Ase Medhvytruck2011 Web

8/3/2019 Ase Medhvytruck2011 Web

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The OfficialASE Study Guide

ASE Medium/HeavyTruck Tests


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Table of Contents

Overview ................................................................................................37

Medium/Heavy Truck Tests .................................................................. 861

GasolineEngines(TestT1).............................................................8

DieselEngines(TestT2) ...............................................................17

DriveTrain(TestT3) ....................................................................24

Brakes(TestT4) ............................................................................30

SuspensionandSteering(TestT5)................................................36

Electrical/ElectronicSystems(TestT6)........................................42

Heating,Ventilation,andAirConditioning

(HVAC)Systems(TestT7) ...........................................................48

PreventiveMaintenanceInspection(PMI)(TestT8)....................54

Industry Training ...............................................................................6265

ASE MEdiuM/HEAvyTruckTESTS


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ASE MEdiuM/HEAvyTruckSTudyGuidE PAGE3

OvErviEw

Introduction

TheOfcial ASE Study Guide for the Medium/Heavy Truck TestsisintendedtohelptechniciansstudyfortheASEcerticationtests.Thespecicmaterialabout

eachtest,includedinthebookletisausefultoolforreviewingthetechnical

knowledgethatiscoveredintheMedium/Heavy Truck tests.Afterperforming

athoroughreview,itshouldbeeasiertoselectadditionalreferencematerialthat

willassistyouwiththetestpreparationneeds.

ASEvoluntarycerticationisameansbywhichtechnicianscanprovetheir

abilitiestothemselves,totheiremployers,andtotheircustomers.Bypassing

ASEtestsyouwillearnthemostvaluablecredentialavailabletotrucktechni-cians.Becausethetestsaretough,youllhavethesatisfactionofprovingto

yourselfthatyouareamongtheeliteinyourprofession.Whatsmore,these

credentialsarerecognizedthroughoutthenation.

Certiedtechnicianspromotecustomertrustandimprovetheimageof

theindustry.Andtrustandprofessionalismaretherststepstoabetter,more

prosperousbusiness.

ASEencouragesyoutotakethetestsandtojointheprovenproswhowear

TheASEBlueSealofExcellence.

How Do I Become Certifed?TherearecurrentlyeighttestsintheMedium/HeavyTruckTechniciancertica-

tionseries.Class4throughClass8trucksarecovered.MediumdutyClass46

is14,001to26,000lbs.grossvehicleweight(GVW).HeavydutyClass78is

26,001andabovegrossvehicleweight(GVW).

Ifyoupassoneormoretestsandhaveatleasttwoyearsofrelevanthands-

onworkexperience,youwillbecomecertiedasanASEMedium/HeavyTruckTechnician.IfyoupasstheDieselEnginesTest(T2)andtestsT3,T4,T5,T6,and

T7youwillearnthecerticateofMasterMedium/HeavyTruckTechnician.

IfyouarecurrentlycertiedinDieselEngines(A9,H2,S2,orT2)

andElectrical/ElectronicSystems(A6,H6,S6,orT6),youareeligibletotakethe

L2ElectronicDieselEngineDiagnosisSpecialisttest.


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PAGE4 ASE MEdiuM/HEAvyTruckSTudyGuidE

Ifyoufailatest,youmaytakeitagainduringanyscheduledtest

administrationinwhichitisoffered.Andremember,youaretheonlyonewho

willreceiveyourtestsscores;resultswillnotbegivenoverthephonenorwill

theybereleasedtoanyonewithoutyourwrittenpermission.

Medium/Heavy Truck TestsASEtestsandcertiestechniciansinthefollowingtruckareas:

GasolineEngines(TestT1)

DieselEngines(TestT2)

DriveTrain(TestT3)

Brakes(TestT4)

SuspensionandSteering(TestT5)

Electrical/ElectronicSystems(TestT6)

Heating,Ventilation,andAirConditioning(HVAC)Systems(TestT7)

PreventiveMaintenanceInspection(PMI)(TestT8)

ASEalsoofferscerticationinAutomobile,TruckEquipment,TransitBus,SchoolBus,CollisionRepair/Renish,PartsSpecialist,andAdvanced Level

specialties.

ForfullinformationonASEtestingaswellasdownloadableStudy Guides,

Registration Booklets,andmore,visitwww.ase.com.Youmayalsorequest

Registration Bookletsbymailingthecouponlocatedonthebackcoverofthis

bookletorbycallingASEat703-669-6600,ext.400.

Who Writes the Questions?Thequestions,writtenbyserviceindustryexpertsfamiliarwithallaspectsof

medium/heavytruckrepair,areentirelyjob-related.Theyaredesignedtotestthe

skillsthatyouneedtoknowinservicingtrucks;theoreticalknowledge

isnotcovered.

EachquestionhasitsrootsinanASEitem-writingworkshopwhere

servicerepresentativesfrommedium/heavytruckmanufacturers,aftermarket

partsandequipmentmanufacturers,workingtechniciansandtechnicaleduca-

torsgettogetherinaworkshopsettingtoshareideasandtranslatethemintotestquestions.Eachtestquestionwrittenbytheseexpertsmustsurvivereviewbyall

membersofthegroup.Thequestionsarewrittentodealwithpracticalproblems

ofdiagnosisandrepairexperiencedbytechniciansintheirday-to-daywork.

OvErviEw (cOnTinuEd)


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Fromthere,allquestionsarepre-testedandquality-checkedonanational

sampleoftechnicians.ThosequestionsthatmeetASEstandardsofqualityand

accuracyareincludedinthetests;therejectsaresentbacktothedrawingboard

ordiscardedaltogether.

Eachcerticationtestismadeupofbetween40and55multiple-choice

questions.Thetestingsessionsare4hoursand15minutes,allowingplenty

oftimetocompleteseveraltests.

Note: Eachtestcouldcontainuptofteenadditionalquestionsthatareincluded

forstatisticalresearchpurposesonly.Youranswerstothesequestionswillnot

affectyourscore,butsinceyoudonotknowwhichonestheyare,youshouldanswerallquestionsinthetest.Theve-yearRecerticationTestwillcoverthe

samecontentareasasthoselistedabove.However,thenumberofquestionsin

eachcontentareaoftheRecerticationTestwillbereducedbyaboutone-half.

How Do I Prepare or the ASE Tests?Becomefamiliarwithtestcontentandquestionformat:TheTestSpecications

foreachofthetestscoveredinthisbookletcontainasummarydescriptionofthe

contentcoveredbyeachtest.TheListsdescribetheactualworkperformedbytechniciansineachspecialtyarea.Together,theseformablueprintforwriting

andassemblingtheASEtests.

Pleasenotethateachquestiononthetestiskeyedorlinkedtoaparticular

orsetoftasksinthelist.Therefore,areviewofthelists,withaneyetojudging

whetheryouknowhowtoperformeachlisted,willprovidevaluableinformation

toprepareforthetests.

Therearevetypesofmultiple-choicequestionsonthetests,eachofwhich

isincludedinthesamplequestionsinthisbooklet.Notethedifferentinstructionsforsomequestions.

Besuretoreadeachquestioncarefully,(twice,ifnecessary)sothatyou

understandexactlywhatisbeingasked.Each question tests a specic diagnostic

or repair problem and has only one best answer.

Tosummarize,wesuggestthefollowingstepstobetakentoprepareforthe

tests:

Step 1. Studythecontentlistforeachtestyouwillattempt.

Step 2. Carefullyreadthelistforeacharea.

Step 3. Go over the sample questions to become familiar with each

questiontype.This is very important.

Step 4. Reviewsteps1through3above,andidentifytheskillareaswhere

youneedadditionalstudy.



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Types o Knowledge Measured by the Tests

Thetypesofknowledgeandskillsyouwillneedtoknowtopassthetestsareasfollows:

Basic technical knowledge:Testsyourknowledgeofwhatisinasystemand

howthesystemworks,andwhataretheproperproceduresand/orprecautions

tobefollowedinmakingrepairsandadjustments.

Service or repair knowledge and skill:Testsyourunderstandingandability

toapplygenerallyacceptedrepairproceduresandprecautionsinassembly,

disassembly,andreconditioningoperations;andinmakingmajorinspections

andadjustments.Alsotestsabilitytouseshopmanualsandprecisiontoolsofthetrade.

Testing and diagnostic knowledge and skill:Testsyourabilitytorecognize

problemsandtousegenerallyavailablemeasurementandtestingequipment

tomakeadiagnosis.Alsotestsyourabilitytotracetheeffectsofaparticular

conditionandndthecauseofaparticularsetofsymptoms.

Ifyouareanexperiencedandcompetenttechnician,acarefulreviewof

thisbooklet,andadditionalbrush-uponthoseareasinwhichyouareweakest,isallyoushouldneedtopasstheASEtests.

Beore The TestsTrytobewell-restedforthetestsoyouwillbealertandefcient.Ifyouaretak-

ingthewrittenversions,pleasebringseveralsharpenedsoft-lead(#2)pencilsand

aneraserwithyou;pencilswillnotbefurnishedatthetestcenter.Ifyouwishto

paceyourself,bringawatch;sometestingroomsmaynothaveclocks.Finally,

besuretobringalongyourtestcenteradmissionticketandacurrentphotoI.D.

At the Test CenterSome TipsArriveearlyenoughtondthebuildingandtestingroom.Whenyoureachthe

location,waitintheassignedareauntiltheproctorbeginsthetestadministration.

Heorshewillinstructyouinllingouttheanswerbooklet(iftakingwritten

tests)orloggingontothecomputer(iftakingcomputer-basedtests).

Oncetestinghasbegun,keeptrackoftime.Donotspendtoolongonany

singlequestion.Besuretoreadeachquestioncarefullysothatyouunderstandexactlywhatisbeingasked.Donotmarkanswersinthetestbooklet;theymust

bemarkedontheanswerbooklet.Yourtestwillnotbescoredifyouranswersare

notonyouranswerbooklet.

Ifaquestionisdifcult,marktheanswerthatyouthinkiscorrectandput

acheckbyitinthetestbook.(Computer-basedtestsallowyoutodothison

screen.)Thengoontothenextquestion.Ifyounishbeforetimeisup,youmay

gobacktothequestionsthatyouchecked.



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It is to your advantage to answer every question. Do not leave any

answers blank. Your score will be based only on the number of correct

answers that you give.

Test Content and Sample QuestionsThefollowingmaterialisdesignedtohelptechniciansprepareforASEcertica-

tiontests.

EachofthesectionsbeginswiththeTestSpecications,whichlistthemain

categoriescoveredonthatparticulartestandthenumberoftestquestionsand

percentageofthetestdevotedtoeachtopic.

TheListdescribestheworkactivitiesatechnicianshouldbeabletoperform

ineachtechnicalareacoveredonthattest.Thislistwasdevelopedbyworking

techniciansandtechnicalexpertsfromacrossthecountryandwillprovideavalu-

ablechecklistofwhattostudyforthetest.

Itshouldbenotedthatthenumberofquestionsineachcontentareamay

notequalthenumberoftaskslisted.Someofthetasksarecomplexandbroad

inscopeandmaybecoveredbyseveralquestions.Othertasksaresimpleand

narrowinscopeandonequestionmaycoverseveraltasks.Themainobjectiveinlistingthetasksistodescribeaccuratelywhatisdoneonthejob,nottomake

eachcorrespondtoaparticulartestquestion.

Samplequestionsfollow.Althoughthesesamequestionswillnotappearon

actualtests,theyareinthesameformatasactualtestquestions.Allvetypesof

multiple-choicequestionsusedontheASEtestsarerepresentedhere.Notethe

differentinstructionsforsomequestions.



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Content Questions PercentageArea in Test of Test

A. General Diagnosis 1 28%

B. Cylinder Head and Valve TrainDiagnosis and Repair 4 8%

C. Engine Block Diagnosis and Repair 4 8%

D. Lubrication and Cooling SystemsDiagnosis and Repair 3 6%

E. Ignition System Diagnosis and Repair 6 12%

F. Fuel, Air Induction, and Exhaust Systems

Diagnosis and Repair 6 12%

G. Emissions Control SystemsDiagnosis and Repair 5 10%

H. Computerized Engine Controls


Total 50 100%

TEST SpEcificATiOnSGASOlinE EnGinES (TEST T1)

A. General Diagnosis (14 questions) 1. Verifythecomplaintand/orroadtestvehicle;reviewdriver/customerinterviewand

pastmaintenancedocuments(ifavailable);determinefurtherdiagnosis.

2. Researchapplicablevehicleandserviceinformation,suchasenginemanagement

systemoperation,vehicleservicehistory,serviceprecautions,technicalservice

bulletins,andservicecampaigns/recalls.

3. Inspectengineassemblyforfuel,oil,coolant,andotherleaks;determineneeded

action.

4. Diagnosenoisesand/orvibrationproblemsrelatedtoengineperformance;determine

neededaction. 5. Diagnosethecauseofunusualexhaustcolor,odor,andsound;determineneeded

action.

6. Performenginemanifoldvacuumorpressuretests;determineneededaction.

7. Performcylinderpowerbalancetest;determineneededaction.

8. Performcylindercompressiontest;determineneededaction.

9. Performcylinderleakage/leak-downtest;determineneededaction.


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T1 liST (cOnTinuEd)

10.Diagnoseenginemechanical,electrical,electronic,fuel,andignitionproblemswithan

oscilloscope,engineanalyzer,digitalmultimeter(DMM),and/orscantool;determine

neededaction.11. Inspectenginecompartmentwiringharness,connectors,seals,locks,vacuumhoses;

checkforproperroutingandcondition;determineneededrepairs.

12. Observeandinterpretinstrumentpanelgaugereadings.

13. Readandinterpretelectricalschematicdiagramsandsymbols.

14. Testanddiagnoseemissionsordriveabilityproblemscausedbybatterycondition,

connections,orexcessivekey-offbatterydrain;determineneededrepairs.

15. Performstartercurrentdrawtest;determineneededaction.

16. Performstarterandchargingcircuitvoltagedroptests;determineneededaction.

17. Inspect,test,andrepairorreplacecomponents,connectors,andwiresinthestarterandchargingcontrolcircuits.

18. Differentiatebetweenelectricalandmechanicalproblemsthatcauseaslowcrank,no

crank,extendedcranking,oracrankingnoisecondition.

19. Testanddiagnoseengineperformanceproblemsresultingfromanundercharge,over-

charge,orano-chargecondition;determineneededaction.

20. Inspect,adjust,andreplacealternator(generator)drivebelts,pulleys,tensioners,and

fans.

B. Cylinder Head and Valve Train Diagnosis and Repair (4 questions) 1. Remove,inspect,disassemble,andcleancylinderheadassembly(s). 2. Inspectthreadedholes,studs,andboltsforserviceability;service/replaceasneeded.

3. Measurecylinderheadthickness;checkmatingsurfacesforwarpageandsurface

nish;inspectforcracks/damage;checkconditionofpassages;inspectcoreand

galleryplugs;determineserviceabilityandneededrepairs.

4. Inspectvalves,guides,seats,springs,retainers,locks,andseals;determineservice-

abilityandneededrepairs.

5. Reassemble,check,andinstallcylinderheadassembly(s)andgasket(s)asspecied

bythemanufacturer. 6. Inspectpushrods,rockerarms,rockerarmshafts,electronicwiringharness,and

brackets;repair/replaceasneeded.

7. Inspect,install,andadjustvalveliftersandretainers;adjustvalveclearance.

8. Inspect,measure,andreplace/reinstalloverheadcamshaftandbearings;measure

andadjustendplay.

C. Engine Block Diagnosis and Repair (4 questions) 1. Remove,inspect,service,andinstallpans,covers,ventilationsystems,gaskets,seals,

andwearsleeves.

2. Disassemble,cleanandinspectengineblockforcracks;checkmatingsurfacesandrelatedcomponentsfordamageorwarpageandsurfacenish;checkdeckheight;

checkconditionofpassages,core,andgalleryplugs;inspectthreadedholes,studs,

dowelpinsandboltsforserviceability;service/replaceasneeded.

3. Inspectandmeasurecylinderwallsforwearanddamage;determineserviceability

andneededrepairs.

4. Inspectin-blockcamshaftbearingsforwearanddamage;replaceasneeded.


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T1 liST (cOnTinuEd)

5. Inspect,measure,andreplace/reinstallin-blockcamshaft;measure/andcorrectend

play;inspect,replace/reinstall,andadjustvalvelifters.

6. Cleanandinspectcrankshaftandjournalsforsurfacecracksanddamage;checkconditionofoilpassages;checkpassageplugs;measurejournaldiameters;check

mountingsurfaces;determineneededrepairs.

7. Diagnosepiston,connectingrodbearing,andmainbearingwearpatternsthatindicate

connectingrodandcrankshaftalignmentorbearingboreproblems;checkbearing

boreandbushingcondition;determineneededrepairs.

8. Determinetheproperselect-tcomponentssuchaspistons,connectingrods,and

mainbearings.

9. Inspectandreplacemainbearings;checkcaptandbearingclearances;checkand

correctcrankshaftendplay.10. Removeand/orreplacethetimingchainandgears;ensurecorrecttiming.

11. Inspect,measure,orreplacepistons,pins,andretainers.

12. Measurepiston-to-cylinderwallclearance.

13. Checkring-to-groovetandendgaps;installringsonpistons.Assemblepistonsand

connectingrodsandinstallinblock;installrodbearingsandcheckclearances.

14. Inspectand/orreplacecrankshaftvibrationdamper.

15. Inspectywheel/explate(includingringgear)andmountingsurfacesforcracks,

wear,andrunout;determineneededrepairs.

D. Lubrication and Cooling Systems Diagnosis and Repair (3 questions) 1. Diagnoseenginelubricationsystemproblems;performoilpressuretests;determine

neededrepairs.

2. Disassembleandinspectoilpump(includesgears,rotors,housing,andpick-upas-

sembly);measureoilpumpclearance;inspectpressurereliefdevicesandpumpdrive;

determineneededrepairs.

3. Inspect,clean,test,reinstall/replaceoilcooler,by-passvalve,linesandhoses.

4. Changeengineoilandlter(s);addpropertype,viscosity,andratingofoil.

5. Inspectandreinstall/replacepulleys,tensioners,anddrivebelts;adjustdrivebeltsandcheckalignment.

6. Diagnoseenginecoolingsystemtemperatureandpressureproblems;determine

neededrepairs.

7. Inspect,test,andreplacethermostat,coolantby-pass,andthermostathousing,seals,

hoses,andttings.

8. Inspectandtestcoolant;drain,ush,andrellcoolingsystemwithrecommended

coolant;bleedairfromcoolingsystemasrequired.

9. Inspectandreplacewaterpump,housing,andhoses.

10. Inspectandreplaceradiator,pressurecap,expansiontank,andcoolantrecovery

system.

11. Inspect,test,andrepair/replacefan(bothelectricalandmechanical),fanclutch,fan

shroud,airdams,andcoolingfanelectricalcircuits.

12. Verifyproperoperationofenginerelatedgaugesandwarningindicators;determine

neededrepairs.


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T1 liST (cOnTinuEd)

E. Ignition System Diagnosis and Repair (6 questions) 1. Diagnoseignitionsystemrelatedproblemssuchasno-starting,hardstarting,engine

misre,poordriveability,sparkknock,powerloss,reducedfueleconomy,and

emissionsproblems;determinerootcause;determineneededrepairs.

2. Interpretignitionsystemrelateddiagnostictroublecodes(DTCs);determineneeded

repairs.

3. Inspect,test,repair,orreplaceignitionprimarycircuitwiringandcomponents.

4. Inspect,test,repair,orreplaceignitionsystemsecondarycircuitwiringand

components.

5. Inspect,test,andreplaceignitioncoil(s).

6. Inspect,test,andreplaceignitionsystemsensors;adjustasnecessary.

7. Inspect,test,and/orreplaceignitioncontrolmodule(ICM)/powertrain/engine

controlmodule(PCM/ECM);reprogramasneeded.

F. Fuel, Air Induction, and Exhaust Systems Diagnosis and Repair (6 questions) 1. Diagnosefuelsystemrelatedproblemssuchasno-starting,hardstarting,poordrive-

ability,incorrectidlespeed,pooridle,ooding,hesitation,surging,enginemisre,

powerloss,stalling,reducedfueleconomy,andemissionsproblems;determineroot

cause;determineneededrepairs.

2. Interpretfuelorinductionsystemrelateddiagnostictroublecodes(DTCs);analyze

fueltrimandotherscantooldata;determineneededrepairs. 3. Inspectfueltank,llerneck,andfuelcap;inspectandreplacefuellines,ttings,and

hoses;checkfuelforcontaminantsandquality.

4. Inspect,test,andreplacefuelpump(s)and/orfuelpumpassembly;inspect,service,

andreplacefuellters.

5. Inspectandtestelectricfuelpumpcontrolcircuitsandcomponents;determineneeded

repairs.

6. Inspect,test,andrepairorreplacefuelpressureregulationsystemandcomponentsof

fuelinjectionsystems;performfuelpressure/volumetest.

7. Inspect,remove,serviceorreplacethrottlebodyassemblyandcontrols,includingelectronicthrottleactuatorcontrol(TAC)systems;makerelatedadjustments.

8. Inspect,test,clean,andreplacefuelinjectorsandfuelrails.

9. Inspect,service,andrepairorreplaceairltrationsystemcomponents.

10. Inspectairinductionsystem,intakemanifold,andgasketsforair/vacuumleaks.

11. Remove,clean,inspect,test,andrepairorreplacefuelsystemvacuumandelectrical

componentsandconnections.

12. Inspect,service,andreplaceexhaustmanifold,gaskets,exhaustpipes,oxygen

sensors,mufers,catalyticconverters,resonators,tailpipes,andheatshields.

13. Testforexhaustsystemrestrictionorleaks;determineneededrepair.


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T1 liST (cOnTinuEd)

G. Emissions Control Systems Diagnosis And Repair (5 questions) 1. Testanddiagnoseemissionsordriveabilityproblemscausedbypositivecrankcase

ventilation(PCV)system.

2. Inspect,service,andreplacepositivecrankcaseventilation(PCV)lter,valve,tubes,

orice/meteringdevice,andhoses.

3. Testanddiagnosedriveabilityproblemscausedbytheexhaustgasrecirculation

(EGR)system.

4. Interpretexhaustgasrecirculation(EGR)relatedscantooldataanddiagnostictrouble

codes(DTCs);determineneededrepairs.

5. Inspect,test,service,andreplacecomponentsoftheexhaustgasrecirculation(EGR)

system,includingEGRvalve,tubing,passages,vacuum/pressurecontrols,lters,

hoses,electrical/electronicsensors,controls,solenoids,andwiringofEGRsystems.

6. Testanddiagnoseemissionsordriveabilityproblemscausedbythesecondaryair

injectionorcatalyticconvertersystems.

7. Interpretsecondaryairinjectionsystemrelatedscantooldataanddiagnostictrouble

codes(DTCs);determineneededrepairs.

8. Inspect,test,service,andreplacemechanicalcomponentsandelectrical/

electronically-operatedcomponentsandcircuitsofsecondaryairinjectionsystem.

9. Inspectcatalyticconverter.Interpretcatalyticconverterrelateddiagnostictrouble

codes(DTCs);analyzerelatedscantooldatatodeterminerootcauseofDTCs;


10. Testanddiagnoseemissionsordriveabilityproblemscausedbytheevaporativeemis-

sionscontrolsystem.

11. Interpretevaporativeemissions-relatedscantooldataanddiagnostictroublecodes

(DTCs);determineneededrepairs.

12. Inspect,test,andreplacecanister,lines,hoses,mechanical,andelectricalcomponents

oftheevaporativeemissionscontrolsystem.

H. Computerized Engine Controls Diagnosis And Repair (8 questions)

1. ResearchOBDIIsystemoperationtodeterminetheenablecriteriaforsettingandclearingdiagnostictroublecodes(DTCs)andmalfunctionindicatorlamp(MIL)

operation.Performappropriatedrivecycletodeterminesystemconditionandverify

repaireffectiveness.

2. InterpretOBDIIscantooldatastream,diagnostictroublecodes(DTCs),freeze

framedata,systemmonitors,monitorreadinessindicators,andtripanddrivecycle

information.

3. Readandinterprettechnicalliterature(servicepublicationsandinformationincluding

wiringschematics).

4. Diagnosethecausesofemissionsordriveabilityproblemswithstoredoractivediag-nostictroublecodes(DTCs).

5. Diagnosethecausesofemissionsordriveabilityproblemswithoutdiagnostictrouble

codes(DTCs).

6. Useascantool,digitalmultimeter(DMM),ordigitalstorageoscilloscope(DSO)to

inspectortestcomputerizedenginecontrolsystemsensors,actuators,circuits,and

powertrain/enginecontrolmodule(PCM/ECM);determineneededrepairs.


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T1 liST (cOnTinuEd)

7. Measureandinterpretvoltage,voltagedrop,amperage,andresistanceusingdigital

multimeter(DMM)readings.

8. Test,remove,inspect,clean,service,andrepairorreplacepowerandgrounddistribu-tioncircuitsandconnections.

9. Removeandreplacethepowertrain/enginecontrolmodule(PCM/ECM);reprogram

asneeded.

10. Diagnosedriveabilityandemissionsproblemsresultingfromfailuresofinterrelated

systems(forexample:cruisecontrol,securityalarms/theftdeterrent,torquecontrols,

tractioncontrols,torquemanagement,A/C,and/ornon-OEMinstalledaccessories).

11. Cleardiagnostictroublecodes(DTCs),runallOBDIImonitors,andverifythe

repair.


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SAMplE QuESTiOnSGASOlinE EnGinES (TEST T1)

QuESTiOnS:

1. TechnicianAsaysthatthecompressiontestreadingsshownabovecouldbe

causedbyablowncylinderheadgasket.

TechnicianBsaysthatthecompressiontestreadingsshownabovecouldbe

causedbywrongvalvetiming.

Whoisright?

*(A)Aonly (C)BothAandB

(B)Bonly (D)NeitherAnorB

2. TechnicianAsaysthatpartXshownaboveisusedtoimprovevalvespring

rotation.

TechnicianBsaysthatpartXshownaboveisusedtocorrectinstalledspring

height.

Whoisright?

(A)Aonly (C)BothAandB

*(B)Bonly (D)NeitherAnorB

COMPRESSIONSPECS

140 PSI

130

140

15

15

140

140

130

135


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8. Whichofthesecancauseacatalyticconvertertooverheat?

(A)Abrokenairpumpdrivebelt

(B)Apluggedcanisterpurgevacuumhose

(C)Afailedexhaustgasrecirculation(EGR)valve

*(D)Adisconnectedsparkplugwire

Question 9 is not like the ones above.

IthasthewordEXCEPT.LookforthechoicethatcouldNOTcausethe

describedsituation.Readtheentirequestioncarefullybeforechoosingyour

answer.9. Enginedetonation(knock)couldbecausedbyanyoftheseEXCEPT:

(A)aleanairfuelmixture.

*(B)retardedignitiontiming.

(C)excesscarboninthecombustionchambers.

(D)astuck-closedexhaustgasrecirculation(EGR)valve.

T1 SAMplE QuESTiOnS (cOnTinuEd)


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A. General Engine Diagnosis 11 20%

B. Cylinder Head and Valve Train 4 7%

Diagnosis and Repair

C. Engine Block Diagnosis and Repair 5 9%

D. Lubrication and Cooling Systems


E. Air Induction and Exhaust Systems


F. Fuel System Diagnosis and Repair 16 29%

G. Starting and Charging

System Diagnosis and Repair 4 7%

H. Engine Brakes 3 5%

Total 55 100%

TEST SpEcificATiOnSAnd TASkliSTdiESEl EnGinES (TEST T2)

A. General Engine Diagnosis (11 questions) 1. Verifythecomplaint,androad/dynotestvehicle;reviewdriver/customerinterview

andpastmaintenancedocuments(ifavailable);determinefurtherdiagnosis.

2. Identifyenginemodelandserialnumbertoresearchapplicablevehicleandservice

information,serviceprecautions,andtechnicalservicebulletins;determineneeded

actions.

3. Inspectengineassemblyandcompartmentforfuel,oil,coolant,exhaust,orother

leaks;determineneededrepairs.

4. Inspectenginecompartmentwiringharness,connectors,seals,andlocks;checkfor

properroutingandcondition;determineneededrepairs.

5. Isolateanddiagnoseenginenoises;determineneededrepairs.

6. Checkengineexhaustforodor,smokecolor,anddensity;determineneededrepairs.

7. Performfuelsupplyandreturnsystemtests;checkfuelforcontamination,quality,

andconsumption;determineneededrepairs.

8. Performairintakesystemrestrictionandleakagetests;determineneededrepairs.

9. Performintakemanifoldpressuretests;determineneededrepairs.

10. Performexhaustbackpressureandtemperaturetests;determineneededrepairs.

11. Performcrankcasepressuretest;determineneededrepairs.

12. Diagnosenocranking,cranksbutfailstostart,hardstarting,andstartsbutdoesnot

continuetorunproblems;determineneededrepairs.


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T2 TASkliST (cOnTinuEd)

13. Diagnosesurging,roughoperation,misring,lowpower,slowdeceleration,slow

acceleration,andshutdownproblems;determineneededrepairs.

14. Isolateanddiagnoseenginerelatedvibrationproblems;determineneededrepairs.15. Checkcoolingsystemforfreezepoint,level,contamination,coolanttype,

temperature,pressure,circulation,conditionerconcentration,ltration,andfan

operation;determineneededrepairs.

16. Checklubricationsystemforcontamination,oillevel,temperature,pressure,

ltration,andoilconsumption;interpretoilanalysisinformation;determineneeded

repairs.

17. Checkandrecordelectronicdiagnosticcodesandtrip/operationaldata;monitor

electronicdata;verifycustomerprogrammableparameters;clearcodes;determine

furtherdiagnosis.18. Performvisualinspectionforphysicaldamageandmissing,modied,ortampered

components;determineneededrepairs.

B. Cylinder Head and Valve Train Diagnosis and Repair (4 questions) 1. Remove,inspect,disassemble,andcleancylinderheadassembly(s).

2. Inspectthreadedholes,studs,andboltsforserviceability;service/replaceasneeded.

3. Measurecylinderheadthickness,andcheckmatingsurfacesforwarpageandsurface

nish;inspectforcracks/damage;checkconditionofpassages;inspectcoreand

galleryplugs;determineserviceabilityandneededrepairs. 4. Inspectvalves,guides,seats,springs,retainers,rotators,locksandseals;determine

serviceabilityandneededrepairs.

5. Inspectand/orreplaceinjectorsleevesandseals;pressuretesttoverifyrepair

(ifapplicable);measureinjectortipornozzleprotrusionwherespeciedby

manufacturer.

6. Inspect,and/orreplacevalvebridges(crossheads)andguides;adjustbridges

(crossheads)ifapplicable.

7. Cleancomponents;reassemble,check,andinstallcylinderheadassembly.

8. Inspectpushrods,rockerarms,rockerarmshafts,electronicwiringharness,andbracketsforwear,bending,cracks,looseness,andblockedoilpassages;repair/

replaceasneeded.

9. Inspect,install,andadjustcamfollowersandretainers.

10. Adjustvalveclearanceandinjectorsettings.

11. Inspect,measure,andreplace/reinstalloverheadcamshaftandbearings;measure

andadjustendplayandbacklash.

C. Engine Block Diagnosis and Repair (5 questions) 1. Remove,inspect,service,andinstallpans,covers,ventilationsystems,gaskets,seals,

andwearrings. 2. Disassemble,cleanandinspectengineblockforcracks;checkmatingsurfacesand

relatedcomponentsfordamageorwarpageandsurfacenish;checkdeckheight;

checkconditionofpassages,core,andgalleryplugs;inspectthreadedholes,studs,

dowelpinsandboltsforserviceability;service/replaceasneeded.

3. Inspectcylindersleevecounterboreandlowerbore;checkboredistortion;determine

neededservice.


19/66


4. Inspectandmeasurecylinderwallsorlinersforwearanddamage;determineneeded

service.

5. Replace/reinstallcylinderlinersandseals;checkandadjustlinerheight/protrusion. 6. Inspectin-blockcamshaftbearingsforwearanddamage;replaceasneeded.

7. Inspect,measure,andreplace/reinstallin-blockcamshaft;measure/adjustendplay;

inspect,replace/reinstall,andadjustcamfollowers(ifapplicable).

8. Cleanandinspectcrankshaftandjournalsforsurfacecracksanddamage;check

conditionofoilpassages;checkpassageplugs;measurejournaldiameters;check

mountingsurfaces;determineneededservice.

9. Inspectandreplacemainbearings;checkcaptandbearingclearances;checkand

correctcrankshaftendplay.

10. Inspect,reinstall,andtimethedrivegeartrain.(Includescheckingenginepositionandspeedindicatorcomponents,gearwear,andbacklashofcrankshaft,camshaft,

auxiliary,drive,andidlergears;serviceshafts,bushings,andbearings.)

11. Clean,inspect,measure,orreplacepistons,pins,andretainers.

12. Measurepiston-to-cylinderwallclearance.

13. Checkring-to-groovetandendgaps;installringsonpistons.

14. Identifypiston,connectingrodbearing,andmainbearingwearpatternsthatindicate

connectingrodandcrankshaftalignmentorbearingboreproblems;checkbearing

boreandbushingcondition;determineneededrepairs.

15. Assemblepistonsandconnectingrodsandinstallinblock;checkpistonheight/protrusion;replacerodbearingsandcheckclearances;checkcondition,position,

andclearanceofpistoncoolingjets(nozzles).

16. Inspectandmeasurecrankshaftvibrationdamper;replaceasneeded.

17. Inspect,install,andalignywheelhousing.

18. Inspectywheel/explate(includingringgear)andmountingsurfacesforcracks,

wear,andrunout;determineneededrepairs.

D. Lubrication and Cooling Systems Diagnosis and Repair (6 questions)

1. Verifyengineoilpressureandcheckoperationofpressuresensor/switchandpressuregauge;verifyengineoiltemperatureandcheckoperationoftemperaturesensor.

2. Inspect,measure,andrepair/replaceoilpump,housing,drives,pipes,andscreens;

adjustdrivegearclearanceifapplicable.

3. Inspectandrepair/replaceoilpressureregulatorvalve(s),andby-passvalve(s).

4. Inspect,clean,test,andreinstall/replaceoilcooler,by-passvalve,oilthermostat;lines

andhoses.

5. Inspectturbochargerlubricationandcoolingsystems;repair/replaceasneeded.

6. Changeengineoilandlters;addpropertypeofoil.

7. Inspectandreinstall/replacepulleys,tensionersanddrivebelts;adjustdrivebeltsandcheckalignment.

8. Verifycoolanttemperatureandcheckoperationoftemperatureandlevelsensors/

switch,andtemperaturegauge.

9. Inspectandreplacethermostat(s),by-passes,housing(s),andseals.

10. Flushandrellcoolingsystem;bleedairfromsystem;recovercoolant.

11. Inspectandrepair/replacecoolantconditioner/lter,valves,lines,andttings.

12. Inspectandrepair/replacewaterpump,housing,hoses,andidlerpulleyordrivegear.



20/66


13. Inspectradiator,pressurecap,andtank(s);determineneededservice.

14. Inspectandrepair/replacefanhub,fan,fanclutch,fancontrols,fanthermostat,and

fanshroud.15. Pressuretestcoolingsystemandradiatorcap;determineneededrepairs.

E. Air Induction and Exhaust Systems Diagnosis and Repair (6 questions) 1. Inspectandservice/replaceairinductionpiping,aircleaner,andelement;check

forairrestriction.

2. Inspect,test,andreplaceturbocharger(s)(includingvariableratio/geometryVGT),

pneumatic,hydraulic,andelectroniccontrolsandactuators;inspect,test,andreplace

wastegateandwastegatecontrols.

3. Inspectandrepair/replaceintakemanifold,gaskets,temperatureandpressuresensors,andconnections.

4. Inspect,test,clean,replacechargeaircoolerandpipingsystem.

5. Inspectandrepair/replaceexhaustmanifold,gaskets,piping,mufers,exhaustafter

treatmentdevices,(includingthree-wayandoxidationcatalystanddieselparticulate

ltersDPF)andmountinghardware.

6. Inspect,test,andrepair/replacepreheater/inletairheater,orglowplugsystemand

controls.

7. Inspect,test,andreplaceexhaustaftertreatmentregenerationsystemandcontrols.

8. Inspect,test,service,andreplaceexhaustgasrecirculation(EGR)systemcompo-

nents;includingEGRvalve,cooler,piping,lter,sensors,controls,andwiring.

F. Fuel System Diagnosis and Repair (16 questions) 1. Inspect,test,andrepair/replacefuelsystemtanks,vents,capsmounts,valves,

single/dualsupplyandreturnlines,andttings.

2. Inspect,clean,test,andrepair/replacefueltransfer(supply)pump,pumpdrives,

strainers,fuel/waterseparators/indicators,lters,heaters,coolers,ECMcooling

plates,andmountinghardware.(Protectfuelsystemcomponentsfrom

contamination),

3. Checkfuelsystemforair;determineneededrepairs;primeandbleedfuelsystem;check,repair/replaceprimerpump.

4. Inspect,test,andrepair/replacelow-pressureregulatorsystems(checkvalves,

pressureregulatorvalvesandrestrictivettings).

5. Inspectandreinstall/replacehigh-pressureinjectionlines,ttings,seals,and

mountinghardware.(Protecthigh-pressureinjectioncomponentsfrom

contamination).

6. Inspect,adjust,andrepair/replaceelectronicthrottleandPTOcontroldevices,

circuits,andsensors.

7. Performon-engineinspections,tests,andadjustmentsonhydraulicelectronicunitinjectors(HEUI)andelectroniccontrols(railpressurecontrol).

8. Performon-engineinspections,testsandadjustmentsonelectronicunitinjectors

(EUI)andelectroniccontrols.

9. Performon-engineinspectionsandtests,onhigh-pressurecommonrailfuelsystems

andelectroniccontrols.

10. Inspect,test,andreplaceengineprotectionandautomaticstop/restartsystem

components.



21/66


11. Inspectandreplaceelectricalconnectorterminals,pins,harnesses,seals,andlocks.

12. Connectdiagnostictooltovehicle/engine;accessandverifyprogrammable

parameters;changeifapplicable.13. Useadiagnostictool(hand-heldorPCbased)toinspectandtestelectronicengine

controlsystem,sensors,actuators,electroniccontrolmodules(ECMs),andcircuits;

determinefurtherdiagnosis.

14. Measureandinterpretvoltage,voltagedrop,amperage,andresistancereadingsusing

adigitalmultimeter(DMM)orappropriatetestequipment.

G. Starting and Charging System Diagnosis and Repair (4 questions) 1. Performbatterystate-of-chargeandloadorcapacitancetests;determineneeded

service. 2. Chargebatteryusingsloworfastchargemethod,asappropriate.

3. Startavehicleusingjumpercablesoraboosterbattery.

4. Inspect,clean,andrepair/replacebatteries,batterycables,andterminalconnections.

5. Inspect,test,andreinstall/replacestarterrelays,safetyswitch(s),andsolenoids.

6. Performalternatorvoltageandamperageoutputtests;determineneededrepairs.

7. Performstarterandchargingcircuitvoltagedroptests;determineneededrepairs.

H. Engine Brakes (3 questions) 1. Inspect,test,andadjustenginecompressionandexhaustbrakes.

2. Inspect,test,adjust,andrepair/replaceenginecompressionandexhaustbrakecontrolcircuits,switches,andsolenoids.

3. Inspectandrepair/replaceenginecompressionandexhaustbrakehousing(s),valves,

seals,springs,lines,andttings.



22/66


SAMplE QuESTiOnSdiESEl EnGinES (TEST T2)

QuESTiOnS:

1. Whenadieselengineisoperatedunderaload,coolantcontinuallycomesout

oftheradiatoroverowandtherearebubblesintheradiator.Whichoftheseis

themostlikelycause?

(A)Toomuchcoolantinthecoolingsystem (B)Acloggedradiator

(C)Astuck-openthermostat

*(D)Compressionleakageintothecoolingsystem

2. Adieselenginehasexcessiveblacksmokewhenstartedinthemorning.

Whichofthesecouldbethecause?

*(A)Abadfuelinjectionnozzle

(B)Arestrictedfuellter (C)Ablockedfueltankvent

(D)Aleakingfuelreturnline

3. Whichofthesecancauseano-startconditiononaHEUIengine?

(A)Highfuelpressure

*(B)Lowinjectioncontrolpressure

(C)Highboostpressure

(D)Lowboostpressure

4. Adieselengineishardtostart,butrunsgoodafterithasbeenprimedandrun

forafewminutes.Themostlikelycauseisa:

(A)leakinginjectorline.

(B)leakingfuelreturnline.

(C)pluggedfueltankvent.

*(D)badtransferpumpcheckvalve.

5. Adieselenginewithwetlinershasbeenrunningtoohot,andthereiscoolantin

thecrankcase.Themostlikelycauseis:

(A)acrackedblock

(B)crackedliners

*(C)leakinglinerseals.

(D)aleakinginjectorseal.


23/66


6. Dieselenginecylinderlinerprotrusion(height)canbeadjustedbyselecting

thecorrectsize:

(A)cylinderliner.

(B)headgasket.

*(C)linershim.

(D)rering.

7. AdieselenginewithEUIhasamisreandthecheckenginelightisON.Fault

codeS4FMI5cylinder4currentbelownormalisactive.Thiscouldbe

causedbya:

(A)failedenginepositionsensor.

(B)sticking#4injectionplunger.

*(C)broken#4injectionwireterminal.

(D)stickingthrottlepositionsensor.

8. Thecauseofaloggedfaultcodeinanelectronicdieselenginehasjustbeen

repaired.

TechnicianAsaysthatthecodesshouldbeclearedbeforereleasingthevehicle.

TechnicianBsaysthatthecustomerspasswordshouldberesetbefore

releasingthevehicle.

Whoisright?



9. Adieselenginehaslowpowerandlowturbochargerboostpressureisfound.

TechnicianAsaysthataleakingexhaustmanifoldcouldbethecause.

TechnicianBsaysthatapluggedturbochargeroilreturnlinecouldbethe

cause.

Whoisright?





24/66



A. Clutch Diagnosis and Repair 11 28%

B. Transmission Diagnosis and Repair 13 33%

C. Driveshaft and Universal Joint


D. Drive Axle Diagnosis and Repair 9 23%

Total 40 100%

TEST SpEcificATiOnSAnd liSTdrivE TrAin (TEST T3)

A. Clutch Diagnosis and Repair (11 questions)

1. Diagnoseclutchnoise,binding,slippage,pulsation,vibration,grabbing,andchatterproblems;determinecauseoffailureandneededrepairs.

2. Inspect,adjust,repair,orreplaceclutchlinkage,cables,levers,brackets,bushings,

pivots,springs,andclutchsafetyswitch(includespushandpulltypeassemblies);

checkpedalheightandtravel.

3. Inspect,adjust,repair,orreplacehydraulicclutchslaveandmastercylinders,lines,

andhoses;bleedsystem.

4. Inspect,orremoveandinstallrelease(throwout)bearing,sleeve,bushings,springs,

housing,levers,releasefork,forkpads,forkrollers,shafts,andseals;measureand

adjustrelease(throwout)bearingposition. 5. Inspect,orremoveandinstallsingle-discclutchpressureplateandclutchdisc;

adjustfreeplayandreleasebearingposition.

6. Inspect,orremoveandinstalltwo-plateclutchpressureplate,clutchdisc,

intermediateplate;determineproperclutchtorquerating;adjustfreeplayand

releasebearingposition.

7. Inspectandreplaceclutchbrakeassembly;inspectandreplaceinputshaftandbear-

ingretainer.

8. Inspect,orremoveandinstallself-adjusting/continuous-adjustingclutchassembly;

performinitialand/orresetadjustmentprocedure. 9. Inspectandreplacepilotbearing.

10. Inspectywheelmountingareaoncrankshaft,rearmainoilseal,andmeasure

crankshaftendplay;determineneededrepairs.

11. Inspectywheel,starterringgear,andmeasureywheelfaceandpilotborerunout;


12. Inspectywheelhousing(s)totransmissionhousing/enginematingsurface(s)and

measureywheelhousingfaceandborerunout;determineneededrepairs.


25/66


T3 liST (cOnTinuEd)

B. Transmission Diagnosis and Repair (13 questions) 1. Determinethecauseoftransmissioncomponentfailure,bothbeforeandduring

disassemblyprocedures.

2. Diagnosetransmissionvibration/noise,shifting,lockup,slipping/jumping

out-of-gear,andoverheatingproblems;determineneededrepairs.

3. Inspect,adjust,repair,orreplacetransmissionremoteshiftlinkages,cables,brackets,

bushings,pivots,andlevers.

4. Inspect,testoperation,adjust,repair,orreplaceairshiftcontrols,lines,hoses,valves,

regulators,lters,andcylinderassemblies.

5. Inspect,testoperation,adjust,repair,orreplaceelectronicshiftcontrols,shift,range

andsplittersolenoids,shiftmotors,indicators,speedandrangesensors,electronic/

transmissioncontrolunits(ECU/TCU),neutral/ingearandreverseswitches,and

wiringharnesses.

6. Inspect,testoperation,repair,orreplaceelectronicshiftselectors(in-cabcontrols),

airandelectricalswitches,displaysandindicators,wiringharnesses,andairlines.

7. Useappropriatediagnostictoolsandsoftware,procedures,andserviceinforma-

tion/owchartstodiagnoseautomatedmechanicaltransmissionproblems;checkand

recorddiagnosticcodes,clearcodes,interpretdigitalmultimeter(DMM)readings,


8. Diagnoseautomatedmechanicaltransmissionproblemscausedbydatalink/bus

interfaceswithrelatedelectroniccontrolsystems.

9. Removeandreplacetransmission;inspectandreplacetransmissionmounts,

insulators,andmountingbolts.

10. Inspectforleakageandreplacetransmissioncoverplates,gaskets,sealants,seals,

vents,andcapbolts;inspectsealsurfaces.

11. Checktransmissionuidlevel,andcondition;determineneededservice,andadd

propertypeoflubricant.

12. Inspect,adjust,andreplacetransmissionshiftlever,cover,rails,forks,levers,

bushings,sleeves,detents,interlocks,springs,andlockbolts.

13. Inspectandreplaceinputshaft,gear,spacers,bearings,retainers,andslingers.

14. Inspectmainshaft,gears,slidingclutches,washers,spacers,bushings,bearings,aux-

iliarydrivegear/assembly,retainers/snaprings,andkeys;determineneededrepairs.

15. Inspectcountershafts,gears,bearings,timingretainer/snaprings,andkeys;check

bearingpreload/endplay;verifymultiplecountershaftgeartiming;determineneeded

repairs.

16. Inspectoutputshaft,gears,washers,spacers,bearings,retainers/snaprings,andkeys;


17. Inspectreverseidlershaft(s),gear(s),bushings,bearings,thrustwashers,and

retainers/snaprings;checkreverseidlergearendplay;determineneededrepairs.

18. Inspectsynchronizerhub,sleeve,keys/inserts,springs,blockingrings,synchronizer

plates,blockerpins,andslidingclutches;determineneededrepairs.

19. Inspecttransmissioncasesincludingmatingsurfaces,bores,bushings,pins,studs,

vents,andmagneticplugs;determineneededrepairs.

20. Inspect,service,orreplacetransmissionlubricationsystemcomponents,pumps,

troughs,collectors,slingers,coolers,lters,andlinesandhoses.

21. Inspect,test,replace,andadjustelectronicspeedometerdrivecomponents.


26/66


T3 liST (cOnTinuEd)

22. Inspect,adjust,service,repair,orreplacepowertake-offassembliesandcontrols.

23. Inspectandtestoperationofbackuplight,neutralstart,andwarningdevicecircuits

andswitches;determineneededrepairs.24. Inspectandtesttransmissiontemperaturesendingunit/sensorandgauge;determine

neededrepairs.

25. Inspect,adjust,repair,orreplacetransfercaseassembliesandcontrols.

C. Driveshat and Universal Joint Diagnosis and Repair (7 questions) 1. Diagnosedriveshaftanduniversaljointnoise,vibration,andrunoutproblems;deter-

minecauseoffailureandneededrepairs.

2. Inspect,service,orreplacedriveshaft,slipjoints/yokes,yokes,driveanges,

universaljoints,driveshaftbootsandseals,andretaininghardware;properly

phase/timeyokes.

3. Inspectandreplacedriveshaftcentersupportbearingsandmounts.

4. Measureandadjustvehiclerideheight;measureandadjustdrivelineslopesand

angles(vehicleloadedandunloaded),includingPTOdriveshafts.

5. Useappropriatedrivelineanalysissoftwaretodiagnosedrivelineproblems.

6. Diagnosedrivelineretarderproblems;determineneededrepairs.

D. Drive Axle Diagnosis and Repair (9 questions) 1. Diagnosedriveaxleunitnoiseandoverheatingproblems;determineneededrepairs.

2. Checkandrepairuidleaks;inspectandreplacedriveaxlehousingcoverplates,

gaskets,sealants,vents,magneticplugs,andseals.

3. Checkdriveaxleuidlevel,andcondition;determineneededservice,addproper

typeoflubricantusingcorrectllprocedure.

4. Removeandreplacedifferentialcarrierassembly.

5. Inspectandreplacedifferentialcaseassemblyincludingspider/piniongears,cross

shaft,sidegears,thrustwashers,casehalves,andbearings.

6. Inspectandreplacecomponentsoflockingdifferentialcaseassembly. 7. Measureringgearbacklashandrunout;determineneededrepairs.

8. Inspectringanddrivepiniongears,spacers,shims,sleeves,bearingcages,and

bearings;determineneededrepairs.

9. Checkringandpiniongeartoothcontactpattern;interpretpatternand


10. Inspectandreplacepowerdivider(inter-axledifferential)assembly.

11. Inspect,adjust,repair,orreplaceairoperatedpowerdivider(inter-axledifferential)

lockoutassemblyincludingdiaphragms,seals,springs,yokes,pins,lines,hoses,

ttings,andcontrols.12. Inspectandmeasuredriveaxlehousingmatingsurfacesandalignment;determine

neededrepairs.

13. Inspect,service,orreplacedriveaxlelubricationsystemcomponents,pump,troughs,

collectors,slingers,tubes,andlters.

14. Inspectandreplacedriveaxleshafts.

15. Removeandreplacewheelassembly;checkdriveaxlewheel/hubsealandaxleange

gasketforleaks;determineneededrepairs.


27/66


T3 liST (cOnTinuEd)

16. Diagnosedriveaxlewheelbearingnoisesanddamage;determineneededrepairs.

17. Clean,inspect,lubricate,andreplacewheelbearingsandraces/cups;replaceseals

andwearrings;adjustdriveaxlewheelbearings(includingoneandtwonuttypes)

tomanufacturersspecications.

18. Inspectandtestdriveaxletemperaturesendingunit/sensorandgauge;determine

neededrepairs.

19. Check,adjust,and/orreplacewheelspeedsensor(s).

20. Inspectorreplaceextendedservice(sealed,close-tolerance,andunitized)

bearingassemblies;performinitialinstallationprocedurestomanufacturers

specications.


28/66


SAMplE QuESTiOnSdrivE TrAin (TEST T3)

QuESTiOnS:

1. Whatoperationisbeingperformed

inthesetupshownabove?

(A)Adjustingtoothcontact *(B)Checkingringgearrunout

(C)Checkingringgearbacklash

(D)Settingdifferentialbearingpreload

2. Atruckdoesnotmoveinanygear.

TechnicianAsaysthatabrokenshifterforkcouldbethecause.

TechnicianBsaysthatabrokenoutputshaftcouldbethecause.

Whoisright? (A)Aonly (C)BothAandB


3. Theshiftleverona13-speedtransmissionishardtomove.

Whichoftheseisthemostlikelycause?

(A)Bentshiftrails

*(B)Galledslidingclutchgears

(C)Worndetentsprings (D)Toomuchmainshaftgearendplay

4. Theairpressureregulatorforatransmissionisbeingchecked.

TechnicianAsaysthatthetractorairpressureshouldbeatmaximumsystem

pressure.

TechnicianBsaysthattheregulatorairltershouldbecleanedandthesystem

recheckediftheairpressurereadingisbelownormal.

Whoisright? (A)Aonly *(C)BothAandB


ROTATE

RING GEAR


29/66


5. Thedriverofatrucksaysthatagrindingnoisecanbeheardwhentheclutch

pedalisdepressed.Whichoftheseisthemostlikelycause?

(A)Toolittleclutchpedalfreeplay

*(B)Awornclutchrelease(throwout)bearing

(C)Alowtransmissionlubricantlevel

(D)Awornclutchpressureplate

6. Atwo-platepull-typeclutchengagesOK,butthetransmissiongrindswhen

goingintorstgearfromneutral.

TechnicianAsaysthatawornclutchbrakecouldbethecause.

TechnicianBsaysthattoolittlefreeplaycouldbethecause.

Whoisright?



7. Whichofthesecouldbethecauseofadriveshaftvibrationonatruck

thathasjusthadaU-jointreplaced?

*(A)Thedriveshaftisout-of-phase

(B)TheU-jointwasinstalledbackwards

(C)TheU-jointwasnotlubricated

(D)Thereisdirtonthedriveshaft

8. Atruckwithasinglerearaxlehastoomuchrearaxlenoiseonlywhenthe

truckispulling.Whichoftheseisthemostlikelycause?

(A)Wornaxleshaftbearings

(B)Wornwheelbearings

(C)Worndifferentialpinion(spider)gears

*(D)Wornringandpiniongears



30/66



A. Air Brakes Diagnosis and Repair 28 56%

1. Air Supply and Service Systems (14)

2. Mechanical/Foundation (10)3. Parking Brakes (4)

B. Hydraulic Brakes Diagnosis and Repair 14 28%

1. Hydraulic System (6)

2. Mechanical System (5)

3. Power Assist Units and Miscellaneous (3)

C. Air and Hydraulic Antilock Brake Systems

(ABS), Automatic traction Control (ATC),

and Electronic Stability Control Systems 5 10%D. Wheel Bearings Diagnosis and Repair 3 6%

Total 50 100%

TEST SpEcificATiOnSAnd liSTBrAkES (TEST T4)

A. Air Brakes Diagnosis and Repair (28 questions)

1. Air Supply and Service Systems (14 questions)

1. Diagnosepoorstopping,prematurewear,brakenoise,airleaks,pulling,grabbing,ordraggingproblemscausedbysupplyandservicesystemcomponents;determine

neededrepairs.

2. Checkairsystembuild-uptime;determineneededrepairs.

3. Drainairreservoirtanks;checkforoil,water,andforeignmaterial;determineneeded

repairs.

4. Inspect,adjust,align,andreplacecompressordrivebeltsandpulleys.

5. Inspectandreplacecompressordrivegearandcoupling.

6. Inspect,repair,orreplaceaircompressor,oilsupply,waterlines,hoses,ttingsand

mountingbrackets. 7. Inspect,test,adjust,andreplacesystempressurecontrols(governor/reliefvalve),

unloaderassembly,lines,hoses,andttings.

8. Inspect,repair,orreplaceairsystemlines,hoses,ttings,andcouplings;checkfor

properrouting.

9. Inspect,test,clean,andreplaceairtankrelief(pop-off)valves,one-way(single)

checkvalves,draincocks,automaticdrain(spitter)valves,heaters,wiring,and

connectors.


31/66


T4 liST (cOnTinuEd)

10. Inspect,test,clean,repair,orreplaceairdriersystems,lters,valves,heaters,wiring,

andconnectors.

11. Inspect,test,repair,orreplacebrakeapplication(foot)valve,ttings,andmounts;checkpedaloperation.

12. Inspect,test,andreplacetwo-way(double)checkvalvesandanti-compounding

valves.

13. Inspect,test,repair,orreplacestopandparkingbrakelightcircuitswitches,wiring,

andconnectors.

14. Inspect,test,repair,orreplacehandbrake(trailer)controlvalve,lines,hoses,

ttings,andmountings.

15. Inspect,test,andreplacebrakerelayvalves.

16. Inspect,test,andreplacequickreleasevalves.17. Inspect,test,andreplacetractorprotectionvalve.

18. Inspect,test,andreplaceinversion/emergency(spring)brakecontrolvalve(s).

19. Inspect,test,andreplacelowpressurewarningdevices.

20. Inspect,test,repairorreplaceairpressuregauges,in-cablines,hoses,ttings,and

pressuresensors(transducers).

21. Determineifairbrakesystemproblemiscausedbytractorortrailersupplyorservice

systemcomponents.

22. Verifythecomplaintandroadtestvehicle;reviewdriver/customerinterviewand


2. Mechanical/Foundation (10 questions) 1. Diagnosepoorstopping,prematurewear,brakenoise,pulling,grabbing,ordragging

problemscausedbyfoundationbrakecomponents;determineneededrepairs.

2. Inspect,test,repair,orreplaceservicebrakechambers,diaphragm,clamp,return

spring,pushrod,clevis,andmountingbrackets.

3. Inspect,service,orreplacemanualandautomaticslackadjusters.

4. InspectandreplaceS-cambrakerollers,bushings,camshafts,seals,spacers,retain-

ers,brakespiders,shields,anchorpins,andsprings. 5. Inspect,clean,rebuildorreplace,andadjustairdiscbrakecaliperassemblies.

6. Inspectandreplacebrakeshoes,orpads;determineneededrepair.

7. Inspectandreplacebrakedrumsorrotorsasneeded.

3. Parking Brakes (4 questions) 1. Inspectandtestparking(spring)brakechamberoperation;replaceparking(spring)

brakechamber;disposeofremovedchambersinaccordancewithlocalregulations.

2. Inspect,test,andreplaceparking(spring)brakecheckvalves,lines,hoses,and

ttings.

3. Inspect,test,andreplaceparking(spring)brakeapplicationandreleasevalve. 4. Manuallyrelease(cage)andreset(uncage)parking(spring)brakes.


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T4 liST (cOnTinuEd)

B. Hydraulic Brakes Diagnosis and Repair (14 questions)

1. Hydraulic System (6 questions) 1. Diagnosepoorstopping,brakenoise,prematurewear,pulling,grabbing,dragging,orpedalfeelproblemscausedbyhydraulicsystemcomponents;determine

neededrepairs.

2. Pressuretesthydraulicsystemandinspectforleaks.

3. Checkandadjustbrakepedalpushrodlength.

4. Inspect,test,andreplacemastercylinder.

5. Inspectandreplacebrakelines,exiblehoses,andttings.

6. Inspect,test,andreplacemetering(hold-off),loadsensing/proportioning,

proportioning,andcombinationvalves. 7. Inspect,test,repair,orreplacebrakepressuredifferentialvalveandwarninglight

circuitswitch,bulbs,wiring,andconnectors.

8. Inspectandreplacewheelcylinders.

9. Inspect,clean,andreplacediscbrakecaliperassemblies.

10. Inspect/testbrakeuid;bleedand/orushsystem;determineproperuidtypefor

application.

11. Inspect,test,repair,orreplacehydraulically-controlledparkingbrakecomponents,

systems,andwarningdevices.

2. Mechanical System (5 questions) 1. Diagnosepoorstopping,brakenoise,prematurewear,pulling,grabbing,dragging,

orpedalfeelproblemscausedbydiscanddrumbrakemechanicalcomponents;


2. Inspect,resurface,orreplacebrakedrumsorrotors.

3. Inspect,adjust,andreplacedrumbrakeshoes,mountinghardware,adjuster

mechanisms,andbackingplates.

4. Inspect,service,andreplacediscbrakepads,hardware,andmounts.

5. Inspect,adjust,repair,orreplacedrivelineparkingbrakedrums,rotors,shoes,

mountinghardware,andadjusters;burnish/seatreplacementshoesasrequired. 6. Inspect,adjust,repair,orreplacedrivelineparkingbrakeapplicationsystempedal,

cables,linkage,levers,pivots,andsprings.

3. Power Assist Units and Miscellaneous (3 questions) 1. Diagnosepoorstoppingcomplaintscausedbybrakeassist(booster)system

problems;determineneededrepairs.

2. Inspect,test,repair,orreplacepowerbrakeassist(booster),hoses,controlvalves

andlters;determineproperuidtypeforapplication.

3. Test,adjust,andreplacebrakestoplightswitch,bulbs,wiring,andconnectors.


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T4 liST (cOnTinuEd)

C. Air and Hydraulic Antilock Brake Systems (ABS), Automatic Traction Control

(ATC), and Electronic Stability Control Systems (5 questions) 1. Observeantilockbrakesystem(ABS)warninglightoperation;determineiffurther

diagnosisisneeded;(includesdashmountedtrailerABSwarninglight).

2. Diagnoseantilockbrakesystem(ABS)electroniccontrol(s)andcomponentsusing

self-diagnosisand/orspeciedtestequipment(scantool,PCbasedsoftware);


3. Diagnosewheellock-upcausedbyfailureoftheantilockbrakesystem(ABS);


4. Inspect,test,andreplaceantilockbrakesystem(ABS)air,hydraulic,electrical,

andmechanicalcomponents.

5. Diagnoseautomatictractioncontrol(ATC)electroniccontrol(s)andcomponents

usingself-diagnosisand/orspeciedtestequipment(scantool,PCbasedsoftware);


6. Diagnoseelectronicstabilitycontrolsystemsandcomponentsusingself-diagnosis

and/orspeciedtestequipment(scantool,PCbasedsoftware);determineneeded

repairs.

D. Wheel Bearings Diagnosis and Repair (3 questions) l. Removeandreplaceaxlewheelassembly.

2. Clean,inspect,lubricate,andreplacewheelbearingsandraces/cups;replacesealsandsealwearrings.

3. Adjuststeeringanddriveaxlewheelbearings(includingoneandtwonuttypes)

tomanufacturersspecications.

4. Inspectorreplaceextendedservice(sealed,close-tolerance,andunitized)

bearingassemblies;performinitialinstallationprocedurestomanufacturers

specications.


34/66


SAMplE QuESTiOnSBrAkES (TEST T4)

QuESTiOnS:

1. Theparkingbrakesfailtoapplyonatruckwithairbrakes.

TechnicianAsaysthatlowairpressureinthespringbrakechambercouldbe

thecause.TechnicianBsaysthatarupturedspringbrakediaphragmcouldbethecause.

Whoisright?


(B)Bonly *(D)NeitherAnorB

2. Atruckhasanunevenbrakingproblem.Whichofthesecouldbethecause?

(A)Abindingtreadle(foot)valve

(B)Lowbrakelineairpressure *(C)Abadbrakedrum

(D)Abadgovernor

3. Aservicebrakeonatruckwithanairbrakesystemreleasestooslowly.

TechnicianAsaysthatlowairpressurecouldbethecause.

TechnicianBsaysthatakinkedairlinecouldbethecause.

Whoisright?

(A)Aonly (C)BothAandB *(B)Bonly (D)NeitherAnorB

4. Aservicebrakechamberleakswhenthebrakesareapplied.Whichofthese

couldbethecause?

(A)Excessivepushrodtravel

*(B)Abadchamberdiaphragm

(C)Abrokenchamberreturnspring

(D)Amisalignedpushrod


35/66


5. Allthewheelsonatruckwithairbrakeslockupwhenasmallamountofpres-

sureisappliedtothetreadle(foot)valve.Whichofthesecouldbethecause?

*(A)Theapplicationvalveisbad.

(B)Thelimitingvalveisleaking.

(C)Thecompressorregulatorissettoohigh.

(D)Thebrakesareadjustedtoohigh.

6. Whenanairreservoirtankisdrained,thereisanexcessiveamountofmoisture.

Thiscouldbecausedbya:

(A)crackedaircompressorbracket.

(B)cloggedaircompressorintake.

(C)failedonewaycheckvalve.

*(D)failedairdryerpurgevalve.

7. Allthebrakesdragonatruckwithhydraulicbrakes.Whichofthesecouldbe

thecause?

(A)Airinthehydraulicsystem

(B)Toohighvacuumsupplytothepowerbrakebooster

(C)Aleakingsecondarycupinthemastercylinder

*(D)Nobrakepedalfreetravel

Questions 8 and 9 are not like the ones above.

EachofthesehasthewordEXCEPT.Foreachquestion,lookforthechoice

thatcouldNOT causethedescribedsituation.Readtheentirequestion

carefullybeforechoosingyouranswer.

8. Atruckwithhydraulicbrakespullstoonesidewhenthebrakesareapplied.

AnyofthesecouldbethecauseEXCEPT a:

(A)stickingwheelcylinderpiston.

(B)greasecontaminatedbrakelining.

(C)crimpedhydraulicline.

*(D)pluggedcompensatingport.

9. Thedriverofatruckwithairbrakessaysithaspoorstoppingpower.

AnyofthesecouldbethecauseEXCEPT:

*(A)thequickreleasevalveexhaustportisplugged.

(B)theairpressureistoolow.

(C)theapplicationlineisrestricted.

(D)thebrakesareoutofadjustment.



36/66



A. Steering System Diagnosis and Repair 12 24.0%

1. Steering Column (3)

2. Steering Units (6)3. Steering Linkage (3)

B. Suspension System Diagnosis and Repair 13 26.0%

C. Wheel Alignment Diagnosis, Adjustment,and Repair 13 26.0%

D. Wheels and Tires Diagnosis and Repair 9 18.0%

E. Frame Service and Repair 3 6.0%

Total 50* 100%

TEST SpEcificATiOnSAnd liSTSuSpEnSiOnAnd STEErinG (TEST T5)

A. Steering System Diagnosis and Repair (12 Questions)

1. Steering Column (3 Questions) 1. Diagnosexedanddriveradjustablesteeringcolumnandshaftnoise,looseness,and

bindingproblems;determineneededrepairs.

2. InspectandreplacesteeringshaftU-joint(s),slipjoints,bearings,bushings,andseals;

phaseshaftU-joints. 3. Checkandadjustcabmountingandrideheight.

4. Removethesteeringwheel(includessteeringwheelsequippedwithelectrical/

electroniccontrolsandcomponents);installandcenterthesteeringwheel.

2. Steering Units (6 Questions) 1. Diagnosepowersteeringsystemnoise,steeringbinding,darting/oversteer,reduced

wheelcut,steeringwheelkick,pulling,non-recovery,turningeffort,looseness,hard

steering,overheating,uidleakage,anduidaerationproblems;determineneeded

repairs.

2. Determinerecommendedtypeofpowersteeringuid;checklevelandcondition;

determineneededservice.

3. Flushandrellpowersteeringsystem;purgeairfromsystem.

4. Performpowersteeringsystempressure,temperature,andowtests;determine

neededrepairs.

5. Inspect,service,orreplacepowersteeringreservoirincludinglter,seals,and

gaskets.


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T5 liST (cOnTinuEd)

6. Inspectandreinstall/replacepowersteeringpumpdrivebelts,pulleysandtensioners;

adjustdrivebeltsandcheckalignment.

7. Inspectorreplacepowersteeringpumpdrivegearandcoupling. 8. Inspect,adjust,orreplacepowersteeringpump,mountings,andbrackets.

9. Inspectandreplacepowersteeringsystemcooler,lines,hoses,clamps/mountings,

andttings.

10. Inspect,adjust,orreplacelinkage-assisttypepowersteeringcylinderorgear

(dualsystem).

11. Inspect,adjust,repair,orreplaceintegraltypepowersteeringgear.

12. Adjustmanualandautomaticsteeringgearpoppet/reliefvalves.

3. Steering Linkage (3 Questions) 1. Inspect,align,andreplacepitmanarm. 2. Inspect,adjust,orreplacedraglink(relayrod)andtierodends(ballandadjustable

sockettype).

3. Inspectandreplacesteeringarms.

4. Inspectorreplaceclampsandretainersoncrosstube/relayrod/centerlink/tierod;

positionasneeded.

5. Checkandadjustwheelstops.

B. Suspension System Diagnosis and Repair (13 Questions)

1. Inspectandreplacefrontaxlebeamandmountinghardware. 2. Inspect,service,adjust,orreplacekingpin,bushings,locks,bearings,seals,and

covers.

3. Inspectandreplaceshockabsorbers,bushings,brackets,andmounts.

4. Inspect,repair,orreplace(leafandparabolic)springs,centerbolts,clips,spring

eyeboltsandbushings,shackles,slippers,insulators,brackets,andmounts.

5. Inspect,adjust,orreplacetorquearms,bushings,andmounts.

6. Inspect,adjust,orreplaceaxlealigningdevicessuchasradiusrods,transversetorque

rods/trackbars,stabilizerbars,andrelatedbushings,mounts,shims,andcams.

7. Inspectorreplacewalkingbeams,center(cross)tube,bushings,mounts,loadpads,brackets,caps,andmountinghardware.

8. Inspect,test,adjust,repair,orreplaceairsuspensionpressureregulatorandheight

controlvalves,linkages,lines,hoses,andttings.

9. Inspect,test,repair,orreplaceairsuspensionsprings(bags),mountingplates,

mainsupportbeams/springs,suspensionarms(radius/torque,andtransversetorque),

andbushings.

10. Measurevehiclerideheight;determineneededadjustmentsorrepairs.

11. Verifyanddiagnosevehiclesuspensioncomplaints.

12. TorqueU-boltstomanufacturersspecications.13. Checkaxleloaddistributionproblemsonrearsuspensions;checkaxleseatplaning

anglesandpinionangles.


38/66


T5 liST (cOnTinuEd)

C. Wheel Alignment Diagnosis, Adjustment, and Repair (13 Questions) 1. Diagnosevehiclewandering,darting,pulling,shimmy,andsteeringeffortproblems;

determineneededadjustmentsandrepairs.

2. CheckcamberandKPI(kingpininclination);determineneededrepairs.

3. Checkandadjustcaster.

4. Checkandadjusttoe.

5. Checkrearaxle(s)alignment(thrustline/centerline)andtracking(lateraloffset,

parallelism);adjustordetermineneededrepairs.

6. Checkturning/Ackermanangle(toe-out-on-turns)andmaximumturningradius

(wheelcut);determineneededrepairs.

D. Wheels and Tires Diagnosis and Repair (9 Questions) 1. Diagnosetirewearpatterns;determineneededrepairs. 2. Diagnosewheelendvibration,shimmy,pounding,hop(tramp)problems;


3. Inspectandreplacewheels,spacers,rims,sideanges,lockingrings,rimclamps,

studs,andnuts.

4. Measurewheelandtireradialandlateralrunout;determineneededrepairsor

adjustments.

5. Inspecttires;checkandadjustairpressuretotiremanufacturersspecications.

6. Performstaticbalanceofwheelandtireassembly. 7. Performdynamicbalanceofwheelandtireassembly.

8. Measuretirediameterandmatchtiresonaxles.

9. Removeandreplacesteeringand/ordriveaxlewheelassembly.

10. Clean,inspect,lubricate,andreplacewheelbearingsandraces/cups;replaceseals

andwearrings;adjuststeeringanddriveaxlewheelbearings(includingoneand

twonuttypes)tomanufacturersspecications.

11. Inspectorreplaceextendedservice(sealed,closetolerance,andunitized)bearing

assemblies;performinitialinstallationprocedurestomanufacturersspecications.

E. Frame Service and Repair (3 Questions) 1. Inspect,adjust,service,repair,orreplacefthwheel,pivotpins,bushings,locking

jawmechanisms,andmountingbolts.

2. Inspect,adjust,service,repair,orreplaceslidingfthwheel,tracks,stops,locking

systems,aircylinders,springs,lines,hoses,andcontrols.

3. Inspectframeandframemembersforcracks,breaks,distortion,elongatedholes,

looseness,anddamage;determineneededrepairs.

4. Inspect,install,orrepairframehangers,brackets,andcrossmembersinaccordance

withmanufacturersrecommendedprocedures.

5. Inspect,install,repairorreplacepintlehooksanddrawbars.


39/66


SAMplE QuESTiOnSSuSpEnSiOnAnd STEErinG (TEST T5)

QuESTiOnS:

1. Whichofthesecouldcausethefronttiresofatrucktoshowafeatherededge

wearpattern?

*(A)Anincorrecttoesetting (B)Anincorrectcambersetting

(C)Anincorrectcastersetting

(D)Incorrecttirepressures

2. Thedriveaxlesonatruckwithawalkingbeamsuspensionareoutofalign-

ment.

TechnicianAsaysthatincorrectlengthtorquerodscouldbethecause.

TechnicianBsaysthatwornwalkingbeambushingscouldbethecause.Whoisright?



3. Thedriverofatruckthathasjusthaditsfrontspringsandhangersreplaced

saysthatitishardtokeepinastraightaheadposition.

TechnicianAsaysthatthiscouldbecausedbyinstallingthecastershims

backwards.TechnicianBsaysthatthiscouldbecausedbyinstallingforwardspring

hangerswhicharetooshort.

Whoisright?



4. Thedriverofatrucksaysthatitishardtosteerandthesteeringreturnispoor.

TechnicianAsaysthattightkingpinscouldbethecause.TechnicianBsaysthattoomuchtoe-incouldbethecause.

Whoisright?




40/66


5. Ruststreakscomingfromaroundthestudholesofadiscwheelcouldbe

causedby:

(A)anoverloadedconditon.

(B)overtorquedlug/capnuts.

*(C)Anoutofbalancecondition.

(D)Looselug/capnuts.

6. Atruckhasahistoryofspringsbreakingatthecenterboltholes.

TechnicianAsaysthatlooseU-boltscouldbethecause.

TechnicianBsaysthatloosespringshacklescouldbethecause.

Whoisright?



7. Aconstantbuzzingnoisecomesfromthepowersteeringpump.

TechnicianAsaysthecausecouldbeairinthesystem.

TechnicianBsaysthecausecouldbethatthereliefvalveisstuckinthe

openposition.

Whoisright?





41/66


8. Thetandemrearaxleairsuspensionrideheightrisesabovenormalasthe

vehicleisunloaded.Whichofthesecouldbethecause?

(A)Akinkedairspring(bag)supplyline

(B)Aleakingheightcontrolvalve

*(C)Apluggedheightcontrolvalveexhaustport

(D)Aleakingpressureprotectionvalve

Question 9 is not like the ones above.

IthasthewordEXCEPT.Forthisquestion,lookforthechoicethatcould

NOT causethedescribedsituation.Readthequestioncarefullybeforechoosingyouranswer.

9. Alloftheseshouldbecheckedbeforealigningthefrontwheelsonatruck

EXCEPT:

(A)tirepressure.

(B)rideheight.

(C)wheelbearingadjustment.

*(D)tirebalance.



42/66



A. General Electrical Diagnosis 14 28%

B. Battery Diagnosis and Repair 4 8%

C. Starting System Diagnosis and Repair 7 14%

D. Charging System Diagnosis and Repair 7 14%

E. Lighting Systems Diagnosis and Repair 6 12%

1. Headlights, Parking, Clearance, Tail,Cab and Dash Lights (3)

2. Stoplights, Turn Signals, Hazard Light,

and Backup Lights (3)

F. Gauges and Warning Devices Diagnosis 4 8%

and Repair

G. Related Systems 8 12%

Total 50 100%

TEST SpEcificATiOnSAnd liSTElEcTricAl/ElEcTrOnic SySTEMS (TEST T6)

A. General Electrical Systems Diagnosis (14 questions) 1. Checkcontinuityinelectrical/electroniccircuitsusingappropriatetestequipment.

2. Checkappliedvoltages,circuitvoltages,andvoltagedropsinelectrical/electronic

circuitsusingdigitalmultimeter(DMM),orappropriatetestequipment. 3. Checkcurrentowinelectrical/electroniccircuitsandcomponentsusingadigital

multimeter(DMM),clamp-onammeter,orappropriatetestequipment.

4. Checkresistanceinelectrical/electroniccircuitsandcomponentsusingadigital

multimeter(DMM),orappropriatetestequipment.

5. Findshorts,grounds,andopensinelectrical/electroniccircuits.

6. Diagnosekey-offbatterydrainproblems.

7. Inspect,test,andreplacefusiblelinks,circuitbreakers,andfuses.

8. Inspectandtestspikesuppressionsdiodes/resistorsandcapacitors.

9. Inspectandtestrelaysandsolenoids.10. Readandinterpretelectricalschematicdiagramsandsymbols.

11. Diagnosefailuresinthedatacommunicationsbusnetwork;determineneededrepairs.

B. Battery Diagnosis and Repair (4 questions) 1. Performbatterytests(loadandcapacitance);determineneededservice.

2. Determinebatterystateofchargebymeasuringterminalpostvoltageusingadigital

multimeter(DMM).

3. Inspect,clean,service,orreplacebatteryandterminalconnections.


43/66


T6 liST (cOnTinuEd)

4. Inspect,clean,repairandreplacebatteryboxes,mounts,andholddowns.

5. Chargebatteryusingsloworfastchargemethodasappropriate.

6. Jumpstartavehicleusingjumpercablesandaboosterbatteryorappropriateauxiliarypowersupply.

7. Diagnoselowvoltagedisconnect(LVD)systems;determineneededrepairs.

C. Starting System Diagnosis and Repair (7 questions) 1. Performstartingcircuitvoltagedroptests;determineneededrepairs.

2. Inspect,test,andreplacecomponentsandwiresinthestartercontrolcircuit.

3. Inspect,test,andreplacestarterrelaysandsolenoids/switches.

4. Removeandreplacestarter;inspectywheelringgearorexplate.

5. Inspect,clean,repair,andreplacebatterycablesandconnectorsinthecrankingcircuit. 6. Differentiatebetweenelectricalandmechanicalproblemsthatcauseaslowcrank,

nocrank,extendedcranking,oracrankingnoisecondition.

7. Test/monitorbatteryvoltageduringcranking.Determineneededrepairs

D. Charging System Diagnosis and Repair (7 questions) 1. Diagnosedashmountedchargemetersand/orindicatorlightsthatshowanocharge,

lowcharge,oroverchargecondition;determineneededrepairs.

2. Diagnosethecauseofnocharge,lowcharge,oroverchargeconditions;determine

neededrepairs(includesremotesensealternators)

3. Inspect,adjust,andreplacealternatordrivebelts/gears,pulleys,fans,mountingbrackets,andtensioners.

4. Performchargingsystemoutputtests;determineneededrepairs.

5. Performchargingcircuitvoltagedroptests;determineneededrepairs.

6. Removeandreplacealternator.

7. Inspect,repair,orreplaceconnectorsandwiresinthechargingcircuit.

E. Lighting Systems Diagnosis and Repair (6 questions)

1. Headlights, Daytime Running Lights, Parking, Clearance, Tail, Cab, and Dash

Lights (3 questions) 1. Diagnosethecauseofbrighterthannormal,intermittent,dim,ornoheadlightand

daytimerunninglight(DRL)operation.

2. Test,aimandreplaceheadlights.

3. Test,repair,andreplaceheadlightanddimmerswitches,wires,connectors,terminals,

sockets,relays,andcontrolcomponents.

4. Inspect,test,repair,orreplaceswitches,bulbs,sockets,connectors,terminals,relays,

wires,andlight-emittingdiodes(LEDs)oflightingcircuitsontrucksandtrailers.

5. Inspect,test,repair,orreplacedashlightcircuitswitches,bulbs,LEDs,sockets,

connectors,terminals,wires,andprintedcircuits. 6. Inspect,test,repair,orreplaceinteriorcablightcircuitswitches,bulbs,LEDs,

sockets,connectors,terminals,orwires.

2. Stoplights, Turn Signals, Hazard Lights and Backup Lights (3 questions) 1. Inspect,test,adjust,repair,orreplacestoplightcircuitswitches,bulbs,LEDs,sockets,

connectors,terminals,relays,andwires.

2. Diagnosethecauseofturnsignalandhazardasherlightmalfunctions;determine

neededrepairs.


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T6 liST (cOnTinuEd)

3. Inspect,test,repair,orreplaceturnsignalandhazardcircuitashers,switches,bulbs,

LEDs,sockets,connectors,terminals,relays,andwires.

4. Inspect,test,adjust,repair,orreplacebackuplightandwarningdevices,circuitswitches,bulbs,LEDs,sockets,connectors,terminals,andwires.

5. Inspectandtesttrailerlightcordconnectorandcable;determineneededrepairs.

F. Gauges and Warning Devices Diagnosis and Repair (4 questions) 1. Diagnosethecauseofintermittent,high,low,ornogaugereadings;determineneeded

repairs.(Doesnotincludechargeindicators.)

2. Diagnosethecauseofdatabusdrivengaugemalfunctions;determineneededrepairs.

3. Inspect,test,adjust,repair,orreplacegaugecircuitsendingunits,sensors,gauges,

connectors,terminals,andwires. 4. Inspect,test,repair,orreplacewarningdevices(lightsandaudible)circuitsending

units,sensors,bulbs,audiblecomponent,socketsconnectors,terminals,wires,and

printedcircuits/controlmodules.

5. Inspect,test,andreplaceelectronicinstrumentationsystems;verifypropercalibration

forvehicleapplication.

G. Related Systems (8 questions) 1. Diagnosethecauseofconstant,intermittent,ornohornoperation.

2. Inspect,test,repair,orreplacehorncircuitrelays,horns,switches,connectors,

terminals,andwires. 3. Diagnosethecauseofconstant,intermittent,ornowiperoperation;diagnosethe

causeofwiperspeedcontroland/orparkproblems.

4. Inspect,test,repair,orreplacewipermotor,resistors,parkswitch,relays,switches,

connectors,terminals,andwires.

5. Inspectandreplacewipermotortransmissionmechanicallinkage,arms,andblades.

6. Inspect,test,repair,orreplacewindshieldwashermotororpump/relayassembly,

switches,connectors,terminals,andwires.

7. Inspect,test,repair,orreplacesideviewmirrormotors,heatercircuitgrids,relays,

switches,connectors,terminals,andwires. 8. Inspect,test,repair,orreplaceheaterandA/Celectricalcomponentsincluding:

A/Cclutches,motors,resistors,relays,switches,controls,connectors,terminals,

andwires.

9. Inspect,test,repair,orreplacecigarettelighterand/orauxiliarypoweroutletcase,

integralfuse,connectors,terminals,andwires.

10. Diagnosethecauseofslow,intermittent,ornopowerwindowoperation.

11. Inspect,test,repair,andreplacemotors,switches,relays,connectors,terminals,

andwiresofpowerwindowcircuits.

12. Diagnoseinverter/shorepowersystems;determineneededrepairs.13. Diagnosethecauseofpoor,intermittent,ornooperationofelectricdoorlocks.

14. Inspect,test,repair,andreplaceswitches,relays,controllers,actuators/solenoids,

connectors,terminals,andwiresofelectricdoorlockcircuits.

15. Inspect,testrepairandreplacecruisecontrolelectricalcomponents.

16. Inspect,test,repair,andreplaceenginecoolingfanelectricalcontrolcomponents.

17. Diagnosefailuresinthedatacommunicationsbusnetwork;determineneeded

repairs.


45/66


SAMplE QuESTiOnSElEcTricAl/ElEcTrOnic SySTEMS (TEST T6)

QuESTiOnS:

1. Inthechargingsystemshownabove,themeterreadingwillshow:

(A)chargingoutputvoltage.

(B)regulatoroperatingvoltage. *(C)chargingcircuitvoltagedrop.

(D)ignitionswitchvoltagedrop.

2. Atruckscabheaterblowermotoroperatesatlowspeedonly.Whichofthese

isthemostlikelycause?

(A)Anopenblowerswitchground

*(B)Abadblowerswitch

(C)Abindingblowercage (D)Ashorttopowerattheblowermotor

ALTERNATOR

BATTERY

BATTERY

TERMINAL

IGNITION TERMINAL

VOLTMETER

IGNITION SWITCH


46/66



3. Thehornsinthecircuitshownaboveonlyblowwhenajumperwireiscon-

nectedbetweenterminals30and87ofthehornrelay.

TechnicianAsaysthatafailedhornrelaycouldbethecause.

TechnicianBsaysthatashorttogroundinthecircuitbetweenthehornrelay

andthehornbuttoncouldbethecause.Whoisright?



4. Atrucksbatterydischargesaftersittingovernight.

TechnicianAsaysthatabadalternatorcouldbethecause.

TechnicianBsaysthatabadstartercouldbethecause.

Whoisright? *(A)Aonly (C)BothAandB


5. Adrivercomplainsthatthetrailermarkerlightsaredimatnightwhilebraking.

Whichoftheseisthemostlikelycause?

(A)Lowbatteryvoltage

(B)Oneburnedoutbrakelightbulb

*(C)Apoorgroundinthetrailerlightcord (D)Toomuchgreaseonthe5thwheel


47/66


6. Bothheadlightsonavehiclearediminhighbeamandnormalinlowbeam.

TechnicianAsaysthatapoorheadlightgroundcouldbethecause.

TechnicianBsaysthatashortedheadlightswitchcouldbethecause.

Whoisright?


(B)Bonly *(D)NeitherAnorB


7. Thevoltagereadingsshownaboveweretakenwhilecrankingtheengine.

Whichoftheseisindicatedbythereadings?

(A)Battery#2hasresistanceinthegroundcable.

*(B)Battery#2isweakerthanbattery#1.

(C)Battery#1islowonelectrolyte. (D)Battery#2shouldbereplaced.


48/66


TEST SpEcificATiOnSAnd TASkliSTHEATinG, vEnTilATiOn,And Air cOndiTiOninG (HvAc)

SySTEMS (TEST T7)


A. HVAC Systems Diagnosis, Service,

and Repair 6 15%

B. A/C System and Component Diagnosis,Service, and Repair 16 40%

1. A/C System General (6)

2. Compressor and Clutch (5)

3. Evaporator, Condenser,

and Related Components (5)

C. Heating and Engine Cooling Systems

Diagnosis, Service, and Repair 6 15%

D. Operating Systems and Related ControlsDiagnosis and Repair 8 20%

1. Electrical (5)2. Air/Vacuum/Mechanical (2)

3. Constant/Automatic

Temperature Control (1)

E. Refrigerant Recovery, Recycling,

Handling,andRetroft 4 10%

Total 40 100%

A. HVAC Systems Diagnosis, Service, and Repair (6 questions) 1. Verifythecomplaint,roadtestthevehicle,reviewdriver/customerinterviewand


2. VerifytheneedofserviceorrepairofHVACsystemsbasedonunusualoperating

noises;determineappropriateaction.

3. VerifytheneedofserviceorrepairofHVACsystemsbasedonunusualvisual,

smell,andtouchconditions;determineappropriateaction.

4. Identifysystemtypeandcomponents(cyclingclutchoricetube-CCOT,expansionvalve,typeofrefrigerant)andconductperformancetest(s)onHVACsystems;

determineappropriateaction.


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B. A/C System and Component Diagnosis, Service, and Repair (16 questions)

1. A/C System. General (6 questions) 1. DiagnosethecauseoftemperaturecontrolproblemsintheA/Csystem;determineneededrepairs.

2. Identifyrefrigeranttypeandcheckforcontamination;determineappropriateaction.

3. DiagnoseA/Csystemproblemsindicatedbypressuregaugereadingsandsightglass/

moistureindicatorconditions(whereapplicable);determineneededservice

orrepairs.

4. DiagnoseA/Csystemproblemsindicatedbyunusualoperatingnoise,visual,

smell,andtouchprocedures;determineneededrepairs.

5. PerformA/Csystemleaktest;determineneededrepairs. 6. EvacuateA/Csystemusingappropriateequipment.

7. InternallycleancontaminatedA/Csystemcomponentsandhoses.

8. ChargeA/Csystemwithcorrecttypeandquantityofrefrigerant.

9. Identifylubricanttypeneededforsystemapplication.

2. Compressor and Clutch (5 questions) 1. DiagnoseA/Csystemproblemsthatcauseprotectiondevices(pressure,thermal,and

electronic)tointerruptsystemoperation;determineneededrepairs.

2. Inspect,test,andreplaceA/Csystempressure,thermal,andelectronicprotection

devices. 3. InspectandreplaceA/Ccompressordrivebelts,pulleys,idlers,andtensioners;

adjustdrivebeltsandcheckalignment.

4. Inspect,test,service,andreplaceA/Ccompressorclutchcomponentsorassembly.

5. InspectandcorrectA/Ccompressorlubricantlevel.

6. Inspect,test,andreplaceA/Ccompressor.

7. Inspect,repair,orreplaceA/Ccompressormountingsandhardware.

3. Evaporator, Condenser, and Related Components (5 questions)

1. Correctsystemlubricantlevelwhenreplacingtheevaporator,condenser,

receiver/drieroraccumulator/drier,andhoses.

2. Inspect,repair,orreplaceA/Csystemhoses,lines,lters,ttings,andseals.

3. InspectA/Ccondenserforproperairow.

4. Inspect,test,andreplaceA/Csystemcondenserandmountings.

5. Inspectandreplacereceiver/drieroraccumulator/drier.

6. Inspect,test,andreplacecab/sleeperrefrigerantsolenoid,expansionvalve(s),

thermostaticswitch(thermistor);andcheckplacementofthermalbulb

(capillarytube).

7. Inspectandreplaceoricetube. 8. Inspect,test,andreplacecab/sleeperevaporatorcore.

9. Inspect,clean,andrepairevaporatorhousingandwaterdrain;inspectand

service/replaceevaporatorairlter.

10. Identify,inspect,andreplaceA/Csystemserviceports/valves(gaugeconnections).

11. DiagnosesystemfailuresresultinginrefrigerantlossfromtheA/Csystemhigh

pressurereliefdevice.


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C. Heating and Engine Cooling Systems Diagnosis, Service, and Repair

(6 questions) 1. Diagnosethecauseofoutletairte

Ase Medhvytruck2011 Web

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