how to conduct a professional technician skills competition
Contents
1. wa 5 Fluidleveboillevel Tee _6 Fluid levelantfreeze tte _7 Coolant protection level checked 3f _8 Coolant protection level d2 we g Refractometerused 2 f 10fCricket gauge used Tt 11 What was the belttension 2 tT jj Total assigned points a es ss Continued on reverse Continued from front page PMI Station udges Score Sheet ries and Wheels inspection TTT 1 Check pressures using gauge 2 TT 2 Tread depths at three pointsete 2f jj 3 Foundlooselugnuts TT 4 Checked rims forcracksetc 2 TT Total assigned points je a ss a Wheel Bearing and Kingpin Inspection J o o T _1 Wheel bearing endplay d2 I T S _2 Dial indicator forkingpincheck 2 3 Jackstandunderaxle 3 H H H C Brake Components Inspection T f _1 Checked drums lining thickness 2 _2 Checked brake rod stroke d2 jj Total assigned points a es ss Steering Column Gearbox Suspension S and Steering Linkage Inspection J D oo Y 1 Did tech state lube as neede 2 2 Play in the steering gearbox 2 f 3 Draglink tie rods inspected _ __ 2 4 Suspension springs shocks etc checked 2f LDPE fg o Ld _ End of PMI Update Paperwork T f 1 Told judge need to fit out RO et TT Total assigned points J3 n Workstation Assigned Points 00 jj Bonus Points o o S S S S Total workstation Score T T So S S Elapsed T2. Please provide credit card information on this form as reservations can t be made without a credit card guarantee Room confirmations will be sent to you directly from the assigned hotel upon request All cancellations or changes to arrival departure dates must be made by contacting the hotel directly If TMC s Host Hotel is full you ll be assigned to an overflow hotel If you have any questions call ATA Marketplace at 800 ATA LINE All reservations for arrival must be Arrival Date accompanied by a one night room deposit which will be applied to the first Sept 05 night s stay Any cancellations no shows or early departures without a 72 hour D t Dat advance notice will result in the forfeiture of the one night deposit eparture wate HOTEL DAILY RATES SELECTION Sept 05 must be completed to be registered Radisson Valley Forge Hotel J 119 single J 129 double J 129 double Valley Forge Scanticon Hotel J 119 single l TMC HOST HOTELS L Non Smoking J No Hotel Required Rad son Valley arse ae CREDIT CARD GUARANTEE 1160 First Ave King of Prussia PA 19406 _J Same Credit Card as in Section B Phone 610 337 2000 J Visa J Mastercard J AMEX J Other Valley Forge Scanticon Hotel councn or Card Exp Date 1200 First Ave ef l King of Prussia PA 19406 ATA Signature Phone 610 265 1500 WY TMC OFFICERS General Chairman Treasurer DAVE REHUREK ALCOA Extrusions Vice Chairman Meetings
3. Chairman MARC CLARK FedEx Express Chairman Study Groups BRAXTON VICK Southeastern Freight Lines Chairman Associates Advisory Group TOM CUTHBERTSON GeoLogic Solutions Chairman Membership amp Publicity AL ANDERSON Consolidated Metco Inc Immediate Past Chairman MIKE JEFFRESS Maverick Transportation Executive Director CARL KIRK TMC DIRECTORS REGINA DE BAKER Watkins Motor Lines Inc LEW FLOWERS United States Postal Service ROY GAMBRELL Truck It Inc HERMAN MILLER Shopko Stores Inc DARRY STUART DWS Fleet Management JACK SUKALA J JEB Manufacturing Company OREN SUMMER FleetNet America LLC TMC MEETINGS VALLEY FORGE PA September 19 22 2005 2005 Fall Meeting amp National Technician Skills Competition Valley Forge Convention Plaza TAMPA FL February 14 17 2006 2006 Annual Meeting amp Exhibit Tampa Convention Center AUSTIN TX September 18 21 2006 2006 Fall Meeting amp National Technician Skills Competition Renaissance Austin Hotel COUNCIL OF em A ATA Ww AMERICAN TRUCKING ASSOCIATIONS TECHNOLOGY amp MAINTENANCE COUNCIL PROVIDING TECHNOLOGY SOLUTIONS FOR THE TRUCKING INDUSTRY SUPER rl 005 Dear TMCSuperTech2005 Contestant September 6 2005 The Technology amp Maintenance Council TMC is pleased to welcome you as a contestant for the trucking industry s first ever National Technician Skills Competi tion TMCSuperTech2005 The eve
4. Page 1 of 2 9 Whatis the rear countershaft bearing preload for the Mack T2090 manual transmission A 0 024 0 018 B 0 003 0 007 C 0 002 0 006 D 0 010 0 090 10 What engine oil is recommended on a Ford 7 3L Diesel that is operated repeatedly below 32 F 0 C A 30W B 5W30 C 10W30 D 15W40 11 To test if there is power to the Bendix 3800 Anti Lock Brake System ABS module on a Navistar with air brakes what connector and pin would you check at the ABS module A Connector C412 pin C B Connector C434 pin J C Connector C412 pin B D Connector C443 pin H 12 When adjusting the valves on a Caterpillar 3406E 6 Cylinder engine where is valve clearance measured for the intake valves Where is valve clearance measured for the exhaust valves A Exhaust valves between rocker arm and bridge Intake valves between rocker arm and bridge B Intake valves between rocker arm and bridge Exhaust valves between rocker arm and valve stem C Intake valves between rocker arm and stem Exhaust valves between rocker arm and valve stem D Intake valves between rocker arm and stem Exhaust valves between rocker arm and bridge 13 With a lowest possible ambient outside temperature of 30 F 1 C the approximate fluid Capacity and recommended fluid for the Eaton Fuller FS 8406 manual transmission is A 19 5 Pts 9 23L of Automotive Gear Oil API MT 1 75W B 18 0 Pts 8 52L of Heavy Duty Engine Oil MIL L 210
5. com or by calling TM C offices at 703 838 1763 me ma TMC THANKS THE 2005 CHARTER MEMBER zm len Savus FRIEND OF THE TECHNICIAN SPONSORS A tat PLATINUM WheelT inn LS Ms b antenge 19 GHE irepair fioe WEHA UN Feces Pec EL Ian a oe et E ef ete se ie d 7 a mr 5 pele x Z m r s L k 8 HOW TO CONDUCT A PROFESSIONAL TECHNICIAN SKILLS COM PETITION GEA gt can HOW IS SUPER ORGANIZED REGISTRATION TM CSuperTech registration forms can be found at http tmc truckline com Registra tions forms must be postmarked by a specific date set by TMC Only preregistered contestants are eligible to compete Contestants are sent a confirmation of their registration and housing accommodations in advance of the event CONTEST LOCATION TM CSuperTech events are co located with the Councils fall meeting which is typically held in September October of each year Check with TM C for the latest event schedule CONTEST FORMAT The National Technician Skills Competition and Technician Training Fair is held on M onday Tuesday and Wednesday during TM C s Fall Meeting The Orientation and First Round Written Challenge is held M onday afternoon The First Round Written Challenge is followed by a reception M onday evening at which TMC announces the names of the contestants who have earned the right to compete in Tuesday s Hands on Skills Chal lenge Contes tants with top scores along with verified State Trucking Associ
6. hoses and brake lining thickness 2 points 2 Did the technician check brake rod stroke 2 points G STEERING COLUMN GEAR BOX SUSPENSION AND STEERING LINKAGE INSPECTION The contestant will inspect the steering column including the gearbox all linkage and suspension components explain to the judge proper steps taken and results of the inspection The judge will determine if the technician performed the inspection correctly 1 Did the tech state lubricate suspension steering as needed 2 points Was there play in the steering gearbox 2 points Was the draglink tie rod components inspected 2 points Was the suspension springs shocks shackles and mounts checked 2 points A UN H END OF PM INSPECTION At this point the contestant would fill out the repair order and update any necessary paperwork and explain to the Judge why it s important 1 Told judge the need to fill out repair order and update paperwork 3 points HHH 4 of 4 Car NATIONAL TECHNICIAN SKILLS COMPETITION an UF C SUPER 20 5 Brakes Station Infor mation Sheet Necessary equipment items 13 15 to be provided by PTDC items 16a e to be provided by Snap On Tools A Station 1 DB OW PO 9 10 11 12 13 14 15 16 5 Trailer axles with brakes on training stand 3 from Meritor and 2 from Spicer a 16 5 x 7 brake b Camshaft 28 spline and 1 5 dia c 30 30 long stroke chambers 75 Contestan
7. must the technician know Operation 1 Starting system control circuit operation and testing DVOM usage carbon pile amp IC 2 Operation 2 Electrical resistance measurement DVOM ohmmeter usage Operation 3 Lighting Circuit Operation and testing DVOM usage Operation 4 Measurement Parasitic Load DVOM ammeter usage Describe the skill station What will the technican do Operation 1 25 points Measuring voltage drops in the Starting System s control circuit Operation 2 25 points Measuring the resistance of electrical components Operation 3 25 points Determine cause of problem with a lighting circuit Operation 4 25 points Measure a parasitic load You will be awarded up to 100 points based on your workmanship and professionalism Competitor number Skill Station number Electrical Testing and Diagnosis Skill Preparation Sheet Necessary Equipment Tools 5 DVOM 5 AMP probes 5 Alech 1800 Trainers 6 Computers with ATech Software 5 Sets of electrical component boards 5 Starting systems on boards with problems inserted 5 Carbon Pile Load testers 5 Intelli Check 2 testers 5 Fuse assemblies 5 Test lights Supplies Replacement wire and components for ATech Trainers wire strippers and cutters extra relays Starter boards component board and battery Additional operations comments safety concerns specific instructions etc e Competitors will wear safety glasses while working in the test station at all times e Scorin
8. work bench will be set up as follows a b Ao Da 1 of each Meritor ASA Haldex ASA AA1 or S ABA 1 single hole ASA clevis and 1 double hole clevis Clevis pins and retainers Push rod clevis lock nut Meritor ASA templates Haldex bracket kit Meritor Haldex installation manuals Shop towels Hand tools Tape measure Soap stone marker Contestant instructions and score sheet 2ofe Car NATIONAL TECHNICIAN SKILLS COMPETITION vin Sins PMI Station Infor mation Sheet PMI Workstation Objectives During the PMI workstation task proper safety precautions should be observed Improper safety procedures will count against an individual Contestant will perform the following inspections on the unit In cab inspection Contestant will inspect the DVIR book for write ups and proper sign off and for defects on the systems inside the cab and explain to the judge what was found defective and why it is defective D O T air brake system evaluation Contestant will not start vehicle While in the cab contestant will explain the proper steps on how to perform a D O T air brake system evaluation Steps taken during the evaluation will be explained to the judge Engine compartment inspection Contestant will inspect the engine and other components for defects Inspect for leaks proper fluid levels and protection levels Explain to the judge what was found and why it failed or passed inspection Tires a
9. 4 D 50 C 14 0 Pts 6 6L of Dexron II Automatic Transmission Fluid D 19 5 Pts 9 23L of Eaton Approved Synthetic Transmission Oil 50 14 In the event that the trinary switch on a Peterbilt HVAC system fails to shut the system off properly situated next to the moisture indicator on the receiver drier rests a Safety Switch designed to vent pressure in excess of A 350 psi 24 6 kg cm B 400 psi 28 1 kg cm C 450 psi 31 6 kg cm D 500 psi 35 2 kg cm 15 What is the torque specification of the retarder module bolts marked 6 and 9 on the Allison HD 4070 automatic transmission built after transmission serial number 6610066447 A 38 45 ft lbs 51 61 N m B 18 21 in Ibs 2 0 3 0 N m C 18 21 ft Ibs 24 29 N m D 74 88 ft Ibs 100 120 N m Elapsed Time Judge Page 2 of 2 Car NATIONAL TECHNICIAN SKILLS COMPETITION A Sins Steer ing Suspension Station udges Score Sheet Contestant Total Score out of 100 1 _ Driver Complaint Condition Driver stated that the truck has a harsh vibration during acceleration and a minor vibration during deceleration Cause Problem Correction 2 Driver Complaint Condition Driver stated that the vehicle has a rough ride and is excessively bouncy after driving over a bump Inspect the vehicle and determine the cause Cause Problem Correction Page 1 of 2 3 Driver Complaint Condition Driver stated that steering wheel turns further i
10. 5 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 12 349 6 7 8 9 10 11 12 13 14 15 Engines 41 42 43 44 45 46 47 48 49 50 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Steering Suspension 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Open Rotation 46 47 48 49 50 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 NATIONAL TECHNICIAN SKILLS COMPETITION S cam Brake Station udges Score Sheet m ME TA 2005 Se SUPER Contestant Total Score Task 1 Haldex ASA Allowed Actual 1 Spring brake fully released 5 points 2 Thread engagement of the push rod into the clevis per specifications 5 points 3 Push rod clevis lock nut installed and tightened 5 points 4 ASA installed on camshaft spacer washers and snap ring or e clip installed 5 points 5 Clevis pin and retaining clips installed 5 points 6 Haldex control arm hardware installed 5 points 7 Cam shaft end play within specifications per axle manufacturer Meritor no spec Spicer 0 005 0 025 5 points 8 ASA angle to push rod within specs 5 points 9 ASA brake free play within specs and recorded 5 points 10 CVSA chamber applied s
11. 6 Using the illustrations on the following page identify whether or not differential action taking place in each of the three differentials Complete the blanks with one of the following 2 choices The first one is completed for you NOTE The spinning wheels are spinning at the same speed 1 Action 2 No action Elapsed Time Judge Car NATIONAL TECHNICIAN SKILLS COMPETITION vin nS PMI Station udges Score Sheet Contestant Total Score out of 100 _ Jin Cab inspection sd Value es No Contestant Readings Score _ _1 CUutch Free pay ooo ae o S i 2 cyhom 2 _3 Windshield washers ST _4 Seat Belt Buckle loose o d2 _5 Fire Extinguisher Mount o 2f J T S 6 Dome Light Inoperative S 7 Trailer brake handle loose 2 l _8 Checked DVIR book RTT _9 Passenger side mirror haze _ o 2f l Total assigned points tt Aoo S S S S i DOT Air Brake Inspection Air System Daned 2 Pressure at which light and buzzergooff 3 _3 Air Compressor Build Time TT Cut out pressure of the air governor 3 o DO O oOo o f Cut in pressure of the air governor oa o T fo O O y _6 Drain primary tank secondaryloss 3 _7 Drain secondary tank primaryloss 3 _8 System airea RTT _9 System leak checks Total assigned points te BE Engine Compartment Inspection _ _1jLoose ac bet Tt _2 intake manifold bolts missing 2f o _3 Oilleakrightside of the engine 2 4 Fluid level powersteering 2
12. Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name oOo0oo0oo0oo0oo0oo0o0000000000000000000000000000000000 0N Goo OOO RE QOO oO IK Oooo0oo0oo0oo0oo0000000000000000000000000000000000 O0 LIN las ae a a a a a a a a 0000000000 000000000000000000000 O las ae a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a O las ae a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a O las ae a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a O Oo0oo0oo0oo0oo0oo0o00000000000000000000000000000000000 las ae a a a a a a a 0000000000 0000000000000000000000 O las ae a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a Oo ScooeooooooocooooSeoooooooososoOooooooOooOoO Ooo T OOO OO hols ta OOO H las ae a a a a a a a a a a a a a a a a a a a a a a a a a a a a a las ae a a a a a a a a a a a a a a a a a a a a a a a a a a a a a G G GO GO GG GO GG OO GO O GOGO O GOGO O GO OO GOGO O GOGO OO Average Scores 16 2 1 2 2 2 tt 2 3 ft 2 2 taf 2 2 fo wa gt Technician Contestant Registration SUPERTECH2005 TMC National Technician Skills Competition e Sept 19 20 Valley Forge Co
13. Developed by HOW TO CONDUCT A PROFESSIONAL Professional Technician TECHNICIAN SKILLS Den Development Committee COMPETITION he A Guide to Holding a Technician Contest Based On TMCS National Technician Skills Competition Technology amp Maintenance Council American Trucking Associations Inc S BEPART OF TMC S NATIONAL TECHNICIAN SKILLS COMPETITION INTRODUCTION The Technology amp Maintenance Councils National Technician Skills Competition TM CSuperTech is an annual event held in conjunction with TMC s Fall Meeting The event is organized by TM C s Profes sional Technician Development Committee PTDC TM CSuperTech is North America s premier skills com petition for professional commercial vehicle technicians TM CSuperTech contes tants come from all segments of the trucking industry and many are state re gional or corporate champions Because of the great interest shown by state trucking associations and maintenance coun cils as well as trucking fleets and service dealers TMC has developed this manual to help organizations conduct their own technician skills competitions so that their local champions will be prepared for competition at the national level This document will e describe how TM CSuperTech is organized offer guidelines on how organizations can establish and promote contests at a state regional or corporate level and detail how organizations can ens
14. NAL TECHNICAN SKILLS CLMPETTTICHN SUPER 2005 Monchy Hanc5 On Skills Cheallenge Cortestart Rotation Schedule Sent 19 2005 ROTATION time 1st 8 8 30 1 2 3 4 5 2nd 8 35 9 05 6 7 8 9 10 3rd 9 10 9 40 11 12 13 14 15 Ath 9 45 10 15 16 17 18 19 20 oth 10 20 10 50 21 22 23 24 25 6th 10 55 11 25 26 27 28 29 30 7th 11 30 12 00 31 32 33 34 35 8th 12 45 1 15 36 37 38 39 40 9th 1 20 1 50 41 42 43 44 45 10th 1 55 2 25 46 47 48 49 50 Electrical Electronics Drivetrains 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 1 2 3 4 5 ROTATION time Service Information Open Rotation 1st 8 8 30 26 27 28 29 30 2nd 8 35 9 05 31 32 33 34 35 3rd 9 10 9 40 36 37 38 39 40 Ath 9 45 10 15 41 42 43 44 45 oth 10 20 10 50 46 47 48 49 50 6th 10 55 11 25 1 2 3 4 5 7th 11 30 12 00 6 7 8 9 10 8th 12 45 1 15 11 12 13 14 15 9th 1 20 1 50 16 17 18 19 20 10th 1 55 2 25 21 22 23 24 25 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 1 2 3 4 5 6 7 8 9 10 HVAC 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 3
15. actometer to check the coolant protection level 2 points 4 Did technician use cricket gauge to check belt tension 2 points What was the belt tension 2 points D TIRES AND WHEELS INSPECTION The contestant will inspect the Tire and Wheel assembly s and explain to the judge the proper steps and results of the inspection 1 Did the technician check pressures using air gage 2 points 2 Did the technician check tread depths at three points around the tire with proper gage while looking for matching size tread patterns cuts debris etc 2 points 3 Did the Technician find the loose lug nut nuts 3 points 4 Did the Technician look for cracks or defects in rim assembly 2 points 3 of 4 E WHEEL BEARING AND KINGPIN INPSECTION The contestant will inspect the front end of the unit and inspect king pin for wear and proper wheel bearing endplay The contestant will explain to the judge what steps he is taking and the results of his inspection to the judge The judge will determine if the contestant accurately performed the inspection 1 Did the technician get the proper endplay readings Should be 001 005 2 points 2 Did the technician use dial indicator for measuring king pin wear 2 points 3 Did the technician use proper safety procedures jack stands 3 points F BRAKE COMPONENTS INSPECTION Contestant will inspect brake components and explain results to the Judge 1 Did the technician check the drums
16. al event TMC does not announce individual scores of contestants nor does it publish a list of all scores after the contest Individual competitors may call TMC for their own scores after the event is concluded RECOM MENDATIONS FOR ESTABLISHING A STATE REGIONAL CORPORATE TECHNICIAN SKILLS COMPETITION M any state trucking associations maintenance councils service dealer operations and individual fleets have expressed strong interest in either establishing a new or modeling an existing technician skills competition based on the TM CSuperTech model In this way their champions will be best prepared to compete at the national level for the TMC event Establishing a technician skills competition is a challenge TMC leveraged the work of established student competitions such as the SkillsUSA annual event as well as that of pioneering state trucking associations and individual fleets that had already established events on their own The following guidelines should be useful to organiza tions wishing to hold their own technician skills competition 1 Volunteer support is key to establishing a successful technician skills competition Few organizations have the economic means to organize and execute a successful technician skills competition without the use of volunteer support Those that do are likely to run into many problems without buy in from their local fleets vendors and trainers Itis best to establish a core group of commit
17. an s proficiency at navigating electronic service information Local fleets are an excellent source of vehicles for the Hands on Skills Challenge portion of the competition If room and resources permit at least some of the skills challenge stations Should feature actual vehicles to H assess technician ek proficiency ina T particular area mam especially engines heating air conditioning and preventive maintenance inspection The success of each skills station lies largely with the volunteers who plan and organize them Whenever possible encourage industry suppliers to sponsor a skills station through donated personnel tools equipment or financial resources HOW TO CONDUCT A PROFESSIONAL TECHNICIAN SKILLS COM PETITION HOW TO CONDUCT A PROFESSIONAL TECHNICIAN SKILLS COM PETITION SAMPLE FORMS This section offers sample forms as a guideline for establishing your own event s operating forms These were used for TM CSuperTech2005 SAMPLE CONTEST SCORING SHEET SuperTech scoring scoring eres No Name S lele ELLE Points soore Contestant name 99 Al Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name O oo AAA BPW NY Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name Contestant name
18. at the 28 minute mark 2 If you complete the objectives prior to the expiration of time remain at the station 3 Once the total station time has expired return to the main table and be seated No conversing with other contestants If you have questions ask the station judge Questions will be answered by the judge only if they relate to skills procedures and not to specific details of a test question or task Oo O A Station objectives A The contestant will be required to correctly identify each component of the inter axle differential The contestant will provide the station judge with written response on the skills test sheet B The contestant will be required to correctly assemble the IAD to reflect its proper assembly in the forward carrier The contestant will signal the station judge after assembly the judge will then visually determine accuracy of the assembly C The contestant will be required to correctly describe in writing the power flow through the IAD assembly The contestant will provide the station judge with written response on the skills test D The contestant will be required to identify whether or not differential action is taking place in each of the three differentials of a tandem axle set when provided with different wheel spin scenarios Car NATIONAL TECHNICIAN SKILLS COMPETITION re dk ONS Electrical Station Infor mation Sheet SUPE Main concept of this skill station What
19. ation Grand Champi ons are eligible to compete in the Hands on Skills Challenge begin ning on Tuesday at 8am All contestants are eligible to attend the PTDC Techni cian Training Fair sessions on Wednesday Competition awards are presented at an awards event on Wednesday evening HOW TO CONDUCT A PROFESSIONAL TECHNICIAN SKILLS COM PETITION PROPER ATTIRE All contestants must wear work appropriate long pants and work shoes meeting accepted industry safety standards Official contes tant caps and T shirts are provided during contestant orientation Other safety related items such as protective eyewear are provided by TMC on an as needed basis at each skills station TM CSuperTech judges also have official attire that makes them easy to identify SAFETY Safety glasses with side shields provided by TMC must be worn at all times during the Hands on Skills Challenge Standard shop safety procedures must be followed at all times All spills must be cleaned up immediately Any accident or injury must be reported to the section judge CONTESTANTS WITH SPECIAL NEEDS Every effort is made to accommodate contestants with special needs These needs must be identified on the contest registration form prior to competition TOOLS AND PARTS All tools manuals and equipment are provided by competition organizers SCORING The competition is designed to measure thorough knowledge of medium and heavy duty co
20. ations Inc ATA 2 Both as to myself and my heirs and personal representatives release TMC ATA its directors employees agents and or any of its affiliates from any and all liability and any right of action that may arise from any damage or injury which may receive while attending or participating in said TMC National Technician Skills Competition TMCSuperTech2005 3 grant TMC ATA and its designated agencies exclusive rights to make use of information about myself along with photographs subsequently taken under TMC ATAS direction in publicity and advertising activities further agree to make myself available for publicity enterprises arranged by TMC ATA with newspaper magazine media writers and radio and television personnel 4 will be bound by all orders rules and regulations governing TMC s National Technician Skills Competition TMCSuperTech2005 while participating in said competition CERTIFICATION BY CONTESTANT certify that am currently employed as a commerical vehicle technician Signature Date PAYMENT INFORMATION I wish to register as shown in the Fees Section of this form Payment method is checked below D Payment enclosed US funds payable to American Trucking Associations Inc Charge CJ VSA CJ MASTERCARD LI AMEX THIS AMOUNT Card Number Expiration Date Signature HOTEL HOUSING POLICY TMC s Host Hotels will not accept room reservations directly from meeting attendees
21. ck and record the stroke in inches on the score sheet When complete the contestant will call for the judge to score the first task The contestant will install the second ASA adjust the brake check and record free stroke and conduct a CVSA chamber applied stroke check and record the stroke in inches on the score sheet When completed with the second ASA the judge will again be called over to score the second task Once scoring is complete on both tasks the contestant will remove the ASA s and related components and place them on the work table VEEG NATIONAL TECHNICIAN SKILLS COMPETITION CIDER 0005 Electrical Station Contestant Worksheet Contestant Total Score out of 100 Operation 1 Measuring voltage drops in the Starting System s control circuit The problem the driver of this vehicle has been reporting is the starter does not always engage when he attempts to start the vehicle Please perform a voltage drop test on the control circuit Record the voltage drop of all three parts of this circuit Note You may refer to TMC s RP 129 Operation 2 Measuring the resistance of electrical components Record the values Please measure and record the resistance value of each of the eleven items on this board Test leads should be connected to each side on the solder You must write the exact value you record to receive full credit This means you must include all zeros One on the items is a diode Please identify the locati
22. ds 5 points ee 5 Check all air modes 5 points OO 6 Performance test Check for symptoms by sight leaks mounting APADs 5 points Check high and low pressures 5 points Compare to performance chart 5 points Check temperature and air flow 5 points Compare to performance chart 5 points Check lines for hot and cold 5 points 7 Check compressor clutch symptoms by sound 5 points Check voltage 5 points 8 Verify complaint Does A C clutch operate properly 5 points e Is air cold enough 5 points 9 Safety 5 points 10 Troubleshooting Recognize amp properly test system fault 5 points Properly repair system fault 5 points Recognize amp properly test electrical fault 5 points Properly repair electrical fault 5 points Elapsed Time Judge FHA AT ee evt Oe SUPER 2005 NATIONAL TECHNICIAN SKILLS COM PETITION Electrical Station udges Score Sheet Contestant Total Score out of 100 1 Measuring voltage drops in the Starting System s control circuit 25 pts Elapsed Time Disconnect s terminal 5 points Draw 80 amps 5 points Voltage drop of leg 1 5 points Voltage drop of magnetic switch disc 5 points Voltage drop of leg 2 5 points Measuring the resistance of electrical components 25 pts Component 1 2 points Component 2 2 points Component 3 2 points Component 4 2 points Component 5 2 points Component 6 2 points Component 7 2 points Component 8 2 poi
23. ember for whom you are substituting Other wise you will be charged the non member rate Please print clearly My Company Is J Motor Carrier U Private Fleet L Municipal Fleet LU Service Dealer L Lam a Technician Champion from a State Trucking Association contest State Year I have been employed as a professional technician in the trucking industry for years REFUND POLICY If your plans to attend the TMC meeting change you may receive a re fund less a 50 administration charge up until August 30 2005 There will be no refunds or credits after August 30 2005 Written cancella tions accepted by mail fax or email tmc trucking org If you require special assistance or dietary needs during your stay contact both TMC and your selected hotel 2200 Mill Road e Alexandria VA 22314 Phone 703 838 1763 s http tmc truckline com Q Check here if you want this address used to update your membership record Copy form for additional registrants ATTENDEE INFORMATION Full Name Nickname for Badge Title Company Address City State Zip Telephone Fax Number Email AGREEMENT AND RELEASE In consideration of my being permitted to participate in TMC s National Technician Skills Competition TMCSuperTech2005 and be eligible for awards offered to participants hereby stipulate and agree to the following 1 acknowledge that am not in the employ of American Trucking Associ
24. ems inside the cab Explain to the judge what was found defective and why it is defective The judge will document all the following on the answer sheet did the technician find all the bugs planted were the explanations correct did the technician do a thorough inspection Induced defects in the cab are No free play in clutch pedal 2 points City horn inoperative 2 points Windshield washers inoperative 2 points Seatbelt buckle assembly loose on drivers seat 2 points Fire extinguisher not mounted to unit 2 points Dome light inoperative 2 points Trailer brake valve handle loose 2 points Checked DVIR book for prior and current write ups sign off 3 points Passenger side mirror hazy 2 points O GO l O Qn E G M B D O T AIR BRAKE SYSTEM EVALUATION WARNING DO NOT START VEHICLE While in the cab the contestant will explain how to perform a brake system evaluation Steps taken during the evaluation will be explained to the judge The judge will determine if the responses given are accurate and if proper sequence of the test was followed 1 Drain system observe that the low air warning buzzer and light are on allow air pressure to build 3 points 2 As the air pressure builds when does the light and buzzer go off 60 75psi 3 points 3 Observe the air compressor build up time System should build air from 80 100psi in less than 40 seconds 3 points 4 Observe the cutout pressure of
25. ft 6 Referring to the power flow section how many gearsets are being used in 3 gear in a 13 speed Note One gearset equals three mating gears Di None Straitughbugthe Box E 2 F 3 G 4 Elapsed Time Judge mm NATIONAL TECHNICIAN SKILLS COMPETITION a 2005 Drivetrain 2 Station udges Score Sheet ag UF SUPER Contestant Total Score out of 100 Drive Axle Station IAD Component Identification assembly and operation scoring sheet 1 Using the inter axle differential assembly from a forward carrier identify each component of the inter axle differential Write in your answers below ltem A ltem B Item C ltem D ltem E 2 Assemble the components onto the IAD stand 3 Using the inter axle differential assembly from a forward carrier trace the power flow through the assembly Conditions are normal driving conditions IAD unlocked Start with the first component receiving torque and finish with the last component delivering torque Write in your answers below 15 component 2 component 390 component 4 component 4 Using the inter axle differential assembly from a forward carrier which two components are delivering torque equally Write in your answers below 1 2 5 Using the inter axle differential assembly from a forward carrier answer the following questions a Which one component drives the rear drive axle b Which one component drives the forward drive axle
26. g criteria is included on the score sheet award points only as directed e Judges must become familiar with the workstation instruction sheet work sheet score sheet and the reference materials e Judges must watch the competitor closely to check DVOM readings and values are recorded for each reading Ean NATIONAL TECHNICIAN SKILLS COMPETITION CIDER 2005 Brakes Station Worksheet Contestant instructions 1 You will have 30 minutes to complete the stated objectives below There will be an audible announcement given at the 15 minute mark and at the 28 minute mark 2 If you complete the objectives prior to the expiration of time remain at the station 3 Once the total station time has expired return to the main table and be seated 4 No conversing with other contestants If you have questions ask the station judge Questions will be answered by the judge only if they relate to skills procedures and not to specific details of a test question or task Ol Station objectives Given the choice of 2 automatic slack adjusters Meritor and Haldex the contestant will correctly install and set up the two ASAS Correct installation will be judged per the manufacturer s procedures TMC Recommended Practices and or the Commercial Vehicle Safety Alliance procedures The contestant will install and set up the first chosen ASA adjust the brake check and record free stroke and conduct a CVSA chamber applied stroke che
27. ils Station starting condition 1 Each work bench will be set up as follows 5 inter axle differential components disassembled Training stand Contestant instructions and skills test Meritor parts book PB 9147 Meritor maintenance manual MM 5L oa Judge responsibilities 1 2 3 4 Cc Remain sitting at each station during the test Be available to answer questions from the contestant Questions will be answered only if they relate to station procedures and not to specific details of a test question or task Arrange tools and manuals in a predetermined order prior to each new contestant entering the station for consistency Score contestant tests on the Judges Score Sheet after completion and return to the station chairman throughout the day Do not do anything that may distract the contestant during their test Do not physically assist the contestant during the skills test If you need help or have questions ask the station chairman At the end of the 30 minute skills test collect the skills test from the contestant and direct that contestant to the chairman s table Car NATIONAL TECHNICIAN SKILLS COMPETITION rx atrain Nr ma 2005 Drivetrain Drive Axle Station Infor mation Sheet SUPE Contestant instructions 1 You will have 30 minutes to complete the stated objectives below There will be an audible announcement given at the 15 minute mark and
28. ime Judge Car NATIONAL TECHNICIAN SKILLS COMPETITION CIDER RC PMI Station J udges Instructions All safety precautions are to be observed during the assigned task The vehicles will not start and all contestants must be informed that the areas where the vehicle would be running under normal testing will be VERBAL only LE contestant will verbally explain inspection procedures Wheels chocked Safety glasses Gloves where appropriate Ear protection where appropriate Jack stands in place lf the proper safety precautions are not used stop the task until the problem is identified and corrected The contestant will have one chance to correct any safety infraction If the problem is not corrected then stop the contestant from proceeding with the task At the PMI workstation the contestant will be provided a vehicle and all tools etc to complete the required inspections Contestant will perform the following inspections on the unit SCORING Each skills test section will be scored as noted Potential assigned task points will be 100 points Individuals completing all of the assigned tasks and scoring 100 will receive 10 additional bonus points WORKSTATION TOOLS Bottle jack Jack stand Dial indicator and magnetic base Cricket gauge Refractometer Required hand tools Disposable Shop towels Antifreeze gauge 1 of 4 A IN CAB INSPECTION The contestant will inspect the DVIR book and inspect for defects on the syst
29. ion chairman IH i j PRIZES All contestants will receive an official TM CSuperTech cap T shirt certificate of participa tion and a gift bag provided by competition sponsors Grand Champion The First Place Grand Champion receives his or her choice of a trip to the Daytona 500 NFL Super Bowl or equivalent package along with other valuable prizes A special trophy engraved with the Grand Champions name is provided to the individual winner A companion plaque is presented to the Grand Champion s company as well The names of all Grand Champions appear on a special TM CSuperTech banner which is displayed at all TM C general meetings Second Place The Second Place winner will receive a trophy and special prize package Third Place The Third Place winner will receive a trophy and special prize package Skills Challenge Station Winner s Individuals with the highest scores at each individual Hands on Skills Chal lenge station will also receive certifi cates of recognition UDGING GUIDELINES J udges consist of volunteers who are recognized experts within each contest area The number of judges required will vary depending on the nature of the station but one judge per station would be an absolute minimum One judge per contestant would not be unheard of for a larger event Each Skill Station Evaluation Sheet and Task Is prepared by individual contest chairmen and each Station s committee Point assessment f
30. is the maximum water pump bearing bore diameter allowed before water pump body replacement is necessary A 1 3970 1 3980 B 1 4500 1 4510 C 1 4970 1 4980 D 1 5970 1 5980 Where is the Electronic Control Module located on a Freightliner Conventional and Cabover A Under drivers seat B Left rear of engine C Right rear of engine D Under center of instrument panel At what interval does the manufacturer recommend adding coolant extender to a Caterpillar 3406E that is using long life coolant A 100 000 miles or every year B 150 000 miles or every 2 years C 200 000 miles or every 2 years D 300 000 miles or every 3 years What is the maximum brake chamber force specification for Dana Spicer ES D 225 air disc brakes A 2125 ft los 2881 N m B 3500 ft lbs 4745 N m C 3125 ft lbs 4237 N m D 2500 ft Ibs 8389 N m On a Volvo VE D12 6 cylinder engine when installing the cylinder liners how far above the block should the sealing surface be A 0 0080 0 0085 0 20 0 26 mm B 0 003 0 005 0 08 0 13 mm C 0 0 mm D 0 0059 0 0078 0 15 0 20 mm What is the torque spec for the adjuster cap screw on a Rockwell automatic slack adjuster A 15 20 ft lbs 20 27 N m B 10 15 ft lbs 14 20 N m C 15 20 in lbs 1 7 2 3 N m D 25 30 ft Ibs 84 41 N m What is the Rotor Coil Resistance Specification for a Leece Neville 3625JC Series Alternator A 2 0 2 2 Ohms B 3 0 3 3 Ohms C 1 9 3 7 Ohms D 2 9 3 7 Ohms
31. l systems including charging lighting and cranking systems Brakes Troubleshoot service and repair of brake systems e HVAC Test service and repair air conditioning and heating sys tems including laws governing refrigerants and all other compo nents dealing with the operator s environment HOW TO CONDUCT A PROFESSIONAL TECHNICIAN SKILLS COM PETITION Engine Troubleshoot service and repair engine induction fuel and exhaust systems under load and or unloaded conditions Steering Service and repair of steering and suspension systems Preventive Maintenance Inspection PM I Demonstrate ability to perform preventive maintenance check procedures Drivetrain Troubleshoot service and repair drivetrain units including transmissions clutch carriers torque converters and driveline Service Information Demonstrate ability to retrieve service information from current accepted industry sources Thirty minutes are allotted to each cycle Orientation instructions and task completion will occur within this time allotment At the end of 30 minutes with appropriate signal contestants are escorted to next contest within rotation NOTE The time allotted to each station will vary depending on the number of stations and the number of contestants It is a good practice however to limit the number of contestants that can proceed from the written challenge to the hands on challenge to ensure the competition proceeds as smoothl
32. mmercial vehicles including both theory and practical application The mandatory First Round Written Challenge consists of a written test covering the eight competition areas The test is based on tests prepared by the National Insti tute for Automotive Service Excellence ASE The written test score counts for 20 percent of the final competition score A limited number of contestants advance to the Hands on Skills Challenge consisting of verified State Trucking Association Grand Champions who auto matically qualify for the Hands on Skills Challenge plus those who scored high est in written competition Ties on the written test are broken by the highest score on specific categories of questions to be determined previously by the TM CSuperTech competition chairman Scoring on the hands on portion of the competi tion is tabulated by monitors using a detailed station score sheet developed by the station technical committee udging scores reflect an assessment of technical skills and knowledge accuracy and quality of workmanship Scoring for each of eight individual workstations is based on 100 points and counts for 10 percent of the final competition score Workstation scores are transferred to a master score sheet and totaled with the written score to obtain the contestant s final score Ties in final score are broken by the highest score In specific workstation categories as predetermined by the TM CSuperTech com petit
33. mportant IF THE TECHNICIA outreach effort as it helps engender in the students the pal professionalism of our industry lt etc to attend and cover the event This is an excel lent opportunity to get the message out about your competition event and technician professionalism to a broader audience ment officials to attend Better yet invite them to participate in the event as judges or organizers For more information please feel free to visit our website Steve Talmadge at http tmc truckline com or call TMC offices at 703 838 E TMCSuper Tech2005 Grand Champion The written challenge is an important part of the overall Making the technician contestants feel welcome and competition for two reasons First it allows competition appreciated should be an important goal At organizers to narrow the field down to a manageable size TMCSuperTech2005 all technicians who qualified for the Second it provides an excellent means of settling tie scores Hands on Skills Challenge received a welcome package of during the hands on portion of the competition donated gifts along with their competition uniform e a eig ea e i U Fa en al al a d n in a a hd y b P E Bann T 79 lat er ii B E a F H k L 7 T L Y Ye b k a 7 e ou Computer skills are absolutely necessary for today s vehicle technician TM CSuperTech2005 featured a Skills station pictured right aimed at assessing a technici
34. n one direction than the other Inspect the vehicle and determine the cause Cause Problem Correction 4 Driver Complaint Condition Driver complains that truck pulls to the right and the steering wheel shakes excessively Perform the correct tie rod end procedure with the tools provided and determine if the tie rod end is the cause Cause Problem Correction Elapsed Time Judge Page 2 of 2 Cl PTD O NATIONAL TECHNICIAN SKILLS COM PETITION CIDER 2005 Drivetrain 1 Station udges Score Sheet Contestant Total Score out of 100 Using the Service Manual provided at this station complete the following task and questions Circle the correct answer on questions 2 thru 6 1 Completely assemble the RTLO 16718 Shift Bar Housing Circle the correct answer on questions 2 thru 6 2 In the following nomenclature what does the 9 represent RTLO 20913A A Design Level Improved Seal System B Ratio Set C Number of Forward Speeds D Nominal Torque Capacity 3 What is the correct torque value for the shift yoke lockscrews A 20 25 lb ft B 8 12 lb ft C 35 45 lb ft D 18 22 lb ft 4 The filter regulator assembly regulates the air pressure to A 38 43 PSI B 58 63 PSI C 48 53 PSI D 68 73 PSI 5 Once the shift bar housing is installed on the main case the capscrews should be torqued to the following value 2505 LDP Ee A 35 45 lb ft B 45 55 lb ft C 55 65 lb
35. nd wheels inspection Contestant will inspect the Tire and Wheel assembly s and explain to the judge the proper steps and results of the inspection Wheel bearing and kingpin inspection Contestant will inspect the king pin for wear and for proper bearing endplay The contestant will explain the steps taken and the results to the judge Brake component inspection Contestant will inspect brake components and explain results to the Judge Steering column gear box suspension and steering linkage inspection Contestant will inspect the steering column including the gearbox all linkage and suspension components Explain to the judge proper steps taken and results of the inspection End of PM inspection At this point contestant would fill out the repair order update any necessary paperwork and explain to the Judge why it s important Gar NATIONAL TECHNICIAN SKILLS COMPETITION A Sins Drivetrain Drive Axle Station Infor mation Sheet Necessary equipment items 6 8 to be provided by PTDC A Station 1 ONOOARWD 6 sets of inter axle differential components a Input shaft IAD assembly forward side gear rear side gear clutch collar 75 Contestant Instructions and Skills Tests 6 Rear Drive Axle Maintenance Manuals 6 Rear Drive Axle Parts Books 6 IAD training stands 6 work benches 1 group meeting table chairman s table 10 chairs B Contestant a Safety glasses b Safety shoes c Penc
36. nt which is being organized by TMC s Profes sional Technician Development Committee PTDC promises to be challenging festive and informative We re very glad to have you with us for this inaugural event Enclosed with this letter please find a copy of the TMCSuperTech2005 regula tions along with some background about the meeting itself Our event is being held at the Valley Forge Convention Plaza in Valley Forge Pa Sept 18 20 The orienta tion and written exam takes place Sunday afternoon Sept 18 from 4 6 pm Plan to arrive by at least 3 pm to pick up your credentials in time for the written exam Our 50 finalists will be named Sunday evening at 6 30 pm during our TMCSuperTech2005 Reception The Hands on Skills Challenge for the 50 finalists will be held on Monday Sept 19 from 8 am 4 pm The winners will be announced during our Industry Awards Luncheon Sept 20 which will be held from 11 30 am 1 30 pm All contestants are also invited to attend our TMC Technician Training Fair Mon day evening and Tuesday morning The Fair is free of charge to all contestants Should you have any additional questions please feel free to call me directly at 703 838 1776 On behalf of TMC good luck and see you in Valley Forge Sincerely Robert Braswell TMC Technical Director Enclosures 2200 Mitt ROAD ALEXANDRIA VA 22314 5388 703 838 1763 FAX 703 684 4328 s E MAIL tmc trucking org HTTP TMC TRUCKLINE COM NATIC
37. nts Component 9 2 points Component 10 2 points Component 11 2 points Diode 2 points Diode Scale 1 point Determine cause of problem with a lighting circuit 25 pts Volt drop measurement 2 points Source voltage 2 points Resistance measurement 2 points Logical approach 2 points High resistance ground bulb 17 points Measure a parasitic load 25 pts Remove the battery cable 5 points Insert the ammeter in series between the battery and removed cable 5 points Measure and record the amp load 5 points If the technician uses the 300m amp scale 5 points If the technician used the fuse assembly first 5 points Judge EEE NATIONAL TECHNICIAN SKILLS COMPETITION han UF SUPER ty 9005 Service Information Station udges Score Sheet Contestant Total Score out of 100 Directions To demonstrate your ability to retrieve service information from currently accepted industry sources read each Heavy Truck related question carefully then using one of the PC workstations locate the appropriate service information and then circle the correct answer Each question answered correctly is worth 10 points for a total possible of 150 points Note All questions shall be answered using the Systems button only 1 On a Delco Remy 37MT Starter what is the pull in winding voltage for a Model No 1115595 24V solenoid A 20 Volts B 5 Volts C 10 Volts D 7 5 Volts Upon disassembly of a water pump on a Detroit Diesel 8 2L V8 what
38. nvention Plaza Valley Forge PA REGISTRATION IN Check here if you are a first time attendee BY FAX Fax this form with credit card information to 703 838 5978 BY MAIL Mail this form with check money order or credit card information to ATA Meeting Registrations PO Box 25381 Alexandria VA 22313 5381 ONLINE http tmc truckline com CONTESTANT REGISTRATION FEES Fees include competition entry access to PTDC Technician Training Fair and all PTDC food functions receptions Fee also includes TMC Technician Membership for balance of 2005 NOTE Contestants must register by Aug 15 2005 to compete in TMCSuperTech2005 CONTESTANT REGISTRATION J TMC Technician Member FREE L Technicians Non member 75 NON CONTESTANT REGISTRATION Those technicians who do not wish to register as a TMCSuperTech2005 Contestant may register separately for the PTDC Technician Training Fair according to the follow ing registration fee schedule PTDC Technician Training Fair Sept 19 20 D 1 day TMC ATA Member 50 D 1 day Non Member 75 J 2 days TMC ATA Member 95 D 2 days Non Member 140 NOTE Non contestants may register at anytime up to the day of the event Substituting for a TMC Member You must be a TMC Member to receive the TMC Member rate Non members from a TMC Member company however may substitute for a TMC Member ifhe or she cannot attend To substitute for another member please print the name of the m
39. of electrical systems including charg ing lighting and cranking systems Specific Challenge Using a Fluke 88 meter the contestant will measure and record readings and diagnosis circuits The workstation will use A Tech training boards Brakes Troubleshoot service and repair of brake systems Specific Challenge Given a heavy vehicle axle with S cam brakes the contestant will correctly perform maintenance tasks per the given instructions No special tools will be used HVAC Test service and repair air conditioning and heating a systems including laws governing refrigerants and all other gi a components dealing with the operator s environment ETE Specific Challenge Contestants will be required to evaluate it and diagnosis electrical and functional aspects of the air condi tioning unit Engine Troubleshoot service and repair engine induction fuel and exhaust systems under load and or unloaded conditions Specific Challenge The engine station will utilize trucks with Detroit Diesel Series 60 EGR engines The technician must be able to navigate a computer with Detroit Diesel Diagnostic Link DDDL in order to complete the required repair assignment Steering Service and repair of steering and suspension systems Specific Challenge Contestant will be required to inspect measure and deter mine steering suspension concerns Preventive M aintenance Inspection PM I Demonstrate ability to perform preven tive main
40. on of the diode ltem 1 ltem 2 Item 3 ltem 4 ltem 5 ltem 6 ltem 7 ltem 8 ltem 9 ltem 10 Item 11 1 of 2 Electrical Station Contestant Wor ksheet continued Operation 3 Determine cause of problem with a lighting circuit Record your findings of your tests Location of fault Component number Type of fault Operation 4 Measure a parasitic load The starter board has a parasitic load load that is constantly drawing current that is drawing current out of the battery Please use the appropriate tool to determine the exact amount of parasitic load Please ensure you do not exceed the capacity of the meter Load HHH 2 of 2 OUP eT EG Technology amp Maintenance Council American Trucking Associations Inc 2200 Mill Road Alexandria Va 22314 703 838 1763 703 684 4328 FAX http tmc tr uckline com
41. or each task is specifically listed as part of each contest evaluation sheet to easily gauge contes tant ability Points are totaled by the individual contest chairman or assigned individual The maximum score for each station is 100 points Task values are broken down as much as possible to enable objective judging udg ing sheets are color coded per station Contestant questions regarding individual issues are brought immediately to the attention of the appropriate contest chairman Should personal professional recog nition of contestant be known by a judge that judge is to be recused and replaced with another judge for that contestant evaluation procedure The judge can resume normal responsibilities after that contestant has finished specific evaluation SKILL STATION GUIDELINES TMC Competition Skill Challenge Stations cover various skill areas The actual stations will vary from year to year and state regional corporate contests need not hold all the stations that TM C holds each year The number of volunteers and resources available usually will determine how many stations can be practically held The following is list of stations that were held during TM CSuperTech2005 and what was evaluated at each station Day One e First Round Written Challenge ASE based test determines the finalists for the Hands on Skills Challenge Day Two Hands on Skill Challenge s Electrical Troubleshoot service and repair of electrica
42. sociation or maintenance council service dealership motor carrier or private fleet It is a good idea to get participation from a diverse group of manufacturers and vendors trade press trade schools and educators as possible Offer sponsorships to suppliers and other organizations to help defray the cost of the competition Sponsorship opportunities can cover food functions setup costs entertainment etc Typical sponsorship recognition opportunities can Include corporate logos on event banners signage competi tion apparel T shirts hats official programs etc state trucking associations hold their technician skills challenge EMD OF THE TECHNICIAN in association with their truck driving championships This will SPONSORS help mitigate much of the cost associated with holding a separate event the event starts This will help solve potential problems before they can begin Have them sign a competition agreement and gr release The following is an example from TM CSuperTech2005 er P raed L o Sample Agreement and Release In consideration of being permitted to participate in TM C s National Technician Skills Competition TM CSuperTech2005 and to be eligible for awards offered participants hereby stipulate and agree to the following a Contestant acknowledges that he or she is not in the employ of American Trucking Associations Inc ATA b Both as to himself or herself and his or her heirs and personal representa
43. t Instructions and Skills Tests 6 Meritor Trailer Axle Maintenance Manuals MM 14 6 BSFB Cam Brake Maintenance Manuals BW7258 6 Haldex ASA Maintenance Manuals L30033HBS of BW7257 6 Meritor ASA templates of each color for a total of 30 Tan brown yellow green and white 6 Meritor automatic slack adjusters 28 spline 1 5 dia 5 5 length 6 Haldex automatic slack adjusters 28 spline 1 5 dia 5 5 length 6 Single hole clevises 5 8 x 18 thread 6 Dual hole clevises 5 8 x 18 thread Assortment of camshaft selective washers snap rings and E clips Assortment of clevis pin retainers both small and large 7 6 or 8 group meeting table 10 chairs 120 psi air drop Hand tools one 1 for each axle 5 total a Combination wrench set to include 5 16 7 16 Q 9 16 b Standard needle nose and side cutter pliers c Snap ring pliers set d Soap stone marker e Rule tape measure B Contestant 1 of 2 Brakes Station Information Sheet continued a Safety glasses and shoes b Pencils Station starting condition 1 Each trailer axle will be set up as follows d h D G C O 16 5 x 7 inch brake including all hardware and camshaft installed Cast brake drum installed Long stroke 30 30 air chamber installed ASA spacer washers and snap ring or e clip removed ASA clevis and push rod clevis lock nut removed Haldex control arm bracket removed 2 Each
44. ted volunteers in an officer or oversight committee format This committee should consist of a e Chairman to oversee the entire operation e Vice Chairman to support the Chairman e Competition Chairman to ensure proper logistical organization of the skills stations and contest preparations such as making sure each station has the vehicles tools and materials needed to function e Rules and Judges Chairman to establish the contest rules and ensure there are NJ LJ Hold the competition in conjunction with an existing event Some Be sure the technician competitors are aware of the rules before HOW TO CONDUCT A PROFESSIONAL TECHNICIAN SKILLS COM PETITION enough volunteer judges to run the competition e Promotions Chairman to focus on promoting the event to fleets service dealers vendors etc e Prize Chairman to solicit and manage the prize packages for winners e Sponsorship Chairman to help solicit funding for the competition food and beverage entertainment and other expenses e Secretary to keep everyone aware of what actions are taken i e press Depending on how large the competition will be this committee structure may need to be adjusted For smaller events one person may perform multiple tasks Building partnerships between all industry segments is important Involving repre sentatives from all industry segments is important whether the establishing organi zation is a state trucking as
45. tenance check procedures Specific Challenge Contestant will perform a PM I ona provided unit in specific areas to be revealed during the Hands on Skills Challenge Drivetrain Troubleshoot service and repair drivetrain units including transmis sions clutch carriers torque converters and driveline Specific Challenge The contestant will be required to correctly identify each component of the inter axle differential IAD and correctly assemble the IAD to reflect its proper assembly in the forward carrier Using appropriate service reference material at the workstation the technician will respond to questions and perform some minor assembly on subcomponents from a manual transmission and a front differential Service Information Demonstrate ability to retrieve service information from Current accepted industry sources Specific Challenge The contestant will be required to answer questions using Mitchell One electronic information system HOW TO CONDUCT A PROFESSIONAL TECHNICIAN SKILLS COM PETITION AFTER THE CONTEST IS OVER All contestants are invited to attend any of the special training sessions as part of TMC s Technician Training Fair The awards ceremony for TM CSuperTech is held on the third day of the event All contestants are invited to attend TMC attempts to combine the awards ceremony with either its existing Industry Awards Luncheon Program or if that is not practical then the Council s group soci
46. the air governor Cutoff between 120 135psi 3 points 5 Bleed off air and observe governor cut in pressure Should be 20 psi between cut in and cut out pressure 3 points 6 Check air tank check valves unit at max pressure drain primary tank Does the secondary tank lose pressure Should not loose any 3 points 2 of 4 7 Build air and repeat steps drain secondary tank Does primary tank loose pressure Should not loose any 3 points 8 Build air to max in unit shut off unit and check for air leaks No more than 4 psi in two minutes 3 points 9 Release parking brake then apply foot valve let system stabilize and check for leaks No more than 6 psi in two minutes 3 points C ENGINE COMPARTMENT INSPECTION The contestant will inspect the engine and other components for defects inspect for leaks proper fluid levels and protection levels Contestant will explain to the judge what was found and why it failed or passed the inspection The judge will determine if the induced defects in the engine compartment were detected 1 Were all bugs found in engine compartment Loose a c belt 2 points Bolts missing in intake manifold 2 points Oil leak on right side of engine 2 points 2 Were all fluid levels checked Power steering level 2 points Oil level 2 points Anti freeze level 2 points 3 Was the protection level checked 3 points What was the coolant protection level 2 points Did the tech use a refr
47. tives contestant releases TM C ATA its directors employees agents and or any of its affiliates from any and all liability and any right of action that may arise from any damage or injury which may be received while attending or participating in said oO J OO FOR MORE INFORM ATION Invite students from local high schools or vocational Invite the local media i e newspapers radio TV Invite local law enforcement and transportation depart TMC National Technician Skills Competition TM CSuperTech2005 Contestant grants TM C ATA and its designated agen cies exclusive rights to make use of information about himself or herself along with photographs subsequently taken under TM C ATA s direction in publicity and advertising activities Contestant further agrees to make himself or herself available for publicity enterprises arranged by TM C ATA with newspaper magazine media writers and radio and television personnel d Contestant will be bound by all orders rules and regulations governing TM C s National Technician Skills Competition TM CSuperTech2005 while participat ing in said competition O This agreement and release was part of the Technician Contestant Registration Form which all contestants used to register for the competition A sample is included in the SAM PLE FORMS section of this document o _ KS THE 2005 CHA schools to observe the competition This is an i
48. troke within specs and recorded 5 points Task 2 Meritor ASA Allowed Actual 1 Spring brake fully released 2 5 pts 2 Correct clevis for the Meritor ASA 2 5 pts 3 Thread engagement of the push rod into the clevis per specifications 5 points 4 Push rod clevis lock nut installed and tightened 5 points 5 ASA installed on camshaft soacer washers and snap ring or e clip installed 5 points 6 Clevis pins and retaining clips installed 5 points 7 Meritor pawl released during adjustment 5 points 8 Cam shaft end play within specifications per axle manufacturer Meritor no spec Spicer 0 005 0 025 5 points 9 ASA angle to push rod within specs 5 points 10 ASA brake free play within specs and recorded 5 points 11 CVSA chamber applied stroke within specs and recorded 5 points Free Stroke Measurement Chamber Applied Stroke Measurement Elapsed Time Judge Bore NATIONAL TECHNICIAN SKILLS COMPETITION CIPER A d HVAC Station J udges Score Sheet Contestant Total Score Contestants will be told that A C performance is poor and sometimes inoperative Gauges will be connected but contestants will be instructed to check all gauge valves for proper position Each item is worth 5 points Task Allowed Score 1 Verify temperature pressure of refrigerant and or gauge connection 5 points 2 Check belt tension and alignment 5 points oo 3 Set controls to proper position 5 points ee 4 Check all blower spee
49. ure their competition champion s registers to compete at the national level in TM CSuperTech WHAT IS SUPERTECH DESCRIPTION TM C s National Technician Skills Competition TM CSuperTech is an annual event held in conjunc tion with the Council s Fall Meeting The Competition consists of a First Round Written Challenge and subsequent Hands On Skills Challenge Contestants take part in the First Round Written Challenge on Day One of the competi tion Following the Written Challenge there is a reception at which TMC announces the names of a predetermined number of contestants who are eligible to compete on Day Two in the Hands on Skills Challenge The last day of the event consists of a Technician Training Fair featuring numerous hands on job related training classes that qualify for NATEF continuing education units followed by an competition awards banquet WHO MAY COMPETE The competition is open to any actively employed commercial vehicle technician How ever all competitors must be TMC Technician M embers Active members are eligible to enter the competition without fee Nonmembers will pay an entry fee and will become members for the remainder of the year Verified champions of state trucking association technician skills competitions may enter without paying a fee Grand Champions of previous TMC National Technician Skills Competitions are eligible to compete M ember ship forms available at http tmc truckline
50. y as possible given the resources and volunteer support available Any communication between contestants and with spectators outside of the immediate Skills Station area is prohibited Spectators are to be in a viewing area outside of the skill station Authorized individuals may enter individual skill station for means of docu menting or administration of contest activity When idle or on break contestants are escorted at all times by competition representatives Once all contestants have com pleted the skill station challenge contestants are held at the skill station until it is determined all scores are received and properly recorded What to Expect at Each Hands on Skills Station The following example is a synopsis of what contestants should expect at each station during TM C s Hands on Skills Challenge Each challenge has been designed to test a technician s general knowl x BRAKES edge in each functional area SKILLS without the need for expert STATION EE familiarity with any particular tool vehicle system or vehicle Bear in mind TM C state regional corporate competitions may vary in terms of the content and number of stations held but these are good general guidelines to follow when establish ing a set of skills stations The following descriptions were used for TM CSuperTech2005 sponsored b HOW TO CONDUCT A PROFESSIONAL TECHNICIAN SKILLS COM PETITION Electrical Troubleshoot service and repair
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