Transition Overwatch

On-the-job Training

• Diesel Engines - General
  • Research vehicle service information, including fluid type, vehicle service history, service precautions, and technical service bulletins.
  • Inspect level and condition of fuel, oil, diesel exhaust fluid (DEF), and coolant.
  • Inspect engine assembly for fuel, oil, coolant, air, and other leaks.
  • Check engine operation (starting and running) including noise, vibration, smoke, etc.
  • Use appropriate electronic service tool(s) and procedures to check, record, and clear diagnostic codes; check and record trip/operational data; reset maintenance monitor (if applicable); interpret digital multimeter (DMM) readings.
  • Identify system components, configurations, and types of the following: cylinder head(s), valve train, engine block, engine lubrication, engine cooling, air induction, exhaust, fuel, and engine braking.
• Diesel Engines - Cylinder Head and Valve Train
  • Inspect electronic wiring harness and brackets for wear, bending, cracks, and looseness.
• Diesel Engines - Engine Block
  • Inspect crankshaft vibration damper; inspect engine mounts.
  • Test engine oil pressure and check operation of pressure sensor, gauge, and/or sending unit; test engine oil temperature and check operation of temperature sensor.
  • Check engine oil level, condition, and consumption; take engine oil sample.
  • Determine proper lubricant; perform oil and filter service.
• Diesel Engines - Engine Block
  • Inspect crankshaft vibration damper; inspect engine mounts.
  • Test engine oil pressure and check operation of pressure sensor, gauge, and/or sending unit; test engine oil temperature and check operation of temperature sensor.
  • Check engine oil level, condition, and consumption; take engine oil sample.
  • Determine proper lubricant; perform oil and filter service.
• Diesel Engines - Cooling System
  • Check engine coolant type, level, condition, and test coolant for freeze protection and additive package concentration.
  • Verify coolant temperature; check operation of temperature and level sensors, gauge, and/or sending unit.
  • Inspect and reinstall/replace pulleys, tensioners, and drive belts; adjust drive belts and check alignment.
  • Recover coolant, flush, and refill with recommended coolant/additive package; bleed cooling system.
  • Inspect coolant conditioner/filter assembly for leaks; inspect valves, lines, and fittings; replace as needed.
  • Inspect water pump, hoses, and clamps.
  • Inspect, and pressure test cooling system(s); pressure test cap, tank(s), and recovery systems; inspect radiator and mountings.
  • Inspect thermostatic cooling fan system (hydraulic, pneumatic, and electronic) and fan shroud.
  • Identify engine block heater(s).
• Diesel Engines - Air Induction and Exhaust Systems
  • Inspect turbocharger(s), wastegate(s), and piping systems.
  • Check air induction system including cooler assembly, piping, hoses, clamps, and mountings; replace air filter as needed; reset restriction indicator (if applicable).
  • Inspect intake manifold, gaskets, and connections.
  • Inspect engine exhaust system, exhaust gas recirculation (EGR) system, and exhaust aftertreatment system for leaks, mounting, proper routing, and damaged or missing components.
  • Inspect crankcase ventilation system; service as needed.
• Diesel Engines - Fuel System
  • Check fuel level and condition.
  • Inspect fuel tanks, vents, caps, mounts, valves, screens, crossover system, hoses, lines, and fittings.
  • Inspect low pressure fuel system components (fuel pump, pump drives, screens, fuel/water separators/indicators, hoses, lines, filters, heaters, coolers, ECM cooling plates, check valves, pressure regulator valves, restrictive fittings, and mounting hardware).
  • Replace fuel filter; prime and bleed fuel system.
  • Inspect high pressure fuel system components (fuel pump, pump drives, hoses, injection lines, filters, hold-downs, fittings, seals, and mounting hardware).
• Diesel Engines - Engine Brakes
  • Inspect engine compression and/or exhaust brake housing, valves, seals, lines, and fittings.
• Drive Train - General
  • Research vehicle service information, including fluid type, vehicle service history, service precautions, and technical service bulletins.
  • Identify drive train components, transmission type, and configuration.
• Drive Train - Clutch
  • Inspect and adjust clutch, clutch brake, linkage, cables, levers, brackets, bushings, pivots, springs, and clutch safety switch (includes push-type and pull-type); check pedal height and travel; determine needed action.
  • Inspect clutch master cylinder fluid level; check clutch master cylinder, slave cylinder, lines, and hoses for leaks and damage; determine needed action.
• Drive Train - Transmission
  • Inspect transmission shifter and linkage; inspect transmission mounts, insulators, and mounting bolts.
  • Inspect transmission for leakage; determine needed action.
  • Replace transmission cover plates, gaskets, seals, and cap bolts; inspect seal surfaces and vents; determine needed action.
  • Check transmission fluid level and condition; determine needed action.
  • Inspect transmission breather; inspect transmission oil filters, coolers, and related components; determine needed action.
  • Inspect speedometer components.
  • Inspect and test function of REVERSE light, neutral start, and warning device circuits.
• Drive Train - Driveshaft and Universal Joints
  • Inspect, service, and/or replace driveshafts, slip joints, yokes, drive flanges, support bearings, universal joints, boots, seals, and retaining/mounting hardware; check phasing of all shafts.
• Drive Train - Drive Axles
  • Check for fluid leaks; inspect drive axle housing assembly, cover plates, gaskets, seals, vent/breather, and magnetic plugs.
  • Check drive axle fluid level and condition; check drive axle filter; determine needed action.
  • Inspect air-operated power divider (inter-axle differential) assembly including diaphragms, seals, springs, yokes, pins, lines, hoses, fittings, and controls.
  • Inspect drive axle shafts; determine needed action.
  • Remove and replace wheel assembly; check rear wheel seal and axle flange for leaks; determine needed action.
• Brakes - General
  • Research vehicle service information, including fluid type, vehicle service history, service precautions, and technical service bulletins.
  • Identify brake system components and configurations (including air and hydraulic systems, parking brake, power assist, and vehicle dynamic brake systems).
  • Identify brake performance problems caused by the mechanical/foundation brake system (air and hydraulic).
• Brakes - Air Brakes: Air Supply and Service Systems
  • Inspect air supply system components such as compressor, governor, air drier, tanks, and lines; inspect service system components such as lines, fittings, mountings, and valves (hand brake/trailer control, brake relay, quick release, tractor protection, emergency/spring brake control/modulator, pressure relief/safety).
  • Verify proper gauge operation and readings; verify low pressure warning alarm operation; perform air supply system tests such as pressure build-up, governor settings, and leakage; drain air tanks and check for contamination.
• Brakes - Air Brakes: Mechanical/Foundation Brake System
  • Inspect service brake chambers, diaphragms, clamps, springs, pushrods, clevises, and mounting brackets; determine needed action.
  • Identify slack adjuster type; inspect slack adjusters; determine needed action.
  • Check camshafts (S-cams), tubes, rollers, bushings, seals, spacers, retainers, brake spiders, shields, anchor pins, and springs; determine needed action.
  • Inspect rotor and mounting surface; measure rotor thickness, thickness variation, and lateral runout; determine needed action.
  • Inspect, clean, and adjust air disc brake caliper assemblies; inspect and measure disc brake pads; inspect mounting hardware; perform needed action.
  • Remove brake drum; clean and inspect brake drum and mounting surface; measure brake drum diameter; measure brake lining thickness; inspect brake lining condition; determine needed action.
• Brakes - Air Brakes: Parking Brake System
  • Inspect and check parking (spring) brake chamber for leaks; determine needed action.
  • Inspect and test parking (spring) brake check valves, lines, hoses, and fittings; determine needed action.
  • Inspect and test parking (spring) brake application and release valve; determine needed action.
  • Manually release (cage) and reset (uncage) parking (spring) brakes.
• Brakes - Hydraulic Brakes: Hydraulic System
  • Check master cylinder fluid level and condition; determine proper fluid type for application.
  • Inspect hydraulic brake system components for leaks and damage.
  • Check hydraulic brake system operation including pedal travel, pedal effort, and pedal feel.
• Brakes - Hydraulic Brakes: Mechanical/Foundation Brake System
  • Inspect rotor and mounting surface; measure rotor thickness, thickness variation, and lateral runout; determine needed action.
  • Inspect and clean disc brake caliper assemblies; inspect and measure disc brake pads; inspect mounting hardware; determine needed action.
  • Remove brake drum; clean and inspect brake drum and mounting surface; measure brake drum diameter; measure brake lining thickness; inspect brake lining condition; inspect wheel cylinders; determine needed action.
• Brakes - Hydraulic Brakes: Parking Brake System
  • Check parking brake operation; inspect parking brake application and holding devices.
• Brakes - Power Assist Systems
  • Check brake assist/booster system (vacuum or hydraulic) hoses and control valves; check fluid level and condition (if applicable).
  • Check operation of emergency (back-up/reserve) brake assist system.
• Brakes - Vehicle Dynamic Brake Systems (Air and Hydraulic): ABS, ATC, and ESC
  • Observe antilock brake system (ABS) warning light operation including trailer and dash mounted trailer ABS warning light.
  • Observe automatic traction control (ATC) and electronic stability control (ESC) warning light operation.
• Brakes - Wheel Bearings
  • Clean, inspect, lubricate, and/or replace wheel bearings and races/cups; replace seals and wear rings; inspect spindle/tube; inspect and replace retaining hardware; adjust wheel bearings; check hub assembly fluid level and condition; verify end play with dial indicator method.
  • Identify, inspect, and/or replace unitized/preset hub bearing assemblies.
• Suspension and Steering - General
  • Research vehicle service information, including fluid type, vehicle service history, service precautions, and technical service bulletins.
  • Disable and enable supplemental restraint system (SRS); verify indicator lamp operation.
  • Identify suspension and steering system components and configurations.
• Suspension and Steering - Steering Column
  • Check steering wheel for free play, binding, and proper centering; inspect and service steering shaft U-joint(s), slip joint(s), bearings, bushings, and seals; phase steering shaft.
  • Check operation of tilt and telescoping steering column
  • Check cab mounting.
• Suspension and Steering - Steering Pump and Gear Units
  • Check power steering pump and gear operation, mountings, lines, and hoses; check fluid level and condition; service filter; inspect system for leaks.
  • Flush and refill power steering system; purge air from system.
• Suspension and Steering - Steering Linkage
  • Inspect tie rod ends, ball joints, kingpins, pitman arms, idler arms, and other steering linkage components; lubricate as needed.
• Suspension and Steering - Suspension Systems
  • Inspect shock absorbers, bushings, brackets, and mounts; determine needed action.
  • Inspect leaf springs, center bolts, clips, pins, bushings, shackles, U-bolts, insulators, brackets, and mounts; determine needed action.
  • Inspect axle and axle aligning devices such as: radius rods, track bars, stabilizer bars, and torque arms; inspect related bushings, mounts, and shims.
  • Inspect tandem suspension equalizer components.
  • Inspect and test air suspension pressure regulator and height control valves, lines, hoses, dump valves, and fittings; check and record ride height.
  • Inspect air springs, mounting plates, springs, suspension arms, and bushings.
• Suspension and Steering - Wheel Alignment
  • Demonstrate understanding of alignment angles.
• Suspension and Steering - Wheels and Tires
  • Inspect tire condition; identify tire wear patterns; measure tread depth; verify tire matching (diameter and tread); inspect valve stem and cap; set tire pressure.
  • Identify wheel/tire vibration, shimmy, pounding, and hop (tramp) problems.
  • Check wheel mounting hardware; check wheel condition; remove and install wheel/tire assemblies (steering and drive axle); torque fasteners to manufacturer’s specification using torque wrench.
• Suspension and Steering - Frame and Coupling Devices
  • Inspect, service, and/or adjust fifth wheel, pivot pins, bushings, locking mechanisms, mounting hardware, air lines, and fittings.
  • Inspect frame and frame members for cracks, breaks, corrosion, distortion, elongated holes, looseness, and damage.
  • Inspect frame hangers, brackets, and cross members.
  • Check pintle hook and mounting (if applicable).
• Electrical/Electronic Systems - General
  • Research vehicle service information, including vehicle service history, service precautions, and technical service bulletins.
  • Demonstrate knowledge of electrical/electronic series, parallel, and series-parallel circuits using principles of electricity (Ohm’s Law).
  • Demonstrate proper use of test equipment when measuring source voltage, voltage drop (including grounds), current flow, continuity, and resistance.
  • Demonstrate knowledge of the causes and effects of shorts, grounds, opens, and resistance problems in electrical/electronic circuits.
  • Use wiring diagrams to trace electrical/electronic circuits.
  • Measure parasitic (key-off) battery drain.
  • Demonstrate knowledge of the function, operation, and testing of fusible links, circuit breakers, relays, solenoids, diodes, and fuses.
  • Inspect, repair (including solder repair), and/or replace connectors, seals, terminal ends, and wiring; verify proper routing and securement.
  • Use appropriate electronic service tool(s) and procedures to check, record, and clear diagnostic codes; interpret digital multimeter (DMM) readings.
  • Check for malfunctions caused by faults in the data bus communications network.
  • Identify electrical/electronic system components and configuration.
• Electrical/Electronic Systems - Battery System
  • Identify battery type and system configuration.
  • Confirm proper battery capacity for application; perform battery state-of-charge test; perform battery capacity test, determine needed action.
  • Inspect battery, battery cables, connectors, battery boxes, mounts, and hold-downs; determine needed action.
  • Charge battery using appropriate method for battery type.
  • Jump-start vehicle using a booster battery and jumper cables or using an appropriate auxiliary power supply.
  • Identify low voltage disconnect (LVD) systems.
• Electrical/Electronic Systems - Starting System
  • Demonstrate understanding of starter system operation.
  • Perform starter circuit cranking voltage and voltage drop tests.
  • Inspect starter control circuit switches, relays, connectors, terminals, wires, and harnesses (including over-crank protection).
• Electrical/Electronic Systems - Charging System
  • Identify and understand operation of the generator (alternator).
  • Check instrument panel mounted voltmeters and/or indicator lamps.
  • Inspect generator (alternator) drive belt condition; check pulleys and tensioners for wear; check fans and mounting brackets; verify proper belt alignment.
  • Inspect cables, wires, and connectors in the charging circuit.
  • Perform charging system voltage and amperage output tests; perform AC ripple test.
  • Test, replace, and aim headlights.
  • Inspect cables, wires, and connectors in the lighting systems.
  • Inspect tractor-to-trailer multi-wire connectors, cables, and holders.
• Electrical/Electronic Systems - Instrument Cluster and Driver Information Systems
  • Check gauge and warning indicator operation.
  • Identify the sensor/sending units, gauges, switches, relays, bulbs/LEDs, wires, terminals, connectors, sockets, printed circuits, and control components/modules of the instrument cluster, driver information system, and warning systems.
• Heating, Ventilation, And Air Conditioning (HVAC) - General
  • Research vehicle service information, including refrigerant/oil type, vehicle service history, service precautions, and technical service bulletins.
  • Identify heating, ventilation, and air conditioning (HVAC) components and configuration.
  • Use appropriate electronic service tool(s) and procedures to check, record, and clear diagnostic codes; interpret digital multimeter (DMM) readings.
• Heating, Ventilation, And Air Conditioning (HVAC) - Refrigeration System Components
  • Inspect A/C compressor drive belts, pulleys, and tensioners; verify proper belt alignment.
  • Check A/C system operation including system pressures; visually inspect A/C components for signs of leaks; check A/C monitoring system (if applicable).
  • Inspect A/C condenser for airflow restrictions; determine needed action.
• Heating, Ventilation, And Air Conditioning (HVAC) - Heating, Ventilation, and Engine Cooling Systems
  • Inspect engine cooling system and heater system hoses and pipes; determine needed action.
  • Inspect HVAC system-heater ducts, doors, hoses, cabin filters, and outlets; determine needed action.
  • Identify the source of A/C system odors.
• Heating, Ventilation, And Air Conditioning (HVAC) - Operating Systems and Related Controls
  • Verify blower motor operation; confirm proper air distribution; confirm proper temperature control; determine needed action.
• Cab - General
  • Research vehicle service information including, vehicle service history, service precautions, and technical service bulletins.
  • Use appropriate electronic service tool(s) and procedures to check, record, and clear diagnostic codes; check and record trip/operational data; reset maintenance monitor (if applicable); interpret digital multimeter (DMM) readings.
• Cab - Instruments and Controls
  • Inspect mechanical key condition; check operation of ignition switch; check operation of indicator lights, warning lights and/or alarms; check instruments; record oil pressure and system voltage; check operation of electronic power take-off (PTO) and engine idle speed controls (if applicable).
  • Check operation of all accessories.
  • Understand operation of auxiliary power unit (APU)/electric power unit (EPU).
• Cab - Safety Equipment
  • Check operation of horns (electric and air); check warning device operation (reverse, air pressure, etc.); check condition of spare fuses, safety triangles, fire extinguisher, and all required decals; inspect seat belts and sleeper restraints; inspect condition of wiper blades and arms.
• Cab - Hardware
  • Check operation of wipers and washer; inspect windshield glass for cracks or discoloration; check sun visor; check seat condition, operation, and mounting; check door glass and window operation; verify operation of door and cab locks; inspect steps and grab handles; inspect mirrors, mountings, brackets, and glass.
  • Record all physical damage.
  • Inspect cab mountings, hinges, latches, linkages, and ride height.
  • Inspect quarter fender, mud flaps, and brackets.
• Hydraulics - General
  • Research vehicle service information, including vehicle service history, service precautions, fluid type, and technical service bulletins.
  • Verify placement of equipment/component safety labels and placards; determine needed action.
  • Identify hydraulic system components; locate filtration system components; service filters and breathers.
  • Check fluid level and condition; take a hydraulic fluid sample for analysis.
  • Inspect hoses and connections for leaks, proper routing, and proper protection; determine needed action.
• Fundamental Tasks - Shop and Personal Safety
  • Identify general shop safety rules and procedures.
  • Utilize safe procedures for handling of tools and equipment.
  • Identify and use proper placement of floor jacks and jack stands.
  • Identify and use proper procedures for safe lift operation.
  • Utilize proper ventilation procedures for working within the lab/shop area.
  • Identify marked safety areas.
  • Identify the location and the types of fire extinguishers and other fire safety equipment; Demonstrate knowledge of the procedures for using fire extinguishers and other fire safety equipment.
  • Identify the location and use of eye wash stations.
  • Identify the location of the posted evacuation routes.
  • Comply with the required use of safety glasses, ear protection, gloves, and shoes during lab/shop activities.
  • Identify and wear appropriate clothing for lab/shop activities.
  • Secure hair and jewelry for lab/shop activities.
  • Identify vehicle systems which pose a safety hazard during service such as: supplemental restraint systems (SRS), electronic brake control systems, stop/start systems, and remote start systems.
  • Identify vehicle systems which pose a safety hazard during service due to high voltage such as: hybrid/electric drivetrain, lighting systems, ignition systems, A/C systems, injection systems, etc.
  • Locate and demonstrate knowledge of safety data sheets (SDS).
• Fundamental Tasks - Tools and Equipment
  • Identify tools and their usage in automotive applications.
  • Identify standard and metric designation.
  • Demonstrate safe handling and use of appropriate tools.
  • Demonstrate proper cleaning, storage, and maintenance of tools and equipment.
  • Demonstrate proper use of precision measuring tools (i.e., micrometer, dial-indicator, dial-caliper).
  • Perform common fastener and thread repair, including removing broken bolts, restoring internal and external threads and repairing internal threads with a thread insert.
• Fundamental Tasks - Preparing Vehicle for Service
  • Identify information needed and the service requested on a repair order.
  • Identify purpose and demonstrate proper use of fender covers, mats.
  • Demonstrate use of the three C’s (concern, cause, and correction).
  • Review vehicle service history.
  • Complete work order to include customer information, vehicle identifying information, customer concern, related service history, cause, and correction.
• Fundamental Tasks – Preparing Vehicle for Customer
  • Ensure vehicle is prepared to return to customer per company policy (floor mats, steering wheel cover, etc.).