Training Syllabus to Instruct/Prepare for the ASE Transit Bus Transmission and Drivetrain Test

Transcription

1 APTA STANDARDS DEVELOPMENT PROGRAM RECOMMENDED PRACTICE American Public Transportation Association 1666 K Street, NW, Washington, DC, APTA BTS-BMT-RP Approved October, 2010 APTA Bus Maintenance Training Working Group Training Syllabus to Instruct/Prepare for the ASE Transit Bus Transmission and Drivetrain Test Abstract: This Recommended Practice provides guidelines for establishing a standardized bus maintenance training related to the ASE certification program syllabus for transmission and drivetrains used in transit buses and coaches. Keywords: Automotive Service Excellence (ASE) H3, bus, certification, drivetrains, training, transit, transmissions Summary: This Recommended Practice allows users to instruct/prepare transit bus technicians and mechanics for the National Automotive Service Excellence (ASE) H3 Transit Bus Transmission and Drivetrain Test and to evaluate, develop or enhance current training programs for the diagnosis, repair and maintenance of transit bus transmission and drivetrain systems. Individual operating agencies should modify these guidelines to accommodate their specific equipment and mode of operation. Scope and purpose: This Recommended Practice reflects the consensus of the APTA Bus Standards Program members in conjunction with transit labor organizations, including ATU and TWU, on the subject material, manuals and textbooks, test equipment, methods and procedures that have provided the best performance record based on the experiences of those present and participating in meetings of the program task forces and working groups. APTA recommends the use of this document by organizations that have a training department or conduct training for the maintenance of transit buses, organizations that contract with others for transit bus maintenance training, and organizations that influence how training for transit bus maintenance is conducted. This Recommended Practice represents a common viewpoint of those parties concerned with its provisions, namely, transit operating/planning agencies, manufacturers, consultants, engineers and general interest groups. The application of any standards, practices or guidelines contained herein is voluntary. In some cases, federal and/or state regulations govern portions of a rail transit system s operations. In those cases, the government regulations take precedence over this standard. APTA recognizes that for certain applications, the standards or practices, as implemented by individual rail transit agencies, may be either more or less restrictive than those given in this document.

2 Contents 1. Learning environment... Error! Bookmark not defined. Participants The American Public Transportation Association greatly appreciates the contributions of the Bus Transit Standards Maintenance Training Working Group, which provided the primary effort in the drafting of this Recommended Practice. 2. Computer skills Questions format Direct question Completion question Illustrated question Technician A and Technician B with stem Technician A and Technician B without stem Except ASE course tasks Exam requirements... 8 References... 9 Definitions... Error! Bookmark not defined. Abbreviations and acronyms American Public Transportation Association

3 1. Learning environment For best application of this Recommended Practice, a combination of classroom lectures, mentoring, practical training and practice tests should be included in the training program. 2. Computer skills Basic computer skills are now a standard for transit bus technicians. Basic skills and knowledge in the operation of a computer in a Microsoft Windows environment is essential. 3. Questions format In order to standardize the question-and-answer format, the ASE format of questions has been adopted. This type of test uses six question formats, discussed in the following sections. 3.1 Direct question The correct answer, one out of four potential answers, must be chosen to answer a direct question. 3.2 Completion question The correct answer, out of four potential answers, must be chosen to complete the statement. 3.3 Illustrated question Referring to an illustration, the correct choice must be indicated. 3.4 Technician A and Technician B with stem With this question, the choice is made as to which technician statement is correct, or if both technician statements are correct or incorrect. A lead-in or descriptive statement prefixes the statements 3.5 Technician A and Technician B without stem With this question, the choice is made as to which technician statement is correct, or if both technician statements are correct or incorrect. 3.6 Except This type of question is sometimes referred to as a negative question because the choice is the incorrect answer. In the answers presented to the question or statement, all of them can be correct EXCEPT one. In this type of question, the word EXCEPT will be capitalized. 4. ASE course tasks Tasks that should be covered in this training course: 2010 American Public Transportation Association 1

4 101 SAFETY & COMPLIANCE Transit Bus Transmission/Drivetrain Demonstrate proper stall test safety procedures Demonstrate proper disposal/recycling of fluids Demonstrate proper disposal of filter Explain importance of complying with manufacturer s recommendations A4 A7, C3, C4 A7 ALL 101 THEORY & USE OF REFERENCE MATERIALS Demonstrate proper use of service manual A3, A4,,,, 4, Describe importance of maintaining transmission fluid at correct level Refer to manufacturer s specs Check OEM manual for proper fluid type 101 PROCEDURES, INSPECTIONS AND TESTING 8, C3 Demonstrate proper use of dipstick for checking fluid level (operating temp, level ground, gear selection) Demonstrate proper use of shifter pad or other level indicators for checking fluid level Visually check for transmission fluid leaks Demonstrate proper use of drain pan Check lines for rubbing or other damage Visually inspect for leaks Visually inspect bolt holes Visually inspect sealant surfaces A7 C2 C5 C6 102 SAFETY & COMPLIANCE Demonstrate proper use of safety equipment Follow proper safety precautions Demonstrate proper use of personal protective equipment (PPE) A3 A5, A6 C American Public Transportation Association 2

5 102 THEORY & USE OF REFERENCE MATERIALS Transit Bus Transmission/Drivetrain Check OEM manual for proper fluid, filter, and fluid capacity Refer to manufacturer s specifications, A7, 6, 7, B3, C1, C2 Demonstrate use of troubleshooting guide Demonstrate ability to refer to manual for proper part number 102 TOOL USAGE & DIAGNOSTICS A7 8 C2 Demonstrate proper use of torque wrench and air pressure gauge A7,,, 7, C4, C6, C7, C8, C9 Demonstrate proper use of jacks and jack stands Demonstrate proper use of handheld diagnostic reader to check level (LED) Demonstrate proper use of seal installers and pullers Demonstrate proper use of U-joint pullers and presses 102 PROCEDURES, INSPECTIONS AND TESTING Check transmission fluid condition Check shift cable operation and for proper lubrication Apply proper torque for drain plug and filter housing bolts Refill fluid to proper level Use of proper external seal and gasket hardware Visually check for leaks Drain and refill fluids Visually inspect for fluids leaks, damaged holes and/or damaged threads Check drive shaft for proper phase Check for drive shaft damage Check mounting flange/fasteners Check U-joint wear Check for proper lubrication Check for play Check for rust Check mounting fasteners/hardware for drive line Check fluid level and condition in rear drive axle Inspect and clean rear drive axle breather 6 8 B2 A6 A7 A7, A8 6 7, B3 B3 B3 B3 C1 C1, C American Public Transportation Association 3

6 103 SAFETY & COMPLIANCE Transit Bus Transmission/Drivetrain Demonstrate proper safety procedures 103 THEORY & USE OF REFERENCE MATERIALS Refer to manufacturer s specs for angle, torque, offset of transmission and flex plate 103 TOOL USAGE & DIAGNOSTICS Demonstrate proper use of mechanical tachometer Demonstrate proper use of gasket sealant Demonstrate proper use of pyrometer (temp gun) and analog thermometer A PROCEDURES, INSPECTIONS AND TESTING Identify transmission fluid condition through sight and smell Check cables, shift linkages Visually inspect cooler, lines, breathers, filters and fittings Inspect breather for clogs and contaminants Visually check mounts and clamping hardware for damage Check drive shaft alignment angle Check output shaft Check pinion shaft Check slip joint and U-joint for proper lubrication and seals A SAFETY & COMPLIANCE Demonstrate proper use of personal protective equipment (PPE) C4, C7, C9 201 THEORY & USE OF REFERENCE MATERIALS Explain causes and consequences of drive shaft vibrations Evaluate oil analysis report Follow manufacturer instructions for flushing machine Refer to manufacturer s specs for proper resistance, clearance and depth Refer to manual for proper torque specs 2 C American Public Transportation Association 4

7 201 TOOL USAGE & DIAGNOSTICS Transit Bus Transmission/Drivetrain Demonstrate proper use of handheld diagnostic equipment Demonstrate use of diagnostic equipment for tachometer reading Demonstrate proper use of pullers, extractors and installers Demonstrate proper use of lifts, forklifts and cranes,,, 4 A4, C4 Demonstrate proper use of digital multimeter (DMM), 2,, 4, 8, 9, 0 Demonstrate proper use of axle puller Demonstrate proper use of dial indicator Demonstrate proper use of wheel jack 201 PROCEDURES, INSPECTIONS & TESTING C2, C6 7, B2, C6, C7, C8, C9 C7, C8 Perform stall test Calibrate dipstick and demonstrate proper dipstick usage Compare electronic (level sensor) reading to mechanical (dipstick) fluid level Verify proper bolts being used and check for cracks or bends Remove air lines Demonstrate proper use of clamping hardware Visually inspect flex plate Check axle mounting hardware Check for pinion play Replace rear axle drive unit fluid and fill to proper level Adjust speed sensor air gap Visually inspect locking and nuts for damage Check fluid level in differential Inspect wheel bearing end play, adjust to manufacturer s specifications or replace as needed Remove, replace and/or seal wear rings Visually inspect for abnormal wear and/or damage Visually inspect locking and nuts for damage Inspect planetary thrust washers and planetary gear for abnormal wear 202 THEORY & USE OF REFERENCE MATERIALS Describe the uses of different seal types A7 A8 C1 C1 C3 C7 C7 C7, C9 C7, C9 C7, C9 C8 C9 C American Public Transportation Association 5

8 Transit Bus Transmission/Drivetrain Use manufacturer s specifications to identify proper runout and engine-to-transmission mounting adapters Refer to service manual for removal and replacement of axle and driveshaft procedures 202 TOOL USAGE & DIAGNOSTICS Demonstrate proper use of analog tachometer (RPMs) Demonstrate proper use of depth gauge Demonstrate proper use of flushing equipment Demonstrate proper use of diagnostic equipment to check temperature circuit Demonstrate ability to choose appropriate diagnostic tool Demonstrate proper use of seal remover and installer 202 PROCEDURES, INSPECTIONS AND TESTING Check related components for vibrations Road test bus to determine shifting problems Perform road test for lockup converter system test Drain/flush torque converter and transmission cooler Demonstrate ability to use proper lines and fittings Demonstrate ability to troubleshoot using known good parts when appropriate Disconnect/Reconnect electrical cables/harnesses Inspect seals and gaskets Inspect wheel bearing end play and adjust to manufacturer's specifications Demonstrate ability to use proper sealing material Inspect axle shafts for cracks Inspect tone ring runout Visually inspect tone ring for missing teeth and other damage 6 C4 A4 A8,, 7 2 8, 9, 0 C7, C8, C9 A5 A7, 6 C1, C8 C4, C5, C6 C5 C7 C7 203 THEORY & USE OF REFERENCE MATERIALS Demonstrate ability to read and interpret schematics Demonstrate knowledge of drive line clearances Demonstrate knowledge of vibrations in transmission and (differential) rear end Demonstrate ability to use troubleshooting guides for drive train mounting problems, TOOL USAGE & DIAGNOSTICS Demonstrate proper use of pressure gauge set, A3, A American Public Transportation Association 6

9 Transit Bus Transmission/Drivetrain Demonstrate proper use of laptop and diagnostic software package, A4,, 4,, 9, 0 Demonstrate proper use of diagnostic equipment for determining input speed of engine and turbine speed of transmission while in operation Demonstrate proper use of temperature gauge or laptop to test temperature drop Demonstrate proper use of pressure test equipment to check transmission cooler for leaks 203 PROCEDURES, INSPECTIONS AND TESTING A5 2 Inspect output speed sensor Repair damaged holes and threads in housing Describe the operation of multiplex interface Demonstrate ability to troubleshoot multiplex interface Check speed sensor for resistance and output C7 301 THEORY & USE OF REFERENCE MATERIALS Describe the various means of data of communication between the drive train and other vehicle components TOOL USAGE & DIAGNOSTICS Demonstrate proper use of angle gauge Demonstrate proper use of dial caliper Demonstrate proper use of offset gauge Demonstrate proper use of spring tension gauge B2 B2 301 PROCEDURES, INSPECTIONS AND TESTING Check pinion shaft backlash Evaluate transmission fluid analysis report C1 C3 302 THEORY & USE OF REFERENCE MATERIALS Explain the role of temperature and resistance TOOL USAGE & DIAGNOSTICS Demonstrate ability to use laptop to check data communication link Determine proper data interface cable to use for laptop 2010 American Public Transportation Association 7

10 Transit Bus Transmission/Drivetrain Determine proper translation module Demonstrate proper use of a micrometer C7, C9 303 THEORY & USE OF REFERENCE MATERIALS Describe the process of data networking between different systems (ABS, ATC, etc.) Demonstrate ability to read hydraulic, pneumatic, electrical and mechanical schematics TOOL USAGE & DIAGNOSTICS Demonstrate proper use of laptop for testing pressure Demonstrate proper use of straight edge and feeler gauge Demonstrate proper use of a breakout box to determine if problem software-related or hardware-related A PROCEDURES, INSPECTIONS AND TESTING Demonstrate ability to reset fast adapt/adaptive shifting Check communications cables Demonstrate ability to interpret communications Exam requirements The minimum acceptable grade to pass the course and all practical tests is 75 percent. Students must pass written tests with a minimum grade of 80 percent American Public Transportation Association 8

11 References National Institute for Automotive Service Excellence (ASE) website. Abbreviations and acronyms ABS APTA ASE ATC ATU DMM LED OEM PPE RPM TWU antilock brake system American Public Transportation Association Automotive Service Excellence automatic traction control Amalgamated Transit Union digital multimeter light-emitting diode original equipment manufacturer personal protective equipment revolutions per minute Transit Workers Union 2010 American Public Transportation Association 9