ASE MedHeavyTruck 2012 WEB

7/29/2019 ASE MedHeavyTruck 2012 WEB

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The OfficialASE Study Guide

ASE Medium/HeavyTruck Tests


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Table of Contents

Overview ................................................................................................38

Medium/Heavy Truck Tests .................................................................. 960 GasolineEngines(TestT1).............................................................9

DieselEngines(TestT2) ...............................................................18

DriveTrain(TestT3) ....................................................................25

Brakes(TestT4) ............................................................................31

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

Electrical/ElectronicSystems(TestT6)........................................41

Heating,Ventilation,andAirConditioning

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

PreventiveMaintenanceInspection(PMI)(TestT8)....................53

Test Prep & Training ................................................................................61

ASE MEdiuM/HEAvyTruckTESTS


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ASE MEdiuM/HEAvyTruckSTudyGuidE PAGE3

OvErviEw

IntroductionTheOfcial ASE Study Guide for the Medium/Heavy Truck Testsisintendedto

helptechniciansstudyfortheASEcerticationtests.Thespecicmaterialabouteachtest,includedinthebookletisausefultoolforreviewingthetechnical

knowledgethatiscoveredintheMedium/Heavy Truck tests.Afterperforming

athoroughreview,itshouldbeeasiertoselectadditionalreferencematerialthat

willassistyouwiththetestpreparationneeds.

ASEvoluntarycerticationisameansbywhichtechnicianscanprovetheir

abilitiestothemselves,totheiremployers,andtotheircustomers.Bypassing

ASEtestsyouwillearnthemostvaluablecredentialavailabletotrucktechni-

cians.Becausethetestsaretough,youllhavethesatisfactionofprovingtoyourselfthatyouareamongtheeliteinyourprofession.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/HeavyTruck

Technician.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,youmaytakeitagainduringanysubsequenttestwindow

inwhichitisoffered.Andremember,youaretheonlyonewhowillreceiveyour

testsscores;resultswillnotbegivenoverthephonenorwilltheybereleasedtoanyonewithoutyourwrittenpermission.

Medium/Heavy Truck TestsThisStudyGuidecontainsTestSpecications,tasklists,andsample

questionsforthefollowingASEtests:

GasolineEngines(TestT1);DieselEngines(TestT2);DriveTrain(TestT3)

Brakes(TestT4);SuspensionandSteering(TestT5);Electrical/Electronic

Systems(TestT6);Heating,Ventilation,andAirConditioning(HVAC)

Systems(TestT7);andPreventiveMaintenanceInspection(PMI)(TestT8).

ASEalsoofferscerticationinAutomobile,TruckEquipment,TransitBus,

SchoolBus,CollisionRepair/Renish,PartsSpecialist,andAdvancedLevel

specialties.

ForfullinformationonASEtestingaswellasdownloadableStudy Guides,

othertestpreparationresources,andmore,visitwww.ase.com.

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.

Fromthere,allquestionsarepre-testedandquality-checkedonanational

sampleoftechnicians.ThosequestionsthatmeetASEstandardsofqualityand

accuracyareincludedinthetests;therejectsaresentbacktothedrawingboard

ordiscardedaltogether.

OvErviEw (cOnTinuEd)


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

foreachofthetestscoveredinthisbookletcontainasummarydescriptionofthecontentcoveredbyeachtest.TheListsdescribetheactualworkperformedby

techniciansineachspecialtyarea.Together,theseformablueprintforwriting

andassemblingtheASEtests.

Pleasenotethateachquestiononthetestiskeyedorlinkedtoaparticular

orsetoftasksinthelist.Therefore,areviewofthelists,withaneyetojudging

whetheryouknowhowtoperformeachlisted,willprovidevaluableinformation

toprepareforthetests.

Therearevetypesofmultiple-choicequestionsonthetests,eachofwhich

isincludedinthesamplequestionsinthisbooklet.Notethedifferentinstructions

forsomequestions.

Besuretoreadeachquestioncarefully,(twice,ifnecessary)sothatyou

understandexactlywhatisbeingasked.Each question tests a specic diagnostic

or repair problem and has only one best answer.


Certifcation RecertifcationTests Tests

Number o Testing Number o Testing

Test Name questions* time questions time

Medium/Heavy Truck Tests

T1 GasolineEngines 60 1hrs. 25 30min.

T2 DieselEngines 65 1hrs. 28 45min.

T3 DriveTrain 50 1hr. 20 30min.

T4 Brakes 60 1hrs. 25 30min.

T5 SuspensionandSteering 60 1hrs. 25 30min.

T6 Electrical/ElectronicSystems 60 1hrs. 25 45min.

T7 Heating,Ventilation,andA/C 50 1hr. 20 30min.

T8 PreventiveMaintenanceInspection 60 1hrs. 25 30min.

*ASEcerticationtestsusuallyincludetenadditionalresearchquestionsthatarenotcounted

forscore.Youwillnotbetoldwhichquestionstheseare,soyoushouldanswereveryquestion.

NoresearchquestionsareaddedtoRecerticationTests.Youareonlyeligibletotakethe

RecerticationTestwhenyouhavepreviouslypassedthecorrespondinginitialcerticationTest.

ASE Tests 2012

How Long are the Tests?


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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.

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;andinmakingmajorinspectionsandadjustments.Alsotestsabilitytouseshopmanualsandprecisiontoolsof

thetrade.

Testing and diagnostic knowledge and skill:Testsyourabilitytorecognize

problemsandtousegenerallyavailablemeasurementandtestingequipment

tomakeadiagnosis.Alsotestsyourabilitytotracetheeffectsofaparticular

conditionandndthecauseofaparticularsetofsymptoms.

Ifyouareanexperiencedandcompetenttechnician,acarefulreviewof

thisbooklet,andadditionalbrush-uponthoseareasinwhichyouareweakest,

isallyoushouldneedtopasstheASEtests.

Beore The TestsTrytobewell-restedforthetestsoyouwillbealertandefcient.Besureto

bringalongyourtestcenteradmissionticketandacurrentphotoI.D.Lockers

willbeprovidedforpersonalitems,includingcellphones.

At the Test CenterSome TipsArriveearlyenoughtoparkandndtheTestCenterofce.Latearrivalsmaybe

turnedawaybytheTestCenterstaff.Ifyoucannottakeatestbecauseyouare

late,youwillforfeityourtestfees.

BringyourAdmissionTicketandphotoIDwithyou.Books,calculators,

andotherreferencematerialwillnotbepermittedinthetestroom.Youwillbe



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assignedalockertostoreallyourpersonalitems(cellphone,coat,hat,etc.)

Noelectronicdevicesareallowedinthetestroom.

Youwillreceivescratchpaperandpencils,andifyouaretakinganAdvancedLeveltest,aCompositeVehiclebooklet.Onceyouareseated,

thesupervisorwillexplainhowtousethecomputerandmouse.Eachtest

appointmentbeginswithashorttutorialthatwillhelpyoubecomefamiliar

withtheoperationofthecomputer-basedtest.Youcanalsopreviewthesystem

onlineatwww.ase.com/cbtbeforeyougototakeyourtest.

Eachtesthasaspecictimelimit,aslistedearlier.Asyoutakeeachtest,

thecomputerscreenwillcontinuouslydisplaytheamountoftimeleft.Youcan

takeabreakifnecessary,buttheclockwillcontinuetorun.Ifyounishearly,youmayreviewyouranswersorcontinuetothenexttest,ifyourappointment

includesmultipletests.Onceyousubmitatestforscoring,youcannotgoback

andreviewit.

Ifaquestionisdifcult,marktheanswerthatyouthinkiscorrectand

agthequestionusingtheon-screenbutton.Thengoontothenextquestion.

Whenyouhavenishedthetest,youmayhavetimetogobacktothosequestions

youhaveagged.Yourscoreisbasedonthenumberofcorrectanswersthatyou

give,soitistoyouradvantagetoanswereveryquestion.

Whenyounishyourlasttest,youwillbegivenashortcustomersatisfac-

tionsurvey.Whenyoucompleteit,youcanreporttothestaffandreceiveyour

scorereports.

Test Content and Sample QuestionsThefollowingmaterialisdesignedtohelptechniciansprepareforASEcertica-

tiontests.

EachofthesectionsbeginswiththeTestSpecications,whichlistthemain

categoriescoveredonthatparticulartestandthenumberoftestquestionsand

percentageofthetestdevotedtoeachtopic.

TheListdescribestheworkactivitiesatechnicianshouldbeabletoperform

ineachtechnicalareacoveredonthattest.Thislistwasdevelopedbyworking

techniciansandtechnicalexpertsfromacrossthecountryandwillprovideavalu-

ablechecklistofwhattostudyforthetest.

Itshouldbenotedthatthenumberofquestionsineachcontentareamaynotequalthenumberoftaskslisted.Someofthetasksarecomplexandbroad

inscopeandmaybecoveredbyseveralquestions.Othertasksaresimpleand

narrowinscopeandonequestionmaycoverseveraltasks.Themainobjective

inlistingthetasksistodescribeaccuratelywhatisdoneonthejob,nottomake

eachcorrespondtoaparticulartestquestion.



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Samplequestionsfollow.Althoughthesesamequestionswillnotappearon

actualtests,theyareinthesameformatasactualtestquestions.Allvetypesof

multiple-choicequestionsusedontheASEtestsarerepresentedhere.Notethedifferentinstructionsforsomequestions.



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Content Questions PercentageArea in Test of Test

A. General Engine Diagnosis 14 28%

B. Cylinder Head and Valve Train

Diagnosis and Repair 4 8%

C. Engine Block Diagnosis and Repair 4 8%

D. Lubrication and Cooling Systems


E. Ignition System Diagnosis and Repair 6 12%

F. Fuel, Air Induction, and Exhaust Systems


G. Emissions Control Systems

Diagnosis and Repair 5 10%I. 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,andwiresinthestarter

andchargingcontrolcircuits.

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,andbrackets;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;checkmatingsurfacesand

relatedcomponentsfordamageorwarpageandsurfacenish;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;check

conditionofoilpassages;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;adjustdrivebeltsand

checkalignment. 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,andhoses;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,including

electronicthrottleactuatorcontrol(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. ResearchOBDIIsystemoperationtodeterminetheenablecriteriaforsettingand

clearingdiagnostictroublecodes(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.

TechnicianBsaysthatthecompressiontestreadingsshownabovecouldbecausedbywrongvalvetiming.

Whoisright?

*(A)Aonly (C)BothAandB

(B)Bonly (D)NeitherAnorB

2. TechnicianAsaysthatpartXshownaboveisusedtoimprovevalvespring

rotation.

TechnicianBsaysthatpartXshownaboveisusedtocorrectinstalledspring

height.

Whoisright?

(A)Aonly (C)BothAandB

*(B)Bonly (D)NeitherAnorB

COMPRESSION

SPECS140 PSI

130

140

15

15

140

140

130

135


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3. Anengineisusingtoomuchoil.TechnicianAsaysthatwornvalveguides

couldbethecause.

TechnicianBsaysthattaperedcylinderwallscouldbethecause.

Whoisright?

(A)Aonly *(C)BothAandB


4. Whileperformingacylinderleakagetestonanengine,thetechnicianseesair

bubblesintheupperradiatortank.

TechnicianAsaysthatacrackedheadcouldbethecause.

TechnicianBsaysthatacrackedblockcouldbethecause.

Whoisright?

(A)Aonly *(C)BothAandB


5. TechnicianAsaysthatmainbearingoilclearancecanbecheckedwithplasti-

gage.

TechnicianBsaysthatmainbearingoilclearancecanbecheckedwithafeeler

gauge.

Whoisright?



6. Thetechnicianndsnosparkandnoinjectorpulsesonavehiclethatwillnot

start.Themostlikelycauseisafailed:

(A)massairowsensor(MAF).

*(B)crankshaftpositionsensor(CKP). (C)throttlepositionsensor(TPS).

(D)fuelpumpmodule(FP).

7. Anenginewithanelectronicfuelinjection(EFI)systemhashighfuelpressure

atidle.Whichofthesecouldbethecause?

*(A)Lowmanifoldvacuum

(B)Aleakingfuelpumpcheckvalve

(C)Apluggedfuelinjector (D)Highmanifoldvacuum

T1 SAMplE QuESTiOnS (cOnTinuEd)


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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.



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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. Identifyenginemodelandserialnumbertoresearchapplicablevehicleandserviceinformation,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;determineserviceabilityandneededrepairs.

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,and

bracketsforwear,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;checkmatingsurfacesandrelatedcomponentsfordamageorwarpageandsurfacenish;checkdeckheight;

checkconditionofpassages,core,andgalleryplugs;inspectthreadedholes,studs,

dowelpinsandboltsforserviceability;service/replaceasneeded.

3. Inspectcylindersleevecounterboreandlowerbore;checkboredistortion;determine

neededservice.


20/62


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.(Includescheckingengineposition

andspeedindicatorcomponents,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/switchandpressure

gauge;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;adjustdrivebeltsand

checkalignment. 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.



21/62


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,andadjustmentsonhydraulicelectronicunit

injectors(HEUI)andelectroniccontrols(railpressurecontrol). 8. Performon-engineinspections,testsandadjustmentsonelectronicunitinjectors

(EUI)andelectroniccontrols.

9. Performon-engineinspectionsandtests,onhigh-pressurecommonrailfuelsystems

andelectroniccontrols.

10. Inspect,test,andreplaceengineprotectionandautomaticstop/restartsystem

components.



22/62


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/replaceenginecompressionandexhaustbrakecontrol

circuits,switches,andsolenoids. 3. Inspectandrepair/replaceenginecompressionandexhaustbrakehousing(s),valves,

seals,springs,lines,andttings.



23/62


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.


24/62


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.

TechnicianBsaysthatapluggedturbochargeroilreturnlinecouldbethecause.

Whoisright?





25/62



A. Clutch Diagnosis and Repair 11 28%

B. Transmission Diagnosis and Repair 13 33%

C. Driveshaft and Universal JointDiagnosis and Repair 7 18%

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,andchatter

problems;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.


26/62


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.


27/62


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;properlyphase/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;determineneededrepairs.

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

collectors,slingers,tubes,andlters.

14. Inspectandreplacedriveaxleshafts.

15. Removeandreplacewheelassembly;checkdriveaxlewheel/hubsealandaxleange

gasketforleaks;determineneededrepairs.


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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.


29/62


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 *(B)Bonly (D)NeitherAnorB

3. Theshiftleverona13-speedtransmissionishardtomove.

Whichoftheseisthemostlikelycause?

(A)Bentshiftrails

*(B)Galledslidingclutchgears

(C)Worndetentsprings

(D)Toomuchmainshaftgearendplay

4. Theairpressureregulatorforatransmissionisbeingchecked.

TechnicianAsaysthatthetractorairpressureshouldbeatmaximumsystem

pressure.

TechnicianBsaysthattheregulatorairltershouldbecleanedandthesystem

recheckediftheairpressurereadingisbelownormal.

Whoisright?

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

ROTATE

RING GEAR


30/62


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



31/62



A. Air Brakes Diagnosis and Repair 33 66%

1. Air Supply and Service Systems (16)2. Mechanical/Foundation and Wheel Hub (13)

3. Parking Brakes (4)

B. Hydraulic Brakes Diagnosis and Repair 12 24%

C. Air and Hydraulic Antilock Brake Systems

(ABS), Automatic Traction Control (ATC),

and Electronic Stability Control Systems 5 10%

Total 50 100%

TEST SpEcificATiOnSAnd liSTBrAkES (TEST T4)

A. Air Brakes Diagnosis and Repair (33 questions)

1. Air Supply and Service Systems (16 questions) 1. Reviewdriver/vehicleinspectionreport(DVIR);verifythecomplaintandroadtest

vehicle;reviewdriver/customerinterviewandpastmaintenancedocuments(ifavail-

able);determinefurtherdiagnosis.

2. Checkairsystembuilduptime;checkairsystemairlossrate(leakage);determine

neededrepairs.

3. Inspect,test,repairorreplaceairpressuregauges,in-cablines,hoses,ttings,andpressuresensors(transducers).

4. Inspect,test,andreplacelowpressurewarningdevices.

5. Drainairreservoirtanks;checkforoil,water,andforeignmaterial;determineneeded

repairs.

6. Inspect,adjust,align,andreplacecompressordrivebeltsandpulleys.

7. Inspectandreplacecompressordrivegearandcoupling.

8. Inspect,repair,orreplaceaircompressor,airinletsupply,oilsupply,waterlines,

hoses,ttingsandmountingbrackets.

9. Inspect,test,adjust,andreplacesystempressurecontrols(governor/reliefvalve),unloaderassembly,lines,hoses,andttings.

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

properroutingandmounting.

11. Inspect,test,clean,andreplaceairtankrelief(popoff)valves,one-way(single)

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

connectors.


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T4 liST (cOnTinuEd)

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

andconnectors.

13. Inspect,test,andreplacebrakeapplication(foot)valve,ttings,andmounts;check

pedaloperation.

14. Inspect,test,repair,orreplacestopandparkingbrakelightcircuitswitches,wiring,

andconnectors.

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

andmountings.

16. Inspect,test,andreplacebrakerelayvalves,quickrelayvalves,andanti-compound-

ingcircuits.

17. Inspect,test,andreplacetractorprotectionvalve.

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

19. Determineifairbrakesystemproblemiscausedbytractorortrailersupplyorservice

systemcomponents.

2. Mechanical/Foundation and Wheel Bearings (13 questions) 1. Diagnosepoorstopping,prematurewear,brakenoise,pulling,grabbing,ordragging

problemscausedbyfoundationbrakecomponents;determineneededrepairs.

2. Inspect,test,andreplaceservicebrakechambers,diaphragms,clamps,returnsprings,

pushrods,clevises,andmountingbrackets.

3. Inspect,service,andreplaceautomaticslackadjusters.

4. InspectandreplaceS-cambrakerollers,bushings,camshafts,seals,spacers,retain-ers,brakespiders,shields,anchorpins,andsprings.

5. Inspect,clean,adjust,andreplaceairdiscbrakecaliperassemblies.

6. Inspectbrakeshoesorpads;determineneededrepairs.

7. Replacebrakeshoesorpads;determinecorrectreplacementlining/padcoefcientof

frictionratingforapplication.

8. Inspectandreplacebrakedrumsorrotorsasneeded.

9. Clean,inspect,lubricate,andreplacewheelhubs,wheelbearingsandraces/cups;

replacesealsandwearrings;adjustwheelbearings(includingoneandtwonuttypes)

tomanufacturersspecications.10. Inspectandreplaceunitizedhubbearingassemblies;performinitialinstallationand

maintenanceprocedurestomanufacturersspecications.

3. Parking Brakes (4 questions) 1. Inspectandtestparking(spring)brakechambersoperationtoincludespringcondi-

tion,leakage,andinstallation/mounting.

2. Replaceparking(spring)brakechambers;disposeofchambersinaccordancewith

localregulations.

3. Inspect,test,andreplaceparking(spring)brakevalves,lines,hoses,andttings.

4. Inspect,test,andreplaceparking(spring)brakedashcontrolvalve. 5. Manuallyrelease(cage)andset(uncage)parking(spring)brakes.

B. Hydraulic Brakes Diagnosis and Repair (12 questions) 1. Diagnosepoorstopping,brakenoise,prematurewear,pulling,grabbing,dragging,

orpedalfeelproblemscausedbyhydraulicsystemcomponents;determineneeded

repairs.

2. Pressuretesthydraulicsystemandinspectforuidleaks;checksystempressure

actuatoroperation,anddiagnosefaultcodesusingaPCcomputerifapplicable.


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T4 liST (cOnTinuEd)

3. Checkbrakepedaloperationandadjustfreeplay.

4. Inspect,test,andreplacemastercylinder;checkpushrodlength.

5. Inspectandreplacebrakelines,exiblehoses,andttings;checkforproperrouting

andmounting.

6. Inspect,test,andreplacemetering(holdoff),loadsensing/proportioning,proportion-

ing,andcombinationvalves.

7. Inspect,test,repair,orreplacebrakepressuredifferentialvalveandwarninglight

circuits,switches,bulbs,wiring,andconnectors.

8. Inspectandreplacewheelcylinders.

9. Inspect,service,andreplacediscbrakecaliperassemblies.

10. Inspect/testbrakeuid;bleedand/orushsystem;determineproperuidtypefor

application.

11. Diagnosepoorstopping,brakenoise,prematurewear,pulling,grabbing,dragging,or

pedalfeelproblemscausedbydiscanddrumbrakemechanicalcomponents;deter-

mineneededrepairs.

12. Inspectandreplacebrakedrumsorrotors;resurfacerotorsifapplicable.

13. Inspect,adjust,andreplacebrakeshoes,mountinghardware,adjustermechanisms,

andbackingplates.

14. Inspect,service,andreplacebrakepads,hardware,andmounts.

15. Inspect,adjust,andreplacedrivelineparkingbrakesystemcomponents.

16. Diagnosepoorstoppingcomplaintscausedbybrakeassist(booster)systemprob-

lems;determineneededrepairs;(includeshydraulicandhydraulic/electricassist

systems).

17. Inspect,test,repair,orreplacepowerbrakeassist(booster),hoses,controlvalvesand

lters;determineproperuidtypeforapplication.

18. Test,adjust,repairorreplacebrakestoplightswitch,bulbs,wiring,andconnectors.

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

(ATC), and Electronic Stability Control Systems (5 questions)

1. Observeantilockbrakesystem(ABS)operation,selftestoperationandwarninglightoperation;determineiffurtherdiagnosisisneeded;(includesdashmountedtrailer

ABSwarninglight).

2. Diagnoseantilockbrakesystem(ABS)electroniccontrolsandcomponentsusing

self-diagnosis(blinkcodes)and/orspeciedtestequipment(scantool,PCbased

software);determineneededrepairs.

3. Diagnosepoorstoppingandwheellock-upcausedbyfailureoftheantilockbrake

system(ABS);determineneededrepairs.

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

mechanicalcomponents. 5. Diagnoseautomatictractioncontrol(ATC)electroniccontrol(s)andcomponentsus-

ingself-diagnosis(blinkcodes)and/orspeciedtestequipment(scantool,PCbased

software);determineneededrepairs.

6. Diagnoseelectronicstabilitycontrolsystemsandcomponentsusingself-diagnosis

(blinkcodes)and/orspeciedtestequipment(scantool,PCbasedsoftware);deter-

mineneededrepairs.


34/62


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?



4. Aservicebrakechamberleakswhenthebrakesareapplied.Whichofthese

couldbethecause?

(A)Excessivepushrodtravel

*(B)Abadchamberdiaphragm

(C)Abrokenchamberreturnspring

(D)Amisalignedpushrod


35/62


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.



36/62



A. Steering System Diagnosis and Repair 12 24%

B. Suspension, Frame, and

5th Wheel Diagnosis and Repair 16 32%

C. Wheel Alignment Diagnosis, Adjustment,

and Repair 13 26%

D. Wheels, Tires, and

Hub Diagnosis and Repair 9 18%

Total 50 100%

TEST SpEcificATiOnSAnd liSTSuSpEnSiOnAnd STEErinG (TEST T5)

A. Steering System Diagnosis and Repair (12 Questions) 1. Diagnosesteeringcolumn(tilt,telescoping,orxed)fornoise,looseness,andbind-

ingproblems;determineneededrepairs.

2. InspectandreplacesteeringshaftUjoint(s),slipjoints,bearings,bushings,andseals;

phaseshaftUjoints.

3. Checkcabmountingandadjustrideheight.

4. Removethesteeringwheel(includessteeringwheelsequippedwithelectrical/elec-

troniccontrolsandcomponents);installandcenterthesteeringwheel.Inspect,test,

replace,andcalibratesteeringanglesensors. 5. Diagnosepowersteeringsystemnoise,steeringbinding,darting/oversteer,reduced

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

steering,overheating,uidleakage,anduidaerationproblems;determineneeded

repairs.

6. Determinerecommendedtypeofpowersteeringuid;checklevelandcondition;

determineneededservice.

7. Flushandrellpowersteeringsystem;purgeairfromsystem.

8. Performpowersteeringsystempressure,temperature,andowtests;determine

neededrepairs. 9. Inspect,service,orreplacepowersteeringreservoirincludinglter,seals,andgas-

kets.

10. Inspectandreinstall/replacepowersteeringpumpdrivebelts,pulleysandtensioners;

adjustdrivebeltsandcheckalignment.

11. Inspect,adjust,orreplacepowersteeringpump,drivegears/shafts,mountings,and

brackets.


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T5 liST (cOnTinuEd)

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

ttings;checkhoserouting.

13. Inspect,adjust,orreplacelinkage-assisttypepowersteeringcylinderorgear(dual

system).

14. Inspect,adjust,repair,orreplaceintegraltypepowersteeringgear.

15. Adjustmanualandautomaticsteeringgearpoppet/reliefvalves.

16. Inspect,align,andreplacepitmanarm.

17. Inspect,adjust,andreplacedraglink(relayrod)andtierodends(ballandadjustable

sockettype).

18. Inspectandreplacesteeringarms.

19. Inspectandreplacetierodcrosstube(relayrod/centerlink),clamps,andretainers;

positionasneeded.

20. Checkandadjustwheelstops.

B. Suspension System Diagnosis and Repair (16 Questions) 1. Inspectandreplacefrontaxlebeamandmountinghardware.

2. Inspect,service,adjust,andreplacekingpins,bushings,locks,bearings,seals,and

covers.

3. Inspectandreplaceshockabsorbers,bushings,brackets,andmounts.

4. Inspect,repair,andreplace(leafandparabolic)springs,centerbolts,clips,springeye

boltsandbushings,shackles,slippers,insulators,brackets,andmounts.

5. Inspect,adjust,andreplaceaxlealigningdevicesincludingradiusrods/arms,torquerods,transversetorquerods/trackbars,stabilizerbars,bushings,mounts,shims,and

cams.

6. Inspectandreplacewalkingbeams,center(cross)tube,bushings,mounts,loadpads,

brackets,caps,andmountinghardware.

7. Inspect,test,andreplaceairsuspensionsprings(bags),mountingplates,andmain

supportbeams/springs,pressureregulatorandheightcontrolvalves,linkages,lines,

hoses,andttings.

8. Diagnose,inspect,andreplace,auxiliaryliftaxlecomponentsandcontrols.

9. Measurefrontandrearvehiclerideheights;determineneededadjustmentsorrepairs.10. Verifyanddiagnosevehiclesuspensioncomplaints;determineneededrepairs.

11. TorqueU-boltstomanufacturersspecications.

12. Checkaxleloaddistributionproblemsonrearsuspensions;checkaxleseatplaning

anglesandpinionangles.

13. Inspectframeandframemembersforcracks,breaks,distortion,elongatedholes,

looseness,anddamage;determineneededrepairs.

14. Inspect,install,orrepairframehangers,brackets,crossmembersandfastenersin

accordancewithmanufacturersrecommendedprocedures.

15. Inspect,adjust,service,repair,orreplacefthwheel,pivotpins,bushings,lockingjawmechanisms,andmountingbolts.

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

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

17. Inspect,install,repairorreplacepintlehooksanddrawbars.


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T5 liST (cOnTinuEd)

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

problems;determineneededadjustmentsandrepairs.

2. CheckcamberandKPI(kingpininclination);determineneededrepairs.

3. Checkandadjustcaster.

4. Checkandadjusttoe.

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

parallelism);adjustordetermineneededrepairs.

6. Checkturning/Ackermanangle(toeoutonturns)andmaximumturningradius

(wheelcut);determineneededrepairs.

D. Wheels, Tires and Hub Diagnosis and Repair (9 Questions)

1. Diagnosetirewearpatterns;determineneededrepairs. 2. Diagnosewheelendvibration,shimmy,pounding,hop(tramp)problems;determine

neededrepairs.

3. Inspectandreplacewheels,mountinghardware,studs,andfasteners.

4. Measurewheelandtireradialandlateralrunout;determineneededrepairsoradjust-

ments

5. Inspecttires;checkandadjustairpressuretomanufacturersspecications.

6. Performstaticbalanceofwheelandtireassembly.

7. Performdynamicbalanceofwheelandtireassembly.

8. Measuretirediameterandmatchtiresonaxles. 9. Removeandreinstalltire/wheelassembliestomanufacturersspecications.

10. Clean,inspect,lubricate,andreplacewheelhubs,wheelbearingsandraces/cups;

replacesealsandwearrings;adjustwheelbearings(includingoneandtwonuttypes)

tomanufacturersspecications.

11. Inspectandreplaceunitizedhubbearingassemblies;performinitialinstallationand

maintenanceprocedurestomanufacturersspecications.


39/62


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?




40/62


5. Ruststreakscomingfromaroundthestudholesofadiscwheelcouldbe

causedby:

(A)anoverloadedconditon. (B)overtorquedlug/capnuts.

*(C)Anoutofbalancecondition.

(D)Looselug/capnuts.

6. Atruckhasahistoryofspringsbreakingatthecenterboltholes.

TechnicianAsaysthatlooseU-boltscouldbethecause.

TechnicianBsaysthatloosespringshacklescouldbethecause.

Whoisright? *(A)Aonly (C)BothAandB


7. Aconstantbuzzingnoisecomesfromthepowersteeringpump.

TechnicianAsaysthecausecouldbeairinthesystem.

TechnicianBsaysthecausecouldbethatthereliefvalveisstuckinthe

openposition.



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.Readthequestioncarefullybefore

choosingyouranswer.

9. Alloftheseshouldbecheckedbeforealigningthefrontwheelsonatruck

EXCEPT:

(A)tirepressure.

(B)rideheight.

(C)wheelbearingadjustment.

*(D)tirebalance.



41/62



A. General Electrical/

Electronic System Diagnosis 14 28%

B. Battery and Starting System


C. Charging System Diagnosis and Repair 7 14%

D. Lighting Systems Diagnosis and Repair 6 12%

E. Related Vehicle Systems


Total 50 100%

TEST SpEcificATiOnSAnd liSTElEcTricAl/ElEcTrOnic SySTEMS (TEST T6)

A. General Electrical/Electronic System Diagnosis (14 questions) 1. Checkappliedvoltages,circuitvoltages,andvoltagedropsinelectrical/electronic

circuitsusingdigitalmultimeter(DMM),orappropriatetestequipment.

2. Checkcurrentowinelectrical/electroniccircuitsandcomponentsusingadigital

multimeter(DMM),clamp-onammeter,orappropriatetestequipment.

3. Checkcontinuityandresistanceinelectrical/electroniccircuitsandcomponentsusing

adigitalmultimeter(DMM),orappropriatetestequipment.

4. Findshorts,grounds,andopensinelectrical/electroniccircuits. 5. Diagnosekey-offbatterydrain(parasiticdraw)problems;determineneededrepairs.

6. Inspectandtestfusiblelinks,circuitbreakers,fuses,andothercircuitprotectionde

vices;includingresetwhenrequired.

7. Inspectandtestspikesuppressiondiodes/resistorsandcapacitors.

8. Inspectandtestrelaysandsolenoids(includingsolidstatedevices).

9. Readandinterpretelectricalschematicdiagramsandsymbols.

10. Diagnosefailuresinthedatacommunicationsbusnetwork;determineneededrepairs.

11. Diagnosevehicleelectroniccontrolsystemsusingappropriatediagnostictools,

software,andserviceinformation;checkandrecorddiagnosticcodes;determineneededrepairs.

12. Connectdiagnostictooltovehicle;accessandverifyparametersandcalibrationset-

tings;performupdatesasneeded.


42/62


T6 liST (cOnTinuEd)

B. Battery and Starting System Diagnosis and Repair (11 questions) 1. Determinebatterystateofchargebymeasuringterminalpostvoltageusingadigital

multimeter(DMM).

2. Performbatterytests(loadandcapacitance);determineneededservice.

3. Inspect,clean,service,orreplacebattery,cables,andterminalconnections.

4. Inspect,clean,repairorreplacebatteryboxes,mounts,andholddowns.

5. Chargebatteryusingappropriatemethodforbatterytype.

6. Jumpstartavehicleusingjumpercablesandaboosterbatteryorappropriate

auxiliarypowersupply.

7. Diagnoselowvoltagedisconnect(LVD)systems;determineneededrepairs.

8. Test/monitorbatteryandstartingsystemvoltageduringcranking;determineneeded

repairs.

9. Performstartingcircuitvoltagedroptests;determineneededrepairs.

10. Inspect,test,andreplacestartercontrolcircuitswitches,relays,connectors,terminals

andwires(includingthermalovercrankprotection).

11. Diagnosestartercrankinginhibitsystems;determineneededrepairs.

12. Inspect,test,andreplacestarterrelaysandsolenoids/switchesincludingintegrated

MAGswitch(IMS).

13. Inspect,clean,repair,orreplacecrankingcircuitcables,connectors,andterminals.

14. Removeandreplacestarter;inspectywheelringgearorexplate.

15. Differentiatebetweenelectricaland/ormechanicalproblemsthatcauseaslowcrank,

nocrank,extendedcranking,oracrankingnoisecondition.

C. Charging System Diagnosis and Repair (7 questions) 1. Verifyoperationofchargingsystemcircuitmonitors;determineneededrepairs.

2. Diagnosethecauseofnocharge,lowcharge,oroverchargeconditions;determine

neededrepairs.

3. Inspect,adjust,andreplacealternatordrivebelts/gears,pulleys,fans,mounting

brackets,andtensioners.

4. Performchargingsystemvoltage(ACandDC)andamperageoutputtests;determine

neededrepairs. 5. Performchargingcircuitvoltagedroptests;determineneededrepairs.

6. Removeandreplacealternator.

7. Inspect,repair,orreplacechargingcircuitconnectors,terminals,andwires.

D. Lighting Systems Diagnosis and Repair (6 questions) 1. Diagnosethecauseofbrighterthannormal,intermittent,dim,ornoheadlightand

daytimerunninglight(DRL)operation;determineneededrepairs.

2. Inspect,replace,andaimheadlightsandauxiliarylights.

3. Inspect,test,repair,orreplaceheadlightswitches,dimmerswitches,control

components,relays,sockets,connectors,terminals,andwires.

4. Inspect,test,repair,orreplacetruckandtrailerlightingcircuitswitches,bulbs,

light-emittingdiodes(LEDs),sockets,controlcomponents,relays,connectors,

terminals,andwires.

5. Inspect,test,repair,orreplaceinstrumentationlightcircuitswitches,bulbs,LEDs,

sockets,beropticcable,circuitboards,connectors,terminals,wires.


43/62


T6 liST (cOnTinuEd)

6. Inspect,test,repair,orreplaceinteriorcablightcircuitswitches,bulbs,LEDs,sock-

ets,connectors,terminals,andwires.

7. Inspect,test,adjust,repair,orreplacestoplightcircuitswitches,relays,bulbs,LEDs,

sockets,connectors,terminals,andwires.

8. Diagnosethecauseofturnsignalandhazardlightsystemmalfunctions;determine

neededrepairs.

9. Inspect,test,repair,orreplaceturnsignalandhazardcircuitashersorcontrolcom-

ponents,switches,relays,bulbs,LEDs,sockets,connectors,terminals,andwires.

10. Inspect,test,adjust,repair,orreplacebackuplightandwarningdevices,circuit

switches,bulbs,LEDs,sockets,connectors,terminals,andwires.

11. Inspectandtesttrailerlightcordconnectorandcable;determineneededrepairs.

E. Related Vehicle Systems Diagnosis and Repair (12 questions) 1. Diagnosethecauseofintermittent,inaccurate,ornogaugereadings;determine

neededrepairs.

2. Diagnosethecauseofdatabusdrivengaugemalfunctions;determineneededrepairs.

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

connectors,terminals,andwires.

4. Inspect,test,repair,orreplacewarningdevices(lightsandaudible)circuitsending

units,sensors,circuitboards/controlmodules,bulbs,audiblecomponent,sockets,


5. Inspect,test,andreplaceelectronicinstrumentationsystems;verifypropercalibrationforvehicleapplication.

6. Diagnosethecauseofconstant,intermittent,ornohornoperation;determineneeded

repairs.

7. Inspect,test,repair,orreplacehorncircuitrelays,horns,switches,clockspring,


8. Diagnosethecauseofconstant,intermittent,ornowiperoperation;diagnosethe

causeofwiperspeedcontroland/orparkproblems;determineneededrepairs.

9. Inspect,test,andreplacewipermotorandtransmissionmechanicallinkage,arms,and

blades,relays,switches,connectors,terminals,andwires.10. Inspect,test,repair,orreplacewindshieldwashermotororpump/relayassembly,

switches,connectors,terminals,andwires.

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

switches,connectors,terminals,andwires.

12. Inspect,test,repair,orreplaceheaterandA/Celectricalcomponentsincluding:A/C

clutches,motors,resistors,sensors,relays,switches,controlmodules,connectors,

terminals,andwires.

13. Inspect,test,repair,orreplacecigarettelighterand/orauxiliarypoweroutlet,integral

fuse,connectors,terminals,andwires.14. Diagnosethecauseofslow,intermittent,ornopowerwindowoperation;determine

neededrepairs.

15. Inspect,test,repair,andreplacepowerwindowmotors,switches,relays,connectors,

terminals,andwires.

16. Diagnoseinverter/shorepowersystems;determineneededrepairs.


44/62


17. Diagnosethecauseofpoor,intermittent,ornooperationofelectricdoorlocks;deter-

mineneededrepairs.

18. Inspect,test,repair,orreplaceelectricdoorlockcircuitswitches,relays,controllers,

actuators/solenoids,connectors,terminals,andwires.

19. Inspect,test,andreplacecruisecontrolelectricalcomponents.

20. Inspect,test,andreplaceenginecoolingfanelectricalcontrolcomponents.

21. Inspect,test,andreplaceelectricfuelsupply/transferpumpcontrolcomponents.

T6 liST (cOnTinuEd)


45/62


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


46/62



3. Thehornsinthecircuitshownaboveonlyblowwhenajumperwireiscon-

nectedbetweenterminals30and87ofthehornrelay.

TechnicianAsaysthatafailedhornrelaycouldbethecause.

TechnicianBsaysthatashorttogroundinthecircuitbetweenthehornrelay

andthehornbuttoncouldbethecause.



4. Atrucksbatterydischargesaftersittingovernight.

TechnicianAsaysthatabadalternatorcouldbethecause.

TechnicianBsaysthatabadstartercouldbethecause.

Whoisright?

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

5. Adrivercomplainsthatthetrailermarkerlightsaredimatnightwhilebraking.

Whichoftheseisthemostlikelycause?

(A)Lowbatteryvoltage

(B)Oneburnedoutbrakelightbulb

*(C)Apoorgroundinthetrailerlightcord

(D)Toomuchgreaseonthe5thwheel


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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.


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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 20 50%

C. Heating and Engine Cooling SystemsDiagnosis and Service 6 15%

D. Operating Systems and Related Controls


Total 40 100%

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

maintenancedocuments(ifavailable);determinefurtherdiagnosis.

2. VerifytheneedforserviceorrepairofHVACsystemsbasedonunusualoperating

noises;determineappropriateaction.

3. VerifytheneedofserviceorrepairofHVACsystemsbasedonunusualvisual,smell,

pressures,andcomponenttemperatureconditions(non-contactthermometer);deter-

mineappropriateaction.

4. Identifysystemtypeandcomponents(cyclingclutchoricetubeCCOT,expansionvalve),andconductperformancetest(s)onHVACsystems(ventoutlettemperature

andairow);determineappropriateaction.

5. IdentifyHVACcontrolsystemtype;checkandrecordelectronicdiagnosticcodes/

indicatorlights;determinefurtherdiagnosis.

B. A/C System and Component Diagnosis, Service, and Repair (20 questions)

A/C SystemGeneral 1. DiagnosethecauseoftemperaturecontrolproblemsintheA/Csystem;determine

neededrepairs. 2. Identifyrefrigerantandlubricanttypeandcheckforcontamination;determineap-

propriateaction.

3. DiagnoseA/Csystemproblemsindicatedbypressuregaugereadingsandsightglass/

moistureindicatorconditions(whereapplicable);comparegaugereadingstoambient

temperature/pressurechart;determineneededserviceorrepairs.

4. PerformA/Csystemleaktest;determineneededrepairs.


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T7 liST (cOnTinuEd)

5. RecoverA/Csystemrefrigerant;determineamountofoilremoved;determine

appropriateaction.

6. EvacuateA/Csystemusingappropriateequipment.

7. InternallycleancontaminatedA/Csystemcomponentsandhoses.

8. ChargeA/Csystemwithcorrecttypeandquantityofrefrigerantandlubricant.

9. Recyclerefrigerant.

10. Handle,labelandstorerefrigerant.

11. TestA/Csystemandrecycledrefrigerantfornon-condensablegases.

12. Maintainandverifycorrectoperationofcertiedequipme

Date post:	14-Apr-2018
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