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The OfficialASE Study Guide
ASE Medium/HeavyTruck Tests
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Table of Contents
Overview ................................................................................................37
Medium/Heavy Truck Tests .................................................................. 861
GasolineEngines(TestT1).............................................................8
DieselEngines(TestT2) ...............................................................17
DriveTrain(TestT3) ....................................................................24
Brakes(TestT4) ............................................................................30
SuspensionandSteering(TestT5)................................................36
Electrical/ElectronicSystems(TestT6)........................................42
Heating,Ventilation,andAirConditioning
(HVAC)Systems(TestT7) ...........................................................48
PreventiveMaintenanceInspection(PMI)(TestT8)....................54
Industry Training ...............................................................................6265
ASE MEdiuM/HEAvyTruckTESTS
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ASE MEdiuM/HEAvyTruckSTudyGuidE PAGE3
OvErviEw
Introduction
TheOfcial ASE Study Guide for the Medium/Heavy Truck TestsisintendedtohelptechniciansstudyfortheASEcerticationtests.Thespecicmaterialabout
eachtest,includedinthebookletisausefultoolforreviewingthetechnical
knowledgethatiscoveredintheMedium/Heavy Truck tests.Afterperforming
athoroughreview,itshouldbeeasiertoselectadditionalreferencematerialthat
willassistyouwiththetestpreparationneeds.
ASEvoluntarycerticationisameansbywhichtechnicianscanprovetheir
abilitiestothemselves,totheiremployers,andtotheircustomers.Bypassing
ASEtestsyouwillearnthemostvaluablecredentialavailabletotrucktechni-cians.Becausethetestsaretough,youllhavethesatisfactionofprovingto
yourselfthatyouareamongtheeliteinyourprofession.Whatsmore,these
credentialsarerecognizedthroughoutthenation.
Certiedtechnicianspromotecustomertrustandimprovetheimageof
theindustry.Andtrustandprofessionalismaretherststepstoabetter,more
prosperousbusiness.
ASEencouragesyoutotakethetestsandtojointheprovenproswhowear
TheASEBlueSealofExcellence.
How Do I Become Certifed?TherearecurrentlyeighttestsintheMedium/HeavyTruckTechniciancertica-
tionseries.Class4throughClass8trucksarecovered.MediumdutyClass46
is14,001to26,000lbs.grossvehicleweight(GVW).HeavydutyClass78is
26,001andabovegrossvehicleweight(GVW).
Ifyoupassoneormoretestsandhaveatleasttwoyearsofrelevanthands-
onworkexperience,youwillbecomecertiedasanASEMedium/HeavyTruckTechnician.IfyoupasstheDieselEnginesTest(T2)andtestsT3,T4,T5,T6,and
T7youwillearnthecerticateofMasterMedium/HeavyTruckTechnician.
IfyouarecurrentlycertiedinDieselEngines(A9,H2,S2,orT2)
andElectrical/ElectronicSystems(A6,H6,S6,orT6),youareeligibletotakethe
L2ElectronicDieselEngineDiagnosisSpecialisttest.
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PAGE4 ASE MEdiuM/HEAvyTruckSTudyGuidE
Ifyoufailatest,youmaytakeitagainduringanyscheduledtest
administrationinwhichitisoffered.Andremember,youaretheonlyonewho
willreceiveyourtestsscores;resultswillnotbegivenoverthephonenorwill
theybereleasedtoanyonewithoutyourwrittenpermission.
Medium/Heavy Truck TestsASEtestsandcertiestechniciansinthefollowingtruckareas:
GasolineEngines(TestT1)
DieselEngines(TestT2)
DriveTrain(TestT3)
Brakes(TestT4)
SuspensionandSteering(TestT5)
Electrical/ElectronicSystems(TestT6)
Heating,Ventilation,andAirConditioning(HVAC)Systems(TestT7)
PreventiveMaintenanceInspection(PMI)(TestT8)
ASEalsoofferscerticationinAutomobile,TruckEquipment,TransitBus,SchoolBus,CollisionRepair/Renish,PartsSpecialist,andAdvanced Level
specialties.
ForfullinformationonASEtestingaswellasdownloadableStudy Guides,
Registration Booklets,andmore,visitwww.ase.com.Youmayalsorequest
Registration Bookletsbymailingthecouponlocatedonthebackcoverofthis
bookletorbycallingASEat703-669-6600,ext.400.
Who Writes the Questions?Thequestions,writtenbyserviceindustryexpertsfamiliarwithallaspectsof
medium/heavytruckrepair,areentirelyjob-related.Theyaredesignedtotestthe
skillsthatyouneedtoknowinservicingtrucks;theoreticalknowledge
isnotcovered.
EachquestionhasitsrootsinanASEitem-writingworkshopwhere
servicerepresentativesfrommedium/heavytruckmanufacturers,aftermarket
partsandequipmentmanufacturers,workingtechniciansandtechnicaleduca-
torsgettogetherinaworkshopsettingtoshareideasandtranslatethemintotestquestions.Eachtestquestionwrittenbytheseexpertsmustsurvivereviewbyall
membersofthegroup.Thequestionsarewrittentodealwithpracticalproblems
ofdiagnosisandrepairexperiencedbytechniciansintheirday-to-daywork.
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ASE MEdiuM/HEAvyTruckSTudyGuidE PAGE5
Fromthere,allquestionsarepre-testedandquality-checkedonanational
sampleoftechnicians.ThosequestionsthatmeetASEstandardsofqualityand
accuracyareincludedinthetests;therejectsaresentbacktothedrawingboard
ordiscardedaltogether.
Eachcerticationtestismadeupofbetween40and55multiple-choice
questions.Thetestingsessionsare4hoursand15minutes,allowingplenty
oftimetocompleteseveraltests.
Note: Eachtestcouldcontainuptofteenadditionalquestionsthatareincluded
forstatisticalresearchpurposesonly.Youranswerstothesequestionswillnot
affectyourscore,butsinceyoudonotknowwhichonestheyare,youshouldanswerallquestionsinthetest.Theve-yearRecerticationTestwillcoverthe
samecontentareasasthoselistedabove.However,thenumberofquestionsin
eachcontentareaoftheRecerticationTestwillbereducedbyaboutone-half.
How Do I Prepare or the ASE Tests?Becomefamiliarwithtestcontentandquestionformat:TheTestSpecications
foreachofthetestscoveredinthisbookletcontainasummarydescriptionofthe
contentcoveredbyeachtest.TheListsdescribetheactualworkperformedbytechniciansineachspecialtyarea.Together,theseformablueprintforwriting
andassemblingtheASEtests.
Pleasenotethateachquestiononthetestiskeyedorlinkedtoaparticular
orsetoftasksinthelist.Therefore,areviewofthelists,withaneyetojudging
whetheryouknowhowtoperformeachlisted,willprovidevaluableinformation
toprepareforthetests.
Therearevetypesofmultiple-choicequestionsonthetests,eachofwhich
isincludedinthesamplequestionsinthisbooklet.Notethedifferentinstructionsforsomequestions.
Besuretoreadeachquestioncarefully,(twice,ifnecessary)sothatyou
understandexactlywhatisbeingasked.Each question tests a specic diagnostic
or repair problem and has only one best answer.
Tosummarize,wesuggestthefollowingstepstobetakentoprepareforthe
tests:
Step 1. Studythecontentlistforeachtestyouwillattempt.
Step 2. Carefullyreadthelistforeacharea.
Step 3. Go over the sample questions to become familiar with each
questiontype.This is very important.
Step 4. Reviewsteps1through3above,andidentifytheskillareaswhere
youneedadditionalstudy.
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PAGE6 ASE MEdiuM/HEAvyTruckSTudyGuidE
Types o Knowledge Measured by the Tests
Thetypesofknowledgeandskillsyouwillneedtoknowtopassthetestsareasfollows:
Basic technical knowledge:Testsyourknowledgeofwhatisinasystemand
howthesystemworks,andwhataretheproperproceduresand/orprecautions
tobefollowedinmakingrepairsandadjustments.
Service or repair knowledge and skill:Testsyourunderstandingandability
toapplygenerallyacceptedrepairproceduresandprecautionsinassembly,
disassembly,andreconditioningoperations;andinmakingmajorinspections
andadjustments.Alsotestsabilitytouseshopmanualsandprecisiontoolsofthetrade.
Testing and diagnostic knowledge and skill:Testsyourabilitytorecognize
problemsandtousegenerallyavailablemeasurementandtestingequipment
tomakeadiagnosis.Alsotestsyourabilitytotracetheeffectsofaparticular
conditionandndthecauseofaparticularsetofsymptoms.
Ifyouareanexperiencedandcompetenttechnician,acarefulreviewof
thisbooklet,andadditionalbrush-uponthoseareasinwhichyouareweakest,isallyoushouldneedtopasstheASEtests.
Beore The TestsTrytobewell-restedforthetestsoyouwillbealertandefcient.Ifyouaretak-
ingthewrittenversions,pleasebringseveralsharpenedsoft-lead(#2)pencilsand
aneraserwithyou;pencilswillnotbefurnishedatthetestcenter.Ifyouwishto
paceyourself,bringawatch;sometestingroomsmaynothaveclocks.Finally,
besuretobringalongyourtestcenteradmissionticketandacurrentphotoI.D.
At the Test CenterSome TipsArriveearlyenoughtondthebuildingandtestingroom.Whenyoureachthe
location,waitintheassignedareauntiltheproctorbeginsthetestadministration.
Heorshewillinstructyouinllingouttheanswerbooklet(iftakingwritten
tests)orloggingontothecomputer(iftakingcomputer-basedtests).
Oncetestinghasbegun,keeptrackoftime.Donotspendtoolongonany
singlequestion.Besuretoreadeachquestioncarefullysothatyouunderstandexactlywhatisbeingasked.Donotmarkanswersinthetestbooklet;theymust
bemarkedontheanswerbooklet.Yourtestwillnotbescoredifyouranswersare
notonyouranswerbooklet.
Ifaquestionisdifcult,marktheanswerthatyouthinkiscorrectandput
acheckbyitinthetestbook.(Computer-basedtestsallowyoutodothison
screen.)Thengoontothenextquestion.Ifyounishbeforetimeisup,youmay
gobacktothequestionsthatyouchecked.
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ASE MEdiuM/HEAvyTruckSTudyGuidE PAGE7
It is to your advantage to answer every question. Do not leave any
answers blank. Your score will be based only on the number of correct
answers that you give.
Test Content and Sample QuestionsThefollowingmaterialisdesignedtohelptechniciansprepareforASEcertica-
tiontests.
EachofthesectionsbeginswiththeTestSpecications,whichlistthemain
categoriescoveredonthatparticulartestandthenumberoftestquestionsand
percentageofthetestdevotedtoeachtopic.
TheListdescribestheworkactivitiesatechnicianshouldbeabletoperform
ineachtechnicalareacoveredonthattest.Thislistwasdevelopedbyworking
techniciansandtechnicalexpertsfromacrossthecountryandwillprovideavalu-
ablechecklistofwhattostudyforthetest.
Itshouldbenotedthatthenumberofquestionsineachcontentareamay
notequalthenumberoftaskslisted.Someofthetasksarecomplexandbroad
inscopeandmaybecoveredbyseveralquestions.Othertasksaresimpleand
narrowinscopeandonequestionmaycoverseveraltasks.Themainobjectiveinlistingthetasksistodescribeaccuratelywhatisdoneonthejob,nottomake
eachcorrespondtoaparticulartestquestion.
Samplequestionsfollow.Althoughthesesamequestionswillnotappearon
actualtests,theyareinthesameformatasactualtestquestions.Allvetypesof
multiple-choicequestionsusedontheASEtestsarerepresentedhere.Notethe
differentinstructionsforsomequestions.
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PAGE8 ASE MEdiuM/HEAvyTruckSTudyGuidE
Content Questions PercentageArea in Test of Test
A. General Diagnosis 1 28%
B. Cylinder Head and Valve TrainDiagnosis and Repair 4 8%
C. Engine Block Diagnosis and Repair 4 8%
D. Lubrication and Cooling SystemsDiagnosis and Repair 3 6%
E. Ignition System Diagnosis and Repair 6 12%
F. Fuel, Air Induction, and Exhaust Systems
Diagnosis and Repair 6 12%
G. Emissions Control SystemsDiagnosis and Repair 5 10%
H. Computerized Engine Controls
Diagnosis and Repair 8 16%
Total 50 100%
TEST SpEcificATiOnSGASOlinE EnGinES (TEST T1)
A. General Diagnosis (14 questions) 1. Verifythecomplaintand/orroadtestvehicle;reviewdriver/customerinterviewand
pastmaintenancedocuments(ifavailable);determinefurtherdiagnosis.
2. Researchapplicablevehicleandserviceinformation,suchasenginemanagement
systemoperation,vehicleservicehistory,serviceprecautions,technicalservice
bulletins,andservicecampaigns/recalls.
3. Inspectengineassemblyforfuel,oil,coolant,andotherleaks;determineneeded
action.
4. Diagnosenoisesand/orvibrationproblemsrelatedtoengineperformance;determine
neededaction. 5. Diagnosethecauseofunusualexhaustcolor,odor,andsound;determineneeded
action.
6. Performenginemanifoldvacuumorpressuretests;determineneededaction.
7. Performcylinderpowerbalancetest;determineneededaction.
8. Performcylindercompressiontest;determineneededaction.
9. Performcylinderleakage/leak-downtest;determineneededaction.
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10.Diagnoseenginemechanical,electrical,electronic,fuel,andignitionproblemswithan
oscilloscope,engineanalyzer,digitalmultimeter(DMM),and/orscantool;determine
neededaction.11. Inspectenginecompartmentwiringharness,connectors,seals,locks,vacuumhoses;
checkforproperroutingandcondition;determineneededrepairs.
12. Observeandinterpretinstrumentpanelgaugereadings.
13. Readandinterpretelectricalschematicdiagramsandsymbols.
14. Testanddiagnoseemissionsordriveabilityproblemscausedbybatterycondition,
connections,orexcessivekey-offbatterydrain;determineneededrepairs.
15. Performstartercurrentdrawtest;determineneededaction.
16. Performstarterandchargingcircuitvoltagedroptests;determineneededaction.
17. Inspect,test,andrepairorreplacecomponents,connectors,andwiresinthestarterandchargingcontrolcircuits.
18. Differentiatebetweenelectricalandmechanicalproblemsthatcauseaslowcrank,no
crank,extendedcranking,oracrankingnoisecondition.
19. Testanddiagnoseengineperformanceproblemsresultingfromanundercharge,over-
charge,orano-chargecondition;determineneededaction.
20. Inspect,adjust,andreplacealternator(generator)drivebelts,pulleys,tensioners,and
fans.
B. Cylinder Head and Valve Train Diagnosis and Repair (4 questions) 1. Remove,inspect,disassemble,andcleancylinderheadassembly(s). 2. Inspectthreadedholes,studs,andboltsforserviceability;service/replaceasneeded.
3. Measurecylinderheadthickness;checkmatingsurfacesforwarpageandsurface
nish;inspectforcracks/damage;checkconditionofpassages;inspectcoreand
galleryplugs;determineserviceabilityandneededrepairs.
4. Inspectvalves,guides,seats,springs,retainers,locks,andseals;determineservice-
abilityandneededrepairs.
5. Reassemble,check,andinstallcylinderheadassembly(s)andgasket(s)asspecied
bythemanufacturer. 6. Inspectpushrods,rockerarms,rockerarmshafts,electronicwiringharness,and
brackets;repair/replaceasneeded.
7. Inspect,install,andadjustvalveliftersandretainers;adjustvalveclearance.
8. Inspect,measure,andreplace/reinstalloverheadcamshaftandbearings;measure
andadjustendplay.
C. Engine Block Diagnosis and Repair (4 questions) 1. Remove,inspect,service,andinstallpans,covers,ventilationsystems,gaskets,seals,
andwearsleeves.
2. Disassemble,cleanandinspectengineblockforcracks;checkmatingsurfacesandrelatedcomponentsfordamageorwarpageandsurfacenish;checkdeckheight;
checkconditionofpassages,core,andgalleryplugs;inspectthreadedholes,studs,
dowelpinsandboltsforserviceability;service/replaceasneeded.
3. Inspectandmeasurecylinderwallsforwearanddamage;determineserviceability
andneededrepairs.
4. Inspectin-blockcamshaftbearingsforwearanddamage;replaceasneeded.
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5. Inspect,measure,andreplace/reinstallin-blockcamshaft;measure/andcorrectend
play;inspect,replace/reinstall,andadjustvalvelifters.
6. Cleanandinspectcrankshaftandjournalsforsurfacecracksanddamage;checkconditionofoilpassages;checkpassageplugs;measurejournaldiameters;check
mountingsurfaces;determineneededrepairs.
7. Diagnosepiston,connectingrodbearing,andmainbearingwearpatternsthatindicate
connectingrodandcrankshaftalignmentorbearingboreproblems;checkbearing
boreandbushingcondition;determineneededrepairs.
8. Determinetheproperselect-tcomponentssuchaspistons,connectingrods,and
mainbearings.
9. Inspectandreplacemainbearings;checkcaptandbearingclearances;checkand
correctcrankshaftendplay.10. Removeand/orreplacethetimingchainandgears;ensurecorrecttiming.
11. Inspect,measure,orreplacepistons,pins,andretainers.
12. Measurepiston-to-cylinderwallclearance.
13. Checkring-to-groovetandendgaps;installringsonpistons.Assemblepistonsand
connectingrodsandinstallinblock;installrodbearingsandcheckclearances.
14. Inspectand/orreplacecrankshaftvibrationdamper.
15. Inspectywheel/explate(includingringgear)andmountingsurfacesforcracks,
wear,andrunout;determineneededrepairs.
D. Lubrication and Cooling Systems Diagnosis and Repair (3 questions) 1. Diagnoseenginelubricationsystemproblems;performoilpressuretests;determine
neededrepairs.
2. Disassembleandinspectoilpump(includesgears,rotors,housing,andpick-upas-
sembly);measureoilpumpclearance;inspectpressurereliefdevicesandpumpdrive;
determineneededrepairs.
3. Inspect,clean,test,reinstall/replaceoilcooler,by-passvalve,linesandhoses.
4. Changeengineoilandlter(s);addpropertype,viscosity,andratingofoil.
5. Inspectandreinstall/replacepulleys,tensioners,anddrivebelts;adjustdrivebeltsandcheckalignment.
6. Diagnoseenginecoolingsystemtemperatureandpressureproblems;determine
neededrepairs.
7. Inspect,test,andreplacethermostat,coolantby-pass,andthermostathousing,seals,
hoses,andttings.
8. Inspectandtestcoolant;drain,ush,andrellcoolingsystemwithrecommended
coolant;bleedairfromcoolingsystemasrequired.
9. Inspectandreplacewaterpump,housing,andhoses.
10. Inspectandreplaceradiator,pressurecap,expansiontank,andcoolantrecovery
system.
11. Inspect,test,andrepair/replacefan(bothelectricalandmechanical),fanclutch,fan
shroud,airdams,andcoolingfanelectricalcircuits.
12. Verifyproperoperationofenginerelatedgaugesandwarningindicators;determine
neededrepairs.
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T1 liST (cOnTinuEd)
E. Ignition System Diagnosis and Repair (6 questions) 1. Diagnoseignitionsystemrelatedproblemssuchasno-starting,hardstarting,engine
misre,poordriveability,sparkknock,powerloss,reducedfueleconomy,and
emissionsproblems;determinerootcause;determineneededrepairs.
2. Interpretignitionsystemrelateddiagnostictroublecodes(DTCs);determineneeded
repairs.
3. Inspect,test,repair,orreplaceignitionprimarycircuitwiringandcomponents.
4. Inspect,test,repair,orreplaceignitionsystemsecondarycircuitwiringand
components.
5. Inspect,test,andreplaceignitioncoil(s).
6. Inspect,test,andreplaceignitionsystemsensors;adjustasnecessary.
7. Inspect,test,and/orreplaceignitioncontrolmodule(ICM)/powertrain/engine
controlmodule(PCM/ECM);reprogramasneeded.
F. Fuel, Air Induction, and Exhaust Systems Diagnosis and Repair (6 questions) 1. Diagnosefuelsystemrelatedproblemssuchasno-starting,hardstarting,poordrive-
ability,incorrectidlespeed,pooridle,ooding,hesitation,surging,enginemisre,
powerloss,stalling,reducedfueleconomy,andemissionsproblems;determineroot
cause;determineneededrepairs.
2. Interpretfuelorinductionsystemrelateddiagnostictroublecodes(DTCs);analyze
fueltrimandotherscantooldata;determineneededrepairs. 3. Inspectfueltank,llerneck,andfuelcap;inspectandreplacefuellines,ttings,and
hoses;checkfuelforcontaminantsandquality.
4. Inspect,test,andreplacefuelpump(s)and/orfuelpumpassembly;inspect,service,
andreplacefuellters.
5. Inspectandtestelectricfuelpumpcontrolcircuitsandcomponents;determineneeded
repairs.
6. Inspect,test,andrepairorreplacefuelpressureregulationsystemandcomponentsof
fuelinjectionsystems;performfuelpressure/volumetest.
7. Inspect,remove,serviceorreplacethrottlebodyassemblyandcontrols,includingelectronicthrottleactuatorcontrol(TAC)systems;makerelatedadjustments.
8. Inspect,test,clean,andreplacefuelinjectorsandfuelrails.
9. Inspect,service,andrepairorreplaceairltrationsystemcomponents.
10. Inspectairinductionsystem,intakemanifold,andgasketsforair/vacuumleaks.
11. Remove,clean,inspect,test,andrepairorreplacefuelsystemvacuumandelectrical
componentsandconnections.
12. Inspect,service,andreplaceexhaustmanifold,gaskets,exhaustpipes,oxygen
sensors,mufers,catalyticconverters,resonators,tailpipes,andheatshields.
13. Testforexhaustsystemrestrictionorleaks;determineneededrepair.
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T1 liST (cOnTinuEd)
G. Emissions Control Systems Diagnosis And Repair (5 questions) 1. Testanddiagnoseemissionsordriveabilityproblemscausedbypositivecrankcase
ventilation(PCV)system.
2. Inspect,service,andreplacepositivecrankcaseventilation(PCV)lter,valve,tubes,
orice/meteringdevice,andhoses.
3. Testanddiagnosedriveabilityproblemscausedbytheexhaustgasrecirculation
(EGR)system.
4. Interpretexhaustgasrecirculation(EGR)relatedscantooldataanddiagnostictrouble
codes(DTCs);determineneededrepairs.
5. Inspect,test,service,andreplacecomponentsoftheexhaustgasrecirculation(EGR)
system,includingEGRvalve,tubing,passages,vacuum/pressurecontrols,lters,
hoses,electrical/electronicsensors,controls,solenoids,andwiringofEGRsystems.
6. Testanddiagnoseemissionsordriveabilityproblemscausedbythesecondaryair
injectionorcatalyticconvertersystems.
7. Interpretsecondaryairinjectionsystemrelatedscantooldataanddiagnostictrouble
codes(DTCs);determineneededrepairs.
8. Inspect,test,service,andreplacemechanicalcomponentsandelectrical/
electronically-operatedcomponentsandcircuitsofsecondaryairinjectionsystem.
9. Inspectcatalyticconverter.Interpretcatalyticconverterrelateddiagnostictrouble
codes(DTCs);analyzerelatedscantooldatatodeterminerootcauseofDTCs;
determineneededrepairs.
10. Testanddiagnoseemissionsordriveabilityproblemscausedbytheevaporativeemis-
sionscontrolsystem.
11. Interpretevaporativeemissions-relatedscantooldataanddiagnostictroublecodes
(DTCs);determineneededrepairs.
12. Inspect,test,andreplacecanister,lines,hoses,mechanical,andelectricalcomponents
oftheevaporativeemissionscontrolsystem.
H. Computerized Engine Controls Diagnosis And Repair (8 questions)
1. ResearchOBDIIsystemoperationtodeterminetheenablecriteriaforsettingandclearingdiagnostictroublecodes(DTCs)andmalfunctionindicatorlamp(MIL)
operation.Performappropriatedrivecycletodeterminesystemconditionandverify
repaireffectiveness.
2. InterpretOBDIIscantooldatastream,diagnostictroublecodes(DTCs),freeze
framedata,systemmonitors,monitorreadinessindicators,andtripanddrivecycle
information.
3. Readandinterprettechnicalliterature(servicepublicationsandinformationincluding
wiringschematics).
4. Diagnosethecausesofemissionsordriveabilityproblemswithstoredoractivediag-nostictroublecodes(DTCs).
5. Diagnosethecausesofemissionsordriveabilityproblemswithoutdiagnostictrouble
codes(DTCs).
6. Useascantool,digitalmultimeter(DMM),ordigitalstorageoscilloscope(DSO)to
inspectortestcomputerizedenginecontrolsystemsensors,actuators,circuits,and
powertrain/enginecontrolmodule(PCM/ECM);determineneededrepairs.
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7. Measureandinterpretvoltage,voltagedrop,amperage,andresistanceusingdigital
multimeter(DMM)readings.
8. Test,remove,inspect,clean,service,andrepairorreplacepowerandgrounddistribu-tioncircuitsandconnections.
9. Removeandreplacethepowertrain/enginecontrolmodule(PCM/ECM);reprogram
asneeded.
10. Diagnosedriveabilityandemissionsproblemsresultingfromfailuresofinterrelated
systems(forexample:cruisecontrol,securityalarms/theftdeterrent,torquecontrols,
tractioncontrols,torquemanagement,A/C,and/ornon-OEMinstalledaccessories).
11. Cleardiagnostictroublecodes(DTCs),runallOBDIImonitors,andverifythe
repair.
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PAGE14 ASE MEdiuM/HEAvyTruckSTudyGuidE
SAMplE QuESTiOnSGASOlinE EnGinES (TEST T1)
QuESTiOnS:
1. TechnicianAsaysthatthecompressiontestreadingsshownabovecouldbe
causedbyablowncylinderheadgasket.
TechnicianBsaysthatthecompressiontestreadingsshownabovecouldbe
causedbywrongvalvetiming.
Whoisright?
*(A)Aonly (C)BothAandB
(B)Bonly (D)NeitherAnorB
2. TechnicianAsaysthatpartXshownaboveisusedtoimprovevalvespring
rotation.
TechnicianBsaysthatpartXshownaboveisusedtocorrectinstalledspring
height.
Whoisright?
(A)Aonly (C)BothAandB
*(B)Bonly (D)NeitherAnorB
COMPRESSIONSPECS
140 PSI
130
140
15
15
140
140
130
135
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PAGE16 ASE MEdiuM/HEAvyTruckSTudyGuidE
8. Whichofthesecancauseacatalyticconvertertooverheat?
(A)Abrokenairpumpdrivebelt
(B)Apluggedcanisterpurgevacuumhose
(C)Afailedexhaustgasrecirculation(EGR)valve
*(D)Adisconnectedsparkplugwire
Question 9 is not like the ones above.
IthasthewordEXCEPT.LookforthechoicethatcouldNOTcausethe
describedsituation.Readtheentirequestioncarefullybeforechoosingyour
answer.9. Enginedetonation(knock)couldbecausedbyanyoftheseEXCEPT:
(A)aleanairfuelmixture.
*(B)retardedignitiontiming.
(C)excesscarboninthecombustionchambers.
(D)astuck-closedexhaustgasrecirculation(EGR)valve.
T1 SAMplE QuESTiOnS (cOnTinuEd)
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Content Questions PercentageArea in Test of Test
A. General Engine Diagnosis 11 20%
B. Cylinder Head and Valve Train 4 7%
Diagnosis and Repair
C. Engine Block Diagnosis and Repair 5 9%
D. Lubrication and Cooling Systems
Diagnosis and Repair 6 11%
E. Air Induction and Exhaust Systems
Diagnosis and Repair 6 11%
F. Fuel System Diagnosis and Repair 16 29%
G. Starting and Charging
System Diagnosis and Repair 4 7%
H. Engine Brakes 3 5%
Total 55 100%
TEST SpEcificATiOnSAnd TASkliSTdiESEl EnGinES (TEST T2)
A. General Engine Diagnosis (11 questions) 1. Verifythecomplaint,androad/dynotestvehicle;reviewdriver/customerinterview
andpastmaintenancedocuments(ifavailable);determinefurtherdiagnosis.
2. Identifyenginemodelandserialnumbertoresearchapplicablevehicleandservice
information,serviceprecautions,andtechnicalservicebulletins;determineneeded
actions.
3. Inspectengineassemblyandcompartmentforfuel,oil,coolant,exhaust,orother
leaks;determineneededrepairs.
4. Inspectenginecompartmentwiringharness,connectors,seals,andlocks;checkfor
properroutingandcondition;determineneededrepairs.
5. Isolateanddiagnoseenginenoises;determineneededrepairs.
6. Checkengineexhaustforodor,smokecolor,anddensity;determineneededrepairs.
7. Performfuelsupplyandreturnsystemtests;checkfuelforcontamination,quality,
andconsumption;determineneededrepairs.
8. Performairintakesystemrestrictionandleakagetests;determineneededrepairs.
9. Performintakemanifoldpressuretests;determineneededrepairs.
10. Performexhaustbackpressureandtemperaturetests;determineneededrepairs.
11. Performcrankcasepressuretest;determineneededrepairs.
12. Diagnosenocranking,cranksbutfailstostart,hardstarting,andstartsbutdoesnot
continuetorunproblems;determineneededrepairs.
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13. Diagnosesurging,roughoperation,misring,lowpower,slowdeceleration,slow
acceleration,andshutdownproblems;determineneededrepairs.
14. Isolateanddiagnoseenginerelatedvibrationproblems;determineneededrepairs.15. Checkcoolingsystemforfreezepoint,level,contamination,coolanttype,
temperature,pressure,circulation,conditionerconcentration,ltration,andfan
operation;determineneededrepairs.
16. Checklubricationsystemforcontamination,oillevel,temperature,pressure,
ltration,andoilconsumption;interpretoilanalysisinformation;determineneeded
repairs.
17. Checkandrecordelectronicdiagnosticcodesandtrip/operationaldata;monitor
electronicdata;verifycustomerprogrammableparameters;clearcodes;determine
furtherdiagnosis.18. Performvisualinspectionforphysicaldamageandmissing,modied,ortampered
components;determineneededrepairs.
B. Cylinder Head and Valve Train Diagnosis and Repair (4 questions) 1. Remove,inspect,disassemble,andcleancylinderheadassembly(s).
2. Inspectthreadedholes,studs,andboltsforserviceability;service/replaceasneeded.
3. Measurecylinderheadthickness,andcheckmatingsurfacesforwarpageandsurface
nish;inspectforcracks/damage;checkconditionofpassages;inspectcoreand
galleryplugs;determineserviceabilityandneededrepairs. 4. Inspectvalves,guides,seats,springs,retainers,rotators,locksandseals;determine
serviceabilityandneededrepairs.
5. Inspectand/orreplaceinjectorsleevesandseals;pressuretesttoverifyrepair
(ifapplicable);measureinjectortipornozzleprotrusionwherespeciedby
manufacturer.
6. Inspect,and/orreplacevalvebridges(crossheads)andguides;adjustbridges
(crossheads)ifapplicable.
7. Cleancomponents;reassemble,check,andinstallcylinderheadassembly.
8. Inspectpushrods,rockerarms,rockerarmshafts,electronicwiringharness,andbracketsforwear,bending,cracks,looseness,andblockedoilpassages;repair/
replaceasneeded.
9. Inspect,install,andadjustcamfollowersandretainers.
10. Adjustvalveclearanceandinjectorsettings.
11. Inspect,measure,andreplace/reinstalloverheadcamshaftandbearings;measure
andadjustendplayandbacklash.
C. Engine Block Diagnosis and Repair (5 questions) 1. Remove,inspect,service,andinstallpans,covers,ventilationsystems,gaskets,seals,
andwearrings. 2. Disassemble,cleanandinspectengineblockforcracks;checkmatingsurfacesand
relatedcomponentsfordamageorwarpageandsurfacenish;checkdeckheight;
checkconditionofpassages,core,andgalleryplugs;inspectthreadedholes,studs,
dowelpinsandboltsforserviceability;service/replaceasneeded.
3. Inspectcylindersleevecounterboreandlowerbore;checkboredistortion;determine
neededservice.
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4. Inspectandmeasurecylinderwallsorlinersforwearanddamage;determineneeded
service.
5. Replace/reinstallcylinderlinersandseals;checkandadjustlinerheight/protrusion. 6. Inspectin-blockcamshaftbearingsforwearanddamage;replaceasneeded.
7. Inspect,measure,andreplace/reinstallin-blockcamshaft;measure/adjustendplay;
inspect,replace/reinstall,andadjustcamfollowers(ifapplicable).
8. Cleanandinspectcrankshaftandjournalsforsurfacecracksanddamage;check
conditionofoilpassages;checkpassageplugs;measurejournaldiameters;check
mountingsurfaces;determineneededservice.
9. Inspectandreplacemainbearings;checkcaptandbearingclearances;checkand
correctcrankshaftendplay.
10. Inspect,reinstall,andtimethedrivegeartrain.(Includescheckingenginepositionandspeedindicatorcomponents,gearwear,andbacklashofcrankshaft,camshaft,
auxiliary,drive,andidlergears;serviceshafts,bushings,andbearings.)
11. Clean,inspect,measure,orreplacepistons,pins,andretainers.
12. Measurepiston-to-cylinderwallclearance.
13. Checkring-to-groovetandendgaps;installringsonpistons.
14. Identifypiston,connectingrodbearing,andmainbearingwearpatternsthatindicate
connectingrodandcrankshaftalignmentorbearingboreproblems;checkbearing
boreandbushingcondition;determineneededrepairs.
15. Assemblepistonsandconnectingrodsandinstallinblock;checkpistonheight/protrusion;replacerodbearingsandcheckclearances;checkcondition,position,
andclearanceofpistoncoolingjets(nozzles).
16. Inspectandmeasurecrankshaftvibrationdamper;replaceasneeded.
17. Inspect,install,andalignywheelhousing.
18. Inspectywheel/explate(includingringgear)andmountingsurfacesforcracks,
wear,andrunout;determineneededrepairs.
D. Lubrication and Cooling Systems Diagnosis and Repair (6 questions)
1. Verifyengineoilpressureandcheckoperationofpressuresensor/switchandpressuregauge;verifyengineoiltemperatureandcheckoperationoftemperaturesensor.
2. Inspect,measure,andrepair/replaceoilpump,housing,drives,pipes,andscreens;
adjustdrivegearclearanceifapplicable.
3. Inspectandrepair/replaceoilpressureregulatorvalve(s),andby-passvalve(s).
4. Inspect,clean,test,andreinstall/replaceoilcooler,by-passvalve,oilthermostat;lines
andhoses.
5. Inspectturbochargerlubricationandcoolingsystems;repair/replaceasneeded.
6. Changeengineoilandlters;addpropertypeofoil.
7. Inspectandreinstall/replacepulleys,tensionersanddrivebelts;adjustdrivebeltsandcheckalignment.
8. Verifycoolanttemperatureandcheckoperationoftemperatureandlevelsensors/
switch,andtemperaturegauge.
9. Inspectandreplacethermostat(s),by-passes,housing(s),andseals.
10. Flushandrellcoolingsystem;bleedairfromsystem;recovercoolant.
11. Inspectandrepair/replacecoolantconditioner/lter,valves,lines,andttings.
12. Inspectandrepair/replacewaterpump,housing,hoses,andidlerpulleyordrivegear.
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13. Inspectradiator,pressurecap,andtank(s);determineneededservice.
14. Inspectandrepair/replacefanhub,fan,fanclutch,fancontrols,fanthermostat,and
fanshroud.15. Pressuretestcoolingsystemandradiatorcap;determineneededrepairs.
E. Air Induction and Exhaust Systems Diagnosis and Repair (6 questions) 1. Inspectandservice/replaceairinductionpiping,aircleaner,andelement;check
forairrestriction.
2. Inspect,test,andreplaceturbocharger(s)(includingvariableratio/geometryVGT),
pneumatic,hydraulic,andelectroniccontrolsandactuators;inspect,test,andreplace
wastegateandwastegatecontrols.
3. Inspectandrepair/replaceintakemanifold,gaskets,temperatureandpressuresensors,andconnections.
4. Inspect,test,clean,replacechargeaircoolerandpipingsystem.
5. Inspectandrepair/replaceexhaustmanifold,gaskets,piping,mufers,exhaustafter
treatmentdevices,(includingthree-wayandoxidationcatalystanddieselparticulate
ltersDPF)andmountinghardware.
6. Inspect,test,andrepair/replacepreheater/inletairheater,orglowplugsystemand
controls.
7. Inspect,test,andreplaceexhaustaftertreatmentregenerationsystemandcontrols.
8. Inspect,test,service,andreplaceexhaustgasrecirculation(EGR)systemcompo-
nents;includingEGRvalve,cooler,piping,lter,sensors,controls,andwiring.
F. Fuel System Diagnosis and Repair (16 questions) 1. Inspect,test,andrepair/replacefuelsystemtanks,vents,capsmounts,valves,
single/dualsupplyandreturnlines,andttings.
2. Inspect,clean,test,andrepair/replacefueltransfer(supply)pump,pumpdrives,
strainers,fuel/waterseparators/indicators,lters,heaters,coolers,ECMcooling
plates,andmountinghardware.(Protectfuelsystemcomponentsfrom
contamination),
3. Checkfuelsystemforair;determineneededrepairs;primeandbleedfuelsystem;check,repair/replaceprimerpump.
4. Inspect,test,andrepair/replacelow-pressureregulatorsystems(checkvalves,
pressureregulatorvalvesandrestrictivettings).
5. Inspectandreinstall/replacehigh-pressureinjectionlines,ttings,seals,and
mountinghardware.(Protecthigh-pressureinjectioncomponentsfrom
contamination).
6. Inspect,adjust,andrepair/replaceelectronicthrottleandPTOcontroldevices,
circuits,andsensors.
7. Performon-engineinspections,tests,andadjustmentsonhydraulicelectronicunitinjectors(HEUI)andelectroniccontrols(railpressurecontrol).
8. Performon-engineinspections,testsandadjustmentsonelectronicunitinjectors
(EUI)andelectroniccontrols.
9. Performon-engineinspectionsandtests,onhigh-pressurecommonrailfuelsystems
andelectroniccontrols.
10. Inspect,test,andreplaceengineprotectionandautomaticstop/restartsystem
components.
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11. Inspectandreplaceelectricalconnectorterminals,pins,harnesses,seals,andlocks.
12. Connectdiagnostictooltovehicle/engine;accessandverifyprogrammable
parameters;changeifapplicable.13. Useadiagnostictool(hand-heldorPCbased)toinspectandtestelectronicengine
controlsystem,sensors,actuators,electroniccontrolmodules(ECMs),andcircuits;
determinefurtherdiagnosis.
14. Measureandinterpretvoltage,voltagedrop,amperage,andresistancereadingsusing
adigitalmultimeter(DMM)orappropriatetestequipment.
G. Starting and Charging System Diagnosis and Repair (4 questions) 1. Performbatterystate-of-chargeandloadorcapacitancetests;determineneeded
service. 2. Chargebatteryusingsloworfastchargemethod,asappropriate.
3. Startavehicleusingjumpercablesoraboosterbattery.
4. Inspect,clean,andrepair/replacebatteries,batterycables,andterminalconnections.
5. Inspect,test,andreinstall/replacestarterrelays,safetyswitch(s),andsolenoids.
6. Performalternatorvoltageandamperageoutputtests;determineneededrepairs.
7. Performstarterandchargingcircuitvoltagedroptests;determineneededrepairs.
H. Engine Brakes (3 questions) 1. Inspect,test,andadjustenginecompressionandexhaustbrakes.
2. Inspect,test,adjust,andrepair/replaceenginecompressionandexhaustbrakecontrolcircuits,switches,andsolenoids.
3. Inspectandrepair/replaceenginecompressionandexhaustbrakehousing(s),valves,
seals,springs,lines,andttings.
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SAMplE QuESTiOnSdiESEl EnGinES (TEST T2)
QuESTiOnS:
1. Whenadieselengineisoperatedunderaload,coolantcontinuallycomesout
oftheradiatoroverowandtherearebubblesintheradiator.Whichoftheseis
themostlikelycause?
(A)Toomuchcoolantinthecoolingsystem (B)Acloggedradiator
(C)Astuck-openthermostat
*(D)Compressionleakageintothecoolingsystem
2. Adieselenginehasexcessiveblacksmokewhenstartedinthemorning.
Whichofthesecouldbethecause?
*(A)Abadfuelinjectionnozzle
(B)Arestrictedfuellter (C)Ablockedfueltankvent
(D)Aleakingfuelreturnline
3. Whichofthesecancauseano-startconditiononaHEUIengine?
(A)Highfuelpressure
*(B)Lowinjectioncontrolpressure
(C)Highboostpressure
(D)Lowboostpressure
4. Adieselengineishardtostart,butrunsgoodafterithasbeenprimedandrun
forafewminutes.Themostlikelycauseisa:
(A)leakinginjectorline.
(B)leakingfuelreturnline.
(C)pluggedfueltankvent.
*(D)badtransferpumpcheckvalve.
5. Adieselenginewithwetlinershasbeenrunningtoohot,andthereiscoolantin
thecrankcase.Themostlikelycauseis:
(A)acrackedblock
(B)crackedliners
*(C)leakinglinerseals.
(D)aleakinginjectorseal.
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6. Dieselenginecylinderlinerprotrusion(height)canbeadjustedbyselecting
thecorrectsize:
(A)cylinderliner.
(B)headgasket.
*(C)linershim.
(D)rering.
7. AdieselenginewithEUIhasamisreandthecheckenginelightisON.Fault
codeS4FMI5cylinder4currentbelownormalisactive.Thiscouldbe
causedbya:
(A)failedenginepositionsensor.
(B)sticking#4injectionplunger.
*(C)broken#4injectionwireterminal.
(D)stickingthrottlepositionsensor.
8. Thecauseofaloggedfaultcodeinanelectronicdieselenginehasjustbeen
repaired.
TechnicianAsaysthatthecodesshouldbeclearedbeforereleasingthevehicle.
TechnicianBsaysthatthecustomerspasswordshouldberesetbefore
releasingthevehicle.
Whoisright?
*(A)Aonly (C)BothAandB
(B)Bonly (D)NeitherAnorB
9. Adieselenginehaslowpowerandlowturbochargerboostpressureisfound.
TechnicianAsaysthataleakingexhaustmanifoldcouldbethecause.
TechnicianBsaysthatapluggedturbochargeroilreturnlinecouldbethe
cause.
Whoisright?
*(A)Aonly (C)BothAandB
(B)Bonly (D)NeitherAnorB
T2 SAMplE QuESTiOnS (cOnTinuEd)
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Content Questions PercentageArea in Test of Test
A. Clutch Diagnosis and Repair 11 28%
B. Transmission Diagnosis and Repair 13 33%
C. Driveshaft and Universal Joint
Diagnosis and Repair 7 18%
D. Drive Axle Diagnosis and Repair 9 23%
Total 40 100%
TEST SpEcificATiOnSAnd liSTdrivE TrAin (TEST T3)
A. Clutch Diagnosis and Repair (11 questions)
1. Diagnoseclutchnoise,binding,slippage,pulsation,vibration,grabbing,andchatterproblems;determinecauseoffailureandneededrepairs.
2. Inspect,adjust,repair,orreplaceclutchlinkage,cables,levers,brackets,bushings,
pivots,springs,andclutchsafetyswitch(includespushandpulltypeassemblies);
checkpedalheightandtravel.
3. Inspect,adjust,repair,orreplacehydraulicclutchslaveandmastercylinders,lines,
andhoses;bleedsystem.
4. Inspect,orremoveandinstallrelease(throwout)bearing,sleeve,bushings,springs,
housing,levers,releasefork,forkpads,forkrollers,shafts,andseals;measureand
adjustrelease(throwout)bearingposition. 5. Inspect,orremoveandinstallsingle-discclutchpressureplateandclutchdisc;
adjustfreeplayandreleasebearingposition.
6. Inspect,orremoveandinstalltwo-plateclutchpressureplate,clutchdisc,
intermediateplate;determineproperclutchtorquerating;adjustfreeplayand
releasebearingposition.
7. Inspectandreplaceclutchbrakeassembly;inspectandreplaceinputshaftandbear-
ingretainer.
8. Inspect,orremoveandinstallself-adjusting/continuous-adjustingclutchassembly;
performinitialand/orresetadjustmentprocedure. 9. Inspectandreplacepilotbearing.
10. Inspectywheelmountingareaoncrankshaft,rearmainoilseal,andmeasure
crankshaftendplay;determineneededrepairs.
11. Inspectywheel,starterringgear,andmeasureywheelfaceandpilotborerunout;
determineneededrepairs.
12. Inspectywheelhousing(s)totransmissionhousing/enginematingsurface(s)and
measureywheelhousingfaceandborerunout;determineneededrepairs.
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T3 liST (cOnTinuEd)
B. Transmission Diagnosis and Repair (13 questions) 1. Determinethecauseoftransmissioncomponentfailure,bothbeforeandduring
disassemblyprocedures.
2. Diagnosetransmissionvibration/noise,shifting,lockup,slipping/jumping
out-of-gear,andoverheatingproblems;determineneededrepairs.
3. Inspect,adjust,repair,orreplacetransmissionremoteshiftlinkages,cables,brackets,
bushings,pivots,andlevers.
4. Inspect,testoperation,adjust,repair,orreplaceairshiftcontrols,lines,hoses,valves,
regulators,lters,andcylinderassemblies.
5. Inspect,testoperation,adjust,repair,orreplaceelectronicshiftcontrols,shift,range
andsplittersolenoids,shiftmotors,indicators,speedandrangesensors,electronic/
transmissioncontrolunits(ECU/TCU),neutral/ingearandreverseswitches,and
wiringharnesses.
6. Inspect,testoperation,repair,orreplaceelectronicshiftselectors(in-cabcontrols),
airandelectricalswitches,displaysandindicators,wiringharnesses,andairlines.
7. Useappropriatediagnostictoolsandsoftware,procedures,andserviceinforma-
tion/owchartstodiagnoseautomatedmechanicaltransmissionproblems;checkand
recorddiagnosticcodes,clearcodes,interpretdigitalmultimeter(DMM)readings,
determineneededrepairs.
8. Diagnoseautomatedmechanicaltransmissionproblemscausedbydatalink/bus
interfaceswithrelatedelectroniccontrolsystems.
9. Removeandreplacetransmission;inspectandreplacetransmissionmounts,
insulators,andmountingbolts.
10. Inspectforleakageandreplacetransmissioncoverplates,gaskets,sealants,seals,
vents,andcapbolts;inspectsealsurfaces.
11. Checktransmissionuidlevel,andcondition;determineneededservice,andadd
propertypeoflubricant.
12. Inspect,adjust,andreplacetransmissionshiftlever,cover,rails,forks,levers,
bushings,sleeves,detents,interlocks,springs,andlockbolts.
13. Inspectandreplaceinputshaft,gear,spacers,bearings,retainers,andslingers.
14. Inspectmainshaft,gears,slidingclutches,washers,spacers,bushings,bearings,aux-
iliarydrivegear/assembly,retainers/snaprings,andkeys;determineneededrepairs.
15. Inspectcountershafts,gears,bearings,timingretainer/snaprings,andkeys;check
bearingpreload/endplay;verifymultiplecountershaftgeartiming;determineneeded
repairs.
16. Inspectoutputshaft,gears,washers,spacers,bearings,retainers/snaprings,andkeys;
determineneededrepairs.
17. Inspectreverseidlershaft(s),gear(s),bushings,bearings,thrustwashers,and
retainers/snaprings;checkreverseidlergearendplay;determineneededrepairs.
18. Inspectsynchronizerhub,sleeve,keys/inserts,springs,blockingrings,synchronizer
plates,blockerpins,andslidingclutches;determineneededrepairs.
19. Inspecttransmissioncasesincludingmatingsurfaces,bores,bushings,pins,studs,
vents,andmagneticplugs;determineneededrepairs.
20. Inspect,service,orreplacetransmissionlubricationsystemcomponents,pumps,
troughs,collectors,slingers,coolers,lters,andlinesandhoses.
21. Inspect,test,replace,andadjustelectronicspeedometerdrivecomponents.
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22. Inspect,adjust,service,repair,orreplacepowertake-offassembliesandcontrols.
23. Inspectandtestoperationofbackuplight,neutralstart,andwarningdevicecircuits
andswitches;determineneededrepairs.24. Inspectandtesttransmissiontemperaturesendingunit/sensorandgauge;determine
neededrepairs.
25. Inspect,adjust,repair,orreplacetransfercaseassembliesandcontrols.
C. Driveshat and Universal Joint Diagnosis and Repair (7 questions) 1. Diagnosedriveshaftanduniversaljointnoise,vibration,andrunoutproblems;deter-
minecauseoffailureandneededrepairs.
2. Inspect,service,orreplacedriveshaft,slipjoints/yokes,yokes,driveanges,
universaljoints,driveshaftbootsandseals,andretaininghardware;properly
phase/timeyokes.
3. Inspectandreplacedriveshaftcentersupportbearingsandmounts.
4. Measureandadjustvehiclerideheight;measureandadjustdrivelineslopesand
angles(vehicleloadedandunloaded),includingPTOdriveshafts.
5. Useappropriatedrivelineanalysissoftwaretodiagnosedrivelineproblems.
6. Diagnosedrivelineretarderproblems;determineneededrepairs.
D. Drive Axle Diagnosis and Repair (9 questions) 1. Diagnosedriveaxleunitnoiseandoverheatingproblems;determineneededrepairs.
2. Checkandrepairuidleaks;inspectandreplacedriveaxlehousingcoverplates,
gaskets,sealants,vents,magneticplugs,andseals.
3. Checkdriveaxleuidlevel,andcondition;determineneededservice,addproper
typeoflubricantusingcorrectllprocedure.
4. Removeandreplacedifferentialcarrierassembly.
5. Inspectandreplacedifferentialcaseassemblyincludingspider/piniongears,cross
shaft,sidegears,thrustwashers,casehalves,andbearings.
6. Inspectandreplacecomponentsoflockingdifferentialcaseassembly. 7. Measureringgearbacklashandrunout;determineneededrepairs.
8. Inspectringanddrivepiniongears,spacers,shims,sleeves,bearingcages,and
bearings;determineneededrepairs.
9. Checkringandpiniongeartoothcontactpattern;interpretpatternand
determineneededrepairs.
10. Inspectandreplacepowerdivider(inter-axledifferential)assembly.
11. Inspect,adjust,repair,orreplaceairoperatedpowerdivider(inter-axledifferential)
lockoutassemblyincludingdiaphragms,seals,springs,yokes,pins,lines,hoses,
ttings,andcontrols.12. Inspectandmeasuredriveaxlehousingmatingsurfacesandalignment;determine
neededrepairs.
13. Inspect,service,orreplacedriveaxlelubricationsystemcomponents,pump,troughs,
collectors,slingers,tubes,andlters.
14. Inspectandreplacedriveaxleshafts.
15. Removeandreplacewheelassembly;checkdriveaxlewheel/hubsealandaxleange
gasketforleaks;determineneededrepairs.
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16. Diagnosedriveaxlewheelbearingnoisesanddamage;determineneededrepairs.
17. Clean,inspect,lubricate,andreplacewheelbearingsandraces/cups;replaceseals
andwearrings;adjustdriveaxlewheelbearings(includingoneandtwonuttypes)
tomanufacturersspecications.
18. Inspectandtestdriveaxletemperaturesendingunit/sensorandgauge;determine
neededrepairs.
19. Check,adjust,and/orreplacewheelspeedsensor(s).
20. Inspectorreplaceextendedservice(sealed,close-tolerance,andunitized)
bearingassemblies;performinitialinstallationprocedurestomanufacturers
specications.
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SAMplE QuESTiOnSdrivE TrAin (TEST T3)
QuESTiOnS:
1. Whatoperationisbeingperformed
inthesetupshownabove?
(A)Adjustingtoothcontact *(B)Checkingringgearrunout
(C)Checkingringgearbacklash
(D)Settingdifferentialbearingpreload
2. Atruckdoesnotmoveinanygear.
TechnicianAsaysthatabrokenshifterforkcouldbethecause.
TechnicianBsaysthatabrokenoutputshaftcouldbethecause.
Whoisright? (A)Aonly (C)BothAandB
*(B)Bonly (D)NeitherAnorB
3. Theshiftleverona13-speedtransmissionishardtomove.
Whichoftheseisthemostlikelycause?
(A)Bentshiftrails
*(B)Galledslidingclutchgears
(C)Worndetentsprings (D)Toomuchmainshaftgearendplay
4. Theairpressureregulatorforatransmissionisbeingchecked.
TechnicianAsaysthatthetractorairpressureshouldbeatmaximumsystem
pressure.
TechnicianBsaysthattheregulatorairltershouldbecleanedandthesystem
recheckediftheairpressurereadingisbelownormal.
Whoisright? (A)Aonly *(C)BothAandB
(B)Bonly (D)NeitherAnorB
ROTATE
RING GEAR
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5. Thedriverofatrucksaysthatagrindingnoisecanbeheardwhentheclutch
pedalisdepressed.Whichoftheseisthemostlikelycause?
(A)Toolittleclutchpedalfreeplay
*(B)Awornclutchrelease(throwout)bearing
(C)Alowtransmissionlubricantlevel
(D)Awornclutchpressureplate
6. Atwo-platepull-typeclutchengagesOK,butthetransmissiongrindswhen
goingintorstgearfromneutral.
TechnicianAsaysthatawornclutchbrakecouldbethecause.
TechnicianBsaysthattoolittlefreeplaycouldbethecause.
Whoisright?
*(A)Aonly (C)BothAandB
(B)Bonly (D)NeitherAnorB
7. Whichofthesecouldbethecauseofadriveshaftvibrationonatruck
thathasjusthadaU-jointreplaced?
*(A)Thedriveshaftisout-of-phase
(B)TheU-jointwasinstalledbackwards
(C)TheU-jointwasnotlubricated
(D)Thereisdirtonthedriveshaft
8. Atruckwithasinglerearaxlehastoomuchrearaxlenoiseonlywhenthe
truckispulling.Whichoftheseisthemostlikelycause?
(A)Wornaxleshaftbearings
(B)Wornwheelbearings
(C)Worndifferentialpinion(spider)gears
*(D)Wornringandpiniongears
T3 SAMplE QuESTiOnS (cOnTinuEd)
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PAGE30 ASE MEdiuM/HEAvyTruckSTudyGuidE
Content Questions PercentageArea in Test of Test
A. Air Brakes Diagnosis and Repair 28 56%
1. Air Supply and Service Systems (14)
2. Mechanical/Foundation (10)3. Parking Brakes (4)
B. Hydraulic Brakes Diagnosis and Repair 14 28%
1. Hydraulic System (6)
2. Mechanical System (5)
3. Power Assist Units and Miscellaneous (3)
C. Air and Hydraulic Antilock Brake Systems
(ABS), Automatic traction Control (ATC),
and Electronic Stability Control Systems 5 10%D. Wheel Bearings Diagnosis and Repair 3 6%
Total 50 100%
TEST SpEcificATiOnSAnd liSTBrAkES (TEST T4)
A. Air Brakes Diagnosis and Repair (28 questions)
1. Air Supply and Service Systems (14 questions)
1. Diagnosepoorstopping,prematurewear,brakenoise,airleaks,pulling,grabbing,ordraggingproblemscausedbysupplyandservicesystemcomponents;determine
neededrepairs.
2. Checkairsystembuild-uptime;determineneededrepairs.
3. Drainairreservoirtanks;checkforoil,water,andforeignmaterial;determineneeded
repairs.
4. Inspect,adjust,align,andreplacecompressordrivebeltsandpulleys.
5. Inspectandreplacecompressordrivegearandcoupling.
6. Inspect,repair,orreplaceaircompressor,oilsupply,waterlines,hoses,ttingsand
mountingbrackets. 7. Inspect,test,adjust,andreplacesystempressurecontrols(governor/reliefvalve),
unloaderassembly,lines,hoses,andttings.
8. Inspect,repair,orreplaceairsystemlines,hoses,ttings,andcouplings;checkfor
properrouting.
9. Inspect,test,clean,andreplaceairtankrelief(pop-off)valves,one-way(single)
checkvalves,draincocks,automaticdrain(spitter)valves,heaters,wiring,and
connectors.
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10. Inspect,test,clean,repair,orreplaceairdriersystems,lters,valves,heaters,wiring,
andconnectors.
11. Inspect,test,repair,orreplacebrakeapplication(foot)valve,ttings,andmounts;checkpedaloperation.
12. Inspect,test,andreplacetwo-way(double)checkvalvesandanti-compounding
valves.
13. Inspect,test,repair,orreplacestopandparkingbrakelightcircuitswitches,wiring,
andconnectors.
14. Inspect,test,repair,orreplacehandbrake(trailer)controlvalve,lines,hoses,
ttings,andmountings.
15. Inspect,test,andreplacebrakerelayvalves.
16. Inspect,test,andreplacequickreleasevalves.17. Inspect,test,andreplacetractorprotectionvalve.
18. Inspect,test,andreplaceinversion/emergency(spring)brakecontrolvalve(s).
19. Inspect,test,andreplacelowpressurewarningdevices.
20. Inspect,test,repairorreplaceairpressuregauges,in-cablines,hoses,ttings,and
pressuresensors(transducers).
21. Determineifairbrakesystemproblemiscausedbytractorortrailersupplyorservice
systemcomponents.
22. Verifythecomplaintandroadtestvehicle;reviewdriver/customerinterviewand
pastmaintenancedocuments(ifavailable);determinefurtherdiagnosis.
2. Mechanical/Foundation (10 questions) 1. Diagnosepoorstopping,prematurewear,brakenoise,pulling,grabbing,ordragging
problemscausedbyfoundationbrakecomponents;determineneededrepairs.
2. Inspect,test,repair,orreplaceservicebrakechambers,diaphragm,clamp,return
spring,pushrod,clevis,andmountingbrackets.
3. Inspect,service,orreplacemanualandautomaticslackadjusters.
4. InspectandreplaceS-cambrakerollers,bushings,camshafts,seals,spacers,retain-
ers,brakespiders,shields,anchorpins,andsprings. 5. Inspect,clean,rebuildorreplace,andadjustairdiscbrakecaliperassemblies.
6. Inspectandreplacebrakeshoes,orpads;determineneededrepair.
7. Inspectandreplacebrakedrumsorrotorsasneeded.
3. Parking Brakes (4 questions) 1. Inspectandtestparking(spring)brakechamberoperation;replaceparking(spring)
brakechamber;disposeofremovedchambersinaccordancewithlocalregulations.
2. Inspect,test,andreplaceparking(spring)brakecheckvalves,lines,hoses,and
ttings.
3. Inspect,test,andreplaceparking(spring)brakeapplicationandreleasevalve. 4. Manuallyrelease(cage)andreset(uncage)parking(spring)brakes.
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B. Hydraulic Brakes Diagnosis and Repair (14 questions)
1. Hydraulic System (6 questions) 1. Diagnosepoorstopping,brakenoise,prematurewear,pulling,grabbing,dragging,orpedalfeelproblemscausedbyhydraulicsystemcomponents;determine
neededrepairs.
2. Pressuretesthydraulicsystemandinspectforleaks.
3. Checkandadjustbrakepedalpushrodlength.
4. Inspect,test,andreplacemastercylinder.
5. Inspectandreplacebrakelines,exiblehoses,andttings.
6. Inspect,test,andreplacemetering(hold-off),loadsensing/proportioning,
proportioning,andcombinationvalves. 7. Inspect,test,repair,orreplacebrakepressuredifferentialvalveandwarninglight
circuitswitch,bulbs,wiring,andconnectors.
8. Inspectandreplacewheelcylinders.
9. Inspect,clean,andreplacediscbrakecaliperassemblies.
10. Inspect/testbrakeuid;bleedand/orushsystem;determineproperuidtypefor
application.
11. Inspect,test,repair,orreplacehydraulically-controlledparkingbrakecomponents,
systems,andwarningdevices.
2. Mechanical System (5 questions) 1. Diagnosepoorstopping,brakenoise,prematurewear,pulling,grabbing,dragging,
orpedalfeelproblemscausedbydiscanddrumbrakemechanicalcomponents;
determineneededrepairs.
2. Inspect,resurface,orreplacebrakedrumsorrotors.
3. Inspect,adjust,andreplacedrumbrakeshoes,mountinghardware,adjuster
mechanisms,andbackingplates.
4. Inspect,service,andreplacediscbrakepads,hardware,andmounts.
5. Inspect,adjust,repair,orreplacedrivelineparkingbrakedrums,rotors,shoes,
mountinghardware,andadjusters;burnish/seatreplacementshoesasrequired. 6. Inspect,adjust,repair,orreplacedrivelineparkingbrakeapplicationsystempedal,
cables,linkage,levers,pivots,andsprings.
3. Power Assist Units and Miscellaneous (3 questions) 1. Diagnosepoorstoppingcomplaintscausedbybrakeassist(booster)system
problems;determineneededrepairs.
2. Inspect,test,repair,orreplacepowerbrakeassist(booster),hoses,controlvalves
andlters;determineproperuidtypeforapplication.
3. Test,adjust,andreplacebrakestoplightswitch,bulbs,wiring,andconnectors.
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C. Air and Hydraulic Antilock Brake Systems (ABS), Automatic Traction Control
(ATC), and Electronic Stability Control Systems (5 questions) 1. Observeantilockbrakesystem(ABS)warninglightoperation;determineiffurther
diagnosisisneeded;(includesdashmountedtrailerABSwarninglight).
2. Diagnoseantilockbrakesystem(ABS)electroniccontrol(s)andcomponentsusing
self-diagnosisand/orspeciedtestequipment(scantool,PCbasedsoftware);
determineneededrepairs.
3. Diagnosewheellock-upcausedbyfailureoftheantilockbrakesystem(ABS);
determineneededrepairs.
4. Inspect,test,andreplaceantilockbrakesystem(ABS)air,hydraulic,electrical,
andmechanicalcomponents.
5. Diagnoseautomatictractioncontrol(ATC)electroniccontrol(s)andcomponents
usingself-diagnosisand/orspeciedtestequipment(scantool,PCbasedsoftware);
determineneededrepairs.
6. Diagnoseelectronicstabilitycontrolsystemsandcomponentsusingself-diagnosis
and/orspeciedtestequipment(scantool,PCbasedsoftware);determineneeded
repairs.
D. Wheel Bearings Diagnosis and Repair (3 questions) l. Removeandreplaceaxlewheelassembly.
2. Clean,inspect,lubricate,andreplacewheelbearingsandraces/cups;replacesealsandsealwearrings.
3. Adjuststeeringanddriveaxlewheelbearings(includingoneandtwonuttypes)
tomanufacturersspecications.
4. Inspectorreplaceextendedservice(sealed,close-tolerance,andunitized)
bearingassemblies;performinitialinstallationprocedurestomanufacturers
specications.
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SAMplE QuESTiOnSBrAkES (TEST T4)
QuESTiOnS:
1. Theparkingbrakesfailtoapplyonatruckwithairbrakes.
TechnicianAsaysthatlowairpressureinthespringbrakechambercouldbe
thecause.TechnicianBsaysthatarupturedspringbrakediaphragmcouldbethecause.
Whoisright?
(A)Aonly (C)BothAandB
(B)Bonly *(D)NeitherAnorB
2. Atruckhasanunevenbrakingproblem.Whichofthesecouldbethecause?
(A)Abindingtreadle(foot)valve
(B)Lowbrakelineairpressure *(C)Abadbrakedrum
(D)Abadgovernor
3. Aservicebrakeonatruckwithanairbrakesystemreleasestooslowly.
TechnicianAsaysthatlowairpressurecouldbethecause.
TechnicianBsaysthatakinkedairlinecouldbethecause.
Whoisright?
(A)Aonly (C)BothAandB *(B)Bonly (D)NeitherAnorB
4. Aservicebrakechamberleakswhenthebrakesareapplied.Whichofthese
couldbethecause?
(A)Excessivepushrodtravel
*(B)Abadchamberdiaphragm
(C)Abrokenchamberreturnspring
(D)Amisalignedpushrod
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5. Allthewheelsonatruckwithairbrakeslockupwhenasmallamountofpres-
sureisappliedtothetreadle(foot)valve.Whichofthesecouldbethecause?
*(A)Theapplicationvalveisbad.
(B)Thelimitingvalveisleaking.
(C)Thecompressorregulatorissettoohigh.
(D)Thebrakesareadjustedtoohigh.
6. Whenanairreservoirtankisdrained,thereisanexcessiveamountofmoisture.
Thiscouldbecausedbya:
(A)crackedaircompressorbracket.
(B)cloggedaircompressorintake.
(C)failedonewaycheckvalve.
*(D)failedairdryerpurgevalve.
7. Allthebrakesdragonatruckwithhydraulicbrakes.Whichofthesecouldbe
thecause?
(A)Airinthehydraulicsystem
(B)Toohighvacuumsupplytothepowerbrakebooster
(C)Aleakingsecondarycupinthemastercylinder
*(D)Nobrakepedalfreetravel
Questions 8 and 9 are not like the ones above.
EachofthesehasthewordEXCEPT.Foreachquestion,lookforthechoice
thatcouldNOT causethedescribedsituation.Readtheentirequestion
carefullybeforechoosingyouranswer.
8. Atruckwithhydraulicbrakespullstoonesidewhenthebrakesareapplied.
AnyofthesecouldbethecauseEXCEPT a:
(A)stickingwheelcylinderpiston.
(B)greasecontaminatedbrakelining.
(C)crimpedhydraulicline.
*(D)pluggedcompensatingport.
9. Thedriverofatruckwithairbrakessaysithaspoorstoppingpower.
AnyofthesecouldbethecauseEXCEPT:
*(A)thequickreleasevalveexhaustportisplugged.
(B)theairpressureistoolow.
(C)theapplicationlineisrestricted.
(D)thebrakesareoutofadjustment.
T4 SAMplE QuESTiOnS (cOnTinuEd)
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Content Questions PercentageArea in Test of Test
A. Steering System Diagnosis and Repair 12 24.0%
1. Steering Column (3)
2. Steering Units (6)3. Steering Linkage (3)
B. Suspension System Diagnosis and Repair 13 26.0%
C. Wheel Alignment Diagnosis, Adjustment,and Repair 13 26.0%
D. Wheels and Tires Diagnosis and Repair 9 18.0%
E. Frame Service and Repair 3 6.0%
Total 50* 100%
TEST SpEcificATiOnSAnd liSTSuSpEnSiOnAnd STEErinG (TEST T5)
A. Steering System Diagnosis and Repair (12 Questions)
1. Steering Column (3 Questions) 1. Diagnosexedanddriveradjustablesteeringcolumnandshaftnoise,looseness,and
bindingproblems;determineneededrepairs.
2. InspectandreplacesteeringshaftU-joint(s),slipjoints,bearings,bushings,andseals;
phaseshaftU-joints. 3. Checkandadjustcabmountingandrideheight.
4. Removethesteeringwheel(includessteeringwheelsequippedwithelectrical/
electroniccontrolsandcomponents);installandcenterthesteeringwheel.
2. Steering Units (6 Questions) 1. Diagnosepowersteeringsystemnoise,steeringbinding,darting/oversteer,reduced
wheelcut,steeringwheelkick,pulling,non-recovery,turningeffort,looseness,hard
steering,overheating,uidleakage,anduidaerationproblems;determineneeded
repairs.
2. Determinerecommendedtypeofpowersteeringuid;checklevelandcondition;
determineneededservice.
3. Flushandrellpowersteeringsystem;purgeairfromsystem.
4. Performpowersteeringsystempressure,temperature,andowtests;determine
neededrepairs.
5. Inspect,service,orreplacepowersteeringreservoirincludinglter,seals,and
gaskets.
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6. Inspectandreinstall/replacepowersteeringpumpdrivebelts,pulleysandtensioners;
adjustdrivebeltsandcheckalignment.
7. Inspectorreplacepowersteeringpumpdrivegearandcoupling. 8. Inspect,adjust,orreplacepowersteeringpump,mountings,andbrackets.
9. Inspectandreplacepowersteeringsystemcooler,lines,hoses,clamps/mountings,
andttings.
10. Inspect,adjust,orreplacelinkage-assisttypepowersteeringcylinderorgear
(dualsystem).
11. Inspect,adjust,repair,orreplaceintegraltypepowersteeringgear.
12. Adjustmanualandautomaticsteeringgearpoppet/reliefvalves.
3. Steering Linkage (3 Questions) 1. Inspect,align,andreplacepitmanarm. 2. Inspect,adjust,orreplacedraglink(relayrod)andtierodends(ballandadjustable
sockettype).
3. Inspectandreplacesteeringarms.
4. Inspectorreplaceclampsandretainersoncrosstube/relayrod/centerlink/tierod;
positionasneeded.
5. Checkandadjustwheelstops.
B. Suspension System Diagnosis and Repair (13 Questions)
1. Inspectandreplacefrontaxlebeamandmountinghardware. 2. Inspect,service,adjust,orreplacekingpin,bushings,locks,bearings,seals,and
covers.
3. Inspectandreplaceshockabsorbers,bushings,brackets,andmounts.
4. Inspect,repair,orreplace(leafandparabolic)springs,centerbolts,clips,spring
eyeboltsandbushings,shackles,slippers,insulators,brackets,andmounts.
5. Inspect,adjust,orreplacetorquearms,bushings,andmounts.
6. Inspect,adjust,orreplaceaxlealigningdevicessuchasradiusrods,transversetorque
rods/trackbars,stabilizerbars,andrelatedbushings,mounts,shims,andcams.
7. Inspectorreplacewalkingbeams,center(cross)tube,bushings,mounts,loadpads,brackets,caps,andmountinghardware.
8. Inspect,test,adjust,repair,orreplaceairsuspensionpressureregulatorandheight
controlvalves,linkages,lines,hoses,andttings.
9. Inspect,test,repair,orreplaceairsuspensionsprings(bags),mountingplates,
mainsupportbeams/springs,suspensionarms(radius/torque,andtransversetorque),
andbushings.
10. Measurevehiclerideheight;determineneededadjustmentsorrepairs.
11. Verifyanddiagnosevehiclesuspensioncomplaints.
12. TorqueU-boltstomanufacturersspecications.13. Checkaxleloaddistributionproblemsonrearsuspensions;checkaxleseatplaning
anglesandpinionangles.
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C. Wheel Alignment Diagnosis, Adjustment, and Repair (13 Questions) 1. Diagnosevehiclewandering,darting,pulling,shimmy,andsteeringeffortproblems;
determineneededadjustmentsandrepairs.
2. CheckcamberandKPI(kingpininclination);determineneededrepairs.
3. Checkandadjustcaster.
4. Checkandadjusttoe.
5. Checkrearaxle(s)alignment(thrustline/centerline)andtracking(lateraloffset,
parallelism);adjustordetermineneededrepairs.
6. Checkturning/Ackermanangle(toe-out-on-turns)andmaximumturningradius
(wheelcut);determineneededrepairs.
D. Wheels and Tires Diagnosis and Repair (9 Questions) 1. Diagnosetirewearpatterns;determineneededrepairs. 2. Diagnosewheelendvibration,shimmy,pounding,hop(tramp)problems;
determineneededrepairs.
3. Inspectandreplacewheels,spacers,rims,sideanges,lockingrings,rimclamps,
studs,andnuts.
4. Measurewheelandtireradialandlateralrunout;determineneededrepairsor
adjustments.
5. Inspecttires;checkandadjustairpressuretotiremanufacturersspecications.
6. Performstaticbalanceofwheelandtireassembly. 7. Performdynamicbalanceofwheelandtireassembly.
8. Measuretirediameterandmatchtiresonaxles.
9. Removeandreplacesteeringand/ordriveaxlewheelassembly.
10. Clean,inspect,lubricate,andreplacewheelbearingsandraces/cups;replaceseals
andwearrings;adjuststeeringanddriveaxlewheelbearings(includingoneand
twonuttypes)tomanufacturersspecications.
11. Inspectorreplaceextendedservice(sealed,closetolerance,andunitized)bearing
assemblies;performinitialinstallationprocedurestomanufacturersspecications.
E. Frame Service and Repair (3 Questions) 1. Inspect,adjust,service,repair,orreplacefthwheel,pivotpins,bushings,locking
jawmechanisms,andmountingbolts.
2. Inspect,adjust,service,repair,orreplaceslidingfthwheel,tracks,stops,locking
systems,aircylinders,springs,lines,hoses,andcontrols.
3. Inspectframeandframemembersforcracks,breaks,distortion,elongatedholes,
looseness,anddamage;determineneededrepairs.
4. Inspect,install,orrepairframehangers,brackets,andcrossmembersinaccordance
withmanufacturersrecommendedprocedures.
5. Inspect,install,repairorreplacepintlehooksanddrawbars.
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SAMplE QuESTiOnSSuSpEnSiOnAnd STEErinG (TEST T5)
QuESTiOnS:
1. Whichofthesecouldcausethefronttiresofatrucktoshowafeatherededge
wearpattern?
*(A)Anincorrecttoesetting (B)Anincorrectcambersetting
(C)Anincorrectcastersetting
(D)Incorrecttirepressures
2. Thedriveaxlesonatruckwithawalkingbeamsuspensionareoutofalign-
ment.
TechnicianAsaysthatincorrectlengthtorquerodscouldbethecause.
TechnicianBsaysthatwornwalkingbeambushingscouldbethecause.Whoisright?
(A)Aonly (C)BothAandB
*(B)Bonly (D)NeitherAnorB
3. Thedriverofatruckthathasjusthaditsfrontspringsandhangersreplaced
saysthatitishardtokeepinastraightaheadposition.
TechnicianAsaysthatthiscouldbecausedbyinstallingthecastershims
backwards.TechnicianBsaysthatthiscouldbecausedbyinstallingforwardspring
hangerswhicharetooshort.
Whoisright?
*(A)Aonly (C)BothAandB
(B)Bonly (D)NeitherAnorB
4. Thedriverofatrucksaysthatitishardtosteerandthesteeringreturnispoor.
TechnicianAsaysthattightkingpinscouldbethecause.TechnicianBsaysthattoomuchtoe-incouldbethecause.
Whoisright?
*(A)Aonly (C)BothAandB
(B)Bonly (D)NeitherAnorB
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PAGE40 ASE MEdiuM/HEAvyTruckSTudyGuidE
5. Ruststreakscomingfromaroundthestudholesofadiscwheelcouldbe
causedby:
(A)anoverloadedconditon.
(B)overtorquedlug/capnuts.
*(C)Anoutofbalancecondition.
(D)Looselug/capnuts.
6. Atruckhasahistoryofspringsbreakingatthecenterboltholes.
TechnicianAsaysthatlooseU-boltscouldbethecause.
TechnicianBsaysthatloosespringshacklescouldbethecause.
Whoisright?
*(A)Aonly (C)BothAandB
(B)Bonly (D)NeitherAnorB
7. Aconstantbuzzingnoisecomesfromthepowersteeringpump.
TechnicianAsaysthecausecouldbeairinthesystem.
TechnicianBsaysthecausecouldbethatthereliefvalveisstuckinthe
openposition.
Whoisright?
*(A)Aonly (C)BothAandB
(B)Bonly (D)NeitherAnorB
T5 SAMplE QuESTiOnS (cOnTinuEd)
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8. Thetandemrearaxleairsuspensionrideheightrisesabovenormalasthe
vehicleisunloaded.Whichofthesecouldbethecause?
(A)Akinkedairspring(bag)supplyline
(B)Aleakingheightcontrolvalve
*(C)Apluggedheightcontrolvalveexhaustport
(D)Aleakingpressureprotectionvalve
Question 9 is not like the ones above.
IthasthewordEXCEPT.Forthisquestion,lookforthechoicethatcould
NOT causethedescribedsituation.Readthequestioncarefullybeforechoosingyouranswer.
9. Alloftheseshouldbecheckedbeforealigningthefrontwheelsonatruck
EXCEPT:
(A)tirepressure.
(B)rideheight.
(C)wheelbearingadjustment.
*(D)tirebalance.
T5 SAMplE QuESTiOnS (cOnTinuEd)
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Content Questions PercentageArea in Test of Test
A. General Electrical Diagnosis 14 28%
B. Battery Diagnosis and Repair 4 8%
C. Starting System Diagnosis and Repair 7 14%
D. Charging System Diagnosis and Repair 7 14%
E. Lighting Systems Diagnosis and Repair 6 12%
1. Headlights, Parking, Clearance, Tail,Cab and Dash Lights (3)
2. Stoplights, Turn Signals, Hazard Light,
and Backup Lights (3)
F. Gauges and Warning Devices Diagnosis 4 8%
and Repair
G. Related Systems 8 12%
Total 50 100%
TEST SpEcificATiOnSAnd liSTElEcTricAl/ElEcTrOnic SySTEMS (TEST T6)
A. General Electrical Systems Diagnosis (14 questions) 1. Checkcontinuityinelectrical/electroniccircuitsusingappropriatetestequipment.
2. Checkappliedvoltages,circuitvoltages,andvoltagedropsinelectrical/electronic
circuitsusingdigitalmultimeter(DMM),orappropriatetestequipment. 3. Checkcurrentowinelectrical/electroniccircuitsandcomponentsusingadigital
multimeter(DMM),clamp-onammeter,orappropriatetestequipment.
4. Checkresistanceinelectrical/electroniccircuitsandcomponentsusingadigital
multimeter(DMM),orappropriatetestequipment.
5. Findshorts,grounds,andopensinelectrical/electroniccircuits.
6. Diagnosekey-offbatterydrainproblems.
7. Inspect,test,andreplacefusiblelinks,circuitbreakers,andfuses.
8. Inspectandtestspikesuppressionsdiodes/resistorsandcapacitors.
9. Inspectandtestrelaysandsolenoids.10. Readandinterpretelectricalschematicdiagramsandsymbols.
11. Diagnosefailuresinthedatacommunicationsbusnetwork;determineneededrepairs.
B. Battery Diagnosis and Repair (4 questions) 1. Performbatterytests(loadandcapacitance);determineneededservice.
2. Determinebatterystateofchargebymeasuringterminalpostvoltageusingadigital
multimeter(DMM).
3. Inspect,clean,service,orreplacebatteryandterminalconnections.
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T6 liST (cOnTinuEd)
4. Inspect,clean,repairandreplacebatteryboxes,mounts,andholddowns.
5. Chargebatteryusingsloworfastchargemethodasappropriate.
6. Jumpstartavehicleusingjumpercablesandaboosterbatteryorappropriateauxiliarypowersupply.
7. Diagnoselowvoltagedisconnect(LVD)systems;determineneededrepairs.
C. Starting System Diagnosis and Repair (7 questions) 1. Performstartingcircuitvoltagedroptests;determineneededrepairs.
2. Inspect,test,andreplacecomponentsandwiresinthestartercontrolcircuit.
3. Inspect,test,andreplacestarterrelaysandsolenoids/switches.
4. Removeandreplacestarter;inspectywheelringgearorexplate.
5. Inspect,clean,repair,andreplacebatterycablesandconnectorsinthecrankingcircuit. 6. Differentiatebetweenelectricalandmechanicalproblemsthatcauseaslowcrank,
nocrank,extendedcranking,oracrankingnoisecondition.
7. Test/monitorbatteryvoltageduringcranking.Determineneededrepairs
D. Charging System Diagnosis and Repair (7 questions) 1. Diagnosedashmountedchargemetersand/orindicatorlightsthatshowanocharge,
lowcharge,oroverchargecondition;determineneededrepairs.
2. Diagnosethecauseofnocharge,lowcharge,oroverchargeconditions;determine
neededrepairs(includesremotesensealternators)
3. Inspect,adjust,andreplacealternatordrivebelts/gears,pulleys,fans,mountingbrackets,andtensioners.
4. Performchargingsystemoutputtests;determineneededrepairs.
5. Performchargingcircuitvoltagedroptests;determineneededrepairs.
6. Removeandreplacealternator.
7. Inspect,repair,orreplaceconnectorsandwiresinthechargingcircuit.
E. Lighting Systems Diagnosis and Repair (6 questions)
1. Headlights, Daytime Running Lights, Parking, Clearance, Tail, Cab, and Dash
Lights (3 questions) 1. Diagnosethecauseofbrighterthannormal,intermittent,dim,ornoheadlightand
daytimerunninglight(DRL)operation.
2. Test,aimandreplaceheadlights.
3. Test,repair,andreplaceheadlightanddimmerswitches,wires,connectors,terminals,
sockets,relays,andcontrolcomponents.
4. Inspect,test,repair,orreplaceswitches,bulbs,sockets,connectors,terminals,relays,
wires,andlight-emittingdiodes(LEDs)oflightingcircuitsontrucksandtrailers.
5. Inspect,test,repair,orreplacedashlightcircuitswitches,bulbs,LEDs,sockets,
connectors,terminals,wires,andprintedcircuits. 6. Inspect,test,repair,orreplaceinteriorcablightcircuitswitches,bulbs,LEDs,
sockets,connectors,terminals,orwires.
2. Stoplights, Turn Signals, Hazard Lights and Backup Lights (3 questions) 1. Inspect,test,adjust,repair,orreplacestoplightcircuitswitches,bulbs,LEDs,sockets,
connectors,terminals,relays,andwires.
2. Diagnosethecauseofturnsignalandhazardasherlightmalfunctions;determine
neededrepairs.
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3. Inspect,test,repair,orreplaceturnsignalandhazardcircuitashers,switches,bulbs,
LEDs,sockets,connectors,terminals,relays,andwires.
4. Inspect,test,adjust,repair,orreplacebackuplightandwarningdevices,circuitswitches,bulbs,LEDs,sockets,connectors,terminals,andwires.
5. Inspectandtesttrailerlightcordconnectorandcable;determineneededrepairs.
F. Gauges and Warning Devices Diagnosis and Repair (4 questions) 1. Diagnosethecauseofintermittent,high,low,ornogaugereadings;determineneeded
repairs.(Doesnotincludechargeindicators.)
2. Diagnosethecauseofdatabusdrivengaugemalfunctions;determineneededrepairs.
3. Inspect,test,adjust,repair,orreplacegaugecircuitsendingunits,sensors,gauges,
connectors,terminals,andwires. 4. Inspect,test,repair,orreplacewarningdevices(lightsandaudible)circuitsending
units,sensors,bulbs,audiblecomponent,socketsconnectors,terminals,wires,and
printedcircuits/controlmodules.
5. Inspect,test,andreplaceelectronicinstrumentationsystems;verifypropercalibration
forvehicleapplication.
G. Related Systems (8 questions) 1. Diagnosethecauseofconstant,intermittent,ornohornoperation.
2. Inspect,test,repair,orreplacehorncircuitrelays,horns,switches,connectors,
terminals,andwires. 3. Diagnosethecauseofconstant,intermittent,ornowiperoperation;diagnosethe
causeofwiperspeedcontroland/orparkproblems.
4. Inspect,test,repair,orreplacewipermotor,resistors,parkswitch,relays,switches,
connectors,terminals,andwires.
5. Inspectandreplacewipermotortransmissionmechanicallinkage,arms,andblades.
6. Inspect,test,repair,orreplacewindshieldwashermotororpump/relayassembly,
switches,connectors,terminals,andwires.
7. Inspect,test,repair,orreplacesideviewmirrormotors,heatercircuitgrids,relays,
switches,connectors,terminals,andwires. 8. Inspect,test,repair,orreplaceheaterandA/Celectricalcomponentsincluding:
A/Cclutches,motors,resistors,relays,switches,controls,connectors,terminals,
andwires.
9. Inspect,test,repair,orreplacecigarettelighterand/orauxiliarypoweroutletcase,
integralfuse,connectors,terminals,andwires.
10. Diagnosethecauseofslow,intermittent,ornopowerwindowoperation.
11. Inspect,test,repair,andreplacemotors,switches,relays,connectors,terminals,
andwiresofpowerwindowcircuits.
12. Diagnoseinverter/shorepowersystems;determineneededrepairs.13. Diagnosethecauseofpoor,intermittent,ornooperationofelectricdoorlocks.
14. Inspect,test,repair,andreplaceswitches,relays,controllers,actuators/solenoids,
connectors,terminals,andwiresofelectricdoorlockcircuits.
15. Inspect,testrepairandreplacecruisecontrolelectricalcomponents.
16. Inspect,test,repair,andreplaceenginecoolingfanelectricalcontrolcomponents.
17. Diagnosefailuresinthedatacommunicationsbusnetwork;determineneeded
repairs.
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SAMplE QuESTiOnSElEcTricAl/ElEcTrOnic SySTEMS (TEST T6)
QuESTiOnS:
1. Inthechargingsystemshownabove,themeterreadingwillshow:
(A)chargingoutputvoltage.
(B)regulatoroperatingvoltage. *(C)chargingcircuitvoltagedrop.
(D)ignitionswitchvoltagedrop.
2. Atruckscabheaterblowermotoroperatesatlowspeedonly.Whichofthese
isthemostlikelycause?
(A)Anopenblowerswitchground
*(B)Abadblowerswitch
(C)Abindingblowercage (D)Ashorttopowerattheblowermotor
ALTERNATOR
BATTERY
BATTERY
TERMINAL
IGNITION TERMINAL
VOLTMETER
IGNITION SWITCH
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T6 SAMplE QuESTiOnS (cOnTinuEd)
3. Thehornsinthecircuitshownaboveonlyblowwhenajumperwireiscon-
nectedbetweenterminals30and87ofthehornrelay.
TechnicianAsaysthatafailedhornrelaycouldbethecause.
TechnicianBsaysthatashorttogroundinthecircuitbetweenthehornrelay
andthehornbuttoncouldbethecause.Whoisright?
*(A)Aonly (C)BothAandB
(B)Bonly (D)NeitherAnorB
4. Atrucksbatterydischargesaftersittingovernight.
TechnicianAsaysthatabadalternatorcouldbethecause.
TechnicianBsaysthatabadstartercouldbethecause.
Whoisright? *(A)Aonly (C)BothAandB
(B)Bonly (D)NeitherAnorB
5. Adrivercomplainsthatthetrailermarkerlightsaredimatnightwhilebraking.
Whichoftheseisthemostlikelycause?
(A)Lowbatteryvoltage
(B)Oneburnedoutbrakelightbulb
*(C)Apoorgroundinthetrailerlightcord (D)Toomuchgreaseonthe5thwheel
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6. Bothheadlightsonavehiclearediminhighbeamandnormalinlowbeam.
TechnicianAsaysthatapoorheadlightgroundcouldbethecause.
TechnicianBsaysthatashortedheadlightswitchcouldbethecause.
Whoisright?
(A)Aonly (C)BothAandB
(B)Bonly *(D)NeitherAnorB
T6 SAMplE QuESTiOnS (cOnTinuEd)
7. Thevoltagereadingsshownaboveweretakenwhilecrankingtheengine.
Whichoftheseisindicatedbythereadings?
(A)Battery#2hasresistanceinthegroundcable.
*(B)Battery#2isweakerthanbattery#1.
(C)Battery#1islowonelectrolyte. (D)Battery#2shouldbereplaced.
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TEST SpEcificATiOnSAnd TASkliSTHEATinG, vEnTilATiOn,And Air cOndiTiOninG (HvAc)
SySTEMS (TEST T7)
Content Questions PercentageArea in Test of Test
A. HVAC Systems Diagnosis, Service,
and Repair 6 15%
B. A/C System and Component Diagnosis,Service, and Repair 16 40%
1. A/C System General (6)
2. Compressor and Clutch (5)
3. Evaporator, Condenser,
and Related Components (5)
C. Heating and Engine Cooling Systems
Diagnosis, Service, and Repair 6 15%
D. Operating Systems and Related ControlsDiagnosis and Repair 8 20%
1. Electrical (5)2. Air/Vacuum/Mechanical (2)
3. Constant/Automatic
Temperature Control (1)
E. Refrigerant Recovery, Recycling,
Handling,andRetroft 4 10%
Total 40 100%
A. HVAC Systems Diagnosis, Service, and Repair (6 questions) 1. Verifythecomplaint,roadtestthevehicle,reviewdriver/customerinterviewand
pastmaintenancedocuments(ifavailable);determinefurtherdiagnosis.
2. VerifytheneedofserviceorrepairofHVACsystemsbasedonunusualoperating
noises;determineappropriateaction.
3. VerifytheneedofserviceorrepairofHVACsystemsbasedonunusualvisual,
smell,andtouchconditions;determineappropriateaction.
4. Identifysystemtypeandcomponents(cyclingclutchoricetube-CCOT,expansionvalve,typeofrefrigerant)andconductperformancetest(s)onHVACsystems;
determineappropriateaction.
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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. DiagnosethecauseoftemperaturecontrolproblemsintheA/Csystem;determineneededrepairs.
2. Identifyrefrigeranttypeandcheckforcontamination;determineappropriateaction.
3. DiagnoseA/Csystemproblemsindicatedbypressuregaugereadingsandsightglass/
moistureindicatorconditions(whereapplicable);determineneededservice
orrepairs.
4. DiagnoseA/Csystemproblemsindicatedbyunusualoperatingnoise,visual,
smell,andtouchprocedures;determineneededrepairs.
5. PerformA/Csystemleaktest;determineneededrepairs. 6. EvacuateA/Csystemusingappropriateequipment.
7. InternallycleancontaminatedA/Csystemcomponentsandhoses.
8. ChargeA/Csystemwithcorrecttypeandquantityofrefrigerant.
9. Identifylubricanttypeneededforsystemapplication.
2. Compressor and Clutch (5 questions) 1. DiagnoseA/Csystemproblemsthatcauseprotectiondevices(pressure,thermal,and
electronic)tointerruptsystemoperation;determineneededrepairs.
2. Inspect,test,andreplaceA/Csystempressure,thermal,andelectronicprotection
devices. 3. InspectandreplaceA/Ccompressordrivebelts,pulleys,idlers,andtensioners;
adjustdrivebeltsandcheckalignment.
4. Inspect,test,service,andreplaceA/Ccompressorclutchcomponentsorassembly.
5. InspectandcorrectA/Ccompressorlubricantlevel.
6. Inspect,test,andreplaceA/Ccompressor.
7. Inspect,repair,orreplaceA/Ccompressormountingsandhardware.
3. Evaporator, Condenser, and Related Components (5 questions)
1. Correctsystemlubricantlevelwhenreplacingtheevaporator,condenser,
receiver/drieroraccumulator/drier,andhoses.
2. Inspect,repair,orreplaceA/Csystemhoses,lines,lters,ttings,andseals.
3. InspectA/Ccondenserforproperairow.
4. Inspect,test,andreplaceA/Csystemcondenserandmountings.
5. Inspectandreplacereceiver/drieroraccumulator/drier.
6. Inspect,test,andreplacecab/sleeperrefrigerantsolenoid,expansionvalve(s),
thermostaticswitch(thermistor);andcheckplacementofthermalbulb
(capillarytube).
7. Inspectandreplaceoricetube. 8. Inspect,test,andreplacecab/sleeperevaporatorcore.
9. Inspect,clean,andrepairevaporatorhousingandwaterdrain;inspectand
service/replaceevaporatorairlter.
10. Identify,inspect,andreplaceA/Csystemserviceports/valves(gaugeconnections).
11. DiagnosesystemfailuresresultinginrefrigerantlossfromtheA/Csystemhigh
pressurereliefdevice.
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C. Heating and Engine Cooling Systems Diagnosis, Service, and Repair
(6 questions) 1. Diagnosethecauseofoutletairte