolts Visual inspection Tighten to recommended torque Head tight against surface Appropriate length and size Safe use operation and maintenance of threads e Taps and dies uses Rev March 2011 Broken tap removal External thread chasers Common tapping problems Thread repair Tap to oversize Heli coil and keensert Broken stud removal Stud slotted or filed flat Nut welded on Punch used to unscrew broken piece Screw extractor Drill
32. lling boot on clean and lubricated piston e Installing piston in clean lubricated bore e Use of small C clamp e Use of shop manual Pad replacement rear disc brakes e Use of special tool to retract piston e Use of shop manual 38 Rev March 2011 Adjustment of cable actuated park brake e Relation of drum brake adjustment to parking brake adjustment e Setting parking brake e Raising the car e Proper adjustment of equalizer e Releasing of brake e Free turning of wheels e Use of shop manual Vacuum booster tests e Pressure check e Pedal travel e Vacuum reading e Release problems e Hard pedal e Grabbing brakes Repair of single diaphragm vacuum booster e Manufacturers guidelines e Pushrod adjustment gauge and air methods e Vacuum hose and engine condition e Parts cleaning solutions e Safety precautions e Cost feasibility of repair and replacement 39 Rev March 2011 Apprenticeship Manitoba Automotive Service Technician Unit Level Duration Overview E1 Batteries One 11 hours Theory 8 hours Practical 3 hours This unit of instruction is designed to provide the Automotive Service Technician apprentice with the knowledge of how batteries work and how to service them Objectives and Content 1 Explain the function of a battery a b c d Starting motor ignition and other electrical devices Supplies electrical power when required Use as capacitor Stores ene
33. lve e Floating control valve e Push rod e Power piston return spring e Reaction plate e Master cylinder push rod e Vacuum check valve e Vacuum power booster operation e Internal valve vacuum and atmospheric operation e Released position e Applied position e Holding position e Brake feel f Vacuum booster tests e Pressure check e Pedal travel e Vacuum reading 36 10 Rev March 2011 8 Explain and demonstrate measuring machining and repairing components a e Release problems e Hard pedal e Grabbing brakes e Check of internal binding Hydraulic boost systems e Pump e Accumulator e Master cylinder e Pressure switch e Reservoir Repair of master cylinder e As outlined in service manual e Clearance between piston and cylinder e Replacement of parts e Pitting as it affects cylinder replacement e Honing procedures e Removing tube seal insert e Bench bleeding e Fluid level Final checks and adjustment to master cylinder e Adjustment procedures as outlined in service manual e Brake pedal height adjustment e Brake pedal free travel e Procedure for adjusting master cylinder push rod for vacuum booster unit Disassembly inspection and repair of the wheel cylinders e As outlined in service manual e Clearance between piston and cylinder e Replacement of parts e Pitting need for cylinder replacement e Honing procedures e Bleeder screws for being free and open Double flare and ISO e Proper cutting tub
34. n e Primary cups e Secondary cups e Stop ring e Push rod e Dust boot e Secondary piston e Breather port e Compensating port e Secondary spring Tandem dual master cylinder e Release position e Brakes applied e Brakes release start and end Tandem dual master cylinder single piston e Line rupture front or rear e Blown wheel cylinder front or rear e Protection oriented design Quick take up master cylinder 30 Rev March 2011 e Residual check valve e Primary spring e Primary piston e Primary cups e Secondary cups e Stop ring e Push rod e Dust boot e Secondary piston e Breather port e Compensating port e Secondary spring e Quick take up valve e Primary high pressure chamber e Primary low pressure chamber e Proportioning valve e Warning switch e Release position e Brakes applied e Brakes release start e Brakes release end Residual pressure valve e Line pre charged e Prevention of air entry e Effect on the wheel cylinder lip e Alternatives including cup expanders Wheel cylinders e Single piston e Double pistons e Stepped 2 Describe lines fluid and bleeding a Brake lines e Steel tubing e Flexible hose Steel lines and protection methods e Double wrapped e Brazed and tin plated e High pressure exceeding 1000 psi 6895 kPa e Straight run avoidance e Long run support e Detour around hot spots Use of rubber grommet Flexible hoses and protection
35. nds on skills required to effectively use shop tools equipment and fasteners Percent of Objectives and Content Unit Mark 1 Describe and use measuring tools 61 a General purpose e Non precision measuring e Precision measuring e History purpose function types styles and application e Metric and imperial measurements and conversions Tool maintenance b Tool construction selection and reading e Steel ruler Outside and inside micrometers e Depth micrometer e Vernier caliper Dial indicator Torque wrench Torque angle wrench Hole gauge e Telescoping gauge e Feeler gauge e Valve seat runout gauge e Cylinder bore dial gauge e Pressure gauge e Vacuum gauge e Plastigauge 2 Describe basic hand tools 10 a Hammers e Ball peen e Brass 5 Rev March 2011 e Soft faced e Dead blow e Rubber mallet e Cross peen e Sledge Screwdrivers e Standard e Phillips e Reed and Prince e Robertson e Speciality Torx Posidrive Socket handles e Ratchet handle e Flex handle e Speed handle e Extension Sockets e Deep e Shallow e 6 point e 12 point e 8 point e Impact e Flex e Spark plug e Screwdriver attachments Hex driver Phillips drive flat tip drive clutch Torx three wing double square e Types of drives 14 3 8 2 34 Wrenches e Open end e Box end e Combination e Adjustable e Allen e Off set e Flare nut Pliers e Combination slip joint
36. ne lubrication operation and service a Construction and operation Purpose Cleans engine Reduction of friction Hydrodynamic suspension Cools Absorbs shock Seals between rings and block Oil pumps Gear Rotor or lobe Oil pump pickup Pipe or cast metal Floating pickup type Filter screen Valve for oil bypass Baffles anti splash pans Prevention of oil displacement Prevention of aeration or foaming Pressure regulating relief valve Purpose Operation Lubrication systems Full pressure system Splash Oil mixed with fuel Lubrication systems operation Crankshaft bearing pressure Rocker arm pressure and splash Piston splash Cylinder walls connecting rod squirthole Camshaft lobe splash Camshaft bearing pressure Oil filtering systems operation Full flow By pass Shunt Oil coolers b Oil filters 26 15 Rev March 2011 Types Cartridge Spin on or throw away Construction of filtering media Surface Depth c Engine oils Purpose and functions SAE and viscosity ratings API service classifications Oil additives Synthetic oils SAE viscosity oil grades and rating systems Oil change intervals Formation of sludge Formation of varnish Oil change intervals 5 Describe cooling system operation and service 15 a Cooling systems construction and operation Purposes of cooling system Removal of surplus heat Efficient operating temperature under all condi
37. ogy e Bore and stroke e Square over and under square engine e Calculation of engine displacement 19 Rev March 2011 e Calculation of compression ratio e TDC e BTDC e BBDC e ATDC Engine classification e Key classifications Valve arrangement Number of cylinders Cylinder arrangement Cycle Type of Cooling Type of fuel e Two stroke vs four stroke cycle e Stroke order four stroke cycle engine Intake Compression Power Exhaust e Exhaust and intake valve operation during four strokes e Valve operational terms Overlap Duration and overlap from a chart Two cycle engine operation reed valve or ported type e Valve arrangements e Cylinder arrangements Inline V Opposed Fuel types e Gasoline e LPG e Diesel Cooling systems e Liquid e Air 2 Explain engine performance a Key terms e Work e Power e Torque Friction force lubrication e Dry metal to metal e Greasy cam lobe and lifter e Viscous engine bearing Engine efficiency e Volumetric efficiency Maximum filling of cylinder Cylinder intrusions e Causes of volumetric efficiency decrease Altitude Dirty air filter Temperature RPM Atmospheric pressure 20 25 Rev March 2011 Exhaust restriction Intake runners configuration e Engine innovations re volumetric efficiency Polishing intake port Less exhaust back pressure High lift cam Variable valve timing Superchargers Turbochargers Thermal efficiency e Mec
38. onents Air intake ductwork Air cleaner assembly Air filters Principles Types paper and polyurethane Intake manifold Super chargers engine driven Service precautions Turbo chargers exhaust driven Service precautions Naturally aspirated Positive filters Pre cleaners After coolers and inter coolers Pressure waves Intake manifold in line and V type engines Cast iron or aluminum Prevention condensation Assistance in vapourization Efficiency in mixing of fuel Air speed to reduce condensation Inline engines runner configuration V configurations open and closed intakes coolant and heat riser passage Attached sensor Tuned intake system Intake manifolds operating principles Cold air Hot air Control Distribution Tuning Variable induction Tuned port induction V type intake manifold vs in line type Shorter runners Better fuel distribution to cylinder 56 Rev March 2011 Apprenticeshi PP Manito Ha Automotive Service Technician Unit Introduction to Hybrid Vehicle Systems Level 1 Duration 7 hours Theory 7 hours Practical 0 hours Overview This unit of instruction is designed to provide the Automotive Service Technician apprentice with an introduction to the knowledge about current generation hybrid vehicle systems Objectives and Content 1 Describe the fundamentals of hybrid technology a Differences compared to traditional non hybrid technologies e Advantages e D
39. or grease soaked e Twisting e Cracked web e Broken weld f Fixed single anchor duo servo and self adjusting rear brake design e Primary shoe e Secondary shoe e Anchor e Retraction springs e Hold down springs e Shoe pins e Shoe guide e Star wheel adjuster assembly e Parking brake cable e Emergency brake strut and spring e Automatic adjuster system g Automatic adjusting servo drum brake e Cable e Cable with over travel spring e Lever with override e Lever and pawl h Faulty brake performances causes and corrections e No pedal no brakes e Spongy pedal e Hard pedal excessive foot pressure required e Brakes grab one or more wheels e Brakes fade e Brakes pulling to one side e Brakes drag e Pulsating pedal rapid up and down movement e Brakes chatter e Brakes squeal e Shoe click e Onset of brake warning light e Non function of automatic shoe adjuster 5 Explain disc brake operation a Disc vs drum brakes e Resistance to heat and fade e Resistance to water fade e More straight line stops 34 10 Rev March 2011 e Automatically adjusts e No servo action disadvantage e Bigger piston and larger reservoir disadvantage b Rotors e Solid rotor e Ventilated rotor e Directional c Calipers e Fixed e Floating e Sliding d Caliper parts e Caliper assembly e Piston e Piston seal e Dust boot e Pad Inner shoe e Outer shoe e Wear indicator tab e Caliper operations e Seal elasticity e Bra
40. pret information provided e Storage of chemicals e Proper labeling of containers new and used e Duties of suppliers employers employees 3 Explain the responsibilities and duties of the first aid person n a a Explain the diagnoses for e Respiratory failure e Burns e Body injury 4 Explain artificial respiration n a a Explain the process of freeing the victim of breathing restrictions b Explain the process of applying mouth to mouth respiration 3 Rev March 2011 Explain emergency treatment n a a Describe the procedure for e Assessing injury e Moving the patient e Arresting bleeding e Completing Workers Compensation Board forms Explain the procedure for treating burns n a a Explain the methods of quenching firm on a victim b Explain treating various burns Explain and demonstrate basic rescuer CPR n a a Explain what cardiovascular disease is and how it kills b Explain how to recognize cardiovascular emergencies severe angina heart attack cardiac arrest etc and choking by their signs and symptoms c Demonstrate how to respond effectively to cardiovascular and choking emergencies 4 Rev March 2011 Apprenticeshi PP Manito Ha Automotive Service Technician Unit A2 Tools Shop Equipment and Fasteners Level One Duration 33 hours Theory 16 hours Practical 17 hours Overview This unit of instruction is designed to provide the Automotive Service Technician apprentice with the knowledge and ha
41. rgy 2 Identify service ratings of batteries a Battery rating e Amp hour e Reserve capacity e Cold crank Battery capacity e Condition of charge e Temperature e Internal structure surface area of plates Tests Parasitic drains Hydrometer Load Three minute charge Open circuit voltage Capacitance testing Diagnosis of battery condition Hydrometer test Load test Three minute charge test Hydrometer reading Hydrometer reading temperature correction 40 Percent of Unit Mark 12 20 Rev March 2011 Explain construction and identify parts of a lead acid battery a b C Electrolyte Cell construction Other types e Maintenance free e Hybrid batteries Operation and chemical reactions Charging and discharging Explain battery charging a Charging methods e Slow charging e Fast charging e Charging of low maintenance batteries e Filling batteries Precautions for fast charging batteries e Temperature e Charger off cables disconnected e Use of manufacturer operating instructions e Exposure to hydrogen gas e Removal of jewelry e Disconnection of ground cable e Use of well ventilated area e Care with metal tools or other objects Describe battery boosting procedures a Procedures and precautions of battery boosting Diagnose battery problems and service batteries a Battery problems e Physical condition e Undercharged e Overcharged e Discharge
42. round e Taper e Physical damage 32 6 Rev March 2011 25 e Concave e Convex e Machining limits Energy conversion process e Inertia e Kinetic energy e Heat transfer Friction e Static e Kinetic Coefficient of friction e Calculation e Calculation of unknown quantity Areas of friction e Shoe and drums Frictional influences e Type of materials in contact e Areas of material e Weight e Friction coefficient e Oil e Grease e Brake fade Weight transfer e Shifting of weight to front e Front brakes 2 3 of braking e Front rear split e Diagonally split Brake shoe materials e Asbestos compound safety issues e Special metallic linings heavy duty resistant to brake fade e Asbestos threads with fine copper wire safety issues e Synthetic substances e Ceramic Backing plate Platform on backing plate e Plate mounting fasteners e Shoe pads e Brake shoe hold down pin holes e Use of high temperature grease e Brake shoe anchor Brake shoe terms e Web e Platform e Heel e Toe Drum brakes primary lining Drum brakes secondary lining Brake shoe action Describe shoe arrangements and frictional materials 33 10 Rev March 2011 e Servo action e Self energizing e Double anchor e Single anchor self centering e Double anchor double cylinder e Single anchor self centering duo servo acting e Self adjusting brakes e Checks to linings and shoes e Worn e Loose e Oil
43. s of capacitors e Purpose construction charge discharge cycle e Uses noise suppressor counter voltage spikes e Types fixed variable e Identification size farads e Fuses e Purpose e Types cartridge blade inline fuse and fusible link e Rating e Role of service manuals f Operation of electrical components e Circuit breakers vs fuse e Flashers e Light bulbs e Coils e Transformers e Relays e Buzzers e Solenoids e Motors g Electrical components in service manual e Circuit breakers state advantage over a fuse e Flashers e Light bulbs e Coils e Transformers e Relays e Buzzers e Solenoids e Motors 6 Describe lighting systems 5 a Exterior lighting e Bulb identification e Sealed housing headlamp e Sealed halogen headlamp e Halogen insert bulb e Single contact bulb e Double contact bulb e Headlights and circuits e Lamp delay and auto dimming system e Park lights e Brake lights e Signal lights e Emergency flashers e Fuses and circuit breakers e Fusible links b Interior lighting e Dome lights 45 Rev March 2011 e Dash lights e Glove compartment lights e Courtesy lights e Illuminated entry c Accessory lighting e Trailer lights e Roof lights e Fog lights d Daytime running lights e Light sensor e Electronic controller e Relay e Lighting system schematic diagram Simple interior light diagram g Electrical lighting circuits and components e Park lights e Brake lights e Signal lights e Em
44. s related to undercar inspection along with wheels and tires Percent of Objectives and Content Unit Mark 1 Describe front and rear wheel bearings seals and lubricants 20 a Front or rear wheel bearings disassembly and inspection e Types of anti friction bearing e Application of different bearing design e Use of manufacturer procedure e Removal of bearing assembly parts e Potential bearing problems Chipping Galling Wear Discoloration Corrosion Electrical pitting Poor lubrication Dirt Perform bearing rotational check Bearing looseness and clearance b Bearing handling and installation e Air spin problems e Problems with heating bearings e Application of force on tight ring c Bearing installation repacking and adjustment Use of grease recommended by manufacturer e Clean and dry before packing e Use of grease packer e Procedure for hand packing e Use of new grease only e Adjustments determined by manufacturers specifications d Chassis lubricants 49 Rev March 2011 Lithium grease Sodium soap Use of grease in chassis parts Drive shaft Steering linkages Ball joints Gear oils Petroleum based Extreme pressure EP Steering gear lubricants manual Steering gear lubricant power Specialty lubricants Transmissions Transfer case Rear differentials 2 Describe and perform underbody inspection suspension steering driveline a Fluid check of underbody parts Automatic transmiss
45. ster Wire Parts of tire Tread Bead wires Soft rubber liner Rubbing strip Width Height Piles Construction of tire plies Bias ply Radial Advantages of radial as compared to bias Run flat Tire and wheel size designations Tire rating systems Ply rating Load range Tubeless tire Tire grade Tread wear Traction Temperature resistance Load index and speed rating Tire size designation Tire types P passenger T temporary LT light truck Sectional width 185 195 205mm etc Aspect ratio 70 75 80 etc Rim diameter 13 14 15 inches etc Non metric alpha numeric system tire sizes Tire letter size F etc Tire types R etc series 78 etc Rim diameter 15 etc 4 Describe and perform tire maintenance and service a Service requirements for wheels and tires Radial and lateral runout Use of dial indicator Use of shop manual Acceptable limits runout not exceeding 1 16 inch or 1 59mm Location of tire inflation specifications Causes of abnormal tire wear Over inflation Under inflation Camber wear Multi problem cupping Toe wear 51 30 Rev March 2011 Problems caused by mixing radial and bias tires Handling problems steering wheel pull Removal and installation of tires Proper mounting technique Installation of tube tires Use of tire lubricant Safety precautions Reasons for torquing wheel nuts to specificat
46. thanol e Methyl tertiary butyl ether MTBE e MMTs f Characteristics of diesel fuel e Viscosity and volatility 53 Rev March 2011 e Cetane number e Diesel fuel grades Summer and winter 2 Describe tank lines and filter a Fuel tank construction e Plated pressed steel aluminum or molded plastic polyethylene e Baffles e Filler neck e Passage for fuel transfer e Ridges e Drain optional Pressure and vacuum filler cap Normal operating conditions e Pressure or vacuum conditions e Relief of vacuum pressure Venting of fuel tanks e Vapour separator e Vapour storage canister e Rollover protection valve inertia switch Fuel re circulating system e In pump e In line Fuel tank inspection e Fuel leaks e Road damage e Corrosion e Rust e Loose e Defective seams Safety precautions for gas tanks e Disconnection of negative battery e Danger of heating bolts on fuel tank e Appropriate disposal of used rags and fuel e Leaks in steel tubing e Fuel line fittings to torque specifications e Proper fuel transfer system e Static electricity precautions 3 Describe fuel pumps filters and delivery systems a Main parts of mechanical fuel pump e Check valve e Diaphragm spring e Diaphragm e Rocker arm e Rocker arm spring e Pulsator diaphragm e Pump body valve and lower body Mechanical fuel pump e Intake stroke e Outlet stroke e Rest stroke chamber full needle valve closed 5
47. tions Efficiency in reaching operation temperature Cooling system types Air Liquid Flow of coolant cross and down flow radiator Radiator Hoses Water pump Thermostat Thermostat bypass Bypass circuit Fan Water jackets Radiator cap Construction and operation of a water pump Centrifugal pump Circulation of water Placement of impeller in closed housing Minimization of pressure Belt driven Key parts and systems Water jacket Thermostat bypass Thermostats pellet bi metal spring bellow b Construction of radiators caps hoses shrouds and fans Radiator cores Round tube and flat fin Flat fin and corrugated fin Flat tube and flat fin Radiator cap pressure and vacuum valves Pressure valve springs Vacuum valve Pressurization of system Relationship between pressure on a liquid and boiling point Construction of radiator hoses 27 Rev March 2011 Rubber single or double ply construction Straight curved or flexible Reinforcement in lower radiator hose Hose clamps types worm drive screw type twin wire spring Fan shroud Efficiency Air flow shape Problems with missing shrouds Radiator fans Rigid Flex blade Clutch drive Electric c Block heaters and antifreeze additives Block heaters and installation procedure Frost plug Inline type Antifreeze Glycol based type Other types Levels of protection when mixed with water Freeze protection
Download Pdf Manuals
Related Search