Bjorge & Associates Custom Technical Training

Introductory Courses Introductory courses typically provide mechanics with an overview of an electrical or mechanical system that they are responsible for maintaining in their fleet. For example, a course on an anti-lock braking system (ABS) might include information on critical parts and how they function, equipment specifications and routine maintenance procedures for each component. Advanced Courses Advanced training gives students in-depth information on specific equipment, including strategies for identifying deformities or signs of wear, and procedures for repairing or replacing parts before they break. Today's Challenges Fleet systems have changed drastically in the last five years and will continue to evolve quickly. We train mechanics to deal with the new systems, especially by developing troubleshooting skills and by learning to evaluate drivability. Understanding drivability helps mechanics assess the total driving experience to diagnose interrelated, multi-system problems effectively.

Course Outlines: Check the sample course outlines at the end of this page to see how we customize training for clients. Fleet Maintenance Expertise: • Electrical systems • Fuel systems • Computer systems • ABS systems-Hydraulics • Preparation for ASE exams • Diesel systems • OBD II systems • Air brakes (certification) • ABS/Air brake systems • Drivability • Transmissions Select only topics you need...we adapt all training for your fleet. Clients Say... Electronic Fuel Injection Course: "All the information in the course was useful and very interesting." "Our technicians enjoy the theory mixed with hands-on shop work."      -Technician & Supervisor Air Brake Course: "The instructor conducted good verbal discussion with the technicians. Workshop could not have been better."      -Technician

Prerequisite: Solid Automotive Background
Course Length: Two days

Course Contents: Day 1

1. Fundamentals of Electricity
   1. Defining Ohm's Law and Watt's Law
   2. Voltage (electrical pressure)
   3. Measure amperage (current flow)
   4. Measure resistance (in ohms)
   5. Define and measure voltage drop
   6. Calculate watts to determine horsepower
2. Electrical Circuits
   1. Series
   2. Parallel
   3. Series Parallel
3. Interpretation of Meters
   1. Analog meters
   2. Digital Volts OHM Meters (DVOM)
   3. Automotive Digital Multi-Meters (DMM)
4. Application
   1. Defining the values of digital readings
   2. Verifying the resistance of bulbs, resisters, diodes and coil
   3. Verify continuity
   4. Measure volts, amps and voltage drop across connections, relays, and accessories

Course Contents: Day 2

1. Batteries
   1. Verification and testing
   2. Charging rates and procedures
   3. Electrical drain test
2. Charging Systems
   1. Verification of voltage and amperage output
   2. System testing
   3. Verify recovery period
3. Cranking Systems
   1. Voltage Draw and Amperage Draw test
   2. Verify manufactures' specifications
   3. Identify the cause if not within specifications (mechanical or electrical)
   4. Verify all ground connections

Prerequisite: Solid Electrical and Meter Diagnostic Skills
Course Length: 12 Hours (Over a two-day period)

Course Contents: Day 1

1. Computer Operation
   1. Define the function of the computer
   2. Define sensor operation and testing
   3. Define actuator control
   4. Verify open/closed loop operation and related parameters
   5. Define the transistors as drivers

Course Contents: Day 2

1. Verification
   1. Verify system input and output parameter valves with DMM (All information is recorded and compared to manufactures' specifications)
2. System Testing
   1. Scan the system and:
      • Evaluate the data
      • Analyze the results
      • Troubleshoot the system
      (If they don't already exist, faults will be added to the system)
      
   2. Compare the input and output obtained with the DMM to the scanner and determine conditions
   3. Troubleshoot the systems

Note: Except for verifying voltages, this program does not cover electricity.
This training is not scanner training; however, it will prepare you for diagnostic scanner training.

Prerequisite: Solid Electrical and Meter Diagnostic Skills; Computer Engine Control Systems
Course Length: 12 Hours (Over a two-day period)

Course Contents: Day 1

1. Fuel Supply System
   1. Types of pumps and filters
   2. Testing electrical circuits; fuses, relays, wiring and connections
2. Fuel Injection and Injectors
   1. Definition of a digital pulse width
   2. Verification of injector voltage input and injector DC hertz
   3. Measuring the injector's resistance
3. Throttle Body Fuel Injection
   1. Single and dual injector low pressure type
   2. Single and dual injector high pressure type
4. Multi-Port Injection
   1. Fuel pressure regulator operation and testing
   2. Fuel pressure verification and testing
   3. Injector pressure balance test

Course Contents: Day 2

1. Injector Digital Input-Output
   1. Verification of the low tension voltage
   2. Ignition module frequency as a reference output measurement
2. Hall Effect Switches
   1. Verification of the system voltage input
   2. Verification of the frequency signal output
3. System Testing

Note: Tests are limited to the availability of vehicles.

Prerequisite: Solid Electrical and Meter Diagnostic Skills; Computer Engine Control Systems
Course Length: 12 Hours (Over a two-day period)

Course Contents: Day 1

1. Basic Hydraulic Principles
   1. Brief explanation of Pascal's law
   2. Lines and valves
   3. Cylinders, pistons and seals
2. Brakes
   1. Friction and heat dissipation
   2. Advantages and disadvantages of common materials
3. Drum Brakes and Brake Hardware
4. Disk Brakes
   1. Types of calipers
   2. Types of disks / rotors
5. Split Systems
   1. Front -rear
   2. Diagonal
   3. Brake bleeding
   4. Adjustment procedures
   5. Parking brake mechanisms and adjustment

Course Contents: Day 2

1. Electronic Functions
   1. Electrical circuit testing
   2. Resistance testing
2. Control Operations (inputs and outputs)
   1. Computers and sensors
   2. Solenoids pulses
   3. Motor and relay commands
   4. Control valve commands
3. System Verification and Testing
   1. ABS light circuit and codes
   2. Wheel sensors (volts, frequency, hertz test)
   3. Wheel sensors resistance test
4. Pumps and Accumulators
   1. Pressurized accumulators
   2. Types of pumps
   3. Brake booster testing

Prerequisite: Solid Diesel Background; Electrical and Computer programs
Course Length: 24 Hours (4 Days)

Course Contents

1. Diesel Operation and Supply Systems Overview
   1. Air supply and exhaust flow
   2. Filters and turbochargers
   3. Volumetric and thermal efficiency
   4. Horsepower and torque output
2. Fuel Supply System Layout
   1. Pressure pump operation
   2. High and low pressure systems
   3. Pressure regulator controls
   4. Function and operation of fuel injectors
3. Electronic Fuel System
   1. Fuel system structure and operation
   2. Pumps, regulators, injectors
4. Engine Electronic Controls
   1. Identifying different engine parameters
   2. Engine sensor outputs (computer inputs and computer outputs to controls)
   3. Fuel injector control module, relays and regulating devices
5. Scanning
   1. Identification of programmed parameters
   2. Monitoring individual sensor output
   3. System testing
6. Systems Management with a Scanner
   1. Identification of fault codes/system malfunctions
   2. Access fault codes for interpretation of conditions
   3. Identify system or component malfunctions

Prerequisite: Basic Electrical Background

Course Contents

1. Safety
   Mechanics will be able to identify and describe all common safety practices when working on mobile hydraulic equipment.
2. Identifying Parts
   Mechanics will demonstrate the ability to identify all major components by name and function.
3. Schematics
   Mechanics will demonstrate the ability to read and interpret mobile hydraulic and electrical schematics.
4. Pumps vs. Motors
   Mechanics will define the difference between motors and pumps by function.
5. Hydraulic System
   1. Mechanics will demonstrate the ability to describe the sequence of operation in a hydraulic system. (Flow vs. Pressure)
   2. Mechanics will identify common types of hydraulic hoses, fittings, procedures and repair practices.
   3. Mechanics will identify hydraulic fluids, contaminated fluids, burned fluid, aerated fluid and the root causes for defective fluids.
   4. Mechanics will demonstrate the ability to verify and adjust the system pressure and pressure relief settings to manufacturer specifications.
6. Power Systems
   Mechanics will identify and maintain power sources including PTO's, engine mounted clutch pumps and electric/hydraulic power units.

Criteria for Completing the Course

1. Parts Identification & Maintenance
   Given a mobile hydraulic aerial lift, the mechanics will correctly answer any and all questions posed by the instructor related to the function of all components, safety procedures or required PM procedures.
2. Troubleshooting Hydraulics
   1. Given an assortment of defective hydraulic fluids, the mechanics will demonstrate the ability to identify common contaminates.
   2. Given a mobile hydraulic aerial lift with incorrect system pressure or relief pressure, the mechanics will identify the fault, locate the correct settings and bring the system back to manufacturers specifications.

Prerequisite: Mobil Hydraulics Program 1

Course Contents

1. Troubleshooting Hydraulics
   Given a specific set of symptoms on a mobile hydraulic device, the mechanic will demonstrate the ability to identify the specific system failure (for example, the boom does not work)
2. Electrical Maintenance
   Ability to test electrical components and repair or replace defective components including but not limited to coils, slip rings, switches, relays, clutches, batteries, motors, fuse and circuit breakers.
3. Cleaning
   Mechanic will be able to define all areas that need cleaning and demonstrate the ability to perform these tasks.
4. Hydraulics Maintenance
   Ability to test hydraulic components and repair or replace defective parts including but not limited to pumps, directional control valves, hose, fittings, filters, pressure relief valves, counterbalance valves, cylinders, and hydraulic motors.
5. Troubleshooting Breakdowns
   Given specific equipment failures, the mechanics will demonstrate the ability to determine which equipment should be replaced or rebuilt.
   
6. Troubleshooting Circuits
   Mechanics will demonstrate the ability to identify defective circuit boards and replace them.
7. Mechanical Maintenance
   Mechanic will visually inspect the mechanical systems to include, but not limited to gears, gear boxes, cables, control mechanisms, lifting hooks, lift arms, hardware, clutch assemblies, chains, bearings and bucket mounts and will identify obvious deficiencies.
8. Identifying Deformed Parts
   Mechanic will demonstrate the ability to locate suspicious structural deformities that will require additional testing or inspections.
9. Gears
   1. Mechanics will demonstrate the ability to adjust gear lash to manufactures' specifications.
   2. Mechanics will demonstrate the ability to lubricate gearboxes, extension booms, and related equipment to manufactures recommendations.

Criteria for Completing the Course

1. Repairing Electrical Problems
   Given a mobile hydraulic device with common electrical problems, the mechanic will demonstrate the ability to locate and repair the fault following a logical troubleshooting sequence.
2. Repairing Hydraulics
   Given a mobile hydraulic device with common hydraulic problems, the mechanic will demonstrate the ability to locate and repair the defective component following a logical troubleshooting sequence.
3. Repairing Mechanical Problems
   Given a mobile hydraulic device with common mechanical faults, the mechanic will demonstrate the ability to locate , repair or replace the defective component.

Prerequisite: Mobil Hydraulics Programs 1 and 2

Course Contents

1. ANSI Requirements
   Mechanics will be able to identify and describe all ANSI requirements including but not limited to: safety, structural integrity, markings, system protection, and controls.
2. ANSI Inspection Criteria
   Mechanics will be able to list all required components of an ANSI inspection, describe what they are looking for on each component in detail.
3. Performing ANSI Inspections
   Mechanics will demonstrate the ability to perform an ANSI inspection following all required ANSI rules and regulation.
4. ANSI Paperwork
   Mechanics will be able to describe the exact process required of all ANSI paperwork.

Criteria for Completing the Course

1. ANSI Inspection
   Given the ANSI Inspection Forms and a mobile hydraulic unit with 10 ANSI violations, the mechanics will perform an ANSI inspection and locate a minimum of 10 faults.

Prerequisite: Mobil Hydraulics Programs 1-3
Course Length: 6 Hours

Course Contents

1. Repairing Booms
   1. Given an extended and damaged or defective boom, mechanics will demonstrate the ability to locate any and all obstructions and electrical conductors.
   2. Given an extended and damaged or defective boom, mechanics will demonstrate the ability to define a logical physical procedure that will safely secure the equipment with minimal additional damage to the equipment.

Criteria for Completing the Course

1. Troubleshooting
   Given 3 descriptions of defective mobile aerial device problems, the mechanic will define and describe a logical sequence of events that will safety secure the equipment.
2. Follow Up Safety Check
   With each of the completed solutions from the previous criterion, the mechanics will additionally define all equipment checks that must be verified before being put back in service.

Prerequisite: None
Course Length: 12 Hours (lunch/dinner provided)

Course Contents

1. Overview of Anti-lock Brake Systems
   1. Define basic functions of ABS brake system
   2. Interpret ABS warning/indicator lights
   3. Define features that can aid in diagnostics and troubleshooting
   4. Verify wheel speed sensors, ABS valves and ABS lamps
   5. Identify the Electronic Control Unit (ECLT) and describe how it communicates with other components.
   6. Identify the different ABS configurations
2. Review How ABS Controls the Following:
   1. Vehicle stability
   2. Steerability under emergency braking
   3. Stable stopping on icy or rain slick roads
3. Anti-Lock Brake System Components
   1. Define main components of the ABS braking system
4. System Operation
   1. Define ABS system operations, Inputs, Processing and Outputs
   2. Define wheel speed sensors operation.
5. Diagnostics and Repair
   1. Describe how system errors are detected and recorded as fault codes and how the electronic control unit (ECU) responds to errors
   2. Define both ways to diagnose ABS systems
   3. Define error detection, response to methods and control system response to errors
   4. Define fault codes; active faults, stored faults
6. Blink-Code Diagnostics and Fault Analysis
   1. Define and identify fault codes stored in ECU memory,
   2. Access and interpret stored fault codes through the blink- code switch and lamp
   3. Clear fault codes from ECU memory, check ARS system configuration
   4. Define blink code operation parameters, procedures and cycles.
   5. Circuit pinpoint test and procedures using Multi meter to test for resistance at the component
7. Identify and Use MSPI Prolink 9000
   1. Access existing and intermittent faults stored in ECU memory
   2. Identify faulty circuits/components.
   3. Perform functional tests on ABS/ATC components
8. Component Removal and Installation-Safety Warnings:
   1. Front wheel and rear wheel speed sensor replacement, valve replacement and installation
   2. Road test procedures

Prerequisite: None
Course Length: 12 Hours (lunch/dinner provided)

Course Contents

1. Introduction to Cam Brakes
   1. Define different types of foundation brake systems; Q brakes, Q plus brakes, wedge
   2. Define cam brake parts and accessories
   3. Define how cam brakes operate
2. Brake Disassembly
   1. Remove wheel components, tires, brake drums, brake shoes and accessories
3. Prepare Brake Parts for Assembly
   1. Inspect brake parts
   2. Layout brake parts for assembly
4. Brake Assembly
   1. Install all brake parts and accessories removed at disassembly
5. Cam Brake Adjustments
   1. Define Department of Transportation (DOT) requirements for brakes Part 393 and Part 396 Federal Motor Carrier Safety Regulations.
   2. Verify proper brake adjustment
6. Lubrication and Maintenance
   1. Define proper lubrication points and specifications
   2. Define inspection and maintenance procedures
   3. Verify periodic services
   4. Define torque tips
7. Troubleshooting Tips for the Brake System

Prerequisite: None
Course Length: 3 Hours / Maximum 15 participants

Course Contents

1. Federal (DOT) Regulations
   1. Standards
   2. Assuring DOT compliance
   3. OSHA standards
   4. Company policies and procedures
2. Preventive Inspections
   1. Tire, wheel and rim types
   2. Normal and abnormal equipment conditions and wear
   3. Tire, wheel and rim maintenance
3. Preventive Maintenance
   1. Tire inflation

Prerequisite: Phase 1
Course Length: 3 Hours / Maximum 5 participants

Course Contents

1. Equipment Standards
   1. Verifying equipment specifications
   2. Troubleshooting wheels, rims, brakes and tires
   3. Replacing defective components that do not require breaking down the tire
2. Breaking Down and Mounting Tires
   1. Following established procedures
   2. Identifying defective or suspicious equipment
   3. Break down and mount tires
3. Maintaining Equipment
   1. Maintaining tools and the shop in a safe condition
   2. Storing tires and equipment
4. Road Repair Policies and Procedures