STANDARD COMPETENCIES:

 

 1. Check fuel level, and condition; determine needed action.

 2. Perform fuel supply and return system tests; determine needed action.

 3. Inspect fuel tanks, vents, caps, mounts, valves, screens, crossover system, supply, and return lines and fittings;

    determine needed action.

 4. Inspect, clean, and test fuel transfer (lift) pump, pump drives, screens, fuel/water separators/indicators, filters,

    heaters, coolers, ECM, cooling plates, and mounting hardware; determine needed action.

 5. Inspect and test pressure regulator systems (check valves, pressure regulator valves, and restrictive fittings); determine needed action.

 6. Check fuel system for air; determine needed action; prime and bleed fuel system; check primer pump.

 7. Inspect and test power and ground circuits and connections; measure and interpret voltage, voltage drop, amperage,

    and resistance readings using a digital multimeter (DMM); determine needed action.

 8. Interface with vehicle’s on-board computer; perform diagnostic procedures using electronic service tool(s) (to include

    PC based software and/or data scan tools); determine needed action.

 9. Check and record electronic diagnostic codes and trip/operational data; monitor electronic data; clear codes; determine further diagnosis.

 10. Locate and use relevant service information (to include diagnostic procedures, flow charts, and wiring diagrams).

 11. Inspect and replace electrical connector terminals, seals, and locks.

 12. Inspect and test switches, sensors, controls, actuator components, and circuits; adjust or replace as needed.

 13. Access and interpret customer programmable parameters using recommended electronic diagnostic tools including PC based software and/or data scan tools.

 14. Perform on-engine inspections, tests and adjustments on electronic unit injectors (EUI); determine needed action.

 15. Remove and install electronic unit injectors (EUI) and related components; recalibrate ECM (if applicable).

 16. Perform cylinder contribution test utilizing recommended electronic diagnostic tool.

 17. Perform on-engine inspections and tests on hydraulic electronic unit injectors (HEUI) and system electronic controls; determine needed action.

 18. Perform on-engine inspections and tests on hydraulic electronic unit injector (HEUI) high pressure oil supply and

     control systems; determine needed action.

 19. Perform on-engine inspections and tests on high pressure common rail (HCPR) type injection systems; determine needed action.

 20. Inspect high pressure injection lines, hold downs, fittings and seals; determine needed action.

 TOPICAL OUTLINE:

 

 I.      Diesel Fuel and Fuel Supply Systems

         A.      Diesel Fuel Quality

         B.      Alternative Fuels

         C.      Fuel Tank Design

         D.      Fuel Supply Pump Design and Operation

         E.      Fuel Filters

         F.      Bleeding Air from the Fuel System

 II.     Diesel Fuel Injection

         A.      Fuel Injection Principles

         B.      Combustion Chamber Design

         C.      Combustion Stage in a Diesel Engine

         D.      Injection Nozzle Function and Operation

         E.      Design and Application of Injection Nozzles

         F.      Diesel Fuel Injection Tubing

         G.      Injector Problems

         H.      Isolating a Faulty Injector Nozzle

         I.      Removing Injection Nozzles

         J.      Injection Nozzle Service

         K.      Installing Injection Nozzles

 III.    Electronic Control of Diesel Fuel Injection--Operating Principles

         A.      Electronic Control Module (ECM) Operation

         B.      Electronic Control Module (ECM) Components

         C.      Input and Output Devices

         D.      Input Sensors and Their Function

         E.      Computer-Controlled Actuators (Output Devices)

         F.      Fault Codes

         G.      Features and Advantages of Electronic Controls