E3 Auxiliary Power Systems Installation and Repair

  • Hydraulic Systems
  • Pumps
  • Filtration/Reservoirs (Tanks) 
  • Hoses, Fittings, and Connections 
  • Control Valves 
  • Actuators 
  • General System Operation
  • Mechanical Systems
  • Pneumatic Systems

Auxiliary Power Systems Installation and Repair

A. Hydraulic Systems (30 questions)

1. Pumps (8 questions)

1. Determine pump type and rotation.

2. Install pump properly to include spline lubrication, brackets/supports, location, driveshaft angles, slip joint location(s), case drain, and hydraulic connections.

3. Diagnose causes of unusual pump noises, temperatures, and flow; determine needed repairs.

4. Verify proper fluid application.

2. Filtration/Reservoirs (Tanks) (5 questions)

1. Identify type of filtration system; verify filter application and flow direction.

2. Install filter(s) in proper locations(s); flush system in accordance with manufacturers’ recommendations.

3. Diagnose cause(s) of system contamination.

4. Service filters and breathers in accordance with manufacturers’ recommendations.

5. Install reservoirs/tanks, related components, and shut off valves in accordance with recommended procedures; flush and clean as required.

3. Hoses, Fittings, and Connections (4 questions)

1. Identify proper applications to include sizes, types, and pressure/flow/temperature ratings.

2. Determine hydraulic layout (length, size, routing, bend radii, and heat, abrasion, or line of sight protection).

3. Determine correct application of thread sealants.

4. Assemble hoses/tubing, connectors, and fittings in accordance with manufacturers’ specifications; use proper procedures to avoid contamination.

5. Diagnose cause of component leakage.

4. Control Valves (2 questions)

1. Identify control valves (directional and accessory) application and porting.

2. Install valves in accordance with recommended procedures regarding location, mounting, and shielding; verify flow direction.

3. Verify system operating pressure and flow; confirm component compatibility.

4. Verify, install, and adjust valve controls (electrical, mechanical, and pneumatic).

5. Actuators (3 questions)

1. Purge/bleed system in accordance with recommended procedures.

2. Diagnose the cause of incorrect actuator movement; determine needed repair.

3. Diagnose the cause of seal failure; determine needed repair.

4. Identify hydraulic motor type and rotation.

5. Verify case drain operation (where applicable).

6. Identify cylinder type (single or double acting).

6. General System Operation (8 questions)

1. Interpret system diagrams, schematics, and layouts.

2. Identify proper tools for installation, diagnosis, maintenance, and repair.

3. Perform general service diagnosis and repair procedures.

4. Assemble and integrate system components.

5. Perform periodic inspection and maintenance on systems.

B. Mechanical Systems (13 questions)

1. Verify PTO type, location, and mounting clearance; remove cover and identify PTO drive gear location and compatibility with PTO.

2. Install supplied gaskets, verify correct fasteners and lock tabs; install PTO, torque to specifications.

3. Remove, where applicable, PTO shifter cover and measure backlash with dial indicator; adjust as needed.

4. Install lubrication line, if required.

5. Install shift controls (electrical, mechanical, and pneumatic).

6. Refill transmission to proper lubrication level with transmission manufacturer’s recommended lubricant.

7. Test operation of PTO; check for unusual noises and leaks; check shifter operation.

8. Verify proper rotational direction of output shaft.

9. Install all warning and operational labels.

10. Determine PTO driveshaft length, application, and operating angles.

11. Install PTO driveshaft; lubricate U-joints and slip joints; check that operating angles are within manufacturers’ recommended specifications.

12. Check for proper PTO shaft timing (phasing).

13. Check belt tension and alignment of belt driven components. Check clutch air gap adjustment (if applicable); verify proper electrical connections, and test operation.

14. Diagnose the causes of vibrations in auxiliary power trains.

15. Test operation of PTO speed controls.

16. Install guarding, if required.

17. Diagnose the cause of abnormal PTO/component wear.

C. Pneumatic Systems (2 questions)

1. Determine proper location for pressure protection valve(s); install valve(s), and check operation.

2. Determine proper location for the air activated control valve(s).

3. Connect DOT specified lines, fittings, and hoses to air activated control valve(s); determine proper routing of air hoses.

4. Verify operation of pressure reducing (air regulator) valve(s).