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The Offi Official cial  ASE Study Guide

 ASE Medium/Heavy Truck Tests

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 ASE MEdiuM /HEAvy  Truck  TESTS Table of Contents

Overview ........................... ......................................................... ............................................................ ....................................... ......... 3–7   Medium/Heavy Truck Truck Tests Tests ............................. ........................................................... ..................................... ....... 8–61

• Gaso GasolineE lineEngine ngines(T s(Test estT1) T1) .............................................................8 • Diesel Engines (Test T2) ...............................................................17 • Drive Train (Test T3) ....................................................................24 • Brakes (Test T4) ............................................................................30 • Sus usp pen enssio ion na an nd dS Ste teeeri rin ng g(T (Teest tT T5)................................................36 • Elec Electrica trical/Elec l/Electronic tronicSys Systems tems(T (Test estT6) T6) ........................................42 • Heat Heatin ing, g,V Ven enti tila lati tion on, ,an and dAi Air rCo Cond ndit itio ioni ning ng (HV (H VAC AC) )Sy Syst stem ems s(T (Tes est tT7 T7)) ...........................................................48 • Pr Prev even enti tive veM Mai aint nten enan ance ceI Ins nspe pect ctio ion n(P (PMI MI) )(T (Tes est tT8 T8)) ....................54  Industry Training .............................. ............................................................ ................................................. ................... 62–65

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O vErviEw

Introduction  TheOfcial ASE Study Guide for the Medium/Heavy Truck Tests isintendedto helptechniciansstudyforthe helptechnician sstudyfortheASEcerticationtes ASEcerticationtests.Thesp ts.Thespecicmaterialabout ecicmaterialabout eachtest,includedinthebook eachtest,inclu dedinthebookletisauseful letisausefultoolforreviewin toolforreviewingthetechnical gthetechnical knowledgethatiscoveredinthe Medium/Heavy   Medium/Heavy Truck tests.Afterperforming athoroughreview athoroughrevi ew,itshouldb ,itshouldbeeasiertoselecta eeasiertoselectadditionalreference dditionalreferencematerialthat materialthat willassistyouwiththet willassist youwiththetestpreparationn estpreparationneeds. eeds. ASEvolun ASEvo luntar taryc ycert ertica icatio tioni nisa same means ansby bywh which ichte techn chnici icians ansca canp nprov rovet ethei heir r abilitiestothemselves,toth abilitiesto themselves,totheiremployers,and eiremployers,andtotheircustom totheircustomers.Bypassing ers.Bypassing ASEtestsyouwillearnthemos ASEtestsyou willearnthemostvaluablecredent tvaluablecredentialavailableto ialavailabletotrucktechni trucktechni cians.Becausethetestsaretough, cians.Becausethe testsaretough,you’llhavethe you’llhavethesatisfactionofp satisfactionofprovingto rovingto yourselfthatyouareamongtheel yourselfthaty ouareamongtheeliteinyourpro iteinyourprofession.W fession.What’ hat’smore,these smore,these credentialsarerecognizedthrougho credentialsarerecog nizedthroughoutthenation. utthenation. Certied Certi edtec techni hnicia cians nspro promot motec ecust ustome omert rtrus rusta tand ndim impro prove veth thei eimag mageo eof f theindustry.Andtrustandprofessionalismaretherststepstoabetter,more prosperousbusiness. ASEencou ASEen courag rages esyou youto tota take kethe thete tests stsan andt dtoj ojoin ointh thep eprov roven enpro prosw swho howe wear ar TheASEBlueSealofExcellence.®

How Do I Become Certifed?  TherearecurrentlyeighttestsintheMedium/Heavy Therearecurrentlyeighttestsin theMedium/HeavyTruck TruckT Techniciancertica tionseries.Class4throughCl tionseries.Cl ass4throughClass8trucksareco ass8trucksarecovered.Mediumduty vered.MediumdutyClass4–6 Class4–6 is14,001to26,000lbs. is14,001to 26,000lbs.grossvehiclewei grossvehicleweight(GVW).Heav ght(GVW).HeavydutyClass7– ydutyClass7–8is 8is 26,001andabovegrossvehicl 26,001andab ovegrossvehicleweight(GVW). eweight(GVW). Ifyoupa Ifyou pass ssone oneor ormo more retes tests tsand andha have veat atlea least sttwo twoye years arsof ofre relev levant antha hands nds-onworkexperience,youwillbecomecertiedasa onworkexperience, youwillbecomecertiedasan nASEMedium/Heavy ASEMedium/HeavyTruck Truck Technician.IfyoupasstheDieselEnginesTest(T2)andtestsT3,T4,T5,T6,and T7youwillearnthecerticateofMasterM T7youwillearnthece rticateofMasterMedium/HeavyT edium/HeavyTruckT ruckTechnician. echnician. Ifyouar Ifyou arec ecurr urrent ently lycer certi tied edin inDie Diesel selEn Engin gines es(A9 (A9,H ,H2, 2,S2, S2,or orT T2) 2) andElectrical/ElectronicSystems(A6 andElectrical/Elect ronicSystems(A6,H6,S6,or ,H6,S6,orT6),youareelig T6),youareeligibletotakethe ibletotakethe L2ElectronicDieselEngineD L2ElectronicD ieselEngineDiagnosisSpeciali iagnosisSpecialisttest. sttest.

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O vErviEw (cOnTinuEd ) Ifyoufa Ifyou fail ilat atest est,y ,you oumay mayta take keit itaga again indur during ingan anys ysche chedul duled edtes test t administrationinwhichitis administration inwhichitisoffered. offered.Andremember Andremember,youaretheonl ,youaretheonlyonewho yonewho willreceiveyourtestsscores;res willreceiveyou rtestsscores;resultswillno ultswillnotbegivenovert tbegivenoverthephonenorwi hephonenorwill ll theybereleasedtoanyonewitho theybereleasedt oanyonewithoutyourwritten utyourwrittenpermission. permission.

Medium/Heavy Medium/He avy Truck Tests  Tests  ASEtestsandcertiestechniciansin ASEtestsandcert iestechniciansinthefollowing thefollowingtruckareas: truckareas: • Gasol GasolineE ineEngin ngines(T es(Test estT1) T1) • Diese DieselEn lEngine gines(T s(Test estT2) T2) • Drive DriveT Train rain(T (Test estT3) T3) • Bra Brakes kes(T (Test estT T4) 4) • Suspe Suspensio nsionand nandSteer Steering( ing(T Test estT5) T5) • Elect Electrical rical/Elect /Electroni ronicSys cSystems tems(T (Test estT6) T6) • Heating,V Heating,Ventilation,an entilation,and dAirCondition AirConditioning(HV ing(HVAC)Systems(T AC)Systems(TestT7) estT7) • Preven Preventive tiveMain Maintenan tenanceIn ceInspect spection ion(PMI) (PMI)(T (Test estT8) T8) ASEalsooff ASEalso offersc erscertic erticatio ationin nin Auto Automobil mobile,T e,Truck ruckEqui Equipment pment,T ,Transi ransitBus tBus, , SchoolBus,CollisionRepair/Renish,E SchoolBus,Coll isionRepair/Renish,EngineMachinist ngineMachinist,PartsSpecialist, ,PartsSpecialist,and and AdvancedLevelspecialties. Forfull Forfu llinf inform ormati ation onon onASE ASEte testi sting ngas aswe well llas asdow downlo nloada adable ble Study Guides,  Registration Booklets ,andmore,visitwww.ase.com.Youmayalsorequest bymailingthecouponlocatedo couponlocatedonthebackcovero nthebackcoverofthis fthis  Registration Booklets bymailingthe bookletorbycallingASEat703-669-6600,ext.400.

Who Writes the Questions?  Thequestions,writtenbyserviceindustryex Thequestions,writtenbyserv iceindustryexpertsfamiliarwith pertsfamiliarwithallaspectsof allaspectsof medium/heavytruckrepair,are medium/heavytruckre pair,areentirelyjob-relat entirelyjob-related.Theyare ed.Theyaredesignedtotes designedtotestthe tthe skillsthatyouneedtokno skillsthaty ouneedtoknowinservicing winservicingtrucks;theoretic trucks;theoreticalknowledge alknowledge isnotcovered. Eachques Eachq uestio tionh nhas asits itsro roots otsin inan an ASE ASE“i “item tem-wr -writi iting” ng”wo works rkshop hopwh where ere servicerepresentativesfrommedium/heavy servicerepresentati vesfrommedium/heavytruckmanufacturers,af truckmanufacturers,aftermarket termarket partsandequipmentmanufacturers,w partsandequip mentmanufacturers,workingtechnicia orkingtechniciansandtechnical nsandtechnicaleduca educa torsgettogetherinaworkshop torsgettogeth erinaworkshopsettingtos settingtoshareideasandtrans hareideasandtranslatethemintot latethemintotest est questions.Eachtestquestio questions.Eac htestquestionwrittenbyth nwrittenbytheseexpertsmusts eseexpertsmustsurvivereviewby urvivereviewbyall all membersofthegroup.Theques membersofthegrou p.Thequestionsarewritten tionsarewrittentodealwithp todealwithpracticalproblems racticalproblems ofdiagnosisandrepairexperienced ofdiagnosisa ndrepairexperiencedbytechnicians bytechniciansintheirday-to-d intheirday-to-daywork. aywork.

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O vErviEw (cOnTinuEd ) Fromther Fromt here, e,all allqu quest estio ions nsare arepr pre-t e-test ested edand andqu quali alityty-che checke ckedo dona nana natio tional nal sampleoftechnicians.Thos sampleoftechnici ans.Thosequestionsth equestionsthatmeet atmeetASEstandardso ASEstandardsofqualityand fqualityand accuracyareincludedinthetests; accuracyareincluded inthetests;the“rejects”aresen the“rejects”aresentbacktothed tbacktothedrawingboard rawingboard ordiscardedaltogether. Eachcert Eachc ertic icati ation ontes testi tism smade adeup upof ofbe betwe tween en40 40and and55 55mu multi ltiple ple-c -choi hoice ce questions.Thetestingses questions. Thetestingsessionsare4hou sionsare4hoursand15minut rsand15minutes,allowingpl es,allowingplenty enty oftimetocompleteseveraltests. Eachtestcouldcontainuptofteen containuptofteenadditionalqu additionalquestionsthatare estionsthatareincluded included  Note: Eachtestcould forstatisticalresearchpurposesonly.Youranswerstothesequestionswillnot affectyourscore,butsinceyo affectyours core,butsinceyoudonotkno udonotknowwhichonesth wwhichonestheyare,youshou eyare,youshould ld answerallquestionsinthete answerallquest ionsinthetest.Theve-yearRece st.Theve-yearRecerticationT rticationTestwillcoverth estwillcoverthe e samecontentareasasthoselisted samecontentareasas thoselistedabove.However above.However,thenumberofqu ,thenumberofquestionsin estionsin eachcontentareaoftheRecertication eachcontentareaof theRecerticationT Testwillberedu estwillbereducedbyabouton cedbyaboutone-half. e-half.

How Do I Prepare or the ASE Tests?  Becomefamiliarwithtestcontentandquestionformat Becomefamiliarwithtestcontentan dquestionformat:The :TheT TestSpecications foreachofthetestscoveredinth foreachofthetes tscoveredinthisbookletcon isbookletcontainasummarydescri tainasummarydescriptionofthe ptionofthe contentcoveredbyeachtest. contentcoveredb yeachtest.TheListsdes TheListsdescribetheactualwo cribetheactualworkperformedby rkperformedby techniciansineachspecialtyarea. techniciansin eachspecialtyarea.T Together ogether,theseforma“blu ,theseforma“blueprint”forwriti eprint”forwriting ng andassemblingtheASEtests. Pleaseno Please note tetha thate teach achqu quest estion ionon onth thet etest estis iske keyed yedor orli linke nkedt dtoa oapa parti rticul cular ar orsetoftasksinthelist. orsetoftasks inthelist.Therefore,areviewo Therefore,areviewofthelists,wi fthelists,withaneyetojud thaneyetojudging ging whetheryouknowhowtoperfo whetheryoukn owhowtoperformeachlisted,wi rmeachlisted,willprovidevalu llprovidevaluableinformation ableinformation toprepareforthetests. Thereare There arev vet etype ypeso sofm fmult ultipl iple-c e-choi hoice ceque questi stions onson onth thet etest ests, s,eac eacho hofw fwhic hich h isincludedinthesampleques isincludedi nthesamplequestionsinthis tionsinthisbooklet.Not booklet.Notethedifferen ethedifferentinstructions tinstructions forsomequestions. Besuret Besur etor oread eadea each chqu quest estion ionca caref refull ully y,( ,(twi twice, ce,if ifne neces cessar sary) y)so sotha thaty tyou ou understandexactlywhatisbeingasked. Each  Each question tests a specic diagnostic or repair problem and has only one best answer. Tos osumm ummari arize, ze,we wesu sugge ggest stthe thefo follo llowin wings gstep tepst stob obet etake akent ntop oprep repare arefo fort rthe he tests:

Step 1. Studythecontentlistforeacht Studythecontentlistforeachtestyouwill estyouwillattempt. attempt. Step 2. Carefu Carefully llyread readthel thelist istfore foreacha acharea. rea. Step 3. Go ov over er th the e sa samp mple le ques questi tion ons s to be beco come me fa fami millia iar r wi with th ea each ch question type. This is very important. Step St ep4 4. . Re Revi view ewst step eps1 s1th thro roug ugh3 h3abo above ve,an ,andi dide dent ntif ifyt ythe hesk skil illar larea easw swhe here re you need additional study.

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Types o Knowledge Measured by the Tests  Thetypesofknowledgeandskillsyouwill Thetypesofknowledgeandski llsyouwillneedtoknowt needtoknowtopassthetest opassthetestsareas sareas follows: • Basic technical knowledge: Testsyourknowledgeofwhatisinasystemand howthesystemworks,andwhataretheproperproceduresand/orprecautions tobefollowedinmakingrepairsa tobefollowedi nmakingrepairsandadjustments. ndadjustments. • Service or repair knowledge and skill: Testsyourunderstandingandability toapplygenerallyacceptedrepairproceduresandprecautionsinassembly, disassembly,andreconditioningoperations;andinmakingmajorinspections andadjustments.Alsotestsabilitytouseshopmanualsandprecisiontoolsof thetrade. • Testing and diagnostic diagnost ic knowledge and skill: ski ll: Testsyourabilitytorecognize problemsandtousegenerallyavailablemeasu problemsandtousege nerallyavailablemeasurementandtestingequi rementandtestingequipment pment tomakeadiagnosis. tomakeadiagn osis.Alsotestsy Alsotestsyourabilityt ourabilitytotracetheef otracetheeffectsofaparticu fectsofaparticular lar conditionandndthecauseofapart conditionand ndthecauseofaparticularsetofsymp icularsetofsymptoms. toms.

Ifyouare Ifyou areanex anexpe peri rien ence cedan dandco dcomp mpet eten entte ttech chni nici cian an,aca ,acare refu fulre lrevi view ewof of thisbooklet,andadditionalbrush-uponthoseareasinwhichyouareweakest, isallyoushouldneedtopassthe isallyoushouldnee dtopasstheASEtests. ASEtests.

Beore The Tests  Trytobewellrestedforthetestssoyo Trytobewellrestedfor thetestssoyouwillbealert uwillbealertandefcient.Havethree andefcient.Havethree orfoursharpenedsoft-lead(#2)penci orfoursharpeneds oft-lead(#2)pencilsandaneraserwi lsandaneraserwithyou;pencil thyou;pencilswillnot swillnot befurnishedatthetestcenter befurnishedatt hetestcenter.Ifyouwish .Ifyouwishtopaceyourself,b topaceyourself,bringawatch,si ringawatch,since nce sometestingroomsmaynothaveclo sometestingroo msmaynothaveclocks.Finally cks.Finally,besuretobrin ,besuretobringalongyourt galongyourtest est centeradmissionticketandsomeform centeradmissiont icketandsomeformofidentication. ofidentication.

 At the Test Center  Whenyoureachthetestcenter,waitintheass Whenyoureachthetestcenter ,waitintheassignedareauntil ignedareauntiltheproctorbegi theproctorbegins ns thetestadministration.Heorsh thetestadminis tration.Heorshewillinstruct ewillinstructyouinllingo youinllingouttheanswerfol uttheanswerfolder der andwilltellyoutheamounto andwilltelly outheamountoftimeallottedfo ftimeallottedforeachtest. reachtest. Oncethe Once thete test sthas hasbe begun gun,k ,keep eeptr track ackof ofti time. me.Do Dono nots tspen pendt dtoo oolo long ngon onany any onequestion.Ifaquestioni onequestion .Ifaquestionisdifcult,markthe sdifcult,marktheanswerthatyou answerthatyouthinkiscor thinkiscor rectandputacheckbyitinth rectandputach eckbyitinthetestbook.T etestbook.Thengoontot hengoontothenextquesti henextquestion.If on.If younishbeforetheallottedtime younishbeforet heallottedtime,youmaygoback ,youmaygobacktothequesti tothequestionsthatyou onsthatyou checked. It is to your advantage to answer every question. Do not leave any answers blank. Your score will be based on the number of correct answers that you give.

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O vErviEw (cOnTinuEd )

Test Content and Sample Questions  Thefollowingmaterialisdesignedtohelptech Thefollowingmaterialisdesig nedtohelptechnicianspreparefor niciansprepareforASEcertica ASEcertica tiontests. Eachoft Eacho fthe hesec sectio tions nsbeg begins inswi with ththe theT Test estSp Speci ecicat cation ions, s,whi which chlis listt tthe hemai main n categoriescoveredonthatparticul categoriescovered onthatparticulartestandthen artestandthenumberoftestques umberoftestquestionsand tionsand percentageofthetestdevotedtoeachtopic. TheList TheLi stdes descri cribes besth thew ework orkac activ tiviti ities esat atech echni nicia cians nshou hould ldbe beabl ablet etop operf erform orm ineachtechnicalareacoveredonthat ineachtechnical areacoveredonthattest.Thi test.Thislistwasdev slistwasdevelopedbyworki elopedbyworking ng techniciansandtechnicalexperts techniciansand technicalexpertsfromacrossthecou fromacrossthecountryandwillp ntryandwillprovideavalu rovideavalu ablechecklistofwhattostud ablechecklist ofwhattostudyforthetest. yforthetest. Itshould Itsho uldbe beno noted tedth that atthe thenu numbe mbero rofq fques uestio tions nsin ineac eachc hcon onten tenta tarea reama may y notequalthenumberoftasksl notequalthe numberoftaskslisted.Someofthe isted.Someofthetasksarecomplexan tasksarecomplexandbroad dbroad inscopeandmaybecoveredbysev inscopeandmay becoveredbyseveralquestions. eralquestions.Othertasksaresi Othertasksaresimpleand mpleand narrowinscopeandonequestio narrowinscope andonequestionmaycoverseveral nmaycoverseveraltasks.The tasks.Themainobjective mainobjective inlistingthetasksisto inlistingt hetasksistodescribeaccurately describeaccuratelywhatisdoneon whatisdoneonthejob,not thejob,nottomake tomake eachcorrespondtoaparticulartest eachcorrespondt oaparticulartestquestion. question. Samplequ Sample quest estion ionsf sfol ollow low. .Alt Althou hough ghthe these sesam sameq eques uestio tions nswil willn lnot otapp appear earon on actualtests,theyareinthesamefo actualtests,t heyareinthesameformatasactualtest rmatasactualtestquestions. questions.Allvetypesof Allvetypesof multiple-choicequestionsused multiple-choice questionsusedonthe ontheASEtestsarereprese ASEtestsarerepresentedhere.Noteth ntedhere.Notethe e differentinstructionsfors differentin structionsforsomequestions. omequestions. 

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 TEST SpEcificATiOnS G ASOlinE EnGinES (TEST T1)

Content Area

Questions in Test

A. General Engine Diagnosis B. Cylinder Head and Valve Train Train Diagnosis and Repair C. Engine Block Diagnosis and Repair D. Lubrication and Cooling Systems Diagnosis and Repair E. Ignition System Diagnosis and Repair F. Fuel, Air Induction, and Exhaust Systems Diagnosis and Repair G. Emissions Control Systems Diagnosis and Repair H. Computerized Engine Controls Diagnosis and Repair

Total

Percentage of Test

14

28%

4 4

8% 8%

3 6

6% 12%

6

12%

5

10%

8

16%

50

100%

 A. General Diagnosis (14 questions) 1. Verifythecompla erifythecomplaintand/orroadtestveh intand/orroadtestvehicle;reviewdrive icle;reviewdriver/customerintervi r/customerinterviewand ewand pastmaintenancedocuments(if pastmaintenan cedocuments(ifavailable);deter available);determinefurtherdiag minefurtherdiagnosis. nosis. 2. Researchappl Researchapplicablevehiclean icablevehicleandserviceinforma dserviceinformation,suchasenginem tion,suchasenginemanagement anagement systemoperation,vehicleservice systemoperati on,vehicleservicehistory history,serviceprecauti ,serviceprecautions,technicalserv ons,technicalservice ice bulletins,andservicecampaigns/recalls. 3. Inspectengine Inspectengineassemblyforfuel assemblyforfuel,oil,coolant,andotherle ,oil,coolant,andotherleaks;determinene aks;determineneeded eded action. 4. Diagnosenois Diagnosenoisesand/orvibrationpr esand/orvibrationproblemsrelatedto oblemsrelatedtoengineperforma engineperformance;determine nce;determine neededaction. 5. Diagnosetheca Diagnosethecauseofunusualexh useofunusualexhaustcolor austcolor,odor,and ,odor,andsound;determine sound;determineneeded needed action. 6. Perf Perform ormengin engineman emanifold ifoldvacu vacuumo umorpre rpressur ssuretes etests;d ts;deter etermine mineneed neededa edaction ction.. 7. Perf Perform ormcylin cylinder derpowe powerbal rbalance ancetest test;det ;determi erminene neneeded ededacti action. on. 8. Perf Perform ormcylin cylinder dercomp compressi ressionte ontest;d st;deter etermine mineneed neededa edaction ction.. 9. Perf Perform ormcylin cylinder derleaka leakage/le ge/leak-d ak-downt owntest; est;dete determin rminenee eneededa dedactio ction. n.

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 T1 liST (cOnTinuEd ) 10.Diagnoseenginemechanical,electrical,electroni 10.Diagnoseenginemechanical,ele ctrical,electronic,fuel,andignitionpro c,fuel,andignitionproblemswithan blemswithan oscilloscope,engineanalyzer oscilloscope,en gineanalyzer,digitalmultimete ,digitalmultimeter(DMM),and/orscan r(DMM),and/orscantool;determine tool;determine neededaction. 11. Inspectenginec Inspectenginecompartmentwir ompartmentwiringharness,conne ingharness,connectors,seals,locks,vac ctors,seals,locks,vacuumhoses; uumhoses; checkforproperroutingandcondi checkforprope rroutingandcondition;determinene tion;determineneededrepairs. ededrepairs. 12. Observeandinte Observeandinterpretinstrumen rpretinstrumentpanelgaugeread tpanelgaugereadings. ings. 13. Readandinterpr Readandinterpretelectricalsche etelectricalschematicdiagramsa maticdiagramsandsymbols. ndsymbols. 14. Testanddiagnose estanddiagnoseemissionsordrive emissionsordriveabilityproblems abilityproblemscausedbybatteryc causedbybatterycondition, ondition, connections,orexcessivekey-of connections,orex cessivekey-offbatterydrain;de fbatterydrain;determineneededr termineneededrepairs. epairs. 15. Performstarter Performstartercurrentdrawtest; currentdrawtest;determineneede determineneededaction. daction. 16. Performstarter Performstarterandcharging andchargingcircuitvoltagedr circuitvoltagedroptests;determin optests;determineneededaction. eneededaction. 17. Inspect,test,andrep Inspect,test,andrepairorreplacecom airorreplacecomponents,connect ponents,connectors,andwiresinthest ors,andwiresinthestarter arter andchargingcontrolcircuits. 18. Differenti Differentiatebetweenelec atebetweenelectricalandmechan tricalandmechanicalproblemstha icalproblemsthatcauseaslowcrank tcauseaslowcrank,no ,no crank,extendedcranking,oracranki crank,extended cranking,oracrankingnoiseconditio ngnoisecondition. n. 19. Testanddiagnose estanddiagnoseengineperforma engineperformanceproblemsresu nceproblemsresultingfromanunde ltingfromanundercharge,ove rcharge,overr charge,orano-chargecon charge,orano -chargecondition;determin dition;determineneededaction. eneededaction. 20. Inspect,adjust,and Inspect,adjust,andreplacealternato replacealternator(generator)driv r(generator)drivebelts,pulleys,tensi ebelts,pulleys,tensioners,and oners,and fans.

B. Cylinder Head and Valve Train Train Diagnosis and Repair (4 questions) 1. Remo Remove,i ve,inspe nspect,d ct,disass isassembl emble,an e,andcle dcleancy ancylinde linderhea rheadass dassembl embly(s). y(s). 2. Inspectthreade Inspectthreadedholes,studs,andbol dholes,studs,andboltsforserviceabili tsforserviceability;service/replace ty;service/replaceasneeded. asneeded. 3. Measurecylind Measurecylinderheadthickness erheadthickness;checkmatingsur ;checkmatingsurfacesforwarpag facesforwarpageandsurface eandsurface nish;inspectforcracks/damage;chec nish;inspectforcr acks/damage;checkconditionofpass kconditionofpassages;inspectcor ages;inspectcoreand eand galleryplugs;determineservicea galleryplugs;de termineserviceabilityandneeded bilityandneededrepairs. repairs. 4. Inspectvalves,gu Inspectvalves,guides,seats,springs,re ides,seats,springs,retainers,locks,andsea tainers,locks,andseals;determineserv ls;determineservice ice abilityandneededrepairs. 5. Reassemble,che Reassemble,check,andinstallcylin ck,andinstallcylinderheadassembl derheadassembly(s)andgasket(s) y(s)andgasket(s)asspecied asspecied bythemanufacturer. 6. Insp Inspectp ectpushr ushrods, ods,rock rockerar erarms,r ms,rocke ockerarm rarmshaf shafts,e ts,electr lectronic onicwiri wiringha ngharnes rness,an s,and d brackets;repair/replaceasneeded. 7. Insp Inspect, ect,insta install,a ll,andad ndadjust justvalve valvelift liftersa ersandre ndretaine tainers;a rs;adjus djustval tvalvecl vecleara earance. nce. 8. Inspect,measure Inspect,measure,andreplace/reinsta ,andreplace/reinstalloverheadcamsh lloverheadcamshaftandbearings; aftandbearings;measure measure andadjustendplay.

C. Engine Block Diagnosis and Repair (4 questions) 1. Remove,inspec Remove,inspect,service,andinstallpa t,service,andinstallpans,covers,ventilati ns,covers,ventilationsystems,gasket onsystems,gaskets,seals, s,seals, andwearsleeves. 2. Disassemble,cle Disassemble,cleanandinspecteng anandinspectengineblockforcrac ineblockforcracks;checkmatingsu ks;checkmatingsurfacesand rfacesand relatedcomponentsfordamageo relatedcompon entsfordamageorwarpageandsurf rwarpageandsurfacenish;checkdec acenish;checkdeckheight; kheight; checkconditionofpassages,core,an checkconditio nofpassages,core,andgalleryplugs;ins dgalleryplugs;inspectthreadedhol pectthreadedholes,studs, es,studs, dowelpinsandboltsforserviceabi dowelpinsandbo ltsforserviceability;service/replac lity;service/replaceasneeded. easneeded. 3. Inspectandmea Inspectandmeasurecylinderwal surecylinderwallsforwearanddam lsforwearanddamage;determinese age;determineserviceability rviceability andneededrepairs. 4. Insp Inspecti ectin-bl n-blockc ockcamsh amshaftb aftbearin earingsfo gsforwe rwearan aranddam ddamage; age;repl replacea aceasnee sneeded. ded.

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 T1 liST (cOnTinuEd ) 5. Inspect,measure Inspect,measure,andreplace/reinstal ,andreplace/reinstallin-blockcamsha lin-blockcamshaft;measure/andcor ft;measure/andcorrectend rectend play;inspect,replace/reinstall,andadju play;inspect,repl ace/reinstall,andadjustvalvelifters. stvalvelifters. 6. Cleanandinspec Cleanandinspectcrankshaftandjo tcrankshaftandjournalsforsurface urnalsforsurfacecracksanddamag cracksanddamage;check e;check conditionofoilpassages;checkpas conditionofoilpa ssages;checkpassageplugs;meas sageplugs;measurejournaldiame urejournaldiameters;check ters;check mountingsurfaces;determinene mountingsurfac es;determineneededrepairs. ededrepairs. 7. Diagnosepiston Diagnosepiston,connectingrodbe ,connectingrodbearing,andmainbe aring,andmainbearingwearpatter aringwearpatternsthatindicate nsthatindicate connectingrodandcrankshaftalig connectingroda ndcrankshaftalignmentorbearing nmentorbearingboreproblems;ch boreproblems;checkbearing eckbearing boreandbushingcondition;determ boreandbushing condition;determineneededrepa ineneededrepairs. irs. 8. Dete Determin rminethe etheprop properse erselect lect-tco -tcompon mponents entssuch suchasp aspiston istons,co s,connect nnectingr ingrods, ods,and and mainbearings. 9. Inspectandrepla Inspectandreplacemainbearings cemainbearings;checkcaptandbear ;checkcaptandbearingclearances;c ingclearances;checkand heckand correctcrankshaftendplay. 10. Removeand/orrep Removeand/orreplacethetimingcha lacethetimingchainandgears;ensu inandgears;ensurecorrecttiming. recorrecttiming. 11. Inspect,measure Inspect,measure,orreplacepistons,pi ,orreplacepistons,pins,andretainers. ns,andretainers. 12. Measurepiston Measurepiston-to-cylinderwal -to-cylinderwallclearance. lclearance. 13. Checkring-to-g Checkring-to-groovetandendgaps roovetandendgaps;installringsonpist ;installringsonpistons.Assemblepistonsand ons.Assemblepistonsand connectingrodsandinstallinblock connectingrods andinstallinblock;installrodbearing ;installrodbearingsandcheckcleara sandcheckclearances. nces. 14. Inspectand/orrepl Inspectand/orreplacecrankshaftvi acecrankshaftvibrationdamper brationdamper.. 15. Inspectywhee Inspectywheel/explate(includi l/explate(includingringgear)andm ngringgear)andmountingsurfaces ountingsurfacesforcracks, forcracks, wear,andrunout;determ wear ,andrunout;determineneededrepair ineneededrepairs. s.

D. Lubrication and Cooling Systems Diagnosis and Repair (3 questions) 1. Diagnoseengin Diagnoseenginelubricationsyste elubricationsystemproblems;perf mproblems;performoilpressurete ormoilpressuretests;determine sts;determine neededrepairs. 2. Disa Disassem ssemblea bleandin ndinspect spectoilp oilpump( ump(inclu includesg desgears ears,roto ,rotors,h rs,housin ousing,an g,andpic dpick-up k-upas as sembly);measureoilpumpcleara sembly);measu reoilpumpclearance;inspectpress nce;inspectpressurereliefdevices urereliefdevicesandpumpdrive; andpumpdrive; determineneededrepairs. 3. Inspect,clean,test,re Inspect,clean,test,reinstall/replaceoilco install/replaceoilcooler,by oler,by-passvalve,linesan -passvalve,linesandhoses. dhoses. 4. Changeengineo Changeengineoilandlter(s);addpro ilandlter(s);addpropertype,viscosity pertype,viscosity,andratingofoil. ,andratingofoil. 5. Inspectandreins Inspectandreinstall/replacepulleys tall/replacepulleys,tensioners,anddriv ,tensioners,anddrivebelts;adjustdrive ebelts;adjustdrivebeltsand beltsand checkalignment. 6. Diagnoseengin Diagnoseenginecoolingsystemte ecoolingsystemtemperatureandpr mperatureandpressureproblems essureproblems;determine ;determine neededrepairs. 7. Inspect,test,andrep Inspect,test,andreplacethermostat,co lacethermostat,coolantby-pass,and olantby-pass,andthermostathousin thermostathousing,seals, g,seals, hoses,andttings. 8. Insp Inspecta ectandte ndtestco stcoolan olant;dr t;drain, ain,ush, ush,andr andrell ellcooli coolingsy ngsystem stemwith withreco recommen mmended ded coolant;bleedairfromcoolingsyst coolant;bleedai rfromcoolingsystemasrequired. emasrequired. 9. Insp Inspecta ectandre ndreplace placewate waterpum rpump,ho p,housin using,an g,andhos dhoses. es. 10. Inspectandrepla Inspectandreplaceradiator ceradiator,pressurecap,expa ,pressurecap,expansiontank,andcoo nsiontank,andcoolantrecovery lantrecovery system. 11. Inspect,test,andrep Inspect,test,andrepair/replacefan(bot air/replacefan(bothelectricalandme helectricalandmechanical),fanclut chanical),fanclutch,fan ch,fan shroud,airdams,andcoolingfanelectr shroud,airdams,an dcoolingfanelectricalcircuits. icalcircuits. 12. Verifyproperopera erifyproperoperationofenginerela tionofenginerelatedgaugesandwa tedgaugesandwarningindicators rningindicators;determine ;determine neededrepairs.

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 T1 liST (cOnTinuEd ) E. Ignition System Diagnosis and Repair (6 questions) 1. Diagnoseigniti Diagnoseignitionsystemrelated onsystemrelatedproblemssuchasn problemssuchasno-starting,hardsta o-starting,hardstarting,engine rting,engine misre,poordriveability misre,poordriveab ility,sparkknock,powe ,sparkknock,powerloss,reducedfuel rloss,reducedfueleconomy economy,and ,and emissionsproblems;determiner emissionsprob lems;determinerootcause;determ ootcause;determineneededrepair ineneededrepairs. s. 2. Interpretignitio Interpretignitionsystemrelatedd nsystemrelateddiagnostictrouble iagnostictroublecodes(DTCs);de codes(DTCs);determineneeded termineneeded repairs. 3. Inspect,test,repair Inspect,test,repair,orreplaceignitio ,orreplaceignitionprimarycircuit nprimarycircuitwiringandcompo wiringandcomponents. nents. 4. Inspect,test,repair Inspect,test,repair,orreplaceignitio ,orreplaceignitionsystemseconda nsystemsecondarycircuitwiringa rycircuitwiringand nd components. 5. Insp Inspect, ect,test, test,and andrepla replaceig ceignitio nitioncoi ncoil(s) l(s).. 6. Insp Inspect, ect,test, test,and andrepla replaceig ceignitio nitionsys nsystem temsenso sensors;a rs;adjus djustasn tasneces ecessary sary.. 7. Insp Inspect, ect,test, test,and/o and/orrep rreplace laceigni ignition tioncont controlm rolmodule odule(ICM (ICM)/pow )/powertra ertrain/en in/engine gine controlmodule(PCM/ECM);repro controlmodule (PCM/ECM);reprogramasneeded. gramasneeded.

F. Fuel, Air Induction, and Exhaust Systems Diagnosis and Repair (6 questions) 1. Diagnosefuelsy Diagnosefuelsystemrelatedprob stemrelatedproblemssuchasno-st lemssuchasno-starting,hardstarting arting,hardstarting,poordrive ,poordrive ability,incorrectidlespe ability ,incorrectidlespeed,pooridle,oodin ed,pooridle,ooding,hesitation,sur g,hesitation,surging,enginemisre, ging,enginemisre, powerloss,stalling,reducedfueleco powerloss,stallin g,reducedfueleconomy nomy,andemissionsprob ,andemissionsproblems;determine lems;determineroot root cause;determineneededrepairs. 2. Interpretfuelor Interpretfuelorinductionsystemr inductionsystemrelateddiagnostic elateddiagnostictroublecodes(DT troublecodes(DTCs);analyze Cs);analyze fueltrimandotherscantooldata;det fueltrimandothe rscantooldata;determineneededre ermineneededrepairs. pairs. 3. Inspectfueltank Inspectfueltank,llerneck,andfuelcap; ,llerneck,andfuelcap;inspectandreplac inspectandreplacefuellines,ttings,and efuellines,ttings,and hoses;checkfuelforcontaminant hoses;checkfue lforcontaminantsandquality sandquality.. 4. Inspect,test,andrep Inspect,test,andreplacefuelpump(s lacefuelpump(s)and/orfuelpumpass )and/orfuelpumpassembly;inspect,ser embly;inspect,service, vice, andreplacefuellters. 5. Inspectandtest Inspectandtestelectricfuelpump electricfuelpumpcontrolcircuitsa controlcircuitsandcomponents; ndcomponents;determineneede determineneeded d repairs. 6. Inspect,test,andre Inspect,test,andrepairorreplacefue pairorreplacefuelpressureregulat lpressureregulationsystemandcom ionsystemandcomponentsof ponentsof fuelinjectionsystems;performfu fuelinjectionsy stems;performfuelpressure/volume elpressure/volumetest. test. 7. Inspect,remove Inspect,remove,serviceorreplaceth ,serviceorreplacethrottlebodyassem rottlebodyassemblyandcontrols,in blyandcontrols,including cluding electronicthrottleactuatorcontr electronicthro ttleactuatorcontrol(T ol(TAC)systems;mak AC)systems;makerelatedadjustm erelatedadjustments. ents. 8. Insp Inspect, ect,test, test,clea clean,an n,andrep dreplace lacefuel fuelinje injector ctorsand sandfuel fuelrail rails. s. 9. Insp Inspect, ect,servi service,a ce,andre ndrepair pairorre orreplac placeair eairltra ltration tionsyst systemc emcompo omponent nents. s. 10. Inspectairinduc Inspectairinductionsystem,intake tionsystem,intakemanifold,andgask manifold,andgasketsforair/vacuumle etsforair/vacuumleaks. aks. 11. Remove,clean,ins Remove,clean,inspect,test,andrepair pect,test,andrepairorreplacefuelsyste orreplacefuelsystemvacuumandele mvacuumandelectrical ctrical componentsandconnections. 12. Inspect,service Inspect,service,andreplaceexhaus ,andreplaceexhaustmanifold,gaskets tmanifold,gaskets,exhaustpipes,oxyg ,exhaustpipes,oxygen en sensors,mufers,catalyticconvert sensors,mufer s,catalyticconverters,resonators,tailp ers,resonators,tailpipes,andheatshield ipes,andheatshields. s. 13. Testforexhaustsy estforexhaustsystemrestrictionor stemrestrictionorleaks;determine leaks;determineneededrepair neededrepair..

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 T1 liST (cOnTinuEd ) G. Emissions Control Systems Diagnosis And Repair (5 questions) 1. Testanddiagnosee estanddiagnoseemissionsordrivea missionsordriveabilityproblemsc bilityproblemscausedbypositivec ausedbypositivecrankcase rankcase ventilation(PCV)system. 2. Inspect,service,an Inspect,service,andreplacepositive dreplacepositivecrankcaseventil crankcaseventilation(PCV)lter ation(PCV)lter,valve,tubes, ,valve,tubes, orice/meteringdevice,andhoses. 3. Testanddiagnosed estanddiagnosedriveabilityprobl riveabilityproblemscausedbythee emscausedbytheexhaustgasrecircu xhaustgasrecirculation lation (EGR)system. 4. Interpretexhau Interpretexhaustgasrecirculatio stgasrecirculation(EGR)related n(EGR)relatedscantooldataandd scantooldataanddiagnostictrouble iagnostictrouble codes(DTCs);determineneededrepairs. 5. Inspect,test,servic Inspect,test,service,andreplacecomp e,andreplacecomponentsoftheexha onentsoftheexhaustgasrecirculati ustgasrecirculation(EGR) on(EGR) system,includingEGRvalve,tubing,pa system,including EGRvalve,tubing,passages,vacuum/pre ssages,vacuum/pressurecontrols,lters, ssurecontrols,lters, hoses,electrical/electronicsensors,co hoses,electrical/ele ctronicsensors,controls,solenoids,an ntrols,solenoids,andwiringofEGRsys dwiringofEGRsystems. tems. 6. Testanddiagnosee estanddiagnoseemissionsordrivea missionsordriveabilityproblemsca bilityproblemscausedbythesecon usedbythesecondaryair daryair injectionorcatalyticconvertersystems. 7. Interpretsecond Interpretsecondaryairinjectionsy aryairinjectionsystemrelatedscan stemrelatedscantooldataanddiagn tooldataanddiagnostictrouble ostictrouble codes(DTCs);determineneededrepairs. 8. Insp Inspect,t ect,test, est,serv service, ice,andr andrepla eplaceme cemechan chanical icalcomp componen onentsan tsandele delectric ctrical/ al/ electronically-operatedcompo electronicallyoperatedcomponentsandcircuits nentsandcircuitsofsecondaryairinj ofsecondaryairinjectionsystem. ectionsystem. 9. Inspectcatalytic Inspectcatalyticconverter converter.Interpretcatalytic .Interpretcatalyticconverterrelated converterrelateddiagnostictroub diagnostictrouble le codes(DTCs);analyzerelatedsca codes(DTCs);an alyzerelatedscantooldatatodeterm ntooldatatodeterminerootcauseofD inerootcauseofDTCs; TCs; determineneededrepairs. 10. Testanddiagnosee estanddiagnoseemissionsordrivea missionsordriveabilityproblemsca bilityproblemscausedbytheevapo usedbytheevaporativeemis rativeemis sionscontrolsystem. 11. Interpretevapo Interpretevaporativeemissionsrativeemissions-relatedscantoold relatedscantooldataanddiagnostic ataanddiagnostictroublecodes troublecodes (DTCs);determineneededrepairs. 12. Inspect,test,andrep Inspect,test,andreplacecanister lacecanister,lines,hoses,mechan ,lines,hoses,mechanical,andelectrical ical,andelectricalcomponents components oftheevaporativeemissionscontrolsystem.

H. Computerized Engine Controls Diagnosis And Repair (8 questions) 1. ResearchOBD ResearchOBDIIsystemoperation IIsystemoperationtodeterminetheen todeterminetheenablecriteriaforse ablecriteriaforsettingand ttingand clearingdiagnostictroublecodes clearingdiagno stictroublecodes(DTCs)andmalfu (DTCs)andmalfunctionindicator nctionindicatorlamp(MIL) lamp(MIL) operation.Performappropriatedri operation.Perfor mappropriatedrivecycletodeterm vecycletodeterminesystemcondit inesystemconditionandverify ionandverify repaireffectiveness. 2. InterpretOBDII InterpretOBDIIscantooldatastrea scantooldatastream,diagnostictroub m,diagnostictroublecodes(DTCs),fr lecodes(DTCs),freeze eeze framedata,systemmonitors,monitor framedata,system monitors,monitorreadinessindica readinessindicators,andtripanddriv tors,andtripanddrivecycle ecycle information. 3. Readandinterpr Readandinterprettechnicallitera ettechnicalliterature(servicepubl ture(servicepublicationsandinfor icationsandinformationincluding mationincluding wiringschematics). 4. Diagnosethecau Diagnosethecausesofemissionso sesofemissionsordriveabilityprob rdriveabilityproblemswithstoredo lemswithstoredoractivediag ractivediag nostictroublecodes(DTCs). 5. Diagnosethecau Diagnosethecausesofemissionso sesofemissionsordriveabilityprob rdriveabilityproblemswithoutdiag lemswithoutdiagnostictrouble nostictrouble codes(DTCs). 6. Useascantool,digi Useascantool,digitalmultimeter(DM talmultimeter(DMM),ordigitalstora M),ordigitalstorageoscilloscope( geoscilloscope(DSO)to DSO)to inspectortestcomputerizedengin inspectortestcom puterizedenginecontrolsystemse econtrolsystemsensors,actuators,cir nsors,actuators,circuits,and cuits,and powertrain/enginecontrolmodule powertrain/engin econtrolmodule(PCM/ECM);determ (PCM/ECM);determineneededrepa ineneededrepairs. irs.

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 T1 liST (cOnTinuEd ) 7. Measureandint Measureandinterpretvoltage,volt erpretvoltage,voltagedrop,amperag agedrop,amperage,andresistanceus e,andresistanceusingdigital ingdigital multimeter(DMM)readings. 8. Test,remove,inspec est,remove,inspect,clean,service,andre t,clean,service,andrepairorreplacepow pairorreplacepowerandgrounddist erandgrounddistribu ribu tioncircuitsandconnections. 9. Removeandrep Removeandreplacethepowertra lacethepowertrain/enginecontrolm in/enginecontrolmodule(PCM/ECM) odule(PCM/ECM);reprogram ;reprogram asneeded. 10. Diagnosedrive Diagnosedriveabilityandemissi abilityandemissionsproblemsresu onsproblemsresultingfromfailure ltingfromfailuresofinterrelated sofinterrelated systems(forexample:cruisecont systems(forexa mple:cruisecontrol,securityalarms rol,securityalarms/theftdeterrent,torqu /theftdeterrent,torquecontrols, econtrols, tractioncontrols,torquemanagem tractioncontro ls,torquemanagement, ent,A/C,and/ornon-OEMin A/C,and/ornon-OEMinstalledaccessori stalledaccessories). es). 11. Cleardiagnosti Cleardiagnostictroublecodes(D ctroublecodes(DTCs),runallOBDIIm TCs),runallOBDIImonitors,andverify onitors,andverifythe the repair.

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S AMplE QuESTiOnS G ASOlinE EnGinES (TEST T1)

QuESTiOnS :

130

140

135

15

130

15

140

140

COMPRESSION SPECS 140 PSI

1. Technic echnician ianA Asays saysthat thatthec thecompre ompression ssiontest testreadi readingss ngsshown hownabove abovecoul couldbe dbe causedbyablowncylinderheadgasket. TechnicianBsaysthatthec echnicianBsaysthatthecompressiontestreadings ompressiontestreadingsshownabovecouldbe shownabovecouldbe causedbywrongvalvetiming. Whoisright? * (A) A only  (C (C) Both A and B  (B (B) B only  (D (D) Neither A nor B

2. Techni echnician cianA Asays saysthat thatpart partXsho Xshowna wnabove boveisus isusedto edtoimpro improveva vevalves lvespring pring rotation. TechnicianBsaysthatpar echnicianBsaysthatpartXshownaboveisuse tXshownaboveisusedtocorrectinstalledspr dtocorrectinstalledspring ing height. Whoisright?  (A (A) A only  (C (C) Both A and B * (B) B only  (D ( D) Neither A nor B

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 T1 S AMplE QuESTiOnS (cOnTinuEd ) 3. Anengine Anengineisus isusingto ingtoomu omuchoil choil.T .Techni echnician cianA Asay saystha sthatwor twornval nvalvegu veguides ides couldbethecause. TechnicianBsaysthattaper echnicianBsaysthattaperedcylinderwallscouldbe edcylinderwallscouldbethecause. thecause. Whoisright?  (A (A) A only * (C) Both A and B  (B (B) B only  (D (D) Neither A nor B 4. Whileper Whileperform forminga ingacyli cylinder nderleaka leakagete geteston stonane anengine, ngine,the thetechn technician iciansees seesair air bubblesintheupperradiatortank. TechnicianAsaysthatacrackedheadcouldbethecause. TechnicianBsaysthata echnicianBsaysthatacrackedblockcouldbethecaus crackedblockcouldbethecause. e. Whoisright?  (A (A) A only * (C) Both A and B  (B (B) B only  (D (D) Neither A nor B 5. Techni echnician cianA Asays saysthat thatmain mainbeari bearingoil ngoilclea clearanc rancecan ecanbec bechecke heckedwit dwithpla hplasti stigage. TechnicianBsaysthatm echnicianBsaysthatmainbearingoilclearanceca ainbearingoilclearancecanbecheckedwithaf nbecheckedwithafeeler eeler gauge. Whoisright? * (A) A only  (C (C) Both A and B  (B (B) B only  (D (D) Neither A nor B 6. Thetechni Thetechnician cianndsn ndsnospa osparkan rkandno dnoinjec injectorp torpulses ulsesona onavehi vehiclet clethatw hatwillno illnot t start.Themostlikelycauseisafailed: (A) mass air ow sensor (MAF). *(B * (B) )cr cran anks ksha haft ftp pos ositi ition ons sen enso sor r(C (CKP KP). ). (C))t (C thr hrot ottl tleep pos osit itio ion nse sens nsor or( (T TPS PS)). (D) fuel pump module (FP). 7. Anengine Anenginewith withanel anelectro ectronicf nicfuelin uelinjectio jection(EF n(EFI)s I)system ystemhas hashighf highfuelp uelpress ressure ure atidle.Whichofthesecouldbethecause? * (A) Low manifold vacuum (B) (B )A A le leak akin ing gffue uel lpu pum mp pch chec eck kva valv lvee (C) A plugged fuel injector (D) High manifold vacuum

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 T1 S AMplE QuESTiOnS (cOnTinuEd ) 8. Whichof Whichofthese thesecan cancause causeaca acatalytic talyticconv converter ertertoo tooverhe verheat? at? (A) Ab bro roke ken nai airrp pum ump pdr driv ive ebe belt lt (B) (B )A Ap plu lugg gged edc can anis iste ter rpu purrge gev vac acuu uum mho hose se (C) (C )A Af fai aile led dex exha haus ust tga gas sre reci circ rcul ulat atio ion n(E (EGR GR) )va valv lvee *(D * (D) )A Ad dis isco conn nnec ecte ted dsp spar ark kpl plug ugw wir iree Question 9 is not like the ones above. Ithasth Ithas thew eword ordEX EXCEP CEPT T.L .Look ookfo for rthe thech choic oicet ethat hatco could uldNO NOT Tcau cause sethe the describedsituation.Readtheentirequestioncarefullybe describedsituation.Readthe entirequestioncarefullybeforechoosingyour forechoosingyour answer. 9. Enginedet Enginedetonatio onation(kn n(knock) ock)could couldbec becaused ausedbya byanyof nyofthes theseEX eEXCEPT CEPT:: (A) a lean air fuel mixture. * (B) B)r ret etar arde ded dig igni niti tion ont tim imin ing. g. (C) (C )ex exce cess ssc car arbo bon nin int the hec com ombu bust stio ion nch cham ambe bers rs.. (D) (D )a ast stuc uckk-cl clos osed ede exh xhau aust stg gas asr rec ecir ircu cula latio tion n(E (EGR GR) )va valv lve. e.

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pEcificATiOnS And  And T ASk  liST  TEST SpEcificATiOnS diESEl EnGinES (TEST T2)

Content Area A. General Engine Diagnosi Diagnosis s B. Cylinder Head and Valve Train Diagnosis and Repair C. Engine Block Diagnosis and Repair D. Lubrication and Cooling Systems Diagnosis and Repair E. Air Induction Induction and Exhaust Systems Systems Diagnosis and Repair F. Fuel System Diagnosis and Repair G. Starting and Charging System Diagnosis and Repair H. Engine Brakes

Total

Questions in Test

Percentage of Test

11 4

20% 7%

5

9%

6

11%

6

11%

16

29%

4 3

7% 5%

55

100%

 A. General Engine Diagnosis (11 questions) 1. Verifythecomplai erifythecomplaint,androad/dynotestve nt,androad/dynotestvehicle;reviewdri hicle;reviewdriver/customerinterv ver/customerinterview iew andpastmaintenancedocuments andpastmainten ancedocuments(ifavailable);det (ifavailable);determinefurtherdia erminefurtherdiagnosis. gnosis. 2. Identifyengine Identifyenginemodelandserialnu modelandserialnumbertoresearch mbertoresearchapplicablevehic applicablevehicleandservice leandservice information,serviceprecautions information,ser viceprecautions,andtechnicalservi ,andtechnicalservicebulletins;deter cebulletins;determineneeded mineneeded actions. 3. Inspectenginea Inspectengineassemblyandcom ssemblyandcompartmentforfuel,oi partmentforfuel,oil,coolant,exhaust,oro l,coolant,exhaust,orother ther leaks;determineneededrepairs. 4. Inspectenginec Inspectenginecompartmentwir ompartmentwiringharness,conne ingharness,connectors,seals,andlocks ctors,seals,andlocks;checkfor ;checkfor properroutingandcondition;dete properroutinga ndcondition;determineneededrep rmineneededrepairs. airs. 5. Isol Isolatea ateanddi nddiagnos agnoseeng eenginen inenoise oises;de s;determ terminen ineneede eededrep drepairs. airs. 6. Checkengineex Checkengineexhaustforodor haustforodor,smokecolor ,smokecolor,anddensity;determ ,anddensity;determineneededrepai ineneededrepairs. rs. 7. Performfuelsup Performfuelsupplyandreturnsyst plyandreturnsystemtests;checkfue emtests;checkfuelforcontaminati lforcontamination,quality on,quality, , andconsumption;determinenee andconsumptio n;determineneededrepairs. dedrepairs. 8. Performairintak Performairintakesystemrestricti esystemrestrictionandleakagetes onandleakagetests;determinenee ts;determineneededrepairs. dedrepairs. 9. Perf Performi ormintak ntakema emanifol nifoldpr dpressur essuretes etests;d ts;deter etermine mineneed neededre edrepairs pairs.. 10. Performexhau Performexhaustbackpressurean stbackpressureandtemperaturetes dtemperaturetests;determinenee ts;determineneededrepairs. dedrepairs. 11. Performcrankc Performcrankcasepressuretest asepressuretest;determineneede ;determineneededrepairs. drepairs. 12. Diagnosenocra Diagnosenocranking,cranksbutfa nking,cranksbutfailstostart,hardstarti ilstostart,hardstarting,andstartsbutdoe ng,andstartsbutdoesnot snot continuetorunproblems;determi continuetorunpr oblems;determineneededrepairs neneededrepairs..

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 T2 T ASk  liST (cOnTinuEd ) 13. Diagnosesur Diagnosesurging,roughopera ging,roughoperation,misring,lowpow tion,misring,lowpower,slow er,slowdeceleration,slow deceleration,slow acceleration,andshutdownproble acceleration,and shutdownproblems;determinene ms;determineneededrepairs. ededrepairs. 14. Isolateanddiagn Isolateanddiagnoseenginerelate oseenginerelatedvibrationproble dvibrationproblems;determinene ms;determineneededrepairs. ededrepairs. 15. Checkcoolingsy Checkcoolingsystemforfreezepo stemforfreezepoint,level,contamina int,level,contamination,coolanttype, tion,coolanttype, temperature,pressure,circulation,co temperature,pre ssure,circulation,conditionerconce nditionerconcentration,ltration,and ntration,ltration,andfan fan operation;determineneededrepairs. 16. Checklubricati Checklubricationsystemforconta onsystemforcontamination,oillevel mination,oillevel,temperature,press ,temperature,pressure, ure, ltration,andoilconsumption;interpre ltration,andoilcons umption;interpretoilanalysisinfor toilanalysisinformation;determin mation;determineneeded eneeded repairs. 17. Checkandrecor Checkandrecordelectronicdiagn delectronicdiagnosticcodesandtri osticcodesandtrip/operationaldata; p/operationaldata;monitor monitor electronicdata;verifycustomerpr electronicdata; verifycustomerprogrammablepa ogrammableparameters;clearco rameters;clearcodes;determine des;determine furtherdiagnosis. 18. Performvisualin Performvisualinspectionforphys spectionforphysicaldamageandm icaldamageandmissing,modied,ortam issing,modied,ortampered pered components;determineneededrepairs.

B. Cylinder Head and Valve Train Train Diagnosis and Repair (4 questions) 1. Remo Remove,i ve,inspe nspect,d ct,disass isassembl emble,an e,andcle dcleancy ancylind linderhe erheada adassem ssembly(s bly(s). ). 2. Inspectthreade Inspectthreadedholes,studs,andbolt dholes,studs,andboltsforserviceabilit sforserviceability;service/replaceas y;service/replaceasneeded. needed. 3. Measurecylind Measurecylinderheadthickness erheadthickness,andcheckmatingsu ,andcheckmatingsurfacesforwarpa rfacesforwarpageandsurface geandsurface nish;inspectforcracks/damage;chec nish;inspectforcra cks/damage;checkconditionofpass kconditionofpassages;inspectcore ages;inspectcoreand and galleryplugs;determineservicea galleryplugs;de termineserviceabilityandneeded bilityandneededrepairs. repairs. 4. Inspectvalves,gu Inspectvalves,guides,seats,springs,ret ides,seats,springs,retainers,rotators,lock ainers,rotators,locksandseals;determ sandseals;determine ine serviceabilityandneededrepairs. 5. Inspectand/orrepla Inspectand/orreplaceinjectorsleev ceinjectorsleevesandseals;pressu esandseals;pressuretesttoverifyrep retesttoverifyrepair air (ifapplicable);measureinjectorti (ifapplicable);m easureinjectortipornozzleprotrus pornozzleprotrusionwherespecied ionwherespeciedby by manufacturer. 6. Insp Inspect,a ect,and/or nd/orrepl replacev acevalve alvebrid bridges( ges(cros crosshea sheads)a ds)andg ndguides uides;adj ;adjustb ustbridg ridges es (crossheads)ifapplicable. 7. Cleancompone Cleancomponents;reassemble,ch nts;reassemble,check,andinstallcyli eck,andinstallcylinderheadassemb nderheadassembly ly.. 8. Insp Inspectp ectpushr ushrods, ods,rocke rockerarm rarms,roc s,rockera kerarms rmshafts hafts,elec ,electroni tronicwir cwiringh ingharnes arness,an s,and d bracketsforwear,bendin bracketsforwea r,bending,cracks,looseness g,cracks,looseness,andblockedoilpas ,andblockedoilpassages;repair/ sages;repair/ replaceasneeded. 9. Insp Inspect,i ect,instal nstall,an l,andadj dadjustc ustcamfo amfollow llowersa ersandre ndretaine tainers. rs. 10. Adjustvalveclea Adjustvalveclearanceandinjecto ranceandinjectorsettings. rsettings. 11. Inspect,measure Inspect,measure,andreplace/reinstal ,andreplace/reinstalloverheadcamsh loverheadcamshaftandbearings;m aftandbearings;measure easure andadjustendplayandbacklash.

C. Engine Block Diagnosis and Repair (5 questions) 1. Remove,inspect Remove,inspect,service,andinstallpa ,service,andinstallpans,covers,ventilatio ns,covers,ventilationsystems,gaskets nsystems,gaskets,seals, ,seals, andwearrings. 2. Disassemble,cle Disassemble,cleanandinspecteng anandinspectengineblockforcrack ineblockforcracks;checkmatingsu s;checkmatingsurfacesand rfacesand relatedcomponentsfordamageor relatedcompon entsfordamageorwarpageandsurf warpageandsurfacenish;checkdeck acenish;checkdeckheight; height; checkconditionofpassages,core,and checkcondition ofpassages,core,andgalleryplugs;insp galleryplugs;inspectthreadedhole ectthreadedholes,studs, s,studs, dowelpinsandboltsforserviceabil dowelpinsandbo ltsforserviceability;service/replace ity;service/replaceasneeded. asneeded. 3. Inspectcylinde Inspectcylindersleevecounterbo rsleevecounterboreandlowerbore reandlowerbore;checkboredistor ;checkboredistortion;determine tion;determine neededservice.

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 T2 T ASk  liST (cOnTinuEd ) 4. Inspectandmea Inspectandmeasurecylinderwal surecylinderwallsorlinersforwear lsorlinersforwearanddamage;deter anddamage;determineneeded mineneeded service. 5. Replace/reinstal Replace/reinstallcylinderlinersan lcylinderlinersandseals;checkanda dseals;checkandadjustlinerheight/pro djustlinerheight/protrusion. trusion. 6. Insp Inspecti ectin-bl n-blockc ockcamsh amshaftb aftbearin earingsfo gsforwe rwearan aranddam ddamage; age;repl replacea aceasnee sneeded. ded. 7. Inspect,measure Inspect,measure,andreplace/reinsta ,andreplace/reinstallin-blockcamsh llin-blockcamshaft;measure/adjust aft;measure/adjustendplay; endplay; inspect,replace/reinstall,andadjustca inspect,replace/re install,andadjustcamfollowers(ifapp mfollowers(ifapplicable). licable). 8. Cleanandinspe Cleanandinspectcrankshaftandjo ctcrankshaftandjournalsforsurfac urnalsforsurfacecracksanddama ecracksanddamage;check ge;check conditionofoilpassages;checkpa conditionofoilpa ssages;checkpassageplugs;meas ssageplugs;measurejournaldiame urejournaldiameters;check ters;check mountingsurfaces;determinene mountingsurfa ces;determineneededservice. ededservice. 9. Inspectandrepl Inspectandreplacemainbearing acemainbearings;checkcaptandbear s;checkcaptandbearingclearances;c ingclearances;checkand heckand correctcrankshaftendplay. 10. Inspect,reinstall Inspect,reinstall,andtimethedrivege ,andtimethedrivegeartrain.(Includesc artrain.(Includescheckingenginepo heckingengineposition sition andspeedindicatorcomponents,ge andspeedindica torcomponents,gearwear arwear,andbacklashofcr ,andbacklashofcrankshaft,camsha ankshaft,camshaft, ft, auxiliary,drive,andidlergears auxiliary ,drive,andidlergears;serviceshafts,bush ;serviceshafts,bushings,andbearings ings,andbearings.) .) 11. Clean,inspect,mea Clean,inspect,measure,orreplacepis sure,orreplacepistons,pins,andretaine tons,pins,andretainers. rs. 12. Measurepiston Measurepiston-to-cylinderwal -to-cylinderwallclearance. lclearance. 13. Checkring-toCheckring-to-groovetandendgaps groovetandendgaps;installringsonpis ;installringsonpistons. tons. 14. Identifypiston,co Identifypiston,connectingrodbea nnectingrodbearing,andmainbeari ring,andmainbearingwearpatternsth ngwearpatternsthatindicate atindicate connectingrodandcrankshaftali connectingrod andcrankshaftalignmentorbearing gnmentorbearingboreproblems;ch boreproblems;checkbearing eckbearing boreandbushingcondition;deter boreandbushin gcondition;determineneededrepa mineneededrepairs. irs. 15. Assemblepisto Assemblepistonsandconnecting nsandconnectingrodsandinstallinbl rodsandinstallinblock;checkpiston ock;checkpistonheight/ height/ protrusion;replacerodbearingsa protrusion;rep lacerodbearingsandcheckclearan ndcheckclearances;checkcondit ces;checkcondition,position, ion,position, andclearanceofpistoncoolingjets(nozzles). 16. Inspectandmea Inspectandmeasurecrankshaftv surecrankshaftvibrationdamper ibrationdamper;replaceasneeded ;replaceasneeded.. 17. Inspect,install,and Inspect,install,andalignywheelho alignywheelhousing. using. 18. Inspectywhe Inspectywheel/explate(includi el/explate(includingringgear)andm ngringgear)andmountingsurfaces ountingsurfacesforcracks, forcracks, wear,andrunout;determ wear ,andrunout;determineneededrepai ineneededrepairs. rs.

D. Lubrication and Cooling Systems Diagnosis and Repair (6 questions) 1. Verifyengineoilpre erifyengineoilpressureandchecko ssureandcheckoperationofpressu perationofpressuresensor/switchan resensor/switchandpressure dpressure gauge;verifyengineoiltemperatu gauge;verifyen gineoiltemperatureandcheckoper reandcheckoperationoftemperat ationoftemperaturesensor uresensor.. 2. Inspect,measure Inspect,measure,andrepair/replaceo ,andrepair/replaceoilpump,housing,driv ilpump,housing,drives,pipes,andscreen es,pipes,andscreens; s; adjustdrivegearclearanceifapplicable. 3. Inspectandrepa Inspectandrepair/replaceoilpressu ir/replaceoilpressureregulatorvalve reregulatorvalve(s),andby-passva (s),andby-passvalve(s). lve(s). 4. Inspect,clean,test Inspect,clean,test,andreinstall/replace ,andreinstall/replaceoilcooler oilcooler,by-passvalve,oilthe ,by-passvalve,oilthermostat;lines rmostat;lines andhoses. 5. Inspectturboch Inspectturbochargerlubric argerlubricationandcooling ationandcoolingsystems;repair/repl systems;repair/replaceasneeded. aceasneeded. 6. Chan Changeen geengine gineoila oilandlt ndlters; ers;add addprop property ertypeof peofoil. oil. 7. Inspectandrein Inspectandreinstall/replacepulley stall/replacepulleys,tensionersanddri s,tensionersanddrivebelts;adjustdriv vebelts;adjustdrivebeltsand ebeltsand checkalignment. 8. Verifycoolanttem erifycoolanttemperatureandchec peratureandcheckoperationoftem koperationoftemperatureandleve peratureandlevelsensors/ lsensors/ switch,andtemperaturegauge. 9. Insp Inspecta ectandre ndreplac placethe ethermos rmostat(s tat(s),by ),by-pass -passes,ho es,housin using(s), g(s),and andseals seals.. 10. Flushandrellcool Flushandrellcoolingsystem;bleeda ingsystem;bleedairfromsystem;rec irfromsystem;recovercoolant. overcoolant. 11. Inspectandrepa Inspectandrepair/replacecoolantc ir/replacecoolantconditioner/lter onditioner/lter,valves,lines,andttings. ,valves,lines,andttings. 12. Inspectandrepa Inspectandrepair/replacewaterpum ir/replacewaterpump,housing,hoses,and p,housing,hoses,andidlerpulleyordriv idlerpulleyordrivegear egear..

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 T2 T ASk  liST (cOnTinuEd ) 13. Inspectradiator Inspectradiator,pressurecap,andta ,pressurecap,andtank(s);determin nk(s);determineneededservice. eneededservice. 14. Inspectandrepa Inspectandrepair/replacefanhub,fan ir/replacefanhub,fan,fanclutch,fancontro ,fanclutch,fancontrols,fanthermostat,an ls,fanthermostat,and d fanshroud. 15. Pressuretestcoo Pressuretestcoolingsystemandrad lingsystemandradiatorcap;determ iatorcap;determineneededrepair ineneededrepairs. s.

E. Air Induction and Exhaust Systems Diagnosis and Repair (6 questions) 1. Inspectandserv Inspectandservice/replaceairinduc ice/replaceairinductionpiping,airclea tionpiping,aircleaner,and ner,andelement;check element;check forairrestriction. 2. Inspect,test,andrep Inspect,test,andreplaceturbochar laceturbocharger(s)(includin ger(s)(includingvariableratio/geom gvariableratio/geometryVGT) etryVGT), , pneumatic,hydraulic,andelectroni pneumatic,hydra ulic,andelectroniccontrolsandactu ccontrolsandactuators;inspect,test,an ators;inspect,test,andreplace dreplace wastegateandwastegatecontrols. 3. Inspectandrepa Inspectandrepair/replaceintakema ir/replaceintakemanifold,gaskets,temp nifold,gaskets,temperatureandpress eratureandpressuresensors, uresensors, andconnections. 4. Insp Inspect,t ect,test,c est,clean, lean,repl replace acechar chargeai geaircoo rcoolera lerandpi ndpiping pingsyst system. em. 5. Inspectandrepa Inspectandrepair/replaceexhaustm ir/replaceexhaustmanifold,gaskets,pip anifold,gaskets,piping,mufers,exhau ing,mufers,exhaustafter stafter treatmentdevices,(includingthree treatmentdevic es,(includingthree-wayandoxidati -wayandoxidationcatalystanddie oncatalystanddieselparticulate selparticulate ltersDPF)andmountinghardware. 6. Inspect,test,andrep Inspect,test,andrepair/replaceprehea air/replacepreheater/inletairheater ter/inletairheater,orglowplugsystem ,orglowplugsystemand and controls. 7. Inspect,test,andrep Inspect,test,andreplaceexhaustafte laceexhaustaftertreatmentregene rtreatmentregenerationsystemand rationsystemandcontrols. controls. 8. Insp Inspect,t ect,test,s est,servic ervice,an e,andrep dreplace laceexha exhaustg ustgasre asrecirc circulati ulation(E on(EGR) GR)syste systemcom mcompo po nents;includingEGRvalve,cooler nents;including EGRvalve,cooler,piping,lter ,piping,lter,sensors,controls,an ,sensors,controls,andwiring. dwiring.

F. Fuel System Diagnosis and Repair (16 questions) 1. Insp Inspect,t ect,test,a est,andre ndrepair pair/repl /replacef acefuels uelsystem ystemtank tanks,ve s,vents, nts,caps capsmoun mounts,va ts,valves, lves, single/dualsupplyandreturnlines,andttings. 2. Insp Inspect,c ect,clean lean,test ,test,and ,andrepa repair/re ir/replace placefuel fueltran transfer sfer(sup (supply) ply)pum pump,pu p,pumpdr mpdrives ives, , strainers,fuel/waterseparators/indica strainers,fuel/wate rseparators/indicators,lters,heaters,coole tors,lters,heaters,coolers,ECMcooling rs,ECMcooling plates,andmountinghardware.(Prot plates,andmounti nghardware.(Protectfuelsystemcom ectfuelsystemcomponentsfrom ponentsfrom contamination), 3. Checkfuelsyste Checkfuelsystemforair;determin mforair;determineneededrepairs; eneededrepairs;primeandbleedfue primeandbleedfuelsystem; lsystem; check,repair/replaceprimerpump. 4. Insp Inspect,t ect,test,a est,andre ndrepair pair/repl /replacel acelow-p ow-press ressurer ureregul egulator atorsyst systems( ems(chec checkva kvalves, lves, pressureregulatorvalvesandrestr pressureregula torvalvesandrestrictivettings). ictivettings). 5. Insp Inspecta ectandre ndreinsta install/re ll/replac placehig ehigh-pr h-pressu essurein reinjecti jectionli onlines, nes,ttin ttings,se gs,seals,a als,and nd mountinghardware.(Protecthighmountinghardw are.(Protecthigh-pressureinjectio pressureinjectioncomponentsfro ncomponentsfrom m contamination). 6. Inspect,adjust,and Inspect,adjust,andrepair/replaceelec repair/replaceelectronicthrottleand tronicthrottleandPTOcontro PTOcontroldevices, ldevices, circuits,andsensors. 7. Performon-eng Performon-engineinspections,tes ineinspections,tests,andadjustments ts,andadjustmentsonhydraulicelec onhydraulicelectronicunit tronicunit injectors(HEUI)andelectronicco injectors(HEU I)andelectroniccontrols(railpressu ntrols(railpressurecontrol). recontrol). 8. Performon-eng Performon-engineinspections,tes ineinspections,testsandadjustment tsandadjustmentsonelectronicuni sonelectronicunitinjectors tinjectors (EUI)andelectroniccontrols. 9. Performon-eng Performon-engineinspectionsan ineinspectionsandtests,onhigh-pre dtests,onhigh-pressurecommonrai ssurecommonrailfuelsystems lfuelsystems andelectroniccontrols. 10. Inspect,test,andrep Inspect,test,andreplaceengineprote laceengineprotectionandautoma ctionandautomaticstop/restartsystem ticstop/restartsystem components.

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 T2 T ASk  liST (cOnTinuEd ) 11. Inspectandrepl Inspectandreplaceelectricalcon aceelectricalconnectorterminals nectorterminals,pins,harnesses,seals ,pins,harnesses,seals,andlocks. ,andlocks. 12. Connectdiagno Connectdiagnostictooltovehicle stictooltovehicle/engine;accessandv /engine;accessandverifyprogramm erifyprogrammable able parameters;changeifapplicable. 13. Useadiagnostic Useadiagnostictool(hand-heldor tool(hand-heldorPCbased)toinspec PCbased)toinspectandtestelectroni tandtestelectronicengine cengine controlsystem,sensors,actuators,ele controlsystem,se nsors,actuators,electroniccontrolm ctroniccontrolmodules(ECMs),an odules(ECMs),andcircuits; dcircuits; determinefurtherdiagnosis. 14. Measureandint Measureandinterpretvoltage,volt erpretvoltage,voltagedrop,amperag agedrop,amperage,andresistancere e,andresistancereadingsusing adingsusing adigitalmultimeter(DMM)orapp adigitalmultime ter(DMM)orappropriatetestequip ropriatetestequipment. ment.

G. Starting and Charging System Diagnosis and Repair (4 questions) 1. Performbattery Performbatterystate-of-char state-of-chargeandloadorcapa geandloadorcapacitancetests;dete citancetests;determineneeded rmineneeded service. 2. Char Chargeba gebatter tteryusi yusingsl ngslowo oworfas rfastcha tcharge rgemeth method,a od,asapp sappropr ropriate. iate. 3. Star Startave tavehicle hicleusin usingjum gjumperc percables ablesora oraboos boosterb terbatte attery ry.. 4. Inspect,clean,and Inspect,clean,andrepair/replacebatte repair/replacebatteries,batterycable ries,batterycables,andterminalconn s,andterminalconnections. ections. 5. Inspect,test,andrei Inspect,test,andreinstall/replacestart nstall/replacestarterrelays,safetyswi errelays,safetyswitch(s),andsolenoid tch(s),andsolenoids. s. 6. Performalterna Performalternatorvoltageandam torvoltageandamperageoutputtes perageoutputtests;determinenee ts;determineneededrepairs. dedrepairs. 7. Performstarter Performstarterandcharging andchargingcircuitvoltagedr circuitvoltagedroptests;determin optests;determineneededrepairs. eneededrepairs.

H. Engine Brakes (3 questions) 1. Insp Inspect, ect,test, test,and andadjus adjusteng tenginec inecompr ompressio essionand nandexh exhaust austbrak brakes. es. 2. Inspect,test,adjust Inspect,test,adjust,andrepair/replaceen ,andrepair/replaceenginecompressio ginecompressionandexhaustbrak nandexhaustbrakecontrol econtrol circuits,switches,andsolenoids. 3. Inspectandrepa Inspectandrepair/replaceengineco ir/replaceenginecompressionandex mpressionandexhaustbrakehous haustbrakehousing(s),valves, ing(s),valves, seals,springs,lines,andttings.

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S AMplE QuESTiOnS diESEl EnGinES (TEST T2)

QuESTiOnS : 1. Whenadie Whenadiesele selengine ngineisop isoperate eratedund dundera eraload, load,cool coolantc antcontinua ontinuallyco llycomes mesout out oftheradiatoroverowandthereare oftheradiatorover owandtherearebubblesintheradiator bubblesintheradiator.Whichof .Whichoftheseis theseis themostlikelycause? (A) (A )T Too oom muc uch hco cool olan ant tin int the hec coo ooli ling ngs sys yste tem m (B) A clogged radiator (C) A stuck-open thermostat *(D * (D) )Co Comp mpre ress ssio ion nle leak akag age ein into tot the hec coo ooli ling ngs sys yste tem m 2. Adies dieselen elengine ginehase hasexcess xcessiveb iveblack lacksmoke smokewhe whensta nstarted rtedinthe inthemor morning. ning. Whichofthesecouldbethecause? *(A * (A) )A Ab bad adf fue uel lin inje ject ctio ion nno nozz zzle le (B) A restricted fuel lter (C) A blocked fuel tank vent (D) A leakin ing g fuel return line 3. Whichof Whichofthese thesecan cancause causean ano-sta o-startco rtconditio nditionon nonaHE aHEUIe UIengine ngine?? (A) High fuel pressure *(B * (B) )Lo Low win inje ject ctio ion nco cont ntro rol lpr pres essu sure re (C) High boost pressure (D) Low boost pressure 4. Adies dieselen elenginei gineisha shardto rdtostar start,but t,butrun runsgoo sgoodaft dafterit erithas hasbeen beenprim primedan edandrun drun forafewminutes.Them forafew minutes.Themostlikelycauseisa: ostlikelycauseisa: (A) leaking injector line. (B) leaking fuel return lin inee. (C) plugged fuel tank vent. *(D * (D) )ba bad dtr tran ansf sfer erp pum ump pch chec eck kva valv lve. e. 5. Adies dieselen elengine ginewith withwet wetliner linershas shasbeen beenrunn runningto ingtoohot ohot,and ,andther thereis eiscoola coolantin ntin thecrankcase.Themostlikelycauseis: (A) a cracked block (B) cracked liners * (C) leaking liner seals. (D) a leaking injector seal.

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 T2 S AMplE QuESTiOnS (cOnTinuEd ) 6. Dieselen Dieselenginec ginecylinde ylinderlin rlinerpr erprotrus otrusion( ion(height height)ca )canbe nbeadjus adjustedb tedbysel yselecting ecting thecorrectsize:  (A (A) cylinder liner.   (B) head gasket. * (C) liner shim. (D) re ring. 7. Adies dieselen elengine ginewith withEUI EUIhasa hasamis misrea reandth ndtheche echecken ckengine ginelight lightisO isON.F N.Fault ault codeS4FMI5“cylinder4currentbelow codeS4FMI5“ cylinder4currentbelownormal”isactive. normal”isactive.Thiscouldbe Thiscouldbe causedbya: (A) (A )ffai aile led deeng ngin ine epo possit itio ion nssen enso sorr. (B))s (B sti ticcki kin ng g#4 #4 in inje ject ctio ion npl plun unge gerr. *(C * (C) )br brok oken en# #4 4in inje ject ctio ion nwi wire ret ter ermi mina nal. l. (D) (D )st stic icki king ng th thro rott ttle le po posi siti tion on se sens nsor or.. 8. Thecause Thecauseofa ofalogge loggedfa dfaultc ultcodein odeinan anelectr electronic onicdiese dieselengi lengineha nehasjus sjustbee tbeen n repaired. Technician echnicianA Asaysthatthecodess saysthatthecodesshouldbeclearedbefore houldbeclearedbeforereleasingthevehicle. releasingthevehicle. TechnicianBsaysthatthe echnicianBsaysthatthecustomer’s customer’spasswordshouldber passwordshouldberesetbefore esetbefore releasingthevehicle. Who is right? * (A) A only  (C (C) Both A and B  (B (B) B only  (D (D) Neither A nor B 9. Adieselenginehaslow dieselenginehaslowpowerandlowtur powerandlowturbochargerboostpr bochargerboostpressureisfound. essureisfound. Technician echnicianA Asaysthataleakingexhaus saysthataleakingexhaustmanifoldcouldbethecaus tmanifoldcouldbethecause. e. TechnicianBsaysthata echnicianBsaysthatapluggedturbocharger pluggedturbochargeroilreturnlinecouldbethe oilreturnlinecouldbethe cause. Whoisright? * (A) A only  (C (C) Both A and B  (B (B) B only  (D (D) Neither A nor B

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pEcificATiOnS And  And liST  TEST SpEcificATiOnS drivE TrAin (TEST T3)

Content Area A. Clutch Diagnosi Diagnosis s and Repair B. Trans Transmission mission Diagnosis and Repair C. Driveshaft and Universal Universal Joint Diagnosis and Repair D. Drive Axle Diagnosis and Repair

Total

Questions in Test

Percentage of Test

11 13

28% 33%

7 9

18% 23%

40

100%

 A. Clutch Diagnosis and Repair (11 questions) 1. Diagnoseclutc Diagnoseclutchnoise,binding,slipp hnoise,binding,slippage,pulsation,vibra age,pulsation,vibration,grabbing,andc tion,grabbing,andchatter hatter problems;determinecauseoffailu problems;deter minecauseoffailureandneededrep reandneededrepairs. airs. 2. Inspect,adjust,rep Inspect,adjust,repair,orrep air,orreplaceclutchlinkag laceclutchlinkage,cables,levers,brac e,cables,levers,brackets,bushings, kets,bushings, pivots,springs,andclutchsafetyswitc pivots,springs,and clutchsafetyswitch(includespusha h(includespushandpulltypeassem ndpulltypeassemblies); blies); checkpedalheightandtravel. 3. Inspect,adjust,rep Inspect,adjust,repair,orrep air,orreplacehydraulicclu lacehydraulicclutchslaveandmas tchslaveandmastercylinders,lines, tercylinders,lines, andhoses;bleedsystem. 4. Inspect,orremov Inspect,orremoveandinstallreleas eandinstallrelease(throwout)beari e(throwout)bearing,sleeve,bushings ng,sleeve,bushings,springs, ,springs, housing,levers,releasefork,forkpads housing,levers,rel easefork,forkpads,forkrollers,shafts,and ,forkrollers,shafts,andseals;measurean seals;measureand d adjustrelease(throwout)bearingposition. 5. Inspect,orremov Inspect,orremoveandinstallsingleeandinstallsingle-discclutchpressu discclutchpressureplateandclutch replateandclutchdisc; disc; adjustfreeplayandreleasebearingposition. 6. Insp Inspect,o ect,orrem rremovea oveandin ndinstall stalltwo two-plat -plateclu eclutchp tchpress ressurep ureplate, late,clut clutchdi chdisc, sc, intermediateplate;determinepro intermediatepl ate;determineproperclutchtorque perclutchtorquerating;adjustfree rating;adjustfreeplayand playand releasebearingposition. 7. Inspectandrepla Inspectandreplaceclutchbrakeas ceclutchbrakeassembly;inspecta sembly;inspectandreplaceinputsh ndreplaceinputshaftandbear aftandbear ingretainer. 8. Inspect,orremov Inspect,orremoveandinstallself-ad eandinstallself-adjusting/continuou justing/continuous-adjustingclutc s-adjustingclutchassembly; hassembly; performinitialand/orresetadjustme performinitiala nd/orresetadjustmentprocedure. ntprocedure. 9. Ins Inspec pecta tand ndrep replac lacep epilo ilotb tbear earing ing.. 10. Inspectywhee Inspectywheelmountingareaon lmountingareaoncrankshaft,rearm crankshaft,rearmainoilseal,andmeas ainoilseal,andmeasure ure crankshaftendplay;determinene crankshaftendp lay;determineneededrepairs. ededrepairs. 11. Inspectywhee Inspectywheel,starterringgear l,starterringgear,andmeasureywh ,andmeasureywheelfaceandpilotb eelfaceandpilotborerunout; orerunout; determineneededrepairs. 12. Inspectywhee Inspectywheelhousing(s)totran lhousing(s)totransmissionhousin smissionhousing/enginematingsurf g/enginematingsurface(s)and ace(s)and measureywheelhousingfacean measureywhe elhousingfaceandborerunout;dete dborerunout;determineneededrep rmineneededrepairs. airs.

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 T3 liST (cOnTinuEd ) B. Transmission Transmission Diagnosis and Repair (13 questions) 1. Dete Determin rminethe ethecau causeof seoftran transmis smission sioncomp componen onentfai tfailure, lure,both bothbefo beforean reanddur dduring ing disassemblyprocedures. 2. Diag Diagnose nosetran transmis smission sionvibr vibration ation/nois /noise,sh e,shiftin ifting,lo g,lockup ckup,slip ,slipping ping/jump /jumping ing out-of-gear,andoverheating out-of-gear ,andoverheatingproblems;determ problems;determineneededrepai ineneededrepairs. rs. 3. Inspect,adjust,rep Inspect,adjust,repair,orrep air,orreplacetransmissio lacetransmissionremoteshiftlink nremoteshiftlinkages,cables,bracke ages,cables,brackets, ts, bushings,pivots,andlevers. 4. Inspect,testopera Inspect,testoperation,adjust,repair tion,adjust,repair,orreplaceairshiftc ,orreplaceairshiftcontrols,lines,hoses,va ontrols,lines,hoses,valves, lves, regulators,lters,andcylinderassemblies. 5. Inspect,testopera Inspect,testoperation,adjust,repair tion,adjust,repair,orreplaceelectro ,orreplaceelectronicshiftcontrols,sh nicshiftcontrols,shift,range ift,range andsplittersolenoids,shiftmotors,ind andsplittersolen oids,shiftmotors,indicators,speedand icators,speedandrangesensors,elec rangesensors,electronic/ tronic/ transmissioncontrolunits(ECU/TC transmissionco ntrolunits(ECU/TCU),neutral/ingearan U),neutral/ingearandreverseswitche dreverseswitches,and s,and wiringharnesses. 6. Inspect,testopera Inspect,testoperation,repair tion,repair,orreplaceelectro ,orreplaceelectronicshiftselectors nicshiftselectors(in-cabcontrols) (in-cabcontrols), , airandelectricalswitches,displays airandelectrica lswitches,displaysandindicators,wir andindicators,wiringharnesses,anda ingharnesses,andairlines. irlines. 7. Usea Useappro ppropriat priatedia ediagnos gnostict tictools oolsands andsoftw oftware,p are,proce rocedure dures,and s,andserv servicei iceinform nformaa tion/owchartstodiagnoseautomat tion/owchartstod iagnoseautomatedmechanicaltra edmechanicaltransmissionproble nsmissionproblems;checkand ms;checkand recorddiagnosticcodes,clearcode recorddiagnos ticcodes,clearcodes,interpretdigitalm s,interpretdigitalmultimeter(DMM ultimeter(DMM)readings, )readings, determineneededrepairs. 8. Diag Diagnose noseauto automate matedme dmechan chanical icaltran transmiss smissionp ionprobl roblemsc emscaused ausedbyd bydatal atalink/b ink/bus us interfaceswithrelatedelectronic interfaceswith relatedelectroniccontrolsystems. controlsystems. 9. Remo Removea veandre ndreplac placetra etransmi nsmissio ssion;in n;inspec spectand tandrepl replace acetrans transmissi missionmo onmounts, unts, insulators,andmountingbolts. 10. Inspectforleaka Inspectforleakageandreplacetra geandreplacetransmissioncover nsmissioncoverplates,gaskets,seala plates,gaskets,sealants,seals, nts,seals, vents,andcapbolts;inspectsealsurfaces. 11. Checktransmis Checktransmissionuidlevel,and sionuidlevel,andcondition;determ condition;determineneededservic ineneededservice,andadd e,andadd propertypeoflubricant. 12. Inspect,adjust,and Inspect,adjust,andreplacetransmis replacetransmissionshiftlever sionshiftlever,cover ,cover,rails,forks,levers, ,rails,forks,levers, bushings,sleeves,detents,interlocks bushings,sleeve s,detents,interlocks,springs,andlockbol ,springs,andlockbolts. ts. 13. Inspectandrepl Inspectandreplaceinputshaft,gear aceinputshaft,gear,spacers,bearings,ret ,spacers,bearings,retainers,andslingers ainers,andslingers.. 14. Inspectmainsha Inspectmainshaft,gears,slidingclutc ft,gears,slidingclutches,washers,space hes,washers,spacers,bushings,bearin rs,bushings,bearings,aux gs,aux iliarydrivegear/assembly iliarydrivegear /assembly,retainers/snaprings,an ,retainers/snaprings,andkeys;determine dkeys;determineneededrepairs. neededrepairs. 15. Inspectcounter Inspectcountershafts,gears,bearin shafts,gears,bearings,timingretainer gs,timingretainer/snaprings,andkeys;ch /snaprings,andkeys;check eck bearingpreload/endplay;verifymu bearingpreload /endplay;verifymultiplecountersha ltiplecountershaftgeartiming;dete ftgeartiming;determineneeded rmineneeded repairs. 16. Inspectoutputsh Inspectoutputshaft,gears,washers,sp aft,gears,washers,spacers,bearings,reta acers,bearings,retainers/snaprings,and iners/snaprings,andkeys; keys; determineneededrepairs. 17. Inspectreverse Inspectreverseidlershaft(s),gear( idlershaft(s),gear(s),bushings,bearin s),bushings,bearings,thrustwashers,an gs,thrustwashers,and d retainers/snaprings;checkreverse retainers/snaprin gs;checkreverseidlergearendplay; idlergearendplay;determineneede determineneededrepairs. drepairs. 18. Inspectsynchro Inspectsynchronizerhub,sleeve,ke nizerhub,sleeve,keys/inserts,springs,blo ys/inserts,springs,blockingrings,synchr ckingrings,synchronizer onizer plates,blockerpins,andslidingclutch plates,blockerpin s,andslidingclutches;determinenee es;determineneededrepairs. dedrepairs. 19. Inspecttransm Inspecttransmissioncasesinclud issioncasesincludingmatingsurfac ingmatingsurfaces,bores,bushings,pi es,bores,bushings,pins,studs, ns,studs, vents,andmagneticplugs;determi vents,andmagne ticplugs;determineneededrepairs neneededrepairs.. 20. Inspect,service,or Inspect,service,orreplacetransmis replacetransmissionlubricationsy sionlubricationsystemcomponen stemcomponents,pumps, ts,pumps, troughs,collectors,slingers,coolers,lter troughs,collecto rs,slingers,coolers,lters,andlinesandhose s,andlinesandhoses. s. 21. Inspect,test,replac Inspect,test,replace,andadjustelectr e,andadjustelectronicspeedomete onicspeedometerdrivecomponen rdrivecomponents. ts.

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 T3 liST (cOnTinuEd ) 22. Inspect,adjust,serv Inspect,adjust,service,repair ice,repair,orreplacepowerta ,orreplacepowertake-offassem ke-offassembliesandcontrol bliesandcontrols. s. 23. Inspectandtestop Inspectandtestoperationofbackup erationofbackuplight,neutralstart,an light,neutralstart,andwarningdevice dwarningdevicecircuits circuits andswitches;determineneededrepairs. 24. Inspectandtesttr Inspectandtesttransmissiontemp ansmissiontemperaturesendingu eraturesendingunit/sensorandgauge nit/sensorandgauge;determine ;determine neededrepairs. 25. Inspect,adjust,rep Inspect,adjust,repair,orrep air,orreplacetransfercase lacetransfercaseassembliesandco assembliesandcontrols. ntrols.

C. Driveshat and Universal Joint Diagnosis and Repair (7 questions) 1. Diagnosedrive Diagnosedriveshaftanduniversa shaftanduniversaljointnoise,vibrati ljointnoise,vibration,andrunoutprobl on,andrunoutproblems;deter ems;deter minecauseoffailureandneededrepairs. 2. Insp Inspect,s ect,servic ervice,or e,orrepl replaced acedrives riveshaft, haft,slip slipjoin joints/yo ts/yokes, kes,yoke yokes,dr s,drive iveange anges, s, universaljoints,driveshaftbootsan universaljoints,dr iveshaftbootsandseals,andretainin dseals,andretaininghardware;prope ghardware;properly rly phase/timeyokes. 3. Insp Inspecta ectandre ndreplace placedriv drivesha eshaftce ftcenter ntersupp supportb ortbearin earingsan gsandmo dmounts unts.. 4. Measureandadj Measureandadjustvehicleridehei ustvehiclerideheight;measureand ght;measureandadjustdrivelineslo adjustdrivelineslopesand pesand angles(vehicleloadedandunload angles(vehicle loadedandunloaded),includingPT ed),includingPTOdriveshafts. Odriveshafts. 5. Usea Useappro ppropriat priatedri edrivelin velineana eanalysi lysissof ssoftwar twareto etodiagn diagnosed osedrive riveline lineprob problems lems.. 6. Diag Diagnose nosedriv drivelin elineret eretarde arderpro rproblem blems;de s;determ terminen ineneede eededrep drepairs airs..

D. Drive Axle Diagnosis and Repair (9 questions) 1. Diagnosedrive Diagnosedriveaxleunitnoiseando axleunitnoiseandoverheatingprobl verheatingproblems;determinen ems;determineneededrepairs. eededrepairs. 2. Checkandrepai Checkandrepairuidleaks;inspec ruidleaks;inspectandreplacedrive tandreplacedriveaxlehousingcove axlehousingcoverplates, rplates, gaskets,sealants,vents,magneticplugs,andseals. 3. Checkdriveaxle Checkdriveaxleuidlevel,andcond uidlevel,andcondition;determinen ition;determineneededservice,add eededservice,addproper proper typeoflubricantusingcorrectllprocedure. 4. Remo Removean veandrep dreplace lacedif differen ferential tialcarr carriera ierassem ssembly bly.. 5. Inspectandrepla Inspectandreplacedifferen cedifferentialcaseassembly tialcaseassemblyincludingspider/pin includingspider/piniongears,cross iongears,cross shaft,sidegears,thrustwashers,caseha shaft,sidegears,thru stwashers,casehalves,andbearings. lves,andbearings. 6. Inspectandrepla Inspectandreplacecomponentso cecomponentsoflockingdiff flockingdifferentialcaseasse erentialcaseassembly mbly.. 7. Meas Measurer ureringg inggearb earbackla acklashan shandrun drunout; out;dete determin rminenee eneeded dedrepai repairs. rs. 8. Insp Inspectr ectringa ingandd nddrive rivepinio piniongea ngears,sp rs,spacer acers,shi s,shims,s ms,sleeve leeves,be s,bearing aringcage cages,an s,and d bearings;determineneededrepairs. 9. Chec Checkrin kringan gandpin dpiniong iongeart eartooth oothcont contactp actpatte attern;i rn;inter nterpret pretpatte patternan rnand d determineneededrepairs. 10. Inspectandrepla Inspectandreplacepowerdivider cepowerdivider(inter-axle (inter-axledifferential differential)assembly )assembly.. 11. Inspect,adjust,rep Inspect,adjust,repair,orrep air,orreplaceairoperatedp laceairoperatedpowerdivider(inte owerdivider(inter-axledif r-axledifferential) ferential) lockoutassemblyincludingdiaph lockoutassemb lyincludingdiaphragms,seals,spring ragms,seals,springs,yokes,pins,lines,hose s,yokes,pins,lines,hoses, s, ttings,andcontrols. 12. Inspectandmea Inspectandmeasuredriveaxlehou suredriveaxlehousingmatingsurfa singmatingsurfacesandalignmen cesandalignment;determine t;determine neededrepairs. 13. Inspect,service,or Inspect,service,orreplacedriveaxle replacedriveaxlelubricationsystem lubricationsystemcomponents,pum components,pump,troughs, p,troughs, collectors,slingers,tubes,andlters. 14. Inspectandrepla Inspectandreplacedriveaxleshaf cedriveaxleshafts. ts. 15. Removeandrep Removeandreplacewheelassem lacewheelassembly;checkdriveax bly;checkdriveaxlewheel/hubsealand lewheel/hubsealandaxleange axleange gasketforleaks;determineneededrepairs.

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 T3 liST (cOnTinuEd ) 16. Diagnosedrive Diagnosedriveaxlewheelbearin axlewheelbearingnoisesanddama gnoisesanddamage;determinenee ge;determineneededrepairs. dedrepairs. 17. Clean,inspect,lub Clean,inspect,lubricate,andreplace ricate,andreplacewheelbearingsan wheelbearingsandraces/cups;replac draces/cups;replaceseals eseals andwearrings;adjustdriveaxlewh andwearrings;a djustdriveaxlewheelbearings(inc eelbearings(includingoneandtwo ludingoneandtwonuttypes) nuttypes) tomanufacturers’specications. 18. Inspectandtestd Inspectandtestdriveaxletempera riveaxletemperaturesendingunit/se turesendingunit/sensorandgauge;de nsorandgauge;determine termine neededrepairs. 19. Check,adjust,and Check,adjust,and/orreplacewheelspe /orreplacewheelspeedsensor(s). edsensor(s). 20. Inspectorrepla Inspectorreplaceextendedservi ceextendedservice(sealed,close-to ce(sealed,close-tolerance,andunitiz lerance,andunitized) ed) bearingassemblies;performinit bearingassemb lies;performinitialinstallationpro ialinstallationprocedurestomanuf cedurestomanufacturers’ acturers’ specications.

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S AMplE QuESTiOnS drivE TrAin (TEST T3) ROTATE RING GEAR

QuESTiOnS : 1. Whato Whatoper perati ation onis isbei being ngper perfor forme med d inthesetupshownabove? (A) Adjusting tooth contact * (B) )Ch Chec ecki king ngr rin ing gge gear arr run unou outt (C) Checking ring gear backlash (D) Se Sett ttin ing gdi difffer eren enti tial al be bear arin ing gpr prel eloa oad d 2. Atr truck uckdo does esnot notm move ovein inan anyg ygear ear. . TechnicianAsaysthatabrokenshifterforkcouldbethecause. TechnicianBsaysthatabr echnicianBsaysthatabrokenoutputshaftcouldbethec okenoutputshaftcouldbethecause. ause. Whoisright?  (A (A) A only  (C (C) Both A and B * (B) B only  (D ( D) Neither A nor B 3. Theshift Theshiftlever leverona ona1313-speed speedtran transmis smission sionisha ishardto rdtomove move. . Whichoftheseisthemostlikelycause? (A) (A )Be Bent nts shi hift ftr rai ails ls                *(B * (B) )Ga Gall lled eds sli lidi ding ngc clu lutc tch hge gear arss (C) Worn detent springs (D) (D )T Too muc uch hm mai ains nsha haft ft ge gear are end ndp pla lay y 4. Theairp Theairpressu ressurer reregulat egulatorf orfora oratran transmis smission sionisbe isbeingch ingchecked ecked. . TechnicianAsaysthatthetractorairpressureshouldbeatmaximumsystem pressure. TechnicianBsaysthatther echnicianBsaysthattheregulatorairltershouldbe egulatorairltershouldbecleanedandthesystem cleanedandthesystem recheckediftheairpressurereadingis recheckediftheair pressurereadingisbelownormal. belownormal. Whoisright?  (A (A) A only * (C) Both A and B  (B (B) B only  (D (D) Neither A nor B

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 T3 S AMplE QuESTiOnS (cOnTinuEd ) 5. Thedriverofatrucksaysthatagrindingnois Thedriverofatrucksaysthatagrindingnoisecanbeheardwhe ecanbeheardwhentheclutch ntheclutch pedalisdepressed.Whichoftheseis pedalisdepressed. Whichoftheseisthemostlikelycause? themostlikelycause? (A) )T Too ool lit ittl tle ecclu lutc tch hpe peda dal lffree eepl play ay *(B * (B) )A Aw wor orn ncl clutc utch hre rele leas ase e(t (thr hrow owou out) t)b bea eari ring ng (C) (C )A Al low owt tra rans nsmi miss ssio ion nlu lubr bric ican ant tle leve vell (D) A wor orn ncclu lutc tch hpr pres essu surre epl plat atee 6. Atwotwo-plate platepull-t pull-typec ypeclutch lutchengage engagesOK sOK,but ,butthe thetrans transmiss missiong iongrinds rindswhe when n goingintorstgearfromneutral. TechnicianAsaysthatawornclutchbrakecouldbethecause. TechnicianBsaysthattoolittle echnicianBsaysthattoolittlefreeplaycouldbetheca freeplaycouldbethecause. use. Whoisright? * (A) A only  (C (C) Both A and B  (B (B) B only  (D (D) Neither A nor B 7. Whichof Whichofthese thesecould couldbethe bethecaus causeof eofadr adrivesha iveshaftvi ftvibrati brationon ononatru atruck ck thathasjusthadaU-jointreplaced? *(A * (A) )Th The edr driv ives esha haft fti is sou outt-of of-p -pha hase se (B) The heU U-j -joi oint ntw was as in inst stal alle led dba back ckw war ards ds (C) The heU U-j -joi oint ntw was as no not tlu lubr bric icat ated ed (D) Th Theere rei is sdi dirrt ton ont the hed drriv ives esha hafft 8. Atruc truckwit kwitha hasingle singlerea rearax raxleha lehastoo stoomuch muchrear rearaxle axlenoise noiseonly onlywhen whenthe the truckispulling.Whichoftheseisthemostlikelycause? (A) Worn axle shaft bearings (B) Worn wheel bearings (C) (C )W Wor orn ndi difffe fere rent ntia ial lpi pini nion on( (sp spid ider er) )ge gear arss *(D * (D) )W Wor orn nri ring nga and ndp pin inio ion nge gear arss

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pEcificATiOnS And  And liST  TEST SpEcificATiOnS BrAkES (TEST T4)

Content Area

Questions in Test

A. Air Brakes Diagnosis and Repair 28 1. Air Supply and Service Systems (14) 2. Mechanical/Foundation (10) 3. Parking Brakes (4) B. Hydraulic Brakes Diagnosis and Repair 14 1. Hydraulic System (6) 2. Mechanical System (5) 3. Power Assist Units and Miscellaneous (3) C. Air and Hydraulic Hydraulic Antilock Brake Brake Systems (ABS), Automatic traction Control (ATC), and Electronic Stability Control Systems 5 D. Wheel Bearings Diagnosis and Repair 3

Total

50

Percentage of Test 56%

28%

10% 6%

100%

 A. Air Brakes Diagnosis and Repair (28 questions) 1. Air Supply and Service Systems (14 questions) 1. Diagnosepoor Diagnosepoorstopping,prematu stopping,prematurewear rewear,brakenoise,airleak ,brakenoise,airleaks,pulling,grabbing, s,pulling,grabbing, ordraggingproblemscausedbysu ordraggingpro blemscausedbysupplyandservice pplyandservicesystemcomponen systemcomponents;determine ts;determine neededrepairs. 2. Chec Checkair kairsyst systemb embuilduild-upti uptime;d me;deter etermine mineneed neededre edrepair pairs. s. 3. Drainairreserv Drainairreservoirtanks;checkfo oirtanks;checkforoil,water roil,water,andforeignmateria ,andforeignmaterial;determineneed l;determineneeded ed repairs. 4. Insp Inspect, ect,adju adjust,al st,align, ign,andr andreplac eplacecom ecompres pressord sordrive rivebelt beltsand sandpull pulleys. eys. 5. Insp Inspecta ectandre ndreplac placecom ecompres pressord sordrive rivegear gearand andcoup coupling ling.. 6. Inspect,repair Inspect,repair,orreplaceaircomp ,orreplaceaircompressor ressor,oilsupply ,oilsupply,waterlines,hoses ,waterlines,hoses,ttingsand ,ttingsand mountingbrackets. 7. Inspect,test,adjus Inspect,test,adjust,andreplacesyste t,andreplacesystempressurecontro mpressurecontrols(governor/relief ls(governor/reliefvalve), valve), unloaderassembly unloaderassem bly,lines,hoses,andttings ,lines,hoses,andttings.. 8. Inspect,repair Inspect,repair,orreplaceairsyste ,orreplaceairsystemlines,hoses,ttings,and mlines,hoses,ttings,andcouplings;check couplings;checkfor for properrouting. 9. Inspect,test,clean Inspect,test,clean,andreplaceairtank ,andreplaceairtankrelief(pop-of relief(pop-off)valves,one-way f)valves,one-way(single) (single) checkvalves,draincocks,automat checkvalves,dr aincocks,automaticdrain(spitter)va icdrain(spitter)valves,heaters,wiring lves,heaters,wiring,and ,and connectors.

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 T4 liST (cOnTinuEd ) 10. Inspect,test,clean Inspect,test,clean,repair,orr ,repair,orreplaceairdriersys eplaceairdriersystems,lters,valves,heat tems,lters,valves,heaters,wiring, ers,wiring, andconnectors. 11. Inspect,test,repair Inspect,test,repair,orreplacebrake ,orreplacebrakeapplication(foot) application(foot)valve,ttings,andmoun valve,ttings,andmounts; ts; checkpedaloperation. 12. Inspect,test,andrep Inspect,test,andreplacetwo-way(do lacetwo-way(double)checkvalv uble)checkvalvesandanti-comp esandanti-compounding ounding valves. 13. Inspect,test,repair Inspect,test,repair,orreplacestopan ,orreplacestopandparkingbrakelig dparkingbrakelightcircuitswitche htcircuitswitches,wiring, s,wiring, andconnectors. 14. Inspect,test,repair Inspect,test,repair,orreplacehandbr ,orreplacehandbrake(trailer)cont ake(trailer)controlvalve,lines,hoses rolvalve,lines,hoses, , ttings,andmountings. 15. Inspect,test,andrep Inspect,test,andreplacebrakerelayv lacebrakerelayvalves. alves. 16. Inspect,test,andrep Inspect,test,andreplacequickreleas lacequickreleasevalves. evalves. 17. Inspect,test,andrep Inspect,test,andreplacetractorprote lacetractorprotectionvalve. ctionvalve. 18. Inspect,test,andrep Inspect,test,andreplaceinversion/eme laceinversion/emergency(spr rgency(spring)brakecontro ing)brakecontrolvalve(s). lvalve(s). 19. Inspect,test,andrep Inspect,test,andreplacelowpressure lacelowpressurewarningdevices warningdevices.. 20. Inspect,test,repair Inspect,test,repairorreplaceairpress orreplaceairpressuregauges,in-cab uregauges,in-cablines,hoses,ttings,and lines,hoses,ttings,and pressuresensors(transducers). 21. Determineifair Determineifairbrakesystemprob brakesystemproblemiscausedbytra lemiscausedbytractorortrailersupp ctorortrailersupplyorservice lyorservice systemcomponents. 22. Verifythecomplai erifythecomplaintandroadtestvehi ntandroadtestvehicle;reviewdriver cle;reviewdriver/customerintervie /customerinterviewand wand pastmaintenancedocuments(ifa pastmaintenan cedocuments(ifavailable);determ vailable);determinefurtherdiagn inefurtherdiagnosis. osis.

2. Mechanical/Foundation (10 questions) 1. Diagnosepoors Diagnosepoorstopping,prematur topping,prematurewear ewear,brakenoise,pulling,gr ,brakenoise,pulling,grabbing,ordraggin abbing,ordragging g problemscausedbyfoundationbr problemscause dbyfoundationbrakecomponents akecomponents;determineneede ;determineneededrepairs. drepairs. 2. Inspect,test,repair Inspect,test,repair,orreplaceservic ,orreplaceservicebrakechambers ebrakechambers,diaphragm,clamp ,diaphragm,clamp,return ,return spring,pushrod,clevis,andmountingbrackets. 3. Insp Inspect,s ect,servic ervice,or e,orrepl replacem acemanua anualand landauto automati maticsla cslackad ckadjuste justers. rs. 4. Inspectandrepl InspectandreplaceS-cambrakero aceS-cambrakerollers,bushings,cam llers,bushings,camshafts,seals,spacer shafts,seals,spacers,retain s,retain ers,brakespiders,shields,anchorpins,andsprings. 5. Insp Inspect,c ect,clean lean,rebu ,rebuildo ildorrep rreplace, lace,and andadju adjustai stairdis rdiscbra cbrakeca kecalipe liperass rassembl emblies. ies. 6. Insp Inspecta ectandre ndreplace placebrak brakesho eshoes,o es,orpad rpads;de s;determ terminen ineneede eededrep drepair air.. 7. Insp Inspecta ectandre ndreplace placebrak brakedru edrumsor msorroto rotorsas rsasnee needed. ded.

3. Parking Brakes (4 questions) 1. Inspectandtestp Inspectandtestparking(spring)br arking(spring)brakechamberope akechamberoperation;replacepa ration;replaceparking(spring) rking(spring) brakechamber;disposeofremove brakechamber ;disposeofremovedchambersinacc dchambersinaccordancewithloc ordancewithlocalregulations. alregulations. 2. Insp Inspect,t ect,test,a est,andre ndreplac placepar eparking king(spr (spring) ing)brak brakeche echeckva ckvalves lves,line ,lines,ho s,hoses,a ses,and nd ttings. 3. Insp Inspect,t ect,test,a est,andre ndreplac placepar eparking king(spr (spring) ing)brak brakeapp eapplicat licationa ionandre ndreleas leaseval evalve. ve. 4. Manu Manually allyrele release( ase(cage cage)and )andrese reset(un t(uncage cage)par )parking king(spr (spring) ing)brak brakes. es.

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 T4 liST (cOnTinuEd ) B. Hydraulic Brakes Diagnosis and Repair (14 questions) 1. Hydraulic System (6 questions) 1. Diag Diagnose nosepoor poorstop stopping, ping,brak brakenoi enoise,p se,prema remature turewear wear,pul ,pulling, ling,grab grabbing, bing, dragging,orpedalfeelproblemscau dragging,orpeda lfeelproblemscausedbyhydraulicsy sedbyhydraulicsystemcomponen stemcomponents;determine ts;determine neededrepairs. 2. Pres Pressure suretest testhydr hydrauli aulicsys csystema temandin ndinspec spectfor tforleak leaks. s. 3. Chec Checkand kandadju adjustbr stbrake akepeda pedalpus lpushrod hrodleng length. th. 4. Insp Inspect,t ect,test,a est,andre ndreplac placemas emasterc tercylin ylinder der.. 5. Insp Inspecta ectandre ndreplace placebrak brakelin elines,e es,exible xiblehose hoses,and s,andttin ttings. gs. 6. Insp Inspect,t ect,test,a est,andre ndreplac placemet emetering ering(hol (hold-of d-off),lo f),loadse adsensin nsing/pro g/proporti portionin oning, g, proportioning,andcombinationvalves. 7. Inspect,test,repair Inspect,test,repair,orreplacebrakep ,orreplacebrakepressurediffe ressuredifferentialvalveand rentialvalveandwarninglight warninglight circuitswitch,bulbs,wiring,andconnectors. 8. Insp Inspecta ectandre ndreplace placewhee wheelcyl lcylinde inders. rs. 9. Insp Inspect,c ect,clean lean,and ,andrepl replaced acediscb iscbrake rakecali calipera perassem ssemblie blies. s. 10. Inspect/testbrake Inspect/testbrakeuid;bleedand/orus uid;bleedand/orushsystem;determi hsystem;determineproperuidtyp neproperuidtypefor efor application. 11. Inspect,test,repair Inspect,test,repair,orreplacehydrau ,orreplacehydraulically-control lically-controlledparkingbrake ledparkingbrakecomponents, components, systems,andwarningdevices.

2. Mechanical System (5 questions) 1. Diagnosepoorst Diagnosepoorstopping,brakenois opping,brakenoise,prematurewear e,prematurewear,pulling,grabbing,dr ,pulling,grabbing,dragging, agging, orpedalfeelproblemscausedbydis orpedalfeelprob lemscausedbydiscanddrumbrakem canddrumbrakemechanicalcomp echanicalcomponents; onents; determineneededrepairs. 2. Insp Inspect,r ect,resurf esurface, ace,orre orreplac placebra ebraked kedrums rumsorro orrotors. tors. 3. Insp Inspect,a ect,adjust djust,and ,andrepl replaced acedrumb rumbrake rakeshoe shoes,mo s,mountin untinghar ghardwar dware,ad e,adjuste juster r mechanisms,andbackingplates. 4. Insp Inspect,s ect,servic ervice,an e,andrep dreplace lacedisc discbrak brakepad epads,har s,hardwar dware,an e,andmou dmounts. nts. 5. Inspect,adjust,rep Inspect,adjust,repair,orrep air,orreplacedrivelinepark lacedrivelineparkingbrakedrums,ro ingbrakedrums,rotors,shoes, tors,shoes, mountinghardware,andadjusters mountinghardw are,andadjusters;burnish/seatreplac ;burnish/seatreplacementshoesasreq ementshoesasrequired. uired. 6. Inspect,adjust,rep Inspect,adjust,repair,orrep air,orreplacedrivelinepark lacedrivelineparkingbrakeapplica ingbrakeapplicationsystempeda tionsystempedal, l, cables,linkage,levers,pivots,andsprings.

3. Power Assist Units and Miscellaneous (3 questions) 1. Diag Diagnose nosepoor poorstop stopping pingcomp complain laintsca tscaused usedbyb bybrake rakeassi assist(b st(boost ooster)s er)syste ystem m problems;determineneededrepairs. 2. Inspect,test,repair Inspect,test,repair,orreplacepower ,orreplacepowerbrakeassist(boos brakeassist(booster),hoses,controlva ter),hoses,controlvalves lves andlters;determineproperuidtype andlters;determin eproperuidtypeforapplication. forapplication. 3. Test,adjust,andreplac est,adjust,andreplacebrakestoplightsw ebrakestoplightswitch,bulbs,wiring,an itch,bulbs,wiring,andconnectors. dconnectors.

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 T4 liST (cOnTinuEd ) C. Air and Hydraulic Antilock Brake Systems (ABS), Automatic Traction Traction Control (ATC), (A TC), and Electronic Stability Control Systems (5 questions) 1. Observeantilo Observeantilockbrakesystem(A ckbrakesystem(ABS)warningligh BS)warninglightoperation;determ toperation;determineiffurther ineiffurther diagnosisisneeded;(includesdas diagnosisisneed ed;(includesdashmountedtrailer hmountedtrailerAB ABSwarninglight). Swarninglight). 2. Diagnoseantilo Diagnoseantilockbrakesystem(A ckbrakesystem(ABS)electronicc BS)electroniccontrol(s)andcom ontrol(s)andcomponentsusing ponentsusing self-diagnosisand/orspeciedtestequ self-diagnosis and/orspeciedtestequipment(scantool,PC ipment(scantool,PCbasedsoftware) basedsoftware); ; determineneededrepairs. 3. Diag Diagnose nosewhee wheelloc llock-up k-upcaus causedb edbyfai yfailure lureofth oftheant eantiloc ilockbra kbrakesy kesystem stem(ABS (ABS); ); determineneededrepairs. 4. Inspect,test,andrep Inspect,test,andreplaceantilockbra laceantilockbrakesystem(ABS)a kesystem(ABS)air,hydra ir,hydraulic,electrical, ulic,electrical, andmechanicalcomponents. 5. Diagnoseautom Diagnoseautomatictractioncon atictractioncontrol(A trol(ATC)electronicco TC)electroniccontrol(s)andcom ntrol(s)andcomponents ponents usingself-diagnosisand/orspeciedte usingself-diag nosisand/orspeciedtestequipment(sca stequipment(scantool,PCbasedsoftw ntool,PCbasedsoftware); are); determineneededrepairs. 6. Diagnoseelect Diagnoseelectronicstabilitycon ronicstabilitycontrolsystemsandco trolsystemsandcomponentsusing mponentsusingself-diagnosis self-diagnosis and/orspeciedtestequipment(scantoo and/orspeciedtesteq uipment(scantool,PCbasedsoftwar l,PCbasedsoftware);determinenee e);determineneeded ded repairs.

D. Wheel Bearings Diagnosis and Repair (3 questions) l. Rem Remove ovean andr drepl eplace aceax axle lewhe wheel elass assemb embly ly.. 2. Clean,inspect,lub Clean,inspect,lubricate,andreplace ricate,andreplacewheelbearingsan wheelbearingsandraces/cups;replac draces/cups;replaceseals eseals andsealwearrings. 3. Adjuststeering Adjuststeeringanddriveaxlewhe anddriveaxlewheelbearings(inclu elbearings(includingoneandtwonu dingoneandtwonuttypes) ttypes) tomanufacturers’specications. 4. Insp Inspecto ectorrep rreplace laceexte extended ndedserv service( ice(seale sealed,clo d,close-to se-toleran lerance,a ce,andun ndunitize itized) d) bearingassemblies;performinit bearingassemb lies;performinitialinstallationpro ialinstallationprocedurestomanuf cedurestomanufacturers’ acturers’ specications.

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S AMplE QuESTiOnS BrAkES (TEST T4)

QuESTiOnS : 1. Theparkin Theparkingbra gbrakesf kesfailto ailtoappl applyon yonatru atruckw ckwitha ithairbr irbrakes. akes. Technician echnicianA Asaysthatlowair saysthatlowairpressureinthespring pressureinthespringbrakechambercouldbe brakechambercouldbe thecause. TechnicianBsaysthatar echnicianBsaysthatarupturedspringbrakediaphr upturedspringbrakediaphragmcouldbethecause. agmcouldbethecause. Whoisright?  (A (A) A only  (C (C) Both A and B  (B (B) B only * (D) Neither A nor B 2. Atruc truckhas khasanu anuneven nevenbrak brakingp ingproble roblem. m.Whic Whichof hofthese thesecould couldbe bethec thecause? ause? (A) (A )A A bi bind ndin ing gtr trea eadl dle e((fo foot ot))v vaalv lvee (B) Low brake line air pressure * (C) A bad brake drum (D) A bad governor 3. Aser service vicebrake brakeona onatruc truckwi kwithan thanair airbrake brakesyst systemr emreleas eleasesto estooslo oslowly wly. . TechnicianAsaysthatlowairpressurecouldbethecause. TechnicianBsaysthata echnicianBsaysthatakinkedairlinecouldbethecaus kinkedairlinecouldbethecause. e. Whoisright?  (A (A) A only  (C (C) Both A and B * (B) B only  (D ( D) Neither A nor B 4. Aser service vicebrake brakecham chamberl berleaks eakswhen whentheb thebrakes rakesare areappl applied. ied.Which Whichoft ofthese hese couldbethecause? (A) Excessive push rod travel *(B * (B) )A Ab bad adc cha hamb mber erd dia iaph phra ragm gm (C)Abrokenchamberreturnspring (D) A misaligned push rod

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 T4 S AMplE QuESTiOnS (cOnTinuEd ) 5. Allthew Allthewheels heelsona onatru truckw ckwithai ithairbr rbrakes akeslock lockupw upwhena henasma smallam llamounto ountofpr fpres essureisappliedtothetreadle(foot)valve. sureisappliedtothetre adle(foot)valve.Whichofthesecouldbe Whichofthesecouldbethecause? thecause? *(A * (A) )Th The eap appl plic icat atio ion nva valv lve eis isb bad ad.. (B) (B )Th The eli lim mit itin ing gva valv lve eis is le leak akin ing. g. (C) (C )Th The eco comp mpre ress ssor orr reg egul ulat ator ori is sse set tto too ohi high gh.. (D) (D )T The br braake kes sar are ead adju just steed dto too ohi high gh.. 6. Whenana Whenanairr irreser eservoir voirtank tankisdr isdrained ained,the ,thereis reisane anexcess xcessivea iveamount mountofm ofmoistur oisture. e. Thiscouldbecausedbya: (A) cracked air compressor bracket. (B) clogged air compressor intake. (C) failed one way check valve. *(D * (D) )fa fail iled eda air ird dry ryer erp pur urge gev val alve ve.. 7. Allthebr Allthebrakes akesdrag dragona onatruck truckwit withhydr hhydraulic aulicbrake brakes. s.Whic Whichof hofthese thesecould couldbe be thecause? (A) Air in th thee hydraulic system (B) (B )T Too ooh hig igh hva vacu cuum ums sup uppl ply yto tot the hep pow ower erb bra rake keb boo oost ster er (C) (C )A Al lea eaki king ngs sec econ onda dary ryc cup upi in nth the ema mast ster erc cyl ylind inder er * (D (D) )No Nob bra rake kep ped edal alf fre ree etr trav avel el Questions 8 and 9 are not like the t he ones above. Eac ach hof of th thes ese eha has sth theew wor ord dEXCEPT.Foreachquestion,lookforthechoice thatcouldNOT causethedescribedsituation.Readtheentirequestion carefullybeforechoosingyouranswer carefullybeforechoos ingyouranswer.. 8. Atruc truckwit kwithhyd hhydrauli raulicbra cbrakes kespulls pullstoon toonesid esidewh ewhenth enthebra ebrakes kesare areapplie applied. d. AnyofthesecouldbethecauseEXCEPT a: (A) (A )st stic icki king ng whe heeel lcy cyli lind nder er pi pissto ton. n. (B))g (B grrea easse eco cont ntam amin inat ated ed br brak ake eli lini ning ng.. (C) crimped hydraulic line. * (D (D) )pl plug ugge ged dco comp mpen ensa sati ting ngp por ort. t. 9. Thedriver Thedriverof ofatru atruckw ckwitha ithairbr irbrakes akessays saysithas ithaspoor poorstop stoppingp pingpower ower. . AnyofthesecouldbethecauseEXCEPT: *(A * (A) )th the equ quic ick kre rele leas ase eva valv lve eex exha haus ust tpo port rti is spl plug ugge ged. d. (B))t (B the he ai airrp prres essu surre eis ist too oo lo low w. (C))t (C the he ap appl plic icat atio ion nli line nei issr res estr tric icte ted. d. (D) (D )th the ebr braake kes sar are eou out tof ofa adj dju ust stm men ent. t.

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pEcificATiOnS And  And liST  TEST SpEcificATiOnS SuSpEnSiOn  And S TEErinG (TEST T5)

Content Area

Questions in Test

A. Steering System Diagnosis and Repair 1. Steering Column (3) 2. Steering Units (6) 3. Steering Linkage (3) B. Suspension System Diagnosis and Repair C. Wheel Alignment Diagnosis, Diagnosis, Adjustment, and Repair D. Wheels and Tires Diagnosis and Repair E. Frame Service and Repair

Total

Percentage of Test

12

24.0%

13

26.0%

13 9 3

26.0% 18.0% 6.0%

50*

100%

 A. Steering System Diagnosis and Repair (12 Questions) 1. Steering Column (3 Questions) 1. Diagnosexedand Diagnosexedanddriveradjustable driveradjustablesteeringcolumnan steeringcolumnandshaftnoise,loose dshaftnoise,looseness,and ness,and bindingproblems;determinenee bindingproblem s;determineneededrepairs. dedrepairs. 2. Inspectandrepla InspectandreplacesteeringshaftU cesteeringshaftU-joint(s),slipjoints -joint(s),slipjoints,bearings,bushings ,bearings,bushings,andseals; ,andseals; phaseshaftU-joints. 3. Chec Checkand kandadju adjustca stcabmo bmountin untingand gandride rideheig height. ht. 4. Remo Removeth vetheste esteerin eringwhe gwheel(i el(includ ncludesst essteeri eeringwh ngwheels eelsequi equipped ppedwith withelec electrica trical/ l/ electroniccontrolsandcompone electroniccontr olsandcomponents);installandcen nts);installandcenterthesteeringwh terthesteeringwheel. eel.

2. Steering Units (6 Questions) 1. Diagnosepowe Diagnosepowersteeringsystemn rsteeringsystemnoise,steeringbindi oise,steeringbinding,darting/overstee ng,darting/oversteer,reduc r,reduced ed wheelcut,steeringwheelkick,pulling wheelcut,steerin gwheelkick,pulling,non-recovery ,non-recovery,turningeffor ,turningeffort,looseness,hard t,looseness,hard steering,overheating,uidleakage,an steering,overhea ting,uidleakage,anduidaerationpr duidaerationproblems;determin oblems;determineneeded eneeded repairs. 2. Determinereco Determinerecommendedtypeof mmendedtypeofpowersteeringu powersteeringuid;checkleveland id;checklevelandcondition; condition; determineneededservice. 3. Flus Flushand handrel rellpow lpowerst ersteerin eeringsys gsystem; tem;pur purgeai geairfro rfromsy msystem stem.. 4. Perf Performp ormpower owerstee steering ringsyst systempr empressur essure,tem e,tempera perature, ture,and andow owtests tests;det ;determin ermine e neededrepairs. 5. Inspect,service,or Inspect,service,orreplacepowerste replacepowersteeringreservoirinc eringreservoirincludinglter ludinglter,seals,and ,seals,and gaskets.

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 T5 liST (cOnTinuEd ) 6. Inspectandrein Inspectandreinstall/replacepower stall/replacepowersteeringpumpdri steeringpumpdrivebelts,pulleysand vebelts,pulleysandtensioners; tensioners; adjustdrivebeltsandcheckalignment. 7. Insp Inspecto ectorrep rreplace lacepowe powerste rsteering eringpump pumpdriv drivegea egearand randcoup coupling. ling. 8. Insp Inspect, ect,adjus adjust,or t,orrepl replacep acepower owerstee steering ringpump pump,mou ,mountin ntings,a gs,andbr ndbracke ackets. ts. 9. Inspectandrepl Inspectandreplacepowersteerin acepowersteeringsystemcooler gsystemcooler,lines,hoses,clamps/mo ,lines,hoses,clamps/mountings, untings, andttings. 10. Inspect,adjust,orre Inspect,adjust,orreplacelinkage-a placelinkage-assisttypepowerste ssisttypepowersteeringcylinderor eringcylinderorgear gear (dualsystem). 11. Inspect,adjust,rep Inspect,adjust,repair,orrep air,orreplaceintegraltype laceintegraltypepowersteeringge powersteeringgear ar.. 12. Adjustmanuala Adjustmanualandautomaticstee ndautomaticsteeringgearpoppet/rel ringgearpoppet/reliefvalves. iefvalves.

3. Steering Linkage (3 Questions) 1. Insp Inspect, ect,align align,and ,andrepl replacep acepitma itmanarm narm.. 2. Inspect,adjust,orre Inspect,adjust,orreplacedraglink(re placedraglink(relayrod)andtierode layrod)andtierodends(ballandadjus nds(ballandadjustable table sockettype). 3. Insp Inspecta ectandre ndreplac placeste esteering eringarms arms.. 4. Inspectorreplac Inspectorreplaceclampsandreta eclampsandretainersoncrosstube/re inersoncrosstube/relayrod/centerlink/tiero layrod/centerlink/tierod; d; positionasneeded. 5. Che Check ckand andad adjus justw twhee heels lstop tops. s.

B. Suspension System Diagnosis and Repair (13 Questions) 1. Insp Inspecta ectandre ndreplac placefro efrontax ntaxlebe lebeaman amandmou dmounting ntinghard hardware ware.. 2. Insp Inspect, ect,servi service,ad ce,adjust, just,orr orreplac eplacekin ekingpin gpin,bus ,bushing hings,loc s,locks,b ks,bearin earings,se gs,seals, als,and and covers. 3. Insp Inspecta ectandre ndreplac placesho eshockab ckabsorb sorbers,b ers,bushin ushings,b gs,brack rackets,a ets,andmo ndmounts. unts. 4. Inspect,repair Inspect,repair,orreplace(leafand ,orreplace(leafandparabolic)spring parabolic)springs,centerbolts,clips,spr s,centerbolts,clips,spring ing eyeboltsandbushings,shackles,slipp eyeboltsandbus hings,shackles,slippers,insulators,brac ers,insulators,brackets,andmounts. kets,andmounts. 5. Insp Inspect, ect,adjus adjust,or t,orrepl replacet acetorqu orquearm earms,bu s,bushing shings,and s,andmoun mounts. ts. 6. Inspect,adjust,orre Inspect,adjust,orreplaceaxlealignin placeaxlealigningdevicessuchasra gdevicessuchasradiusrods,transver diusrods,transversetorque setorque rods/trackbars,stabilizerbars,andrela rods/trackbars,stab ilizerbars,andrelatedbushings,moun tedbushings,mounts,shims,andcams. ts,shims,andcams. 7. Inspectorreplac Inspectorreplacewalkingbeams ewalkingbeams,center(cross)tube ,center(cross)tube,bushings,mounts,loa ,bushings,mounts,loadpads, dpads, brackets,caps,andmountinghardware. 8. Inspect,test,adjust Inspect,test,adjust,repair,or ,repair,orreplaceairsuspen replaceairsuspensionpressurereg sionpressureregulatorandheight ulatorandheight controlvalves,linkages,lines,hoses,andttings. 9. Inspect,test,repair Inspect,test,repair,orreplaceairsusp ,orreplaceairsuspensionsprings(b ensionsprings(bags),mountingpla ags),mountingplates, tes, mainsupportbeams/springs,suspens mainsupportbe ams/springs,suspensionarms(radius/tor ionarms(radius/torque,andtransverse que,andtransversetorque), torque), andbushings. 10. Measurevehic Measurevehiclerideheight;dete lerideheight;determineneededadj rmineneededadjustmentsorrepair ustmentsorrepairs. s. 11. Verifyanddiagnos erifyanddiagnosevehiclesuspens evehiclesuspensioncomplaints. ioncomplaints. 12. TorqueU-boltstom orqueU-boltstomanufacturers’ anufacturers’specications. specications. 13. Checkaxleload Checkaxleloaddistributionprobl distributionproblemsonrearsuspen emsonrearsuspensions;checkaxle sions;checkaxleseatplaning seatplaning anglesandpinionangles.

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 T5 liST (cOnTinuEd ) C. Wheel Alignment Diagnosis, Adjustment, and Repair (13 Questions) 1. Diagnosevehic Diagnosevehiclewandering,darti lewandering,darting,pulling,shimmy ng,pulling,shimmy,andsteeringef ,andsteeringeffortproblems; fortproblems; determineneededadjustmentsandrepairs. 2. Chec Checkcam kcambera berandK ndKPI(k PI(kingp ingpinin ininclin clination ation);de );determ terminen ineneede eededrep drepairs. airs. 3. Che Check ckand andad adjus justc tcast aster er.. 4. Ch Chec eck kan and dad adju just stt toe oe.. 5. Checkrearaxle( Checkrearaxle(s)alignment(thru s)alignment(thrustline/centerline) stline/centerline)andtracking(later andtracking(lateraloffset, aloffset, parallelism);adjustordeterminen parallelism);ad justordetermineneededrepairs. eededrepairs. 6. Chec Checktur kturning ning/Acke /Ackerman rmanangl angle(to e(toe-ou e-out-on t-on-turn -turns)an s)andma dmaximu ximumtur mturning ningradi radius us (wheelcut);determineneededrepairs.

D. Wheels and Tires Diagnosis and Repair (9 Questions) 1. Diag Diagnose nosetire tirewear wearpatt patterns erns;det ;determi erminene neneeded ededrepa repairs. irs. 2. Diag Diagnose nosewhee wheelend lendvibr vibratio ation,sh n,shimmy immy,pou ,poundin nding,ho g,hop(tr p(tramp) amp)prob problems; lems; determineneededrepairs. 3. Insp Inspecta ectandre ndreplace placewhee wheels,sp ls,spacer acers,rim s,rims,sid s,sidean eanges, ges,lock lockingr ingrings ings,rim ,rimclam clamps, ps, studs,andnuts. 4. Meas Measurew urewheel heeland andtire tireradia radialand landlate lateralr ralrunou unout;de t;determ terminen ineneede eededrep drepairs airsor or adjustments. 5. Inspecttires;che Inspecttires;checkandadjustairpre ckandadjustairpressuretotiremanu ssuretotiremanufacturers’ facturers’specications. specications. 6. Perf Performs ormstati taticbal cbalance anceofw ofwheel heeland andtire tireassem assembly bly.. 7. Perf Performd ormdynam ynamicba icbalanc lanceof eofwhee wheeland landtire tireasse assembly mbly.. 8. Meas Measuret uretired irediame iametera terandm ndmatch atchtires tiresona onaxles. xles. 9. Remo Removean veandrep dreplace lacestee steering ringand/o and/ordri rdrivea veaxlew xlewheel heelasse assembly mbly.. 10. Clean,inspect,lubr Clean,inspect,lubricate,andreplacew icate,andreplacewheelbearingsand heelbearingsandraces/cups;replace races/cups;replaceseals seals andwearrings;adjuststeeringandd andwearrings;ad juststeeringanddriveaxlewheelbe riveaxlewheelbearings(including arings(includingoneand oneand twonuttypes)tomanufacturers’ twonuttypes)tom anufacturers’specications. specications. 11. Inspectorreplac Inspectorreplaceextendedservic eextendedservice(sealed,closetole e(sealed,closetolerance,andunitized rance,andunitized)bearing )bearing assemblies;performinitialinstall assemblies;per forminitialinstallationprocedures ationprocedurestomanufacturer tomanufacturers’ s’specications. specications.

E. Frame Service and Repair (3 Questions) 1. Inspect,adjust,serv Inspect,adjust,service,repair ice,repair,orreplacefthwheel,pi ,orreplacefthwheel,pivotpins,bushings,loc votpins,bushings,locking king  jawmechanisms,andmountingbolts. 2. Inspect,adjust,serv Inspect,adjust,service,repair ice,repair,orreplaceslidingfthw ,orreplaceslidingfthwheel,tracks,stops,loc heel,tracks,stops,locking king systems,aircylinders,springs,lines,hos systems,aircylind ers,springs,lines,hoses,andcontrols. es,andcontrols. 3. Inspectframean Inspectframeandframemembers dframemembersforcracks,breaks,di forcracks,breaks,distortion,elongated stortion,elongatedholes, holes, looseness,anddamage;determine looseness,anddam age;determineneededrepairs. neededrepairs. 4. Inspect,install,orre Inspect,install,orrepairframehange pairframehangers,brackets,andcros rs,brackets,andcrossmembersinacco smembersinaccordance rdance withmanufacturers’recommendedprocedures. 5. Insp Inspect,i ect,instal nstall,re l,repair pairorre orreplace placepint pintleho lehooksa oksanddr nddrawba awbars. rs. 

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S AMplE QuESTiOnS SuSpEnSiOn  And S TEErinG (TEST T5)

QuESTiOnS: 1. Whichof Whichofthese thesecoul couldcau dcauseth sethefr efrontt onttires iresofa ofatruc truckto ktoshow showaf afeathe eatherede rededge dge wearpattern? *(A * (A) )An Ani inc ncor orre rect ctt toe oes set etti ting ng (B) An incorrect camber setting (C) An incorrect caster setting (D) Incorrect tire pressures 2. Thedrive Thedriveaxles axlesona onatruc truckwi kwitha thawalk walkingbe ingbeams amsuspen uspension sionare areoutof outofalig align nment. Technician echnicianA Asaysthatincorrect saysthatincorrectlengthtorquerodscouldbethe lengthtorquerodscouldbethecause. cause. TechnicianBsaysthatw echnicianBsaysthatwornwalkingbeambus ornwalkingbeambushingscouldbethecause. hingscouldbethecause. Whoisright?  (A (A) A only  (C (C) Both A and B * (B) B only  (D ( D) Neither A nor B 3. Thedriver Thedriverof ofatru atruckth ckthatha athasjus sjusthad thadits itsfron frontspr tsprings ingsandh andhanger angersre sreplace placed d saysthatitishardtokeepinastraightaheadposition. Technician echnicianA Asaysthatthiscouldbec saysthatthiscouldbecausedbyinstallingthecaster ausedbyinstallingthecastershims shims backwards. TechnicianBsaysthatthis echnicianBsaysthatthiscouldbecausedbyinstallingfor couldbecausedbyinstallingforwardspring wardspring hangerswhicharetooshort. Whoisright? * (A) A only  (C (C) Both A and B  (B (B) B only  (D (D) Neither A nor B 4. Thedrive Thedriverof rofatru atrucks cksayst aysthatit hatitis ishard hardtost tosteer eerandth andthest esteerin eeringret greturni urnispoo spoorr. Technician echnicianA Asaysthattightkingpinscouldbe saysthattightkingpinscouldbethecause. thecause. TechnicianBsaysthattoom echnicianBsaysthattoomuchtoe-incouldbethecaus uchtoe-incouldbethecause. e. Whoisright? * (A) A only  (C (C) Both A and B  (B (B) B only  (D (D) Neither A nor B

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 T5 S AMplE QuESTiOnS (cOnTinuEd ) 5. Ruststrea Ruststreaksc kscoming omingfro fromar maround oundthes thestudho tudholeso lesofa fadisc discwhee wheelcou lcouldbe ldbe causedby: (A) an overloaded conditon. (B) overtorqued lug/cap nuts. *(C * (C) )An Ano out uto of fba bala lanc nce eco cond ndit itio ion. n. (D) Loose lug/cap nuts. 6. Atruc truckhas khasahi ahistory storyof ofsprin springsbr gsbreaking eakingatt atthece hecenter nterbolth boltholes. oles. TechnicianAsaysthatlooseU-boltscouldbethecause. TechnicianBsaysthatloose echnicianBsaysthatloosespringshacklescouldbethe springshacklescouldbethecause. cause. Whoisright? * (A) A only  (C (C) Both A and B  (B (B) B only  (D (D) Neither A nor B 7. Acons constantb tantbuzzin uzzingnois gnoisecom ecomesf esfrom romthepo thepower werstee steering ringpump. pump. TechnicianAsaysthecausecouldbeairinthesystem. TechnicianBsaystheca echnicianBsaysthecausecouldbethattherelief usecouldbethatthereliefvalveisstuckinthe valveisstuckinthe openposition. Whoisright? * (A) A only  (C (C) Both A and B  (B (B) B only  (D (D) Neither A nor B

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 T5 S AMplE QuESTiOnS (cOnTinuEd ) 8. Thetandem Thetandemrear rearaxle axleair airsusp suspensio ensionrid nridehei eheightr ghtrises isesabove abovenorm normalas alasthe the vehicleisunloaded.Whichofthesecouldbethecause? (A) (A )A Ak kin inke ked dai air rsp spri ring ng( (ba bag) g)s sup uppl ply yli line ne (B) (B )A A le leak akin ing ghe heig ight htc con ontr trol ol va valv lvee *(C * (C) )A Ap plu lugg gged edh hei eigh ght tco cont ntro rol lva valv lve eex exha haus ust tpo port rt (D) (D )A Al lea eaki king ngp pre ress ssur ure epr prot otec ecti tion onv val alve ve Question 9 is not like the ones above. It has the word EXCEPT.Forthisquestion,lookforthechoicethatcould NOT causethedescribedsituation.Readthequestioncarefullybefore choosingyouranswer. 9. Allofth Alloftheses eseshould houldbech bechecked eckedbef beforea orealignin ligningthe gthefro frontwh ntwheels eelsona onatruck truck EXCEPT: (A) tire pressure. (B) ride height. (C) wheel bearing adjustment. * (D) tire balance.

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pEcificATiOnS And  And liST  TEST SpEcificATiOnS ElEcTricAl /ElEcTrOnic S ySTEMS (TEST T6)

Content Area A. B. C. D. E.

Questions in Test

General Electrical Diagnosis Battery Diagnosis and Repair Starting System Diagnosis and Repair Charging System Diagnosis and Repair Lighting Systems Diagnosis and Repair 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 and Repair G. Related Systems

Total

Percentage of Test

14 4 7 7 6

28% 8% 14% 14% 12%

4

8%

8

12%

50

100%

 A. General Electrical Systems Diagnosis (14 questions) 1. Checkcontinuit Checkcontinuityinelectrical/electr yinelectrical/electroniccircuitsusin oniccircuitsusingappropriateteste gappropriatetestequipment. quipment. 2. Checkappliedvo Checkappliedvoltages,circuitvolt ltages,circuitvoltages,andvoltagedr ages,andvoltagedropsinelectrical/elec opsinelectrical/electronic tronic circuitsusingdigitalmultimeter(D circuitsusingdig italmultimeter(DMM),orappropria MM),orappropriatetestequipment tetestequipment.. 3. Checkcurrento Checkcurrentowinelectrical/elec winelectrical/electroniccircuitsand troniccircuitsandcomponentsusin componentsusingadigital gadigital multimeter(DMM),clamp-onamm multimeter(DM M),clamp-onammeter,or eter,orappropriateteste appropriatetestequipment. quipment. 4. Checkresistanc Checkresistanceinelectrical/electr einelectrical/electroniccircuitsandc oniccircuitsandcomponentsusing omponentsusingadigital adigital multimeter(DMM),orappropriate multimeter(DM M),orappropriatetestequipment. testequipment. 5. Findshorts,groun Findshorts,grounds,andopensinelect ds,andopensinelectrical/electroniccir rical/electroniccircuits. cuits. 6. Diag Diagnose nosekeykey-off offbatt batteryd erydrain rainprob problems lems.. 7. Inspect,test,andrep Inspect,test,andreplacefusiblelinks,ci lacefusiblelinks,circuitbreakers,and rcuitbreakers,andfuses. fuses. 8. Inspectandtestsp Inspectandtestspikesuppressions ikesuppressionsdiodes/resistorsand diodes/resistorsandcapacitors. capacitors. 9. Insp Inspecta ectandte ndtestre strelays laysands andsoleno olenoids. ids. 10. Readandinterpr Readandinterpretelectricalschem etelectricalschematicdiagramsan aticdiagramsandsymbols. dsymbols. 11. Diagnosefailur Diagnosefailuresinthedatacomm esinthedatacommunicationsbusne unicationsbusnetwork;determine twork;determineneededrepairs. neededrepairs.

B. Battery Diagnosis and Repair (4 questions) 1. Performbattery Performbatterytests(loadandcapa tests(loadandcapacitance);determ citance);determineneededservi ineneededservice. ce. 2. Determinebatte Determinebatterystateofchar rystateofchargebymeasuring gebymeasuringterminalpostvolt terminalpostvoltageusingadigital ageusingadigital multimeter(DMM). 3. Inspect,clean,serv Inspect,clean,service,orreplacebatte ice,orreplacebatteryandterminalco ryandterminalconnections. nnections.

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 T6 liST (cOnTinuEd ) 4. Inspect,clean,rep Inspect,clean,repairandreplacebat airandreplacebatteryboxes,mounts teryboxes,mounts,andholddowns. ,andholddowns. 5. Chargebat Chargebatteryusingsloworfa teryusingsloworfastchargeme stchargemethodasappropria thodasappropriate. te. 6. Jumpstartavehic Jumpstartavehicleusingjumperca leusingjumpercablesandaboosterb blesandaboosterbatteryorappropr atteryorappropriate iate auxiliarypowersupply. 7. Diagnoselowvo Diagnoselowvoltagedisconnec ltagedisconnect(L t(LVD)systems;de VD)systems;determineneededre termineneededrepairs. pairs.

C. Starting System Diagnosis and Repair (7 questions) 1. Performstartin Performstartingcircuitvoltagedr gcircuitvoltagedroptests;determin optests;determineneededrepairs. eneededrepairs. 2. Inspect,test,andrep Inspect,test,andreplacecomponen lacecomponentsandwiresinthesta tsandwiresinthestartercontrolcircui rtercontrolcircuit. t. 3. Inspect,test,andrep Inspect,test,andreplacestarterrelay lacestarterrelaysandsolenoids/switc sandsolenoids/switches. hes. 4. Removeandrep Removeandreplacestarter;inspe lacestarter;inspectywheelringge ctywheelringgearorexplate. arorexplate. 5. Inspect,clean,repair,andreplacebatterycablesandconnectorsinthecrankingcircuit. 6. Differenti Differentiatebetweenelec atebetweenelectricalandmechan tricalandmechanicalproblemstha icalproblemsthatcauseaslowcrank tcauseaslowcrank, , nocrank,extendedcranking,oracran nocrank,extende dcranking,oracrankingnoisecondit kingnoisecondition. ion. 7. Test/monitorbattery est/monitorbatteryvoltageduringcr voltageduringcranking.Determin anking.Determineneededrepairs eneededrepairs

D. Charging System Diagnosis and Repair (7 questions) 1. Diagnosedash Diagnosedashmountedchar mountedchargemetersand/orind gemetersand/orindicatorlightsthatsh icatorlightsthatshowanocharg owanocharge, e, lowcharge,orovercharg lowcharge ,oroverchargecondition;deter econdition;determineneededrepa mineneededrepairs. irs. 2. Diagnosetheca Diagnosethecauseofnochar useofnocharge,lowcharge ge,lowcharge,orovercharge ,oroverchargeconditions;deter conditions;determine mine neededrepairs(includesremote neededrepairs (includesremotesensealternators sensealternators)) 3. Inspect,adjust,and Inspect,adjust,andreplacealternato replacealternatordrivebelts/gears,pu rdrivebelts/gears,pulleys,fans,mounting lleys,fans,mounting brackets,andtensioners. 4. Performchar Performchargingsystemoutpu gingsystemoutputtests;determine ttests;determineneededrepairs. neededrepairs. 5. Performchar Performchargingcircuitvoltag gingcircuitvoltagedroptests;determ edroptests;determineneededrepa ineneededrepairs. irs. 6. Remo Removea veandre ndreplac placealt ealterna ernator tor.. 7. Inspect,repair Inspect,repair,orreplaceconnect ,orreplaceconnectorsandwiresinthec orsandwiresinthechargingcirc hargingcircuit. uit.

E. Lighting Systems Diagnosis and Repair (6 questions) 1. Headlights, Daytime Running Lights, Parking, Clearance, Tail, Cab, and Dash Lights (3 questions) 1. Diagnosetheca Diagnosethecauseofbrighterthan useofbrighterthannormal,intermitte normal,intermittent,dim,ornoheadligh nt,dim,ornoheadlightand tand daytimerunninglight(DRL)operation. 2. Test, est,aima aimandre ndreplac placehea eheadlig dlights. hts. 3. Test,repair est,repair,andreplaceheadlig ,andreplaceheadlightanddimmersw htanddimmerswitches,wires,conne itches,wires,connectors,terminals, ctors,terminals, sockets,relays,andcontrolcomponents. 4. Inspect,test,repair Inspect,test,repair,orreplaceswitch ,orreplaceswitches,bulbs,sockets,con es,bulbs,sockets,connectors,terminal nectors,terminals,relays, s,relays, wires,andlight-emittingdiodes(LE wires,andlight-e mittingdiodes(LEDs)oflightingcir Ds)oflightingcircuitsontrucksand cuitsontrucksandtrailers. trailers. 5. Inspect,test,repair Inspect,test,repair,orreplacedashlig ,orreplacedashlightcircuitswitche htcircuitswitches,bulbs,LEDs,socket s,bulbs,LEDs,sockets, s, connectors,terminals,wires,andprin connectors,term inals,wires,andprintedcircuits. tedcircuits. 6. Inspect,test,repair Inspect,test,repair,orreplaceinterio ,orreplaceinteriorcablightcircuitsw rcablightcircuitswitches,bulbs,LED itches,bulbs,LEDs, s, sockets,connectors,terminals,orwires.

2. Stoplights, Turn Turn Signals, Hazard Lights and Backup Lights (3 questions) 1. Inspect,test,adjust Inspect,test,adjust,repair,or ,repair,orreplacestoplight replacestoplightcircuitswitches,bu circuitswitches,bulbs,LEDs,sockets, lbs,LEDs,sockets, connectors,terminals,relays,andwires. 2. Diagnosetheca Diagnosethecauseofturnsignalan useofturnsignalandhazardasherlig dhazardasherlightmalfunctions htmalfunctions;determine ;determine neededrepairs.

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 T6 liST (cOnTinuEd ) 3. Inspect,test,repair Inspect,test,repair,orreplaceturnsig ,orreplaceturnsignalandhazardcirc nalandhazardcircuitashers,switch uitashers,switches,bulbs, es,bulbs, LEDs,sockets,connectors,terminals LEDs,sockets,con nectors,terminals,relays,andwires. ,relays,andwires. 4. Inspect,test,adjust Inspect,test,adjust,repair,orr ,repair,orreplacebackuplig eplacebackuplightandwarningdev htandwarningdevices,circuit ices,circuit switches,bulbs,LEDs,sockets,connec switches,bulbs,LE Ds,sockets,connectors,terminals,andw tors,terminals,andwires. ires. 5. Inspectandtesttr Inspectandtesttrailerlightcordcon ailerlightcordconnectorandcable; nectorandcable;determineneede determineneededrepairs. drepairs.

F. Gauges and Warning Devices Diagnosis and Repair (4 questions) 1. Diagnosethecau Diagnosethecauseofintermittent seofintermittent,high,low ,high,low,ornogaugereading ,ornogaugereadings;determineneed s;determineneeded ed repairs.(Doesnotincludechar repairs.(Doesnot includechargeindicators.) geindicators.) 2. Diagnosethecau Diagnosethecauseofdatabusdrive seofdatabusdrivengaugemalfunct ngaugemalfunctions;determinen ions;determineneededrepairs. eededrepairs. 3. Inspect,test,adjust Inspect,test,adjust,repair,orr ,repair,orreplacegaugecirc eplacegaugecircuitsendingunits,sen uitsendingunits,sensors,gauges, sors,gauges, connectors,terminals,andwires. 4. Inspect,test,repair Inspect,test,repair,orreplacewarnin ,orreplacewarningdevices(lightsa gdevices(lightsandaudible)circu ndaudible)circuitsending itsending units,sensors,bulbs,audiblecompone units,sensors,bulbs ,audiblecomponent,socketsconnec nt,socketsconnectors,terminals,wire tors,terminals,wires,and s,and printedcircuits/controlmodules. 5. Inspect,test,andrep Inspect,test,andreplaceelectronicin laceelectronicinstrumentationsy strumentationsystems;verifyprop stems;verifypropercalibration ercalibration forvehicleapplication.

G. Related Systems (8 questions) 1. Diagnosethecau Diagnosethecauseofconstant,inter seofconstant,intermittent,ornohornop mittent,ornohornoperation. eration. 2. Inspect,test,repair Inspect,test,repair,orreplacehorncir ,orreplacehorncircuitrelays,horns,sw cuitrelays,horns,switches,connector itches,connectors, s, terminals,andwires. 3. Diagnosethecau Diagnosethecauseofconstant,inter seofconstant,intermittent,ornowiper mittent,ornowiperoperation;diagno operation;diagnosethe sethe causeofwiperspeedcontroland/orpa causeofwiperspe edcontroland/orparkproblems. rkproblems. 4. Inspect,test,repair Inspect,test,repair,orreplacewiperm ,orreplacewipermotor,re otor,resistors,parkswitch sistors,parkswitch,relays,switches, ,relays,switches, connectors,terminals,andwires. 5. Inspectandrepla Inspectandreplacewipermotortra cewipermotortransmissionmech nsmissionmechanicallinkage,arm anicallinkage,arms,andblades. s,andblades. 6. Inspect,test,repair Inspect,test,repair,orreplacewindsh ,orreplacewindshieldwashermoto ieldwashermotororpump/relayasse rorpump/relayassembly mbly, , switches,connectors,terminals,andwires. 7. Inspect,test,repair Inspect,test,repair,orreplacesidevie ,orreplacesideviewmirrormotors,he wmirrormotors,heatercircuitgrids atercircuitgrids,relays, ,relays, switches,connectors,terminals,andwires. 8. Inspect,test,repair Inspect,test,repair,orreplaceheater ,orreplaceheaterand andA/Celectricalcomp A/Celectricalcomponentsincluding onentsincluding: : A/Cclutches,motors,resistors,relays,swit A/Cclutches,motors ,resistors,relays,switches,controls,conn ches,controls,connectors,terminals, ectors,terminals, andwires. 9. Inspect,test,repair Inspect,test,repair,orreplacecigare ,orreplacecigarettelighterand/oraux ttelighterand/orauxiliarypoweroutle iliarypoweroutletcase, tcase, integralfuse,connectors,terminals,andwires. 10. Diagnosethecau Diagnosethecauseofslow seofslow,intermittent,ornopo ,intermittent,ornopowerwindowoper werwindowoperation. ation. 11. Inspect,test,repair Inspect,test,repair,andreplacemoto ,andreplacemotors,switches,relays,co rs,switches,relays,connectors,termina nnectors,terminals, ls, andwiresofpowerwindowcircuits. 12. Diagnoseinver Diagnoseinverter/shorepowersyst ter/shorepowersystems;determinene ems;determineneededrepairs. ededrepairs. 13. Diagnosethecau Diagnosethecauseofpoor seofpoor,intermittent,orno ,intermittent,ornooperationofelectr operationofelectricdoorlocks. icdoorlocks. 14. Inspect,test,repair Inspect,test,repair,andreplaceswitc ,andreplaceswitches,relays,controll hes,relays,controllers,actuators/soleno ers,actuators/solenoids, ids, connectors,terminals,andwiresofele connectors,term inals,andwiresofelectricdoorlockcir ctricdoorlockcircuits. cuits. 15. Inspect,testrepai Inspect,testrepairandreplacecruis randreplacecruisecontrolelectrica econtrolelectricalcomponents. lcomponents. 16. Inspect,test,repair Inspect,test,repair,andreplaceengin ,andreplaceenginecoolingfanelec ecoolingfanelectricalcontrolcom tricalcontrolcomponents. ponents. 17. Diagnosefailur Diagnosefailuresinthedatacomm esinthedatacommunicationsbusne unicationsbusnetwork;determine twork;determineneeded needed repairs.

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S AMplE QuESTiOnS ElEcTricAl /ElEcTrOnic S ySTEMS (TEST T6)

QuESTiOnS:

VOLTMETER BATTERY TERMINAL IGNITION TERMINAL

IGNITION SWITCH BATTERY

ALTERNATOR

1. Inthecha Inthechargin rgingsys gsystem temshow shownabov nabove,t e,theme hemeterr terreading eadingwil willshow lshow:: (A) charging output voltage. (B) regulator operating voltage. * (C (C) )ch char argi ging ngc cir ircu cuit itv vol olta tage ged dro rop. p. (D) ignitio ion n switc tch h voltage drop. 2. Atruc truck’ k’scab scabheat heaterb erblower lowermoto motorope roperates ratesatl atlows owspeed peedonly only.W .Whicho hichofthe fthese se isthemostlikelycause? (A) )A An nop open en bl blow ower ers sw wit itcch hgr grou ound nd * (B) Ab bad ad bl blow ower ers sw wit itch ch (C) A binding blower cage (D) (D )A As sho hort rtt to opo powe wer rat att the heb blo lowe wer rmo moto tor r

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 T6 S AMplE QuESTiOnS (cOnTinuEd )

3. Thehorns Thehornsinthe inthecir circuits cuitshown hownabove aboveonlyb onlyblow lowwhen whenajum ajumper perwire wireisc iscon onnectedbetweenterminals30and87ofthehornr nectedbetweenterminals 30and87ofthehornrelay elay. . TechnicianAsaysthatafailedhornrelaycouldbethecause. TechnicianBsaysthatas echnicianBsaysthatashorttogroundinthecircuitbe horttogroundinthecircuitbetweenthehornrelay tweenthehornrelay andthehornbuttoncouldbethecause. Whoisright? * (A) A only  (C (C) Both A and B  (B (B) B only  (D (D) Neither A nor B 4. Atruc truck’ k’sba sbattery tterydisc discharg hargesa esafter ftersitti sittingov ngovernig ernight. ht. TechnicianAsaysthatabadalternatorcouldbethecause. TechnicianBsaysthata echnicianBsaysthatabadstartercouldbethec badstartercouldbethecause. ause. Whoisright? * (A) A only (C) Both A and B  (B (B) B only  (D (D) Neither A nor B 5. Adri driverc vercompla omplainsth insthatth atthetra etrailer ilermark markerli erlights ghtsare aredima dimatnig tnightwh htwhileb ilebrakin raking. g. Whichoftheseisthemostlikelycause? (A)L Low owb baatt tteery vo volt ltag age e       (B) B)O One neb bur urne ned dou out tbr brak akeel lig ight htb bul ulb b *(C * (C) )A Ap poo oor rgr grou ound ndi in nth the etr trai aile ler rli ligh ght tco cord rd (D) Too much grease on the 5thwheel

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 T6 S AMplE QuESTiOnS (cOnTinuEd ) 6. Bothheadli Bothheadlights ghtsona onavehic vehiclear learedim ediminh inhighbe ighbeama amandnor ndnormal malinlow inlowbeam beam. . Technician echnicianA Asaysthatapoorhea saysthatapoorheadlightgroundcouldbethecause. dlightgroundcouldbethecause. TechnicianBsaysthatas echnicianBsaysthatashortedheadlightswitchcouldbe hortedheadlightswitchcouldbethecause. thecause. Whoisright?  (A (A) A only  (C (C) Both A and B  (B ( B) B only * (D) Neither A nor B

7. Thevoltage Thevoltageread readings ingsshow shownabo nabovew vewere eretaken takenwhile whilecra cranking nkingthee theengine. ngine. Whichoftheseisindicatedbythereadings? (A) (A )Ba Batt tter ery y#2 #2h has asr res esis ista tanc nce ein int the heg gro roun und dca cabl ble. e. *(B * (B) )Ba Batte ttery ry# #2 2i is swe weak aker ert tha han nba batt tter ery y#1 #1.. (C) (C )Ba Batt tteery #1 #1i issl low ow on one ele lect ctrrol olyt ytee. (D) (D )Ba Batt tter ery y#2 #2s sho houl uld dbe be rep epla lace ced. d.

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pEcificATiOnS And  And T ASk  liST  TEST SpEcificATiOnS EnTilATiOn,  And A ir ir cOndiTiOninG (HvAc) HEATinG, v EnTilATiOn S ySTEMS (TEST T7)

Content Area

Questions in Test

A. HVAC Systems Diagnosis, Service, and Repair B. A/C System and Component Component Diagnosis, Diagnosis, Service, and Repair 1. A/C System – General (6) 2. Compressor and Clutch (5) 3. Evaporator, Condenser, and Related Components (5) C. Heating and Engine Cooling Cooling Systems Systems Diagnosis, Service, and Repair D. Operating Systems and and Related Controls Diagnosis and Repair 1. Electrical (5) 2. Air/Vacuum/Mechanical (2) 3. Constant/Automa C onstant/Automatic tic Temperature Control (1) E. Refrigerant Refriger ant Recovery, Recyclin Recycling, g, Handling, and Retroft

Total

Percentage of Test

6

15%

16

40%

6

15%

8

20%

4

10%

40

100%

 A. HVAC Systems Diagnosis, Service, and Repair (6 questions) 1. Verifythecomplain erifythecomplaint,roadtestthevehicl t,roadtestthevehicle,reviewdriver/cust e,reviewdriver/customerinterviewan omerinterviewand d pastmaintenancedocuments(ifav pastmaintenanc edocuments(ifavailable);determ ailable);determinefurtherdiagno inefurtherdiagnosis. sis. 2. Verifytheneedofser erifytheneedofserviceorrepairofHV viceorrepairofHVACsystemsbased ACsystemsbasedonunusualoperat onunusualoperating ing noises;determineappropriateaction. 3. Verifytheneedofser erifytheneedofserviceorrepairofHV viceorrepairofHVACsystemsbased ACsystemsbasedonunusualvisual, onunusualvisual, smell,andtouchconditions;determ smell,andtouchco nditions;determineappropriateac ineappropriateaction. tion. 4. Identifysystem Identifysystemtypeandcompone typeandcomponents(cyclingclutc nts(cyclingclutchoricetube-CCOT horicetube-CCOT,expansion ,expansion valve,typeofrefrigerant)andcondu valve,typeofrefrig erant)andconductperformancete ctperformancetest(s)onHV st(s)onHVACsystems; ACsystems; determineappropriateaction.

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 T7 liST (cOnTinuEd ) B. A/C System and Component Diagnosis, Service, and Repair (16 questions) 1. A/C System. General (6 questions) 1. Diagnosetheca Diagnosethecauseoftemperatur useoftemperaturecontrolproblem econtrolproblemsinthe sintheA/Csystem;determi A/Csystem;determine ne neededrepairs. 2. Identifyrefrige Identifyrefrigeranttypeandchec ranttypeandcheckforcontaminati kforcontamination;determineapp on;determineappropriateaction. ropriateaction. 3. Diagnose DiagnoseA/Csystemproblem A/Csystemproblemsindicatedbypres sindicatedbypressuregaugereadin suregaugereadingsandsightglass/ gsandsightglass/ moistureindicatorconditions(w moistureindica torconditions(whereapplicable) hereapplicable);determineneede ;determineneededservice dservice orrepairs. 4. Diagnose DiagnoseA/Csystemproblem A/Csystemproblemsindicatedbyunus sindicatedbyunusualoperatingnoi ualoperatingnoise,visual, se,visual, smell,andtouchprocedures;determ smell,andtouchpr ocedures;determineneededrepa ineneededrepairs. irs. 5. Perf Perform ormA/Cs A/Csystem ystemleak leaktest test;det ;determi erminene neneeded ededrepa repairs. irs. 6. Evac Evacuate uate A/Csy A/Csystem stemusin usingapp gappropri ropriatee ateequip quipment ment.. 7. Inte Internall rnallycle ycleanco ancontam ntaminate inated dA/Cs A/Csystem ystemcomp componen onentsan tsandho dhoses. ses. 8. Char Charge geA/Cs A/Csyste ystemwit mwithco hcorrect rrecttype typeand andquan quantity tityofre ofrefrig frigeran erant. t. 9. Iden Identify tifylubr lubricant icanttype typeneed neededfo edforsys rsystema temappli pplicatio cation. n.

2. Compressor and Clutch (5 questions) 1. Diagnose DiagnoseA/Csystemproblem A/Csystemproblemsthatcauseprotec sthatcauseprotectiondevices(pres tiondevices(pressure,thermal,and sure,thermal,and electronic)tointerruptsystemope electronic)toint erruptsystemoperation;determin ration;determineneededrepairs. eneededrepairs. 2. Inspect,test,andrep Inspect,test,andreplace laceA/Csystempressu A/Csystempressure,thermal,andelec re,thermal,andelectronicprotection tronicprotection devices. 3. Inspectandrepl Inspectandreplace aceA/Ccompressordri A/Ccompressordrivebelts,pulleys,idle vebelts,pulleys,idlers,andtensioners; rs,andtensioners; adjustdrivebeltsandcheckalignment. 4. Inspect,test,servic Inspect,test,service,andreplace e,andreplaceA/Ccompressorclu A/Ccompressorclutchcomponents tchcomponentsorassembly orassembly.. 5. Insp Inspecta ectandco ndcorrec rrect tA/Cco A/Ccompre mpressor ssorlubr lubrican icantlev tlevel. el. 6. Insp Inspect, ect,test, test,and andrepla replace ceA/Cc A/Ccompr ompresso essorr. 7. Insp Inspect, ect,repai repair, r,orre orreplac place eA/Cc A/Ccompr ompresso essormou rmounting ntingsand sandhar hardwar dware. e.

3. Evaporator, Condenser, and Related Components (5 questions) 1. Correctsystem Correctsystemlubricantlevelwh lubricantlevelwhenreplacingtheev enreplacingtheevaporator aporator,condenser ,condenser, , receiver/drieroraccumulator/drier receiver/drierora ccumulator/drier,andhoses. ,andhoses. 2. Inspect,repair Inspect,repair,orreplace ,orreplaceA/Csystemhoses,lin A/Csystemhoses,lines,lters,ttings,andseals. es,lters,ttings,andseals. 3. Insp Inspect ectA/Cc A/Cconden ondenserf serforpr orproper operair airow ow.. 4. Insp Inspect, ect,test, test,and andrepla replace ceA/Cs A/Csyste ystemcon mcondense denserand randmoun mountings tings.. 5. Insp Inspecta ectandre ndreplac placerec ereceive eiver/dri r/drieror eroraccu accumula mulator/dr tor/drier ier.. 6. Insp Inspect, ect,test, test,and andrepla replaceca cecab/sle b/sleeper eperrefr refriger igerants antsolen olenoid, oid,expa expansion nsionvalv valve(s) e(s), , thermostaticswitch(thermistor thermostaticsw itch(thermistor);andcheckplacem );andcheckplacementofthermalbu entofthermalbulb lb (capillarytube). 7. Ins Inspec pecta tand ndrep replac laceo eori rice cetub tube. e. 8. Insp Inspect, ect,test, test,and andrepla replaceca cecab/sle b/sleeper eperevap evaporato oratorcor rcore. e. 9. Insp Inspect, ect,clean clean,and ,andrepa repairev irevapora aporatorh torhousi ousingan ngandwat dwaterdr erdrain; ain;insp inspecta ectand nd service/replaceevaporatorairlter service/replacee vaporatorairlter.. 10. Identify Identify,inspect,andreplac ,inspect,andreplaceA eA/Csystemservicepor /Csystemserviceports/valves(gaugecon ts/valves(gaugeconnections). nections). 11. Diagnosesyste Diagnosesystemfailuresresultin mfailuresresultinginrefrigerantlos ginrefrigerantlossfromthe sfromtheA/Csystemhigh A/Csystemhigh pressurereliefdevice.

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 T7 liST (cOnTinuEd ) C. Heating and Engine Cooling Systems Diagnosis, Service, and Repair  (6 questions) 1. Diagnosethecau Diagnosethecauseofoutletairtemp seofoutletairtemperaturecontrolp eraturecontrolproblemsintheHV roblemsintheHVACsystem; determineneededrepairs. 2. Diag Diagnose nosewind windowf owfoggin oggingpro gproblem blems;de s;determ terminen ineneede eededrep drepairs. airs. 3. Perf Performe ormengin nginecoo ecooling lingsyst systemte emtestsf stsforle orleaks, aks,prote protection ctionleve level,co l,contam ntaminati ination, on, coolantlevel,temperature,coolantty coolantlevel,tem perature,coolanttype,andconditione pe,andconditionerconcentration; rconcentration;determine determine neededrepairs. 4. Insp Inspecta ectandre ndreplace placeengi engineco necooling olingand andheat heatings ingsyste ystemhos mhoses,l es,lines ines,ttin ,ttings,a gs,and nd clamps. 5. Inspectandtestra Inspectandtestradiator diator,pressurecap,andcoo ,pressurecap,andcoolantrecoverysys lantrecoverysystem(surgeta tem(surgetank); nk); determineneededrepairs. 6. Insp Inspectw ectwater aterpump pumpand anddrive drivesyst system;d em;determ eterminen ineneede eededrep drepairs airs.. 7. Inspectandtestth Inspectandtestthermostats,by-pas ermostats,by-passes,housings,andsea ses,housings,andseals;determinedne ls;determinedneeded eded repairs. 8. Flus Flushand handrel rellcoo lcooling lingsyst system;b em;bleed leedairf airfrom romsyste system. m. 9. Insp Inspect,t ect,test,a est,andre ndrepair pairorr orreplac eplacefan efan,fan ,fanhub, hub,fan fanclutc clutch,fa h,fancon ncontrol trols,fan s,fan thermostat,andfanshroud. 10. Inspect,test,andrep Inspect,test,andreplaceheatingsyste laceheatingsystemcoolantcontro mcoolantcontrolvalve(s)andman lvalve(s)andmanual ual shut-offvalves. 11. Inspect,ush,andre Inspect,ush,andreplaceheatercore placeheatercore..

D. Operating Systems and Related Controls Diagnosis and Repair (8 questions) 1. Electrical (5 questions) 1. Diagnosethecau DiagnosethecauseoffailuresinHV seoffailuresinHVACelectricalco ACelectricalcontrolsystems;de ntrolsystems;determine termine neededrepairs. 2. Inspect,test,repair Inspect,test,repair,andreplace ,andreplaceA/Cheaterblowerm A/Cheaterblowermotors,resistors,switc otors,resistors,switches,relays, hes,relays, modules,wiring,andprotectiondevices. 3. Inspect,test,repair Inspect,test,repair,andreplace ,andreplaceA/Ccompressorclu A/Ccompressorclutchrelays,modules tchrelays,modules,wiring, ,wiring, sensors,switches,diodes,andprotectiondevices. 4. Inspectandtest InspectandtestA/C-relatedelectr A/C-relatedelectronicenginecontr onicenginecontrolsystems;determ olsystems;determineneeded ineneeded repairs. 5. Inspect,test,repair Inspect,test,repair,andreplaceengin ,andreplaceenginecooling/condens ecooling/condenserfanmotors,relay erfanmotors,relays, s, modules,switches,sensors,wiring,and modules,switche s,sensors,wiring,andprotectiondevice protectiondevices. s. 6. Inspect,test,repair Inspect,test,repair,andreplaceelect ,andreplaceelectricactuatormoto ricactuatormotors,relays/modules,swi rs,relays/modules,switches, tches, sensors,wiring,andprotectiondevices. 7. Inspect,test,repair Inspect,test,repair,orreplaceHV ,orreplaceHVACsystemelect ACsystemelectricalcontrolpane ricalcontrolpanelassemblies. lassemblies.

2. Air/Vacuum/Mechanical (2 questions) 1. Diagnosethecau DiagnosethecauseoffailuresinHV seoffailuresinHVACair ACair,vacuum,andmech ,vacuum,andmechanicalswitchesa anicalswitchesand nd controls;determineneededrepairs. 2. Inspect,test,repair Inspect,test,repair,orreplaceHV ,orreplaceHVACsystemair/vacu ACsystemair/vacuum/mechanicalco um/mechanicalcontrolpanel ntrolpanel assemblies. 3. Inspect,test,adjust Inspect,test,adjust,orreplaceHV ,orreplaceHVACsystemair/vac ACsystemair/vacuum/mechanicalc uum/mechanicalcontrolcables ontrolcables andlinkages. 4. Inspect,test,andrep Inspect,test,andreplaceHV laceHVACsystemvacu ACsystemvacuumpumps,actuato umpumps,actuators(diaphragms/ rs(diaphragms/ motors)andhoses.

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 T7 liST (cOnTinuEd ) 5. Identify Identify,inspect,test,andrepl ,inspect,test,andreplaceHV aceHVACsystemvacuu ACsystemvacuumreservoir(s),che mreservoir(s),check ck valve(s),andrestrictors. 6. Inspect,test,adjust Inspect,test,adjust,repair,or ,repair,orreplaceHV replaceHVACsystemducts ACsystemducts,doors,andoutlets. ,doors,andoutlets.

3. Constant/Automatic Temperature Temperature Control (1 question) 1. Diagnosecons Diagnoseconstant/automatictemp tant/automatictemperaturecontrolsy eraturecontrolsystemproblems; stemproblems;determineneeded determineneeded repairs. 2. Insp Inspect, ect,test, test,and andrepla replacecl ceclimat imatecon econtrol troltemp temperatu eraturese resensor nsors. s. 3. Inspect,test,repair Inspect,test,repair,andreplacetemp ,andreplacetemperatureblenddo eratureblenddoor/powerservosyste or/powerservosystem. m. 4. Insp Inspect, ect,test, test,adju adjustor storrepl replaceh aceheate eaterwat rwaterva ervalvea lveandco ndcontro ntrols. ls. 5. Inspect,test,andrep Inspect,test,andreplaceelectric,air laceelectric,air,andvacuummotor ,andvacuummotors,solenoids,andswit s,solenoids,andswitches. ches. 6. Insp Inspect, ect,test testandr andrepla eplaceco ceconstan nstant/auto t/automati matictem ctempera perature turecont controlp rolpanels anels.. 7. Inspect,test,andrep Inspect,test,andreplaceconstant/auto laceconstant/automatictemperatu matictemperaturecontrolmicrop recontrolmicroprocessor rocessor (climatecontrolcomputer/programmer).

E. Rerigerant Recovery, Recycling, Recycling, Handling, and Retroft (4 questions)  Note:Tasks1through5shouldbeaccomplishedinaccordancewithpublishedEPAand appropriateSAE“J”standardsforR-12,R-134a,andEPAapprovedrefrigerant blends. 1. Main Maintain tainand andverif verifycor ycorrect rectoper operatio ationof nofcerti certiede edequip quipment ment.. 2. Iden Identify tifyandr andrecov ecover erA/Cs A/Csystem ystemrefr refrigera igerant. nt. 3. Re Recy cycl cle ere refr frig iger eran ant. t. 4. Hand Handle,l le,label abelands andstore torerefr refrigera igerant. nt. 5. Testr estrecyc ecycledr ledrefri efrigera gerantfo ntfornon rnon-cond -condensa ensableg blegases ases.. 6. Retrot RetrotA/Csystemsfollow A/Csystemsfollowingindustry/manuf ingindustry/manufacturers’ acturers’acceptedproced acceptedproceduresand uresand federal/locallaws.

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S AMplE QuESTiOnS EnTilATiOn,  And A ir ir cOndiTiOninG (HvAc) HEATinG, v EnTilATiOn S ySTEMS (TEST T7) QuESTiOnS : 1. Atruc truck’ k’s sA/C A/Csyste systemdo mdoesno esnotcoo tcoolpro lproperly perlydue duetoan toanicin icingeva gevaporat porator or problem. Technician echnicianA Asaysthatastuck-clos saysthatastuck-closedcyclingswitchcouldbethe edcyclingswitchcouldbethecause. cause. TechnicianBsaysthatar echnicianBsaysthatarefrigerantoverchar efrigerantoverchargecouldbethecause. gecouldbethecause. Whoisright? * (A) A only  (C (C) Both A and B  (B (B) B only  (D (D) Neither A nor B 2. Thesleepe Thesleeper rA/C A/Cuniti unitisnot snotcool cooling. ing.A Asys systemc temcheck heckshows showsall allpress pressures uresare are normal.Whichoftheseisthemostlikelycause? (A) A plugged receiver drier (B) As stu tucckk-o ope pen neexp xpan ansi sion on va valv lvee (C) As sho hort rteed dhi high gh pr preess ssur ure esw swit itcch *(D * (D) )A As stuc tuckk-cl clos osed edr ref efri rige gera rant ntso sole leno noid idv val alve ve 3. AnA/C AnA/Csyste systemha mhasa salowd lowdischa ischarge rgepres pressure. sure.whic whichof hofthese thesecould couldbe be thecause? *(A * (A) )A Al lea eaki king ngc com ompr pres esso sor rse seal al (B) (B )A Ar res estr tric icte ted dre refr frig iger eran ant to ow win int the hec con onde dens nser er (C) (C )A Ar res estr tric iced eda air ir ow owo ove ver rth the eco cond nden ense serr (D) (D )A Ac com ompr pres esso sor rcl clut utch cht tha hat twi will lln not ote eng ngag agee 4. Duringre Duringreplace placement, ment,iti itisnot snoticed icedthat thatthetu thetubeso besonthe ntheinle inletand tandoutlet outletof of aheatercoreareruptured.The aheatercoreare ruptured.Themostlikelycauseis: mostlikelycauseis: (A) a low coolant level. (B) air in the cooling system. *(C * (C) )in inco corr rrec ect tco cool olan ant tpr prot otec ecti tion on.. (D) a bad heater contr tro ol valve.

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 T7 S AMplE QuESTiOnS (cOnTinuEd ) 5. Noairis Noairisow owingf ingfrom romatru atruck’ ck’sHV sHVACd ACducts. ucts. TechnicianAsaysthatafailedblowermotorcouldbethecause. TechnicianBsaysthata echnicianBsaysthatastuckrecirculationairdoor stuckrecirculationairdoorcouldbethecause. couldbethecause. Whoisright? * (A) A only (C) Both A and B  (B (B) B only  (D (D) Neither A nor B 6. Arec recovery overy/recy /recyclem clemachin achinehas ehasbeen beenuse usedto dtorecyc recyclea leavehicl vehicle’ e’sre srefrig frigerant erant. . Themoistureindicatoronthemachineshows Themoistureindicator onthemachineshowsthatmoistureispresent. thatmoistureispresent. Themostlikelycauseisa: (A) full refrigerant storage tank. (B) faulty air purge valve. * (C (C) )sa satu tura rate ted dl lte terr/d /dri rieer. (D) (D )fa faul ulty tys sto tora rage get tan ank kpr pres essu sure res swi witc tch. h. Question 7 is not like the ones above. It has the word EXCEPT.Forthisquestion,lookforthechoicethatcould NOT causethedescribeds causethedescribedsituation.Readtheentirequestion ituation.Readtheentirequestioncarefullybefore carefullybefore choosingyouranswer. 7. Atruc truck’ k’s sA/C A/Csyste systemhas mhasjust justbeen beenrepa repaired iredandl andlledw ledwithth iththepr eproper operamou amount nt ofrefrigerant.Thesystemblows ofrefrigerant. Thesystemblowscool,butnotcoldair cool,butnotcoldair.Thehigh-s .Thehigh-sidepressure idepressure is250psi,andthelow-sidepressureis5 is250psi,andthelowsidepressureis50psi. 0psi.Anyofthesecouldbe Anyofthesecouldbethecause thecause EXCEPT: (A) (A )th the eco cool olin ing gffan is in inop oper erat ativ ive. e. *(B * (B) )a apa part rtia iall lly yre rest stri rict cted ede exp xpan ansi sion onv val alve ve.. (C))a sy (C sysste tem mo ove verc rcha harrge ged dw wit ith hoi oil. l. (D) (D )a am mis issi sing ng ra radi diat ator orf fan an sh shrrou oud. d.

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pEcificATiOnS And  And liST  TEST SpEcificATiOnS prEvEnTivE M AinTEnAncE  And inSpEcTiOn (pMi) (TEST T8)

Content Area A. B. C. D.

Questions in Test

Engine Systems Cab and Hood Electrical/Electronics Electrical/Elec tronics Frame and Chassis 1. Brakes (10) 2. Drivetrain (4) 3. Steering, Tires, and Wheels (4) 4. Suspension, Frame, and 5th Wheel (4) E. Road/Oper Road/Operational ational Test

Total

Percentage of Test

10 5 10 22

20% 10% 20% 44%

3

6%

50

100%

 A. Engine Systems (10 questions) 1. Reviewpastma Reviewpastmaintenance/repaird intenance/repairdocuments,driverv ocuments,drivervehiclecondition ehicleconditionreports,and reports,and brake/tirewearreport.Checkandrec brake/tirewearre port.Checkandrecordelectronicdia ordelectronicdiagnosticcodesand gnosticcodesandtrip/opera trip/opera tionaldata.Clearcodesanddata. 2. Checkengineo Checkengineoperation(includ peration(includingunusualnoises ingunusualnoises,vibration,andexce ,vibration,andexcessiveexhaust ssiveexhaust smoke);recordidlerpm,governed smoke);recor didlerpm,governedrpm,andPTO rpm,andPTOrpm(ifapplicable) rpm(ifapplicable).. 3. Ins Inspec pectv tvibr ibrati ation ondam damper per.. 4. Inspectcondit Inspectconditionofbelt(s),tensio ionofbelt(s),tensioner(s),andpulley( ner(s),andpulley(s);checkandadjus s);checkandadjustbelttension. tbelttension. 5. Checkenginef Checkengineforoil,coolant,air oroil,coolant,air,andfuelleaks(Eng ,andfuelleaks(EngineOffandEn ineOffandEngineRunning). gineRunning). 6. Insp Inspecte ectengine nginemoun mountsfo tsforloo rloosene senessan ssanddet ddeterio erioratio ration. n. 7. Chec Checkeng kengineo ineoille illevela velandco ndconditi ndition;c on;check heckdips dipstick tickseal sealand andllca llcapsea pseal. l. 8. Chec Checkeng kenginec inecompa ompartme rtmentwi ntwiring ring,har ,harnesse nesses,co s,connec nnectors, tors,and andseals sealsford fordamag amage, e, mounting,andproperrouting. 9. Checkfueltank Checkfueltanks,vents,mountings,lin s,vents,mountings,lines,caps,andseals;ch es,caps,andseals;checkanti-siphond eckanti-siphondevice evice (ifapplicable). 10. Inspectwaters Inspectwaterseparator/fuelheate eparator/fuelheater;drainwaterfrom r;drainwaterfromseparator;replac separator;replacefuellter(s); efuellter(s); primeandbleedfuelsystem. 11. Inspectcrankc Inspectcrankcaseventilationsy aseventilationsystem. stem. 12. Checkexhaus Checkexhaustsystemmounting tsystemmountingsforloosenessand sforloosenessanddamage. damage. 13. Checkenginee Checkengineexhaustsystemfor xhaustsystemforleaks,excessiveno leaks,excessivenoise,properrouting ise,properrouting,andmissing ,andmissing ordamagedcomponents(heatsh ordamagedcom ponents(heatshieldsandguards) ieldsandguards).. 14. Checkairinduc Checkairinductionsystempipin tionsystempiping,chargeairco g,chargeaircooler,hos oler,hoses,clamps,mountin es,clamps,mountings, gs, properrouting,andindicators;che properrouting ,andindicators;checkforairrestrictio ckforairrestrictionsandleaks. nsandleaks.

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 T8 liST (cOnTinuEd ) 15. Inspectturboch Inspectturbocharger(s)for arger(s)fornoise,oilandexhaus noise,oilandexhaustleaks;checkmou tleaks;checkmountingsand ntingsand connections;checkwastegate,va connections;ch eckwastegate,variablegeometrytu riablegeometryturbocharge rbocharger(VGT),linkages r(VGT),linkages, , andhoses. 16. Serviceorrepla Serviceorreplaceairlter(s)asneede ceairlter(s)asneeded. d. 17. Inspectdieselem Inspectdieselemissioncontrolsy issioncontrolsystems,includingex stems,includingexhaustgasrecircu haustgasrecirculation(EGR), lation(EGR), exhaustgasrecirculation(EGR) exhaustgasreci rculation(EGR)cooler cooler,dieselparticulatelte ,dieselparticulatelter(DPF),and/orcata r(DPF),and/orcata lyticconverter. 18. Checkfanclutch Checkfanclutch/huboperation,bear /huboperation,bearingconditionandn ingconditionandnoise(includingvi oise(includingviscous/ scous/ thermostatic,air,andelectricfanty thermostatic,air ,andelectricfantypes);inspectfanas pes);inspectfanassemblyandshrou semblyandshroudformissing dformissing anddamagedcomponents. 19. Inspectradiato Inspectradiator(includingairow r(includingairowrestriction,missin restriction,missing/corrodedns,leaks,and g/corrodedns,leaks,and damage)andmountings. 20. Pressuretestcoo Pressuretestcoolingsystemandra lingsystemandradiatorcap. diatorcap. 21. Inspectcoolant Inspectcoolanthosesandclampsf hosesandclampsforleaks,damage,and orleaks,damage,andproperrouting. properrouting. 22. Inspectcoolant Inspectcoolantrecoverysystem recoverysystem.. 23. Identifycoolan Identifycoolanttype;checkcoola ttype;checkcoolantforcontaminat ntforcontamination,supplemental ion,supplementalcoolant coolant additives(SCAs),andprotectionle additives(SCA s),andprotectionlevel(freezepoint) vel(freezepoint).. 24. Servicecoolan Servicecoolantlter/conditioner tlter/conditioner.. 25. Drainandrellcool Drainandrellcoolingsystem;bleed ingsystem;bleedairfromsystem;rec airfromsystem;recovercoolant. overcoolant. 26. Inspectwaterpu Inspectwaterpumpforleaksandbe mpforleaksandbearingplay aringplay.. 27. Changeengine Changeengineoilandlters;visually oilandlters;visuallycheckoilforcoolan checkoilforcoolantorfuelcontamin torfuelcontamination; ation; inspectandcleanmagneticdrainplugs. 28. Takeanengineoilsa akeanengineoilsample. mple.

B. Cab and Hood (5 questions) 1. Insp Inspectk ectkeyco eyconditi nditionan onandch dchecko eckopera peration tionofig ofignitio nitionsw nswitch. itch. 2. Chec Checkope koperatio rationof nofindic indicator atorlight lights,wa s,warning rningligh lightsan tsand/or d/oralarm alarms. s. 3. Chec Checkope koperatio rationof nofinstr instrumen uments/gau ts/gaugesa gesandp ndpanel anelligh lighting. ting. 4. Checkoperatio Checkoperationofelectronicpow nofelectronicpowertakeoff(P ertakeoff(PTO)andengi TO)andengineidlespeedcontr neidlespeedcontrols ols (ifapplicable). 5. Checkoperatio Checkoperationofdefroster nofdefroster,heater,ve ,heater,ventilation,and ntilation,andA/C(HV A/C(HVAC)controls. AC)controls. 6. Chec Checkope koperatio rationof nofalla allacces ccessorie sories. s. 7. Used Usediagn iagnostic ostictool tooloro oron-boa n-boarddi rddiagno agnostic sticsyst systemto emtoread readcurr currenta entandhi ndhistor storic ic diagnostictroublecodesfromelec diagnostictrou blecodesfromelectronicmodules(i tronicmodules(includingengine ncludingengine,transmission, ,transmission, brake,supplementalrestraint,tract brake,suppleme ntalrestraint,tractioncontrolandbod ioncontrolandbodycontrolsystems ycontrolsystems). ). 8. Chec Checkope koperatio rationof nofelect electrica ricandai ndairhor rhorns. ns. 9. Chec Checkcon kconditio ditionofs nofsafety afetyequi equipmen pment,inc t,includin ludingar gares,s es,spare parefuse fuses,re s,reect ective ive triangles,reextinguisher triangles,reexting uisher,andallrequireddec ,andallrequireddecals. als. 10. Inspectseatbelt Inspectseatbelts,seattethers,andslee s,seattethers,andsleeperrestraints. perrestraints. 11.Checksupplementalrestraintsys Checksupplementalrestraintsystem(SRS)forprop tem(SRS)forproperwarninglighto erwarninglightoperationand perationand diagnostictroublecodes(ifapplicable). 12. Inspectwiperbl Inspectwiperbladesandarms. adesandarms. 13. Checkwiperand Checkwiperandwasheroperatio washeroperation. n. 14. Checkforallrequ Checkforallrequiredvehicleperm iredvehiclepermits,registration,dec its,registration,decals,andinspection als,andinspectionpapers. papers. 15. Inspectwindsh Inspectwindshieldglassforcrack ieldglassforcracks,chips,clarity s,chips,clarity,discoloration/glazi ,discoloration/glazing,orother ng,orother damage;checksunvisoroperation.

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 T8 liST (cOnTinuEd ) 16. Checkseatcond Checkseatcondition,operation,mou ition,operation,mounting,andsuspens nting,andsuspensioncomponents. ioncomponents. 17. Checkdoorglass Checkdoorglassandwindowoper andwindowoperation. ation. 18. Inspectstepsand Inspectstepsandgrabhandles. grabhandles. 19. Inspectmirrorm Inspectmirrormountings,bracket ountings,brackets,glass,heaters,andmo s,glass,heaters,andmotors. tors. 20. Inspectandreco Inspectandrecordallobservedphy rdallobservedphysicaldamage. sicaldamage. 21. Lubricateallcab Lubricateallcabandhoodgreasettin andhoodgreasettings. gs. 22. Inspectandlubri Inspectandlubricatedoorandhood catedoorandhoodhinges,latches,strik hinges,latches,strikers,lockcylinders ers,lockcylinders,linkages, ,linkages, andcables. 23. Inspectcabmou Inspectcabmountings,hinges,latche ntings,hinges,latches,linkages;servic s,linkages;serviceasneeded. easneeded. 24. Inspecttiltcabhy Inspecttiltcabhydraulicpump,line draulicpump,lines,andcylindersfor s,andcylindersforleakage;inspect leakage;inspecttiltcabsafety tiltcabsafety devices;serviceasneeded. 25. Checkaccelera Checkaccelerator,clut tor,clutch,andbrakepedal ch,andbrakepedaloperationandcon operationandcondition. dition. 26. Checkcabridehe Checkcabrideheight;inspectcaba ight;inspectcabairsuspensionspri irsuspensionsprings,mounts,hoses,val ngs,mounts,hoses,valves, ves, shockabsorbers,andttingsforleaksanddamage. 27. Inspectfrontbum Inspectfrontbumper,fai per,fairings,andmounts. rings,andmounts. 28. Inspect InspectA/Ccondenserandli A/Ccondenserandlinesforconditiona nesforconditionandvisibleleaks;ch ndvisibleleaks;checkmountings. eckmountings. 29. Inspect InspectA/Ccompressorand A/Ccompressorandlinesforcondition linesforconditionandvisibleleaks; andvisibleleaks;checkclutch;chec checkclutch;check k mountings. 30. Check CheckA/Csystemcondit A/Csystemconditionandoperation ionandoperation.. 31. CheckHV CheckHVACairinletltersan ACairinletltersandducts;serviceas dducts;serviceasneeded. needed. 32Checkauxiliarypowerunit(AP 32Checkauxilia rypowerunit(APU)operationandm U)operationandmounting;inspec ounting;inspectfordamage,leaks, tfordamage,leaks, andbelttension.

C. Electrical/Electronics (10 questions) 1. Insp Inspectb ectbatte atterybo rybox(es x(es),co ),cover(s ver(s),an ),andmou dmounting ntings. s. 2. Inspectbatteryh Inspectbatteryholddowns,connec olddowns,connections,cables,andcab tions,cables,andcablerouting;service lerouting;serviceasneeded. asneeded. 3. Checkandrecor Checkandrecordbatterystateofch dbatterystateofcharge(openci arge(opencircuitvoltage)and rcuitvoltage)andcondition. condition. 4. Perf Performb ormbatte atteryte rytest(l st(loada oadandca ndcapacit pacitance ance). ). 5. Insp Inspects ectstarte tarter, r,moun mounting ting,con ,connect nections, ions,cabl cables,a es,andca ndcabler blerouti outing. ng. 6. Engagestarter; Engagestarter;checkforunusualn checkforunusualnoises,starterdrag,an oises,starterdrag,andstartingdifculty dstartingdifculty.. 7. Insp Inspecta ectaltern lternator ator,mou ,mountin nting,wi g,wiring, ring,and andwiri wiringro ngroutin uting. g. 8. Perf Performa ormalter lternato natorcur rcurrent rentoutp outputte uttest. st. 9. Perf Performa ormalter lternato natorvol rvoltage tageoutp outputte uttest. st. 10. Checkoperatio Checkoperationofinteriorlights;s nofinteriorlights;serviceasneeded. erviceasneeded. 11. Checkallexterio Checkallexteriorlights,lenses,andre rlights,lenses,andreectors;checkhe ectors;checkheadlightalignmen adlightalignment;service t;service asneeded. 12. Inspectandtesttr Inspectandtesttrailerpowercordco ailerpowercordconnector nnector,cable,andholder;se ,cable,andholder;serviceasneeded. rviceasneeded.

D. Frame and Chassis (22 questions) 1. Brakes (10 questions) 1. Chec Checkair kairpark parkingb ingbrake rakeoper operation ation.. 2. Chec Checkand kandreco recordai rdairgov rgoverno ernorcut rcut-ina -inandcu ndcut-ou t-outset tsetting tings(ps s(psi). i). 3. Serviceairdriera Serviceairdrierasneeded.Checkair sneeded.Checkairdrierpurgeva drierpurgevalveoperationand lveoperationandairdrierheater airdrierheater, , ifequipped. 4. Chec Checkair kairsyst systemfo emforlea rleaks(b ks(brake rakesrel srelease eased). d). 5. Chec Checkair kairsyst systemfo emforlea rleaks(b ks(brake rakesapp sapplied) lied).. 6. Drai Drainair nairtank tanks;te s;teston stone-wa e-wayand yanddoub double-c le-check heckvalv valves. es.

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 T8 liST (cOnTinuEd ) 7. Chec Checklow klowair airpress pressurew urewarni arningde ngdevices vices.. 8. Checkspringbr Checkspringbrakeinversion/emer akeinversion/emergency(spring) gency(spring)brakecontrolvalv brakecontrolvalve,ifequipped. e,ifequipped. 9. Chec Checktra ktractor ctorprote protection ctionvalv valve,if e,ifequi equipped pped.. 10. Testairpressurebu estairpressurebuild-uptime. ild-uptime. 11. Checkconditio Checkconditionandoperationofh nandoperationofhandbrake(trailer andbrake(trailer)controlvalve,ifequ )controlvalve,ifequipped. ipped. 12. Performantiloc Performantilockbrakesystem(A kbrakesystem(ABS)operationals BS)operationalsystemself-test.Per ystemself-test.Performautomatic formautomatic tractioncontrol(A tractioncontro l(ATC)operationals TC)operationalsystemself-test,ifeq ystemself-test,ifequipped. uipped. 13. Inspectcouplin Inspectcouplingairlines,holders,an gairlines,holders,andgladhands. dgladhands. 14. Checkbrakecha Checkbrakechambersandairline mbersandairlinesforsecuremount sforsecuremountings,damage,andmi ings,damage,andmissing ssing cagingplugs. 15. Inspectandreco Inspectandrecordfrontandrearbr rdfrontandrearbrakelining/padcondi akelining/padconditionandthickness tionandthickness.. 16. Inspectconditi Inspectconditionoffrontandrearb onoffrontandrearbrakedrums/rotors. rakedrums/rotors. 17. Checkoperatio Checkoperationandadjustment nandadjustmentoffrontandrearbra offrontandrearbrakeautomaticslac keautomaticslackadjusters. kadjusters. 18. CheckS-camsh CheckS-camshaftandbushingco aftandbushingcondition. ndition. 19. Lubricateallair Lubricateallairbrakecomponen brakecomponentgreasettings. tgreasettings. 20. Checkmastercy Checkmastercylinderforleaksan linderforleaksanddamage;check ddamage;checkuidlevelandcond uidlevelandcondition. ition. 21. Inspecthydrau Inspecthydraulicbrakelines,ttings,e licbrakelines,ttings,exiblehoses,andval xiblehoses,andvalvesforleaksand vesforleaksand damage. 22. Checkhydraul Checkhydraulicparkingbrakeop icparkingbrakeoperation;inspectp eration;inspectparkingbrakeapp arkingbrakeapplicationand licationand holdingdevices. 23. Checkoperatio Checkoperationofhydraulicsyst nofhydraulicsystem;pedaltravel,pe em;pedaltravel,pedaleffort,and daleffort,andpedalfeel(drift). pedalfeel(drift). 24. Inspectcaliper Inspectcalipersand/orwheelcylind sand/orwheelcylindersforleaksandda ersforleaksanddamage. mage. 25. Inspectpowerb Inspectpowerbrakebooster(s),ho rakebooster(s),hoses,andcontrolvalv ses,andcontrolvalves. es. 26. Checkand/oradjus Checkand/oradjusthydraulicdrumb thydraulicdrumbrakes. rakes. 27. Checkoperatio Checkoperationofhydraulicassi nofhydraulicassistback-upsystem stback-upsystemandwarningdevic andwarningdevices. es.

2. Drivetrain (4 questions) 1. Chec Checkope koperatio rationof nofrelea release/thr se/throwou owoutbea tbearing ringand andclutc clutchbra hbrake. ke. 2. Checkclutchlin Checkclutchlinkage/cableandleve kage/cableandleversforloosenessor rsforloosenessorbinding;lubricate binding;lubricaterelease/ release/ throwoutbearingasrequired. 3. Checkclutchma Checkclutchmastercylinderuid stercylinderuidlevel;checkclutc level;checkclutchmastercylinder hmastercylinder,slavecylinder ,slavecylinder, , lines,andhosesforleaksanddamage. 4. Che Check ckand and/or /orad adjus justc tclut lutch. ch. 5. Checktransmis Checktransmissionand/ortransfer sionand/ortransfercasehousing,fasten casehousing,fasteners,seals,lter ers,seals,lter,cooler,an ,cooler,and d coolerlinesforcracks,leaks,andprop coolerlinesforcr acks,leaks,andproperrouting,ifequipp errouting,ifequipped. ed. 6. Checktransmis Checktransmissionwiring,conne sionwiring,connectors,seals,andharn ctors,seals,andharnessesfordamage essesfordamageandproper andproper routing. 7. Insp Inspectt ecttrans ransmiss missionb ionbreat reather her,serv ,servicea iceasnee sneeded. ded. 8. Insp Inspectt ecttrans ransmiss missionm ionmount ountsfor sforloos looseness enessand anddete deteriora rioration tion.. 9. Chec Checktra ktransmis nsmission sionoil/ oil/uidl uidlevel eveland andcond condition ition.. 10. InspectU-joint InspectU-joints,yokes,driveshafts s,yokes,driveshafts,andcenterbearing ,andcenterbearingsforlooseness,dam sforlooseness,damage,and age,and properphasing. 11. Inspectaxlehou Inspectaxlehousing(s)forcracks sing(s)forcracksandleaks. andleaks. 12. Inspectaxlebre Inspectaxlebreather(s);service ather(s);serviceasneeded. asneeded. 13. Lubricatealldri Lubricatealldrivetraingreasetting vetraingreasettings. s. 14. Checkdriveaxle Checkdriveaxle(s)oillevel. (s)oillevel. 15. Changedriveax Changedriveaxle(s)oilandlter;che le(s)oilandlter;checkandcleanmagn ckandcleanmagneticplugs. eticplugs.

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 T8 liST (cOnTinuEd ) 16. Checkpowertak Checkpowertakeoff(PT eoff(PTO)unitoperationa O)unitoperationandmounting;che ndmounting;checkPTOU-jo ckPTOU-joints ints anddriveshaftforlooseness,damag anddriveshaftfo rlooseness,damage,andproperphasi e,andproperphasing,ifequipped. ng,ifequipped. 17. Changetransmi Changetransmissionoil/uidandlters ssionoil/uidandlters;checkandcleanm ;checkandcleanmagneticplugs. agneticplugs. 18. Taketransmission aketransmissionoilsample. oilsample. 19. Takedriveaxle(s) akedriveaxle(s)oilsample. oilsample.

3. Steering, Tires, and Wheels (4 questions) 1. Chec Checkste ksteerin eringwhe gwheelan elandco dcolumn lumnoper operatio ationfor nforfree freeplay playand andbind binding. ing. 2. Chec Checkpow kpowerst ersteeri eeringpu ngpumpa mpandho ndhosesf sesforle orleaksa aksandmo ndmountin unting;ch g;check eckuidl uidlevel evel andcondition. 3. Chan Changepo gepowers wersteer teering inguida uidandlt ndlter er.. 4. Insp Inspects ectsteer teeringg inggear( ear(s)or s)orrack rack-and-and-pinio pinionfor nforleak leaksand sandmou mounting nting.. 5. Inspectsteering InspectsteeringshaftsandU-joint shaftsandU-jointsconditionandfor sconditionandforproperphasing;in properphasing;inspectpinch spectpinch bolts,splines,Pitmanarm-to-steerin bolts,splines,Pitma narm-to-steeringsectorshaft,dragli gsectorshaft,draglink,tierodends,crosstu nk,tierodends,crosstube, be, andwheelstops. 6. Chec Checkkin kkingpin gpinand andthru thrustbe stbearin aringwea gwearr. 7. Chec Checkfro kfrontan ntandrea drearwh rwheelb eelbeari earings/h ngs/hubas ubassemb semblies liesforl forloose ooseness nessandn andnoise oise, , includingextendedservice(seale includingexten dedservice(sealed,closetolerance,an d,closetolerance,andunitized)assem dunitized)assemblies. blies. 8. Chec Checkoil koilleve leveland landcond condition itioninal inallnon lnon-dri -driveax veaxlehu lehubs;c bs;check heckfor forleaks leaks.. 9. Adjustwheelbea Adjustwheelbearingsasneeded(in ringsasneeded(includingoneandtw cludingoneandtwonuttypes)inacco onuttypes)inaccordance rdance withmanufacturer’sspecications. 10. Inspecttiresforir Inspecttiresforirregularwearpatt regularwearpatternsandpropermo ernsandpropermountingofdirectio untingofdirectionaltires. naltires. 11. Inspecttiresforcu Inspecttiresforcuts,cracks,bulges,and ts,cracks,bulges,andsidewalldamage sidewalldamage.. 12. Inspectvalvecap Inspectvalvecapsandstems. sandstems. 13. Measureandrec Measureandrecordtiretreaddepth ordtiretreaddepth;probeforimbedd ;probeforimbeddeddebris. eddebris. 14. Checkandrecor Checkandrecordtireairpressure;a dtireairpressure;adjustasneeded. djustasneeded. 15. Checkforlooselu Checkforlooselugsand/orslippedwh gsand/orslippedwheels;checkmount eels;checkmountinghardwarecon inghardwarecondition; dition; serviceasneeded. 16. Retorquelugs/nuts Retorquelugs/nutsinaccordancewit inaccordancewithmanufacturers hmanufacturers’’specications. 17. Inspectwheelsa Inspectwheelsandspacersforcrac ndspacersforcracksordamage. ksordamage. 18. Checktirematch Checktirematching(diameterand ing(diameterandtread)ondualtirein tread)ondualtireinstallations. stallations. 19. Lubricateallstee Lubricateallsteeringgreasettings. ringgreasettings.

4. Suspension, Frame, and 5th Wheel (4 questions) 1. Inspectfrontand Inspectfrontandrearsuspensionco rearsuspensioncomponents(sprin mponents(springs,hangers,shackle gs,hangers,shackles,spring s,spring U-bolts,insulators,radiusrods,torque U-bolts,insulator s,radiusrods,torquerods,loadpads,walki rods,loadpads,walkingbeams,and ngbeams,and equalizers);checkU-bolttorquein equalizers);che ckU-bolttorqueinaccordancewith accordancewithmanufacturers manufacturers’’specications. 2. Insp Inspects ectshock hockabso absorbers rbersforl forleaks eaksandm andmount ounting. ing. 3. Insp Inspecta ectairsu irsuspen spension sioncomp componen onents(a ts(airsp irspring rings/bag s/bags,mo s,mounts unts,arm ,arms,hos s,hoses,v es,valves alves, , linkage,andttings)forleaksanddamag linkage,andttings) forleaksanddamage;checksuspens e;checksuspensionrideheight. ionrideheight. 4. Insp Inspecto ectopera peration tionofta oftag/pus g/pushera heraxlea xleandco ndcompon mponents entsform formounti ountingan nganddam ddamage. age. 5. Lubr Lubricate icatealls allsuspe uspension nsiongrea greaset settings tings.. 6. Che Check cktan tandem demax axle lespa spacin cing. g. 7. Inspectfthwheelm Inspectfthwheelmount,bolts,slider ount,bolts,slider,airlines,locks,pivot ,airlines,locks,pivotpins,bushings,and pins,bushings,and stops. 8. Testo estopera peration tionoff offthwh thwheell eellockin ockingdev gdevice; ice;adju adjustas stasneed needed. ed. 9. Chec Checkmud kmudaps aps,brac ,brackets, kets,and andree reective ctivedevi devices. ces. 10. Checkpintlehoo Checkpintlehookassembly kassembly,mountingbolts,an ,mountingbolts,andlocks. dlocks.

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 T8 liST (cOnTinuEd ) 11. Cleanandinspe Cleanandinspectfthwheelplateforc ctfthwheelplateforcracksanddamage racksanddamage;lubricatefthwhee ;lubricatefthwheel l plateandallgreasettings. 12. Inspectframean Inspectframeandframemember dframemembersforcracksanddam sforcracksanddamage. age. 13. Inspectbodyatt Inspectbodyattachinghardware achinghardware.. 14. Inspectcar Inspectcargoramps.Inspectli goramps.Inspectliftgates,cylinders,co ftgates,cylinders,controls,hoses,wiring ntrols,hoses,wiring,andwarning ,andwarning decals;checkuidlevel,serviceasneeded. 15. Inspectrear(IC Inspectrear(ICC/DOT)impactgua C/DOT)impactguard. rd.

E. Road/Operational Test (3 questions) 1. Chec Checkope koperatio rationof nofclutc clutchand handgear gearshif shift. t. 2. Chec Checkope koperatio rationof nofalli allinstru nstrument ments,gau s,gauges, ges,andl andlight ights. s. 3. Chec Checkste ksteering eringwhee wheelfor lforplay play,bin ,binding ding,and ,andcent centerin ering. g. 4. Chec Checkope koperatio rationof nofautom automatic aticorau orautoma tomatedm tedmechan echanical icaltran transmiss smission. ion. 5. Che Check ckroa roads dspee peedl dlimi imiter ter.. 6. Ch Chec eck kcr crui uise sec con ontr trol ol.. 7. Obse Observee rveexhau xhaustfo stforexc rexcessi essivesm vesmoke. oke. 8. Test estse servi rvice cebra brakes kes.. 9. Verify erifyengi engine/ex ne/exhaus haustbra tbrakeor keorreta retarder rderoper operation ation.. 10. Checkoperatio Checkoperationofbackupwarni nofbackupwarningdevices. ngdevices. 

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S AMplE QuESTiOnS prEvEnTivE M AinTEnAncE inSpEcTiOn (pMi) (TEST T8) QuESTiOnS : 1. Whichof Whichofthese theseist isthem heminimum inimumtire tiretrea treaddep ddepthpe thpermitt rmittedby edbyfed federal eralDOT DOT standardsonallsteeraxletiresontrucks,tr standardsonallsteer axletiresontrucks,tractors,orbuses? actors,orbuses? (A) 1/32 in. (B) 2/32 in. * (C) 4/32 in. (D) 5/32 in. 2. Technic echnician ianA Asays saysthat thatthelo thelowai wairbr rbrakep akepress ressure urewarn warningla inglamps mpshould houldbelit belit whenthesupplysystempressureisbelow60psi. TechnicianBsaysthatthepa echnicianBsaysthattheparkingbrakesshouldautomatica rkingbrakesshouldautomaticallyapplywhenthe llyapplywhenthe supplysystemairpressurefallsbelow45psi. Whoisright?  (A (A) A only * (C) Both A and B  (B (B) B only  (D (D) Neither A nor B 3. Thedriver Thedriverof ofatra atractor/ ctor/trail trailerr erreport eportstha sthatthe ttheengin engine’ e’sfa sfanhits nhitsthe theshrou shroudwh dwhen en acceleratingunderaload.Themostlikelycauseis: (A) overspeeding the engine. (B) improper vehicle shif iftting. (C) excessive fan blade exing. * (D (D) )a alo loos ose een engi gine ne mou ount nt.. 4. Adriv driveaxl eaxlelub elubrican ricantis tisami amilkyc lkycolor olor.T .Them hemostli ostlikely kelycause causeis: is: (A) metal contamination. (B) mixing lubricant types. (C) gasket sealer contamination. * (D (D) )w wat ater er co cont ntam amin inat atio ion. n.

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 T8 S AMplE QuESTiOnS (cOnTinuEd ) 5. ThePM ThePMin inspe specto ctorn rnoti otices cesth that at part“X”ismissing.Thiscouldcause: * (A) uid contaminatio ion n. (B) loss of static pressure. (C) excessive pedal effort. (D) (D )br brak ake ew war arni ning ngl lam amp pil illu lumi mina nati tion on.. 6. Whenp Whenpres ressur suret etest esting inga acoo cooling lingsy syste stem, m, thetechnicianshouldapply: (A) (A )5 5po poun und ds sof of pr preess ssur ureew wit ith hth the e enginerunning. * (B (B) )th the eam amou ount nto of fpr pres essu sure rel lis iste ted d ontheradiatorcap. (C) (C )pr pres essu sure ren not ott to oex exce ceed edt the hed dan ange ger rzo zone ne onthepressuregauge. (D) (D )5 5po poun unds dsm mor ore epr pres essu sure ret tha han nli list sted edo on nthe ther rad adia iato tor rca cap. p. 7. Whenperf Whenperformin orminga gabatter batteryload yloadtes teston tonamul amultiple tiplebatter batteryveh yvehicle: icle: (A)c (A )conn onnect ectth thel eload oadte test stcla clamps mpsto toan anyp yposi ositive tiveba batte ttery rypos posta tand ndgro ground und.. (B) (B )di disc scon onne nect ctt the heg gro roun und dca cabl ble( e(s) s)f fro rom mth the efr fram ame. e. (C)co (C) conne nnect ctthe thelo load adtes testa tamps mpscl clamp ampar aroun ounda dane negat gative iveve vehic hicle lebat batter teryc ycabl able. e. *(D * (D) )di disc scon onne nect ctt the heb bat atte teri ries esf fro rom mea each cho oth ther er.. Question 8 is not like the ones above. It has the word EXCEPT.Forthisquestion,lookforthechoicethatcould NOT causethedescribedsituation.Readtheentirequestioncarefullybefore choosingyouranswer. 8. Azer zerore oreading adingonan onanair airres restricti trictionda ondashga shgaugec ugecould ouldbeca becaused usedbyal byallof lofthese these EXCEPT: (A) a bad restric icttio ion n gauge. * (B (B))a pl plug ugge ged dai air rl lte terr. (C))a (C an nop open enin ing gin int the he in inta take ke sy sysste tem m. (D) a torn air lter.

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induSTry  TrAininG Thefollowingsourcesofinformationprovidecomprehensivelistingsoftra Thefollowingsourcesofinformationprovidecomprehe nsivelistingsoftrainingresources iningresources availabletoworkingtechnicians:

Delmar Cengage Learning

MD Publications

P.O.Box6904 Florence,KY41022 1-800-487-8488 www.autoed.cengage.com www.cengage.com/delmar

UndercarDigest,JulyIssue TransmissionDigest,SeptemberIssue P.O.Box2210 Springeld,MO65801 1-800-274-7890

Motor Age Training Training or Certifcation

Motor Source Guide

131WestFirstStreet Duluth,MN55802 800-240-1968 www.motorage.com

HearstBusinessPublishing,Inc. 645StewartAve. GardenCity,NY11530 www.motor.com

 In Canada

Fleet Equipment, April Issue

 Thomson Learning Nelson Canada

P.O.Box7605 Mt.Prospect,IL60056-7605 www.truklink.com

1120BirchmountRoad Scarborough,OntarioM1K5G4 1-800-268-222 E-mail:[email protected]

Spanish Language Training Resources Foralistingoftrainingproviderswhooffer training,ortrainingmaterialsinSpanish gotowww.ase.com;oncethere,enterthe “ServiceProfessionals”areaandclickon “SpanishLanguageTrainingResources.”

Recursos de Educación en Español Paraobteneraccesoalalistadeproveedores deeducación,ómaterialeseducativosen Españoldiríjaseawww.ase.com;unavesallí, entreenlasección“Español”yprosigaalárea “ListadeEducadoresyMaterialesDidácticos.”

CASE: ASE Certication for Training Providers of Continuing Automotive Service Education. Visit www.natef.org/case/case_certied.cfm for periodic updates to this list.

TheNationalInstituteforAutomotiveService TheNationalInstitutefor AutomotiveServiceExcellence(AS Excellence(ASE)anditseducati E)anditseducational onal foundation,theNationalAutomotiveTechniciansEducationFoundation(NATEF),offer avoluntarycerticationprogramforinstituti avoluntarycertica tionprogramforinstitutionsandorganizat onsandorganizationsprovidingcontinuing ionsprovidingcontinuing automotiveserviceeducation. automotiveservic eeducation.ASEseekstoimprove ASEseekstoimprovethequalityofcontinui thequalityofcontinuingautomotive ngautomotive educationandhelpautomotivetechnic educationandhelpa utomotivetechniciansidentifyappropria iansidentifyappropriatetrainingsourcesa tetrainingsourcesandactivities ndactivities byevaluatingandcertifyingprovidersofcontinuinga byevaluatingandce rtifyingprovidersofcontinuingautomotiveservice utomotiveserviceeducationagainst educationagainst CASEStandards. TheCASEprogramdiffersfrom TheCASEprogramdif fersfromASE’ ASE’sexistingentry-leve sexistingentry-leveltrainingprogramcert ltrainingprogramcertication ication inthatitaddressesthetrainingprovider’ inthatitaddress esthetrainingprovider’sprocessofdevelopingandde sprocessofdevelopinganddeliveringtrainingas liveringtrainingas opposedtoprescribingspecicprogramcontent.Ele opposedtoprescribingspec icprogramcontent.Elementsoforganiza mentsoforganization,structureand tion,structureand methodswhichappeartocontributesignicant methodswhichappeart ocontributesignicantlytothedevelopment lytothedevelopmentanddeliveryofhigh anddeliveryofhigh qualityautomotiveserviceeducat qualityautomotive serviceeducation,havebeenidentieda ion,havebeenidentiedandincorporatedintotheC ndincorporatedintotheCASE ASE Standards. Thefollow Thef ollowingt ingtraini rainingpro ngprovider vidershav shaveac eachieve hievedCAS dCASEce Ecertic rticatio ation.Pl n.Please easenote notetha that* t* indicatesaproprietaryprogramunavaila indicatesaproprie taryprogramunavailabletoalltechni bletoalltechnicians. cians.

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induSTry  TrAininG 3M Industrial and Transportation Transportation Business Services Training and Development 3MCenterBuilding225-1N-01 St.Paul,MN55144 651-737-0141 www.3m.com/automotive

 ACDelco Service Ser vice Training Training 6200GrandPointDr.,MC#2-316 GrandBlanc,MI48439 800-825-5886prompt1 www.acdelcotechconnect.com

 Afnia Under Vehicle Group TechnicalServicesDepartment 4400PrimeParkway McHenry,IL60050 815-363-9000–askfortechnical www.raybestos.com

 AKZO NOBEL Coatings Inc., Car Refnishes 5555SpaldingDr. Norcross,GA30092 770-242-5760 www.akzonobelcarrenishes.net

 American Automobile Association, Inc. 1000AAADr. Heathrow,FL32746 407-444-7169or407-444-8041 AllanStanley,[email protected] LenJohannes,[email protected] www.aaa.com

 *American Honda Automobile Service  Training 1919TorranceBlvd. Torrance,CA90501 310-783-3557 www.honda.com

 Automotive Spray Equipment   Technologies (ASET) 3703WestParkwayBlvd. SaltLakeCity,UT84120 801-964-6646 www.asetusa.com

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 ATech  AT ech Traini raining, ng, Inc 12290ChandlerDr. POBox297 Walton,KY41094 859-485-7229ext.109 www.atechtraining.com

BASF Automotive Refnish Division 26701TelegraphRd. Southeld,MI48034 248-304-5200 www.basfrenish.com

BP Global Fuels Technology  Technology  150W.WarrenvilleRd. 800Building Naperville,IL60563 312-729-4212 www.fuelcertication.com

Chie Automotive Systems 996IndustrialDr. Madison,IN47250 800-445-9262 www.chiefautomotive.com

CARQUEST Technical Technical Institute 4401AtlanticAve. Raliegh,NC27604 919-573-3000 www.CARQUEST.com/CTI

Collision Management Services Inc. 2040RLordBaltimoreDr. Baltimore,MD21244 410-944-3383 www.ineedcms.com/Training.html

Delphi Integrated Service Solutions 5820DelphiDr. Troy,MI48098 800-545-2220 CustomerSupport www.delphi-iss.com

DuPont Perormance Coatings 500EagleviewBlvd. Exton,PA19341 610-458-6323 www.pc.dupont.com

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induSTry  TrAininG EAST Training Inc.

Kent Automotive

4404SylonBlvd. Hainesport,NJ08036 609-267-2223 www.easttraining.com

6200OakTreeBlvd.,#350 Independence,OH44131 216-642-5973 www.kent-automotive.com

Federal Mogul Technical Education Centers

Lawson State Community College

6565WellsAve. St.Louis,MO63133 314-977-0684 www.federal-mogul.com

Fox Valley Technical College 1825N.BluemoundDr. Appleton,WI54912 920-993-5163 www.fvtc.edu/public

 *General Motors Service Technical Technical College 30501VanDykeAve.,M/C480-204-100 Warren,MI48090 586-947-9704 www.gmstc.com

Hunter Engineering 11250HunterDr. Bridgeton,MO63044 314-731-0000 www.hunter.com

I-CAR (Inter-Industry Conerence on  Auto Collision Repair) 5125TrilliumBlvd. HoffmanEstates,IL60192 800-422-7872 www.i-car.com

Iwata Medea 3703WestParkwayBlvd. WestValleyCity,UT87120 801-964-6646 www.asetusa.com

11009thAve.,SW Bessemer,AL35022 205-929-3521 www.lawsonstate.edu

Lew Kinney & Associates On-siteWeldingTrainingandCertications POBox511,184StateRoute314 Centerburg,OH43011 740-625-6342

 *Lexus, A Division o Toyota Motor  Sales, Inc., U.S.A. 19001S.WesternAve. Torrance,CA90509 TechnicalTraining310-468-4958 www.lexus.com

Martin Senour Automotive Finishes 7019HighgroveRd. BurrRidge,IL60527 630-887-7516 www.martinsenour-autopaint.com

Megatech Corporation 525WoburnSt.,Suite3 Tewksbury,MA01876 800-767-6342(US) 978-937-9600(Int’l) www.megatechcorp.com

Melior, Inc. 200CahabaParkCircleWest,Suite250 Birmingham,AL35242 205-298-8300 www.melioronline.com

Jiy Lube International

National Automotive Parts Association (NAPA)

700Milam,Room24038PNT Houston,TX77002 713-546-3957 www.jiffylube.com

2999Circle75Pkwy. Atlanta,GA30339 800-292-NIAT(6428) www.niat-training.com

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induSTry  TrAininG National Appraisal Institute

SEM Products, Inc.

10150CanogaAve Chatsworth,CA91311 818-775-1370 www.nainstitute.com

1685OverviewDr. RockHill,SC29730 803-207-8231 www.semproducts.com

Nationwide Training Training Organization

Sherwin-Williams Automotive Finishes Corp.

9243ColumbusPike LewisCenter,OH43035 614-840-7169 www.nationwide.com

 *Navistar, Inc. 3033WayneTerrace FortWayne,IN46806 260-461-1951 www.navistar.com

 *Nissan North America, Inc. CustomerLoyaltyandTraining P.O.Box685001 Franklin,TN37068 615-725-8319 www.nissantechinfo.com

 *Penske Truck Leasing Route10PheasantRd.,POBox563 Reading,PA19607 610-775-6479 www.gopenske.com

PPG Industries

7019HighgroveRd. BurrRidge,IL60527 630-887-7516 www.sherwin-automotive.com

Solera, Inc. P.O.Box151376 AltamonteSprings,FL32715 858-724-1600 www.training.audatex.us

Specialty Products Company  4045SpecialtyPlace Longmont,CO80504 303-772-2103 www.spcalignment.com

 Technical Training, Inc. (TTi) 2750ProductDr. RochesterHills,MI48309 248-853-5550or800-837-5222 www.ttinao.com

 *Toyota Motor Sales, USA, Inc.

19699ProgressDr. Strongsville,OH44149 440-572-6784 www.ppg.com

19001S.WesternAve. Torrance,CA90509-2991 310-468-7171 www.toyota.com

Raytheon Proessional Services L.L.C.

*

1919TechnologyDr. Troy,MI48083 248-837-6777 www.rps.com

This program is proprietary and therefore not available to all technicians.

Saint Gobain Abrasives 1NewBondSt. Worcester,MA01606 508-795-2774 www.nortonautomotive.com www.aa.carborundumabrasives.com

COPYRIGHT © 2010 by

National Institute for   AUTOMOTIVE SERVICE EXCELLENCE

All rights reserved  ASE M   /H   EdiuM   EAvy  T   ruck  S  Tudy  GuidE  Tudy 

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A  S  E   , T  1    e   0   l    1    e  B D   p l    h    u  o  o  w n  e   n  e   S   l    e   o  :    a   a  7   l     d   0    3   D  f    o  6    .r  r   6    ,  m  9    S  -  .E   s   6   2   6    . , 4   0    S   /   7   0    u i     a   (     t    e   t   F  A  w X 1    w  :    0    w  7    ,1   L   .  a  0    3    e   s  -  e   e   6    .  c   6    s   b    o  9    u m  6   -   g r   !   1    , 2    V  3   A   )    2    0   1    7    5  

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T   e   c  h   n i     c  i     a  n

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E  m   p l     o   y  e   ,r   w i     t   h    _  _  _  _  _  t    e   c  h   n i     c  i     a  n  s 

I    ’     v  e   c  h    e   c  k    e   d     (   

 

  )     a    p   p r   o   p r  i     a   t    e   b    o x  .

i    n P  l     c   e  l     a   u  d    s   e  i    n  s    g  e  n  t    e   d    s   _  t    _ r   _  e    g  _ i     _  s   t   r   c   o  a    p  t   i    i     o  e  n  s  f     o  o f    r  m A  S   s   . E  ’     s  R  e    g i     s   t   r   a   t   i     o n B  o  o k   l     e   t  

T   e  l     e    p h    o n  e   N  u m  b    e  r   _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _

 C  i     t     y  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  S   t    a   t    e   _  _  _  _  _ Z  i      p  _  _  _  _  _  _  _  _

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 S  h    o   p  N  a  m  e   _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _

 N  a  m  e 

 _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _  _

L  1    e   0    e  1    s   b   B  u  u l    r   e    g  ,  S   V  e  A  a  2   l     0   D 1   r   ,  7    .  5    S   .E   .  ,  S   u i     t    e  1    0   1  

A   U  T   O  M  O  T  I   V  E   S  E  R  V  I    C  E  E  X   C  E  L  L  E  N   C  E 

 N  a   t   i     o n  a  l    I    n  s   t   i     t    u  t    e  f     o r 

T   o  :  

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