Mechanical Aptitude Test 080609

8/13/2019 Mechanical Aptitude Test 080609

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CCCLLLAAARRRKKK

MECHANICAL

APTITUDE

TEST

CLARKMaterial Handling Company

700 Enterprise Drive

Lexington, KY 40510


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CCLLAARRKK Material Handling Company Mechanical Aptitude TestRevised 08/09

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MECHANICAL APTITUDE TEST

Success in mechanical work depends on Training as well as Aptitude. ThisTest is designed to measure your present mechanical knowledge, as well as your

trainability.

Interest, Motivation, and Personality are all essential to achieve success as a

Mechanical Technician. But of utmost importance is your Mechanical Aptitude and

Ability to Learn. We hope this Test will help to measure these capabilities.

The Table of Contents for the Test Question Booklet is as follows:

PAGE PAGE1.) Shop Arithmetic 3 9.) Brake Systems 34

2.) Shop Processes 7 10.) Hydraulics 37

3.) Basic Lift Trucks 11 11.) Electrical 42

4.) Internal Combustion Engines 14 12.) Cooling System 47

5.) Gas, LPG, and Diesel Fuels 18 13.) Lubrication 50

6.) Emission Controls 22 14.) Safety 53

7.) Steering System 25 15.) Welding 56

8.) Transmission, Differential,and Drive Axle

28 16.) Space Relations 58

There is no time limit, so answer the questions at your own rate. It will

probably take you several hours to complete the Test, there are a total of 300

Questions. You will not be expected to get every question correct, But Do Your

Best!

Check your equipment, you should have:

This Test Booklet.Several Pencils.

A Work Tablet for Calculations.

Now in the space provided carefully fill in Your Name, Address, Telephone

Number, Date, Company Name, and Company Address.


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CANDIDATE INFORMATION

Candidates Name (Printed): ___________________________________________________________

Candidates Name (Signature): __________________________________________________________

Candidates Address: __________________________________________________________________

Candidates Telephone Number: ______________________________ Date: _________________

Company Name: _____________________________________________________________________

Company Address: ____________________________________________________________________

How long have you been a Mechanic / Technician: Years: ________ Months: ________

IMPORTANT: Answer the following questions by fillingin the term or terms, circling True or False, or circling theletter of the answer you select. This Test is designed to

measure your present mechanical knowledge, as well as your

trainability. There is no Passing Score, But Do Your Best!!!

If you change your answer erase you prior answer

completely, DO NOT SCRATCH IT OUT!!

If there are any questions ask them now, your Examiner

WILL NOT ANSWER any questions after you start the Test.

You are now ready to start the Test.


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SECTION 1:

Shop Arithmetic

1.) A Road Technician has 2 Gallons, 3 Quarts, and 1 Pint of Dexron II Transmission Fluid ininventory on his Road Truck. During a P.M. at a Customer Site he uses 7 Pints of the Dexron IITransmission Fluid from the Road Truck inventory. How many Pints of Dexron II Transmission

Fluid are left in inventory on the Technicians Road Truck?A.) 8 Pints.

B.) 16 Pints.

C.) 22 Pints.D.) None of the above.

Use Figure #1 in order to answer questions 2 & 3.2.) How Long is A?

A.) 4 Inches.B.) 6 Inches.

C.) 8 Inches.D.) None of the above.

3.) What is the Diameter of the circle?A.) 4 Inches.

B.) 6 Inches.

C.) 8 Inches.

D.) 10 Inches.

Use Figure #2 in order to answer questions 4, 5, & 6.4.) What is the total length of the 3 Rods?

A.) 312 Inches.

B.) 402 Inches.

C.) 412 Inches.D.) 512 Inches.

5.) How long is A?A.) 3 Feet.

B.) 12 Feet.

C.) 13 Feet.

D.) 52 Feet?

6.) B is how many times as long as C?

A.) 128.0.B.) 3.0.

C.) 2.5.

D.) 1.2.

FIGURE #1

FIGURE #2


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7.) In the picture to the right, what is the reading at A?A.) 2.8 Inches.

B.) 2.0 Inches.

C.) 1.5 Inches.D.) 2.5 Inches.

8.) In the picture to the right, when the larger wheel hasmade 60 complete revolutions, how many revolutions

has the smaller wheel made?A.) 60.B.) 75.C.) 80.D.) None of the above.

9.) In the picture to the right, how long is A?

A.) 12 Inches.

B.) 15 Inches.C.) 16 Inches.

D.) 18 Inches.

10.) In the picture to the right, when the 16-tooth gear

turns 4 times, how many times does the8-gear tooth turn?

A.) 2.

B.) 4.

C.) 8.D.) 16.

Use Figure #3 in order to answer questions 11, 12, & 13.11.) What is the Reading at B?

A.) 3.40 Inches.

B.) 3.25 Inches.C.) 3.04 Inches.

D.) 1.25 Inches.

12.) How much longer is the reading at C than

the reading at A?

A.) .30 Inches.

B.) .03 Inches.C.) .25 Inches.

D.) 1.75 Inches.

13.) How much is the reading at D multiplied by the reading at C?

A.) 468.00 Square Inches.

B.) 46.80 Square Inches.C.) 4.68 Square Inches.

D.) 2.88 Square Inches.

FIGURE #3


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14.) In the picture to the right, how long is A?A.) 8 Inches.

B.) 5 Inches.

C.) 4 Inches.D.) 3 Inches.

Use Figure #4 in order to answer questions 15, 16, & 17.15.) This rod is to be cut into two parts so that one is twice as long as

the other. If 1/8 inch is wasted in cutting, how long will

the longer part be?

A.) 14 Inches.B.) 10 1/2 Inches.

C.) 7 Inches.

D.) 5 1/4 Inches.

16.) How many 2-inch pieces can be cut from thisrod if 1/8 inch is wasted in each cut?

A.) 10 1/2.B.) 10.C.) 9.D.) 5.

17.) This rod is 50% as long as a second rod. How long is

the second rod?

A.) 40 Inches.B.) 41.50 Inches.C.) 41.75 Inches.D.) None of the above.

Use Figure #5 in order to answer questions 18 & 19.18.) What is the measurement of Angle A?

A.) 20.

B.) 30.

C.) 60.D.) 90.

19.) Line B is ______________ the Hypotenuse

of the Triangle.A.) Less than.B.) Equal to.C.) Greater than.D.) None of the above.

FIGURE #4

FIGURE #5


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Use Figure #6 in order to answer questions 20 & 19.20.) What is distance A?

A.) 12 3/4.

B.) 12 3/8.C.) 12 1/4.

D.) 12 1/8.

21.) What is distance B?

A.) 15 1/4.B.) 2 3/4.

C.) 2 1/4.

D.) 1 1/4.

TOTAL POSSIBLE FOR SHOP ARITHMETIC IS 21.

TOTAL CORRECT: _______________

FIGURE #6


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SECTION 2:

Shop Processes

22.) The tool shown to the right of this question is used to:A.) Measure Water Temperature.

B.) Lubricate Machinery.C.) Test Storage Batteries.

D.) Water Plants.

23.) The tools shown to the right of this question are used to:

A.) Drill holes in wood.B.) Drill holes in metal.

C.) Drill holes in plate glass.D.) Remove broken screws / bolts.

24.) The purpose of a Torque Wrench is to:

A.) Measure Bolt Size.

B.) Loosen tight Bolts.

C.) Test the strength of Bolts and Nuts.D.) Tighten Bolts and Nuts properly.


A.) Punch holes in Gasket Material.

B.) Remove broken Screws.C.) Measure the Depth of Holes.

D.) Test the hardness of Metals.

26.) The tool shown to the right of this question is used to:

A.) Measure the depth of Holes.

B.) Measure Thickness.C.) Measure Inside Dimensions.

D.) All of the above.


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27.) In threading a hole, the proper tool to use is:A.) A Reamer.

B.) A Bit.

C.) A Tap.D.) A Die.

28.) The tool shown to the right of this question is used in:

A.) Picking up small Electronic Devices.B.) Measuring Outside Dimensions of Small Objects.

C.) Drawing Circles.

D.) Measuring Inside Dimensions.

29.) When the Meter to the right of this questionreads 28, what Function is it performing?

A.) Measuring Ignition Point Setting.B.) Measuring Engine R.P.M.s.C.) Measuring Ignition Timing.D.) Measuring Manifold Vacuum.

30.) To secure a most accurate hole, a Draftsman would specify which of the following processes?

A.) Boring.B.) Drilling.

C.) Coring.D.) Reaming.

31.) The tool shown to the right of this question is used for:

A.) Pulling Gears off Shafts.B.) Threading Pipes.

C.) Measuring Outside Diameters.

D.) Removing Cylinder Glaze.


A.) Punch Holes in Leather.B.) Test Hardness of Metal.

C.) Hold very Small Objects together.

D.) Measure Thickness.

33.) In threading a rod, the proper tool to use is:

A.) A Reamer.B.) A Bit.

C.) A Tap.

D.) A Die.


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A.) Checking Capacitors.B.) Checking Diodes.

C.) Checking Silicone Controlled Rectifiers.D.) All of the above.


A.) Check and properly adjust Brake Lining to

Drum Clearance.

B.) Check and properly adjust Upright Roller to

Rail Clearance.C.) Check and properly adjust the

Steer Axle Alignment.D.) Check and properly adjust Drive Wheel Run-Out.


A.) Measuring Oil Flow Rate in a Hydraulic Circuit.B.) Measuring Oil Temperatures in a Hydraulic Circuit.C.) Measuring Oil Pressure in a Hydraulic Circuit.



A.) Performing diagnostic evaluations of theUpright Hydraulic Circuits.

B.) Performing diagnostic evaluations of the

Cooling System.C.) Performing diagnostic evaluations of the

Transmission Hydraulic Circuits.



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38.) When using a 1/4"-20UNC-2B Bolt, what does the number 20 in the Unified and AmericanThreads Callout Number for the Bolt identify?

A.) The Major Diameter of the Thread by Number Size.

B.) The Class of Fit.C.) The Number of Threads per Inch.

D.) The Thread Tolerance.

39.) In order to aid in the proper Thread Tapping process, which of the following lubricants may be

used when Tapping Threads into a pre-drilled hole in a piece of Aluminum?A.) Mineral Oil.B.) WD-40.C.) 3-In-One Oil.D.) All of the above.

40.) When Hand Tapping a Thread into a pre-drilled hole in a piece of Steel, why is it recommended to

periodically reverse the rotation of the Tap?

A.) To break the chip formed during the cutting process, thuspreventing crowding which could break the Tap.

B.) To permit penetration of the Cutting Lubricant in order to flush andlubricate the pre-drilled hole.

C.) To ensure the newly cut Threads and smooth and clean.D.) All of the above.

41.) The tool shown to the right of this question is used for:A.) Bleeding an Upright Lift Cylinder.

B.) Bleeding air from the Sump Tank.C.) Bleeding air from the Cooling System.D.) Bleeding Hydraulic Brake Lines.

42.) The tool shown to the right of this question is used for:A.) Measuring the Power Steering Oil Pressure.

B.) Measuring the Transmission Oil Pressure.

C.) Measuring the Hydraulic System Oil Pressure.


TOTAL POSSIBLE FOR SHOP PROCESSES IS 21.



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SECTION 3:

Basic Lift Trucks

43.) Technician A states that a Lift Trucks maximum allowable Load must be indicated on the TrucksData Plate. Technician B States that a raised Load stabilizes the Lift Truck. Which Technicianis correct?

A.) A only.B.) B only.

C.) Both A and B.

D.) Neither A nor B.

44.) If rated capacity of a Lift Truck is 4500 pounds at a 24 Inch Load Center, what would capacity be

at a 30 Inch Load Center?

A.) 4,300 lbs.

B.) 3,400 lbs.C.) 3,900 lbs.

D.) 3,600 lbs.

45.) The picture below and to the right of this question is a _______________ Lift Truck.

A.) Class I.B.) Class II.

C.) Class III.

D.) Class IV.

46.) What is the general ratio of a Lift Trucks Weight to its Capacity Load weight?A.) 1:1.B.) 2:1.

C.) 3:1.

D.) 4:1.

47.) Technician A states that a Lift Truck with Four Wheels is supported at Four Points. Technician B

states that on a Counterbalanced Lift Truck, the Fulcrum Point is a vertical line through the middleof the Drive Wheel Hub. Which Technician is correct?

A.) A only.

B.) B only.

C.) Both A and B.D.) Neither A nor B.

48.) The picture below and to the right of this question is a _______________ Lift Truck.A.) Class II.

B.) Class III.

C.) Class IV.D.) Class V.


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49.) Technician A states that on a Counterbalanced Lift Truck, without a Load on the Forks, travel up

and down a Ramp with the Forks pointing Downgrade. Technician B states that when operating a

Pallet Truck, with a with a Load on the Forks, travel up and down a Ramp with the Forks pointingDowngrade. Which Technician is correct?

A.) A only.B.) B only.C.) Both A and B.


50.) Technician A states that when charging an Electric Lift Truck Battery the Battery should

never be allowed to reach or exceed 110 Fahrenheit in temperature. Technician Bstates after charging an Electric Lift Truck Battery it can be placed back into service after

a ten minute cool down period. Which Technician is correct?

A.) A only.

B.) B only.


51.) OSHA considers a truck to be unattended if the operator is _________ feet away or out

of sight of the truck.

A.) 10 feet.B.) 15 feet.

C.) 25 feet.

D.) 50 feet.

52.) When operating a Lift Truck the Service Valve on the L. P. Gas Tank should be

__________________ when the L. P. Gas Tank is properly installed and the Engineis running.

A.) 1/2 Turn Opened.

B.) 1 Full Turn Opened.

C.) Fully Opened and Back Seated.D.) Fully Opened and then Closed 1/4 of a Turn.

53.) The picture below and to the right of this question is a _______________ Lift Truck.A.) Class I.

B.) Class II.

C.) Class IV.

D.) Class V.

54.) The is a Safety Device designed to protect the Lift TruckOperator from falling objects.

A.) Drivers Overhead Guard.B.) Overhead Guard.C.) D. O. G.D.) All of the Above.


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55.) The Rear Wheel Steering on Lift Trucks:A.) Causes the Counterweight End to swing more than an Automobile.

B.) Causes the Lift Truck to Steer approximately the same as an

Automobile.C.) Causes the Counterweight End to swings less than an Automobile.

D.) Allows the Lift Truck to take sharp turns at high speeds.

56.) Technician A states that when charging an Electric Lift Truck Battery the Battery Vent Caps

should be removed to allow the Hydrogen Gas to vent off. Technician B states that Back-UpAlarms are required equipment on all Lift Trucks. Which Technician is correct?

A.) A only.

B.) B only.C.) Both A and B.


57.) The Amp Hour Capacity of the Charger used to charge an Electric Lift Truck Battery,

should be within __________ of the Amp Hour Rating of the Electric Lift Truck Battery.A.) 5%.

B.) 10%.C.) 20%.

D.) 25%.

58.) On a Lift Truck, when handling loads, the Forks must be at least what Length of the Load?

A.) 1/2 the Length of the Load.

B.) 2/3 the Length of the Load.

C.) 3/4 the Length of the Load.D.) The full Length of the Load.

59.) The picture below and to the right of this question is a _______________ Lift Truck.A.) Class I.

B.) Class II.

C.) Class III.E.) Class V.

60.) Technician A states that if a Sit Down Rider Counterbalance Lift Truck begins to tip over while

you are operating it you should not attempt to leap from the unit, you should stay with the Lift

Truck. Technician B states that if a Stand-Up Rider Counterbalance Lift Truck begins to tip over

you are to step off and away from the unit as quickly and safely as possible. Which Technician iscorrect?

A.) A only.



TOTAL POSSIBLE FOR BASIC LIFT TRUCKS IS 18.



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SECTION 4:

Internal Combustion Engines

61.) Technician A states that Internal Combustion Engines are classified as to whether they operate on

either a Two-Cycle or Three-Cycle Principle. Technician B States that after 100 hours ofoperation of a Lift Trucks Engine, if the Spark Plug Insulator is in the proper Heat Range the colorshould be grey. Which Technician is correct?


C.) Both A and B.


62.) The Full-Floating Piston Connecting Rod Wrist-Pin is usually one of the following:

A.) Dished in the Connecting Rod.

B.) Free-Fit in the Piston.

C.) Locked in the Connecting Rod and floats in the Piston.D.) Free to float in the Connecting Rod and also the Piston.

63.) The object of Positive Rotators is to:

A.) Be sure the Valves are well lubricated.

B.) Prevent Valves from sticking.C.) Give a self-cleaning action to prevent particles from sticking and burning.

D.) Save Fuel.

64.) The object that is the foundation of the Internal Combustion Engine and the point to which allother parts are attached is called the:

A.) Piston.B.) Crankshaft.C.) Cylinders.

D.) Cylinder Block.

65.) Technician A states that the Piston is connected to the Crankshaft by the Connecting Rods.

Technician B says that the Crankshaft continues turning between Combustion Pulses because of

the Flywheel Inertia. Which Technician is correct?A.) A only.

B.) B only.

C.) Both A and B.


66.) When regrinding Crankshafts, it is an absolute MUST that the3 Fillet be maintained in the corner

of the Crankshaft for which of the following reasons:A.) To give a better Oil seal.B.) To keep the Connecting Rod Bearing centered.C.) To give adequate strength to the Crankshaft in this area.D.) To prevent the Connecting Rod from hitting the throws of the Crankshaft.


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67.) Technician A states that excessive oil consumption may be caused by a bad P.C.V. Valve.

Technician B states that a cold running Engine may indicate incorrect Ignition Timing. Which

Technician is correct?A.) A only.

B.) B only.C.) Both A and B.D.) Neither A nor B.

68.) Technician A states that the Camshaft of an Internal Combustion Engine has a separate Cam for

each Piston. Technician B states that on a Six-Cylinder Engine, when the Ignition Distributor has

one set of Ignition Points, the Distributor Cam will have twelve Lobes. Which Technician iscorrect?

A.) A only.

B.) B only.

C.) Both A and B.


69.) When the volume above the Piston at Bottom Dead Center is divided by the volume above thePiston at Top Dead Center, the result is called:

A.) Air Fuel Ratio.

B.) Compression Ratio.C.) Engine Volume Displacement.

D.) Volumetric Efficiency.

70.) Technician A states that a smoky, black exhaust can be caused by an overheated Engine.Technician B states that when using a Timing Light on an Internal Combustion Engine, if the

Ignition Distributor is badly worn, the Timing Mark will not remain stationary. WhichTechnician is correct?

A.) A only.

B.) B only.


71.) What is the Compression Ratio on some Diesel Engines?A.) 25:1.

B.) 8:1.

C.) 10:1.

D.) 6:1.

72.) Technician A states that when performing a Valve Job on an Internal Combustion Engine the

Tip End of the Valve Stem should be ground flat. Technician B states that the purpose ofCrankcase Ventilation is to clean the air going into the Crankcase. Which technician is correct?

A.) A only.




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73.) On an L. P. Gas Fueled, Internal Combustion Engine, which of the following is considered a

Lean Air Fuel Mixture?

A.) 13:1.B.) 17:1.

C.) 11:1.D.) 12:1.

74.) Technician A states that in order to start a cold Internal Combustion Engine requires a Rich AirFuel Mixture. Technician B states that when measuring the size of an Internal Combustion

Engine Piston, you should measure the Piston at its Skirt. Which Technician is correct?


C.) Both A and B.


75.) What is the best Air-Fuel Ratio for a Gasoline Fueled Internal Combustion Engine?A.) 14.7:1.

B.) 18.3:1.C.) 13.2:1.

D.) 12.1:3.

76.) Technician a states that when installing Spark Plug Wires in the Distributor Cap of an Internal

Combustion Engine you must know the Firing Order of the Engine and the Engine Piston

Displacement. Technician B states that when taking a Compression Test on an Internal

Combustion Engine, it is important to remove the Oil Breather Cap. Which Technician iscorrect?



77.) A Diesel Engine ignites the Air/ Fuel Mixture from:

A.) The heat of Compression.

B.) A Spark Plug.C.) The Fuel Injection.

D.) Exhaust from the prior Cylinder burn.

78.) Technician A states that when reringing an Internal Combustion Engine because of excessive OilConsumption, it will be necessary to cut the Ring Groove from the top of the Cylinder Bore, break

the Glaze on the Cylinder Walls, and clean and check the Ring Lands of the Piston. Technician B

states that excessive clearance between the Oil Pump Body and Gears in an Internal CombustionEngine may result in a sticking Oil By-Pass Valve. Which Technician is correct?

A.) A only.




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79.) Technician A states that in an Internal Combustion Engine with Three-Ring Pistons, the Scraper

Ring is usually the Bottom Ring. Technician B states that the Taper Wear in the Cylinder Bore of

an Internal Combustion Engine will be greatest at the area just under the Ridge Ring. WhichTechnician is correct?



80.) The Diesel Engines use to deliver the Fuel into the Combustion Chamber.

A.) Fuel Injection.B.) Carburetors.

C.) Throttle Bodies.

D.) Electric Motors.

81.) Technician A states that the Main Bearing Clearances on an Internal Combustion Engine can bechecked by using Shims or a Dial Indicator. Technician B states that on an Internal Combustion

Engine, if the Timing Light flashes before the Timing Marks line up with the TimingPointer/Reference Mark it usually means the Ignition Timing is too late. Which Technician is

correct?


C.) Both A and B.


82.) In an Internal Combustion Engine, Which Efficiency measures the Airflow in the Engine?

A.) Volumetric.B.) Thermal.C.) Mechanical.

D.) Electrical.

83.) Technician A states that a Four-Valve per Cylinder Internal Combustion Engine is designed to

improve the Volumetric Efficiency of the Engine. Technician B states that a Four-Valve Internal

Combustion Engine is designed to produce more Horsepower. Which Technician is correct?A.) A only.

B.) B only.

C.) Both A and B.


TOTAL POSSIBLE FOR INTERNAL COMBUSTION ENGINES IS 23.



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SECTION 5:

Gasoline, L. P. Gas, and Diesel Fuel

84.) Technician A states that most L. P. Gas Systems used on Lift Trucks are known as LiquidWithdrawal Systems. Technician B states that the same amount of air that always enters the

Cylinders of a Diesel Engine, but the amount of Fuel is varied to change the Engine speed andpower. Which Technician is correct?

A.) A only.



85.) On a Tier 0 Internal Combustion Lift Truck that uses Gasoline for its Fuel, the Carburetor

operates on the Principle of:A.) Ohms Law.B.) Daltons Partial Pressure Theory.C.) Newtons Law of Gravity.D.) Pressure Differentials.

86.) On a Tier 0 Internal Combustion Lift Truck that uses Gasoline for its Fuel, with the Throttle

Valve of the Carburetor wide open, the Venturi Action, which produces a Low Pressure, causes

Fuel to discharge:

A.) From the Main Nozzle.B.) From the Low-Speed Port.C.) From the Accelerator Jet.D.) From all of the above.

87.) On a Tier 0 Internal Combustion Lift Truck that uses Liquefied Petroleum Gas for its Fuel, the

Compression Ratio of the Engine:A.) Must be lowered.B.) Remains the same.C.) Can be raised.D.) Is eliminated.

88.) Technician A states that a lower Octane Number causes Fuel to burn faster. Technician B states

that the most commonly required adjustments for a Gasoline Carburetor used in a Lift Truck arethe Float Level and the Anti-Percolator Needle Valve Clearance. Which Technician is correct?

A.) A only.B.) B only.C.) Both A and B.D.) Neither A nor B.


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89.) The breaking up of a Liquid into fine droplets by spraying is called:

A.) Vaporization.

B.) Carburetion.C.) Atomization.

D.) Venturi Effect.

90.) Technician A states that Gasoline Fumes are lighter than air. Technician B states that when using

L. P. Gas as an Internal Combustion Engine Fuel it must be vaporized because it will not burnas a Liquid. Which Technician is correct?


91.) Technician A states that the Carburetor Throttle Valve regulates Engine Speed by controlling the

Float Level and Height in the Carburetor. Technician B states that Crankcase dilution is causedby a lean mixture in the Combustion Chamber. Which Technician is correct?


92.) In a Diesel Engine, Fuel Oil is Injected into the cylinder at the end of:

A.) The Intake Stroke.

B.) The Compression Stroke.C.) The Power Stroke.

D.) The Exhaust Stroke.

93.) Two of the gasses produced when Gasoline burns:

A.) Carbon Dioxide and Hydra-Carbons.

B.) Nitrogen Oxide and Carbon Monoxide.C.) Oxygen and Carbon Monoxide.


94.) Technician A states that a dirty or partially clogged Air Filter will decrease Fuel Efficiency.

Technician B states that a high Fuel Level in the Carburetor Bowl will cause a Rich Air/Fuel

Mixture. Which Technician is correct?



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95.) Technician A states that in a Diesel Engine the Fuel and Air are mixed when the Air exits the

Turbo Charger. Technician B states that when adjusting the Carburetor on a L.P. Gas fueled Lift

Truck, it is mandatory to adjust the Power Screw/Jet first. Which Technician is correct?A.) A only.B.) B only.C.) Both A and B.D.) Neither A nor B.

96.) Technician A states that a 12:1 Air Fuel Ratio is a Lean Mixture. Technician B states that a

Rich Air-Fuel Mixture is 17:1. Which Technician is correct?


C.) Both A and B.


97.) Which, if any, of the following will influence the Octane Number needed in anInternal Combustion Engine?

A.) Carburetor settings.B.) Air temperature.

C.) Altitude.


98.) Technician A states that a Mechanical Fuel Pump is generally used when the Fuel Supply is

higher than the Bowl of the Carburetor. Technician B states that when an Internal Combustion

Engine, that uses Gasoline for its Fuel, is running and the Throttle Plate is wide open, theVenturi Action in the Carburetor produces a Low Pressure Area which will cause Fuel to be

discharged from the Carburetors Main Nozzle. Which Technician is correct?A.) A only.B.) B only.

C.) Both A and B.


99.) With the L.P. Gas Vaporizer and Second-Stage Regulator isolated from the Carburetor on most

Industrial Engines, it is very important to limit the restriction of the Air Cleaner due to whichone of the following items?

A.) Full-Power Operation.

B.) Idling Characteristics.

C.) Air-Fuel Ratio Mixture.D.) Starting Characteristics.

100.) L.P. Gas Engine Fuel must be vaporized because:A.) It is more economical.

B.) It is easier to control.

C.) It creates less spark plug fouling.D.) It will not burn as a liquid.


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101.) To pressure test an L.P. Gas Fuel System, you install a Pressure Gauge in the:

A.) Final regulator.

B.) Primary regulator.C.) The line from bulkhead fitting.

D.) The intake manifold.

TOTAL POSSIBLE FOR GASOLINE, L. P. GAS, AND DIESEL FUEL IS 18.



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SECTION 6:

Emission Controls

102.) Solenoids, Relays, Servomotors and Switching Transistors are Controlled by the

Computer Microprocessor.A.) Outputs.B.) Analogs.

C.) Systems.D.) Binaries.

103.) Technician A states that Outputs such as Engine Speed and Engine Coolant Temperature arecontrolled by the Microprocessor. Technician B states that Sensor Inputs such as the Throttle

Position and Barometric Pressure are fed to the Microprocessor. Which Technician is correct?

A.) A only.

B.) B only.

C.) Both A & B.D.) Neither A nor B.

104.) Technician A says that a common form of Output of the Computer is to control a Relay.

Technician B says that a common form of Input to the Computer is from a Variable Resistor.

Which Technician is correct?A.) A only.

B.) B only.

C.) Both A and B.


105.) The Sensor that is able to pick up small, changes in the Engines Intake Manifold Pressureis called the:

A.) EGR Sensor.

B.) MAP Sensor.

C.) TPS Sensor.D.) MAF Sensor.

106.) Technician A states that as the Engine Air-Fuel Ratio becomes Leaner, Nitrogen Oxides increase.Technician B states that as the Engine Air-Fuel Ratio becomes Richer, Hydrocarbons increase.

Which Technician s correct?

A.) A only.

B.) B only.C.) Both A & B.


107.) As Combustion Efficiency increases to reduce HC and CO emissions, what happens to NOx?

A.) NOx increases. .

B.) NOx decreases.C.) There is no effect on NOx.

D.) None of the above.


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108.) Which Compression Ratio is used for Internal Combustion Engines in Lift Trucks, using

L.P. Gas for Fuel, that are designed to reduce Emissions?A.) 12:1.

B.) 11:1.C.) 10:1.D.) 8:1.

109.) The PVC Valve ______ the amount of Vapor being burned in the Combustion Chamber during

Low Speeds.

A.) Increases.B.) Decreases.

C.) Has no effect.


110.) Technician A states that when a Vane is used to interrupt a Magnetic Field, this type ofSensor is called the Hall-Effect Sensor. Technician B states that the Hall-Effect Sensor uses a

Fixed Magnet and a Semi-Conductor Wafer to operate. Which Technician is correct?A.) A only.

B.) B only.C.) A and B.D.) Neither A nor B.

111.) When using the Four-Gas Analyzer to Tune an Internal Combustion Engine in a Lift Truck that

does not have Emission Controls, the Carbon Monoxide at Idle should be no more thanPercent, while the Carbon Monoxide Emissions at No-Load Governed Speed should be no more

than percent.A.) 1.50 / 3.00.B.) 3.00 / 1.00.

C.) 3.00 / 3.00.

D.) 1.50 / 1.00.

112.) The Stoichometeric Point occurs at what point, on a Four-Gas Analyzer, when checking an

Internal Combustion Engine that is well tuned?A.) When CO exceeds 02.

B.) When HC and C02 are approximately the same.

C.) When C02 is low and HC is high.

D.) When C02 is at its peak level.

113.) When using a Four-Gas Analyzer, what Gas will not change appreciably once the Air/Fuel Ratio

goes above 15/1?A.) 02.

B.) C0.

C.) C02.D.) HC.


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114.) The correct stoichiometric ratio for a gasoline engine is:

A.) 12.2 to 1.

B.) 14.7 to 1.C.) 16.7 to 1.

D.) 18.7 to 1.115.) Technician A states that the amount of HC and NOx that are in the Exhaust Gases exiting the

Engine Cylinder are determined by the temperature at which the Air Fuel Mixture is burned.Technician B states that NOx is directly proportional to CO. Which Technician is correct?


116.) What is the name of the sensor in the Exhaust Gas Stream that tells the Computer the efficiency of

the burn in the Combustion Chamber?A.) The Manifold Absolute Pressure Sensor.

B.) The Throttle Position Sensor.C.) The Mass Air Flow Sensor.

D.) The Oxygen Sensor.

117.) Technician A states that during closed loop operation, the oxygen sensor is not being used as an

input. Technician B states that open loop operation doesnt start until the engine reaches 150

degrees Fahrenheit. Which Technician is correct?



TOTAL POSSIBLE FOR EMISSION CONTROLS IS 16.



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SECTION 7:

Steering System

118.) Technician A states that incorrect Camber will cause excessive play in the Steering System.Technician B states that over inflated Tires will cause Hard Steering. Which Technician is

correct?


C.) Both A & B.


119.) Backlash in the Steering Gear is removed by adjusting the Pitman Sector in relation to the:A.) Tie Rod Ends.

B.) Pitman Arm.C.) Worm Gear.

D.) Steering Wheel.

120.) Technician A states that Toe-In may be checked with a Telescoping Guage. Technician B states

that the Caster Adjustment is made to a Lift Trucks Steer Axle by Bending the Steer Axle.

Which Technician is correct?



121.) When the Tires on the Steer Axle End of a Lift Truck, are worn uneven, the probable

cause may be:A.) A bent Steer Axle.B.) Improperly adjusted Tie-Rods.C.) Worn out King Pin Bearings.D.) All of the above.

122.) Technician A states that Inclined King Pins are used in the Steering System for Gradeability

purposes. Technician B states that no power action on the Steering Gear when the Engine isrunning could be caused by a faulty Relief Valve in the Power Steering System. Which

Technician is correct?



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123.) Technician A states that on a Power Steering equipped vehicle, in the event of a complete Power

Steering Pump failure, the Operator will still have limited Steering. Technician B states that in aSteering System the Recirculating Balls will be used in the Power Steering Booster Cylinder

Assembly. Which Technician is correct?A.) A only.B.) B only.C.) Both A and B.D.) Neither A nor B.

124.) When checking the Wheel Alignment on a Lift Truck, you should check for:A.) Bent Steering Arms.

B.) Proper inflation of all Tires.

C.) Check the Pitman Arm for excessive wear.


125.) Technician A states that on a Lift Truck the Steer Axle Camber is adjusted by bending the Steer

Axle. Technician B states that the Steer Wheel Toe-In is adjusted by adjusting the Drag Link.Which Technician is correct?


126.) Power Steering on a Rack and Pinion Steering System pushes which component?A.) The Pitman Arm.

B.) The Rack.C.) The Pinion.D.) The Spool Valve.

127.) A buzzing sound is heard from the Power Steering Unit. Technician A states that the PowerSteering Fluid may be low. Technician B states that there may be air in the Power Steering Fluid.

Which Technician is correct?


128.) Which of the following Power Steering Spool Valves changes passageways by rotating?

A.) The Sliding Spool Valve.

B.) The Rotary Spool Valve.C.) The Linkage Spool Valve.D.) The Vane Spool Valve.


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129.) The Adjusting Sleeve is attached to what item or items listed below?A.) Pitman Arm.

B.) Tie Rods.

C.) Center Link.D.) Idler Arm.

130.) Technician A states that one Alignment Angle Adjustment will not affect the other AlignmentAdjustments. Technician B states any one Alignment Angle Adjustment is interrelated with all of

the other Alignment Angle Adjustments and will affect those adjustments. Which Technician iscorrect?


TOTAL POSSIBLE FOR STEERING SYSTEM IS 13.



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SECTION 8:

Transmission, Differential, and Drive Axle

131.) The device shown to the right of this question is a:A.) Clutch Packet.

B.) Clutch Plate.C.) Brake Band.

D.) Pressure Plate Cover.

132.) The clutch release bearing pushes against the _________ to disengage the friction disc.A.) Pressure Plate Release Levers.

B.) Pressure Plate Springs and Linkage.

C.) Flywheel.D.) Torsion Springs.

133.) Technician A states that the pressure plate can be checked for warpage. Technician B states that

the pressure plate should be checked for the correct amount of lubricant. Which Technician is

correct?A.) A only.

B.) B only.

C.) Both A and B.


134.) A clutch seems to be scraping when being engaged. Technician A states that the rivets maytouching the pressure plate. Technician B states that the rivets may be touching the flywheelsurface. Which Technician is correct?

A.) A only.



135.) The principal rotating parts of a Torque Converter are known as:

A.) Impeller and Turbine.

B.) Flywheel and Vanes.

C.) Primary Pump and Turbine.D.) Stator 1 and Stator 2.

136.) On a set of gears, if the input gear has 12 teeth and the output gear has 24 teeth, what isthe gear ratio?

A.) 3 to 1.

B.) 2 to 1.C.) 1 to 1.

D.) 1 to 3.


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Use Figure #7 in order to answer questions #137 thru #140.137.) The Gears as shown in Figure #7 are in:

A.) Low Gear.

B.) Neutral.C.) Second Gear.

D.) High Gear.

138.) In Reverse Gear, the following gears in

Figure #7 would be meshed together:A.) 1 and 2.B.) 3 and 4.C.) 3 and 7.D.) 3 and 8.

139.) The Reverse Idler Gear is identified as:

A.) 8.

B.) 7.C.) 6.

D.) 4.

140.) The Countershaft Second Gear is

identified as:A.) 4.

B.) 5.

C.) 6.

D.) 7.

141.) Misalignment between the Standard Transmission and the Engine is most apt to cause:A.) The Transmission to slip out of High Gear.B.) The Transmission to slip out of Reverse Gear.

C.) Damage to the Gearshift Linkage.

D.) Damage to the Clutch Linkage.

142.) Technician A states that if the Engine Coolant is too hot, the Transmission may be overheated and

damaged. Technician B states that the Cooling System has no effect on the operation ortemperature of the Transmission. Which Technician is correct?

A.) A only.

B.) B only.


143.) Technician A states that the Transmission Fluid Level should be checked when the Transmissionis at Operating Temperature. Technician B states that it should be checked when the

Transmission is cold. Which Technician is correct?


C.) Both A and B.


FIGURE #7


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144.) A Lift Trucks ATF smells burnt. Technician A states that the Transmission Clutches are bad.Technician B states that the Transmission Bands are bad. Which Technician is correct?

A.) A only.



Use Figure #8 in order to answer questions #145 thru #148.145.) In Figure #8, what is the name of item #1?

A.) Pump / Impeller.

B.) Turbine.C.) Cover.

D.) Stator.

146.) In Figure #8, what is the name of item #2?

A.) Pump / Impeller.B.) Turbine.

C.) Cover.D.) Stator.

147.) In Figure #8, what is the name of item #3?A.) Pump / Impeller.

B.) Turbine.

C.) Cover.

D.) Stator.

148.) In Figure #8, what is the name of item #4?A.) Pump / Impeller.B.) Turbine.

C.) Cover.

D.) Stator.

149.) In a Torque Converter the output to the Transmission is taken off of the:A.) Turbine.

B.) Stator.

C.) Impeller.

D.) Cover.

150.) In the Torque Converter, oil flowing from the Turbine is redirected to increase its helping force by

means of the curved:A.) Turbine Vanes.B.) Pump Vanes.C.) Stator Vanes.D.) Secondary Turbine Vanes.

FIGURE #8

1

2

3

4


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151.) The Torque Converter action is multiplied by:A.) Increasing the Oil Flow Dynamic Force.

B.) Adding extra Rotating Members.

C.) Not allowing the Secondary Pump to Over Speed.D.) Bolting the Stator to the Impeller.

152.) If a Torque Converter has a broken Mounting Strap or Flex Plate, the trouble may be caused by:A.) A cracked Flywheel Housing or Converter Housing.

B.) Excessive Flywheel Runout.C.) Missing Dowel Bolts or Pins.



A.) Clutch Cover.

B.) Clutch Drum.C.) Clutch Plates.

D.) Clutch Discs.


A.) Clutch Cover.B.) Clutch Drum.

C.) Clutch Plates.

D.) Clutch Discs.


A.) Clutch Cover.B.) Clutch Drum.C.) Clutch Plates.

D.) Clutch Discs.

156.) Technician A states that without a Differential a Lift Trucks Drive Wheels could not rotate at the

same speed. Technician B states that in a Differential, the size of the Ring and Pinion Gears

determines the Gear Ratio. Which Technician is correct?A.) A only.B.) B only.

C.) Both A and B.


157.) Technician A states that in the Differential the Ring Gear is attached to the Rear Axles.

Technician B states that the Hyatt Flexible Roller Bearings are the type of Bearings that are mostoften used in Universal Joints. Which Technician is correct?

A.) A only.



FIGURE #9

1

2

3


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A.) Pinion Gear Shaft.

B.) Ring Gear.C.) Axle Shafts.

D.) Pinion Gear.


A.) Pinion Gear Shaft.B.) Ring Gear.

C.) Axle Shafts.

D.) Pinion Gear.


A.) Pinion Gear Shaft.

B.) Ring Gear.

C.) Axle Shafts.D.) Pinion Gear.


A.) Differential Pinion Carrier Stud.

B.) Differential Gears (Side Gears).C.) Differential Housing.

D.) Differential Pinion Carrier Gears.

162.) In Figure #10, what is the name of item #5?A.) Differential Pinion Carrier Stud.

B.) Differential Gears (Side Gears).C.) Differential Housing.D.) Differential Pinion Carrier Gears.

163.) In Figure #10, what is the name of item #6?A.) Differential Pinion Carrier Stud.

B.) Differential Gears (Side Gears).

C.) Differential Housing.D.) Differential Pinion Carrier Gears.


A.) Differential Pinion Carrier Stud.B.) Differential Gears (Side Gears).

C.) Differential Housing.

D.) Differential Pinion Carrier Gears.


A.) Pinion Gear Shaft.B.) Ring Gear.

C.) Axle Shafts.

D.) Pinion Gear.


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166.) Helically cut Gears are not only smoother running than Spur Gears but also:

A.) Have less Weight.

B.) Handle greater Torque.C.) Have Gear Teeth parallel to Shaft.

D.) Resist breakage due to Hot Shifting.

167.) The type of Differential Gearing most commonly used on Lift Trucks at the present time is the:

A.) Straight Spur.B.) Straight Bevel.

C.) Spiral Bevel.

D.) Worm.

168.) A Dial Indicator is used to measure what specification in a Differential?

A.) Backlash between Gears.

B.) Depth of the Gear Teeth.

C.) Condition of the Differential Bearings.D.) Differential Gear Ratio.

TOTAL POSSIBLE FOR TRANSMISSION, DIFFERENTIAL, AND DRIVE AXLE IS 38.



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SECTION 9:

Brake Systems

169.) Which of the following is a good service tip when working on brakes?A.) Bleed the system of Air.

B.) Replace the Brake Linings that show excessive wear.C.) Keep all Wheel Cylinder parts clean and coated with Brake Fluid.


170.) Friction on a Lift Trucks Brakes depends on which of the following?

A.) Power Steering Pressure.

B.) Amount of spring pressure on the parking brake.

C.) Speed of vehicle.

D.) Pressure between the drum and linings.

171.) During Braking a scraping sound is heard. Technician A states the problem is the bearings.Technician B states the Brake Shoes are worn and touching the Drum. Which Technician is

correct?


C.) Both A and B.


172.) The Pads on a Disc Brake System move ___________ the Rotor.

A.) Perpendicular to.B.) Parallel to.C.) Never touching.

D.) Attached to.

173.) Which of the following are Modes of Operation on Power Braking Systems?

A.) Apply mode.

B.) Hold mode.C.) Release mode.


174.) Brake Fluid passes around the Primary Cup in the Master Cylinder:A.) During the Return Stroke.

B.) During the Forward Stroke.

C.) During Parking Brake Action.D.) During Rapid Braking Action.


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175.) A Wheel Cylinder is leaking slightly. Technician A states that the Wheel Cylinder should beHoned and the old parts replaced. Technician B states a New Wheel Cylinder Kit should be put

in after the Wheel Cylinder is Honed slightly. Which Technician is correct?



176.) When a Brake Shoe becomes tighter against the Drum from rotation, this is called:A.) Residual Braking.

B.) Regenerative Braking.

C.) Self-Energization or Servo-Acting.D.) The Compensating System.

177.) A small amount of pressure is kept on the Hydraulic Fluid on certain Brake Systems:

A.) By the Compensating Port.

B.) By the Residual Pressure Check Valve.C.) By the Parking Brake.

D.) By the Springs in the Wheel Cylinder.

178.) When a Lift Truck is being stopped, it pulls to the right. Technician A states that the Left Wheel

Cylinder is leaking. Technician B states that the Right Wheel Cylinder is leaking. WhichTechnician is correct?

A.) A only.

B.) B only.


179.) The Primary Brake Shoe is __________________.A.) Shorter than the Secondary Brake Shoe.

B.) Longer that the Secondary Brake Shoe.

C.) The same length as the Secondary Brake Shoe.D.) Placed to the rear on the Wheel Cylinder.

180.) The _______________ is located to the front of the Wheel on vehicles with the Drum Brakes.A.) Secondary Brake Shoe.

B.) Brake Caliper.

C.) Master Cylinder.

D.) Primary Brake Shoe.

181.) Brake Shoes can be adjusted ____________________.

A.) Manually.B.) Automatically.

C.) Using the Star Wheel.



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182.) The Hydraulic Fluid used in Lift Trucks Braking System:

A.) Transfers the Pressure from the Master Cylinder to the Wheel Cylinder.B.) Cannot be compressed.

C.) Must withstand very High Pressures.


183.) Technician A states that a Spongy Brake Pedal is caused by air in the Hydraulic Brake System.Technician B states that a Spongy Brake Pedal is caused by a weak Brake Return Spring. WhichTechnician is correct?


C.) Both A and B.


184.) Technician A states that an improperly adjusted Brake Pedal may cause all of the Brakes Drag.

Technician B states that a properly bled Brake System will supply a solid column of Non-

Compressible Fluid from the Master Cylinder to the Wheel Cylinders. Which Technician is

correct?A.) A only.



185.) Technician A states that a Hydraulic Brake Fluid leak past the Primary Cup in the Master Cylinder

will not show any External Evidence, but eventually it will cause a blocked By-Pass Port in the

Master Cylinder. Technician B states that when the Service Brake Pedal of a Lift Truck can be

pushed to the Floorboard without any resistance the trouble may be caused by improper BrakeShoe Adjustment. Which Technician is correct?



TOTAL POSSIBLE FOR BRAKE SYSTEMS IS 17.



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SECTION 10:

Hydraulics

186.) Technician A states that in a Hydraulic System that utilizes a Pilot-Operated Check Valve,

Hydraulic Pressure must be applied to the Check Valve to Lock and Unlock the Valve.Technician B states that a badly worn Hydraulic Pump will deliver no Hydraulic Oil under aNo-Load condition. Which Technician is correct?


187.) A customer is having a problem with the hydraulic system on a lift truck that has a hydraulic pump

that delivers 1.5 gallons of oil per minute. Technician A states that the pump should deliver 13.5

gallons of oil in nine (9) minutes. Technician B states that the pump should deliver 90 gallons in

one hour. Which Technician is correct?A.) A only.


D.) Neither A or B.

188.) Viscosity of an Oil refers to the tendency of the Oil to resist:

A.) Acid accumulation.

B.) Flowing.

C.) Carbonizing.D.) Oxidation.

189.) Which one of the following items have nothing to do with Hydraulics?A.) M.P.H.

B.) P.S.I.

C.) G.P.M.D.) R.P.M.

190.) The purpose of the pressure relief valve is to do which one of the following?A.) Limit fluid flow to the actuators.

B.) Limit maximum pressure in the system.

C.) Relieve fluid pressure in a cylinder.

D.) Maintain a specific pressure in the system.

191.) What is the difference between a hydraulic cylinder and a hydraulic ram?

A.) A ram is meant to be used for higher forces.B.) A cylinder is longer.

C.) The rod of a ram has a cross sectional area greater than half that of the piston face.

D.) The rod of a cylinder usually will retract at a faster rate.


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192.) In a hydraulic system that uses a vented hydraulic reservoir, what causes fluid to flow from thehydraulic reservoir to the inlet port of a positive-displacement pump?

A.) Atmospheric Pressure.

B.) The Pressure Compensating Valve.C.) The height of the Pump in relation to the hydraulic reservoir.


193.) In a hydraulic system, what is the purpose of the hydraulic pump?

A.) To pump pressure.B.) To cause fluid to flow.

C.) To regulate the flow of fluid.

D.) To agitate fluid.

194.) Under certain conditions of heat, lowered pressure, or turbulence, gas or air bubbles called cavities

are created in fluids. When this condition occurs in hydraulic pumps, what is it known as?

A.) Volumetric Inefficiency.

B.) Intermittent Pressure Dispersement.C.) Reverse Flow Agitation.

D.) Cavitation.

195.) Technician A states that Pressure Compensation in a Hydraulic Pump means that the pump varies

its output automatically to meet the system demand. Technician B states that PressureCompensation in a Hydraulic Pump means that the pump saves energy and reduces the likelihood

of oil breakdown from excessive heat. Which Technician is correct?

A.) A only.


D.) Neither A or B.

196.) Technician A states that the reverse flow within a pump due to the fluid leaking back within the

pump itself because of system pressure is called slippage. Technician B states that there can be no

leakage on positive-displacement pumps because they must continually deliver a specific amountof oil. Which Technician is correct?

A.) A only.


D.) Neither A or B.

197.) What causes pressure in a functioning Hydraulic System?A.) Resistance to flow.

B.) Pressure Relief Valve.

C.) Pressure Compensating Valve.D.) Load Drop Check Valve.


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198.) A valve that is a device used to define the flow of fluid whose purpose is to control valve elements

rather than to drive actuators is known as what type of valve?

A.) Counterbalance Valve.B.) Pilot Valve.

C.) Flow Control Valve.D.) Pressure Control Valve.

199.) A valve that is made to lift or tilt a load, then block return flow to support the load in placehydraulically is known as what type of valve?

A.) Counterbalance Valve.

B.) Pilot Valve.C.) Flow Control Valve.

D.) Pressure Control Valve.

200.) In a pressure relief valve, what term is used to describe the pressure at which the valve becomes

fully open, allowing full fluid flow back to the tank?A.) Cracking Pressure.

B.) Valve Setting.C.) Full Actuating Pressure.

D.) Pressure Range.

201.) A valve that regulates the rate of fluid flow in a specific part of a circuit, is known as what

type of valve?

A.) Counterbalance Valve.

B.) Pilot Valve.C.) Flow Control Valve.

D.) Pressure Control Valve.

202) Technician A states that a cushioned hydraulic cylinder is used to keep the hydraulic cylinder

quiet and ergonomically acceptable. Technician B states that a cushioned cylinder must be used

when there is a possibility of damage from the impact at the end of the piston stroke because ofhigh speeds and heavy loads. Which Technician is correct?

A.) A only.


D.) Neither A or B.

203.) An increase of pressure in a Hydraulic Cylinder will enable you to:A.) Have no effect.

B.) Increase the Force from the Cylinder.

C.) Increase the speed at which the Cylinder Rod extends.D.) None of Above.


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204.) The Hydraulic Cylinder in Figure #11, to the right,

is known as what type of Cylinder?A.) Single-Acting Cylinder.B.) Double-Acting Cylinder.C.) Triple-Acting Cylinder.D.) Captive Cylinder.

205.) With 2,000 PSI applied to both Hydraulic Cylinders, as shown in Figure #12 below, the Cylinderwith the 1 Diameter Rod will:

A.) Perform the same amount of workas the Cylinder with the

1.0 Diameter Rod.

B.) Perform no work.C.) Perform more work than the

Cylinder with the 1.0 Diameter Rod.

D.) Perform less work than theCylinder with the 1.0 Diameter Rod.

206.) When servicing a Hydraulic Cylinder, extreme care must be taken when installing the:

A.) Base.B.) Gland Nut.

C.) U Cups.


Use Figure #13 to answer questions 207 & 208207.) Using the Hydraulic Pump shown in Figure #13,

in order for the Hydraulic Oil to flow in the direction

of the arrows, GEAR A must rotate in what direction?

A.) Will not rotate as shown.B.) Clockwise.

C.) Back and forth.

D.) Counter-Clockwise.

208.) Using the Hydraulic Pump shown in Figure #13,

in order for the Hydraulic Oil to flow in the direction

of the arrows, GEAR B must rotate in what direction?A.) Will not rotate as shown.

B.) Clockwise.

C.) Back and forth.D.) Counter-Clockwise.

FIGURE #11

FIGURE #12

FIGURE #13


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Use Figure #14 to answer questions 209 & 210209.) The amount of Output Force of Piston J in

Figure #14 is:A.) 25 Pounds.B.) 50 Pounds.

C.) 100 Pounds.D.) 200. Pounds.

210.) The amount of Force being applied by Piston Mto Piston L in Figure #14 is:

A.) 25 Pounds.

B.) 50 Pounds.

C.) 100 Pounds.

D.) 200. Pounds.

TOTAL POSSIBLE FOR BRAKE SYSTEMS IS 25.


FIGURE #14


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SECTION 11:

Electrical

211.) What is the Name of the Electrical Circuit shownin Figure #15 to the right of this question?

A.) Parallel Circuit.B.) Series Circuit.C.) Series-Parallel Circuit.D.) Alternating Circuit.

212.) When storing lead-acid batteries, Technician A states that the batteries should be fully charged and

then drained of electrolyte and placed in a cool damp area to keep the plate material from

corroding and breaking away from the grid plates. Technician B states that the battery should befully charged, cleaned, the battery case must be dry, and the batteries need to be stored in an

unheated dry area. Which Technician is correct?A.) A only.

B.) B only.

C.) Both A and B.D.) Neither A or B.

213.) A warehouse operation has 24, 36 and 48 volt lift trucks, Technician A says that the operators

cannot plug the batteries into the wrong voltage chargers because the connectors are differentsizes. Technician B states that color coded connectors should be used to help prevent connecting

a battery of the wrong voltage to the wrong charger or truck. Which Technician is correct?A.) A only.B.) B only.

C.) Both A and B.

D.) Neither A or B.

214.) What is the name of the rotating switch that connects the Spark Plugs of an Internal Combustion

Engine to the Ignition Coil Secondary Circuit in the regular and correct Firing Order?A.) Distributor Points and Rotor.B.) Distributor Points and Condenser.C.) Distributor Cap and Rotor.D.) Distributor Cap and Points.

215.) The two types of Field Coils used in D.C. Motors are:

A.) Series and Separately Excited.B.) Compensated and Fixed.

C.) Strong Field and Weak Field.

D.) Static and Variable.

FIGURE #15


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216.) A winding having a changing Magnetic Field will induce a Voltage and Current in a second

winding held in the same Magnetic Field. This action is called:

A.) Self-Induction.B.) Mutual Ignition.

C.) Mutual Induction.D.) Magnetic Field Collapse.

217.) The Meter in Figure #16, shown to the right, may be used to measure:

A.) Voltage.B.) Current.C.) Resistance.D.) All of the above.

218.) What is the value of the reading shown by the Display of the

Meter in Figure #17 shown to the right of this question?

A.) 11.52 Milli-Volts.B.) 11.52 Amps.C.) 11.52 Ohms.D.) 11.52 Volts.

219.) Technician A states that when conducting an Amp Draw Test on a Cranking-Motor you should not

operate the Cranking-Motor5 for more than 30 seconds in order to prevent it from overheating.

Technician B states that when making the Current Limit Adjustment on a Series Wound TractionMotor, with an SCR Controller in a Lift Truck, you should not stall the Traction Motor for longer

than 10 seconds in order to prevent damaging the Motor. Which Technician is correct?


C.) Both A and B.


220.) Technician A states that if the Commutator of an Electric Motor is not too dirty it may be cleaned

by going over it lightly with a Fine Tooth File. Technician B states that a Negative Plate Group

and a Positive Plate Group, nested together, with separators between them is called a Cell. WhichTechnician is correct?

A.) A only.



FIGURE #16

FIGURE #17


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Use the Figures #18 through #23 below to answer questions 221, 222, 223, 224, 225, and 226.

221.) The component shown in Figure #18 is a:

A.) Diode.

B.) DC Electrolytic Capacitor.

C.) Silicone Controlled Rectifier (SCR).D.) Commutating Capacitor.


A.) Transistor.

B.) Diode.C.) Silicone Controlled Rectifier (SCR).

D.) Commutating Capacitor.

223.) The Contactor shown in Figure #20 may be used for a:A.) Directional Contactor.

B.) Field Weakening Contactor.C.) 1A By-Pass Contactor.D.) Regenerative Braking Contactor.

224.) The Contactor shown in Figure #21 may be used for a:A.) Pump Contactor.

B.) 1A By-Pass Contactor.

C.) Regenerative Braking Contactor.D.) All of the above.


A.) Transistor.B.) DC Electrolytic Capacitor.

C.) Silicone Controlled Rectifier (SCR).

D.) Diode.

226.) Figure #23 shown above is a:

A.) Diode.B.) DC Electrolytic Capacitor.

C.) Silicone Controlled Rectifier (SCR).

D.) Commutating Capacitor.

FIGURE #18 FIGURE #19 FIGURE #20 FIGURE #21

FIGURE #23FIGURE #22


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Meter in Figure #24 shown to the right of this question?A.) 6.50 Milli-Volts.B.) 6.50 Amps.C.) 6.50 Ohms.D.) 6.50 Volts.

228.) Technician A states that Battery Power is always Direct Current. Technician B states that, in an

Electric Motor, weak Brush Holder Springs will cause the Brushes to wear out the Commutator.Which Technician is correct?


229.) Technician A states that when measuring Voltage you are measuring rate of flow. Technician B

states that when measuring Ohms you are measuring Electrical Pressure. Which Technician is

correct?A.) A only.B.) B only.C.) Both A and B.D.) Neither A nor B.

230.) In a Internal Combustion Lift Truck that uses an Alternator to charge the Battery, if whenconnecting the Battery the Technician reverses the Polarity of the Battery Cables:

A.) The Engine wont Crank to Start.B.) The Engine will kick back on Start Up.C.) The Rectifier Diodes will be irreparably damaged.D.) The Engine will Stall at High Speeds.

231.) The Drawing shown in Figure #25, to the right of

this question is an Electrical Schematic of a:

A.) Series Drive Motor.B.) Separately Excited Field Drive Motor.

C.) AC Drive Motor that is Delta Wound.

D.) AC Drive Motor that is Wye Wound.

FIGURE #24

FIGURE #25


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Meter in Figure #26 shown to the right of this question?A.) 6,169 Ohms.B.) 6.169 Amps.C.) 6.169 Ohms.D.) 6.169 Volts.

233.) The Iron Frame and Pole Shoes of a D.C. Motor, provide a place on which the Field Coils can beassembled. What other purpose does the Frame and Pole Shoes serve in a D.C. Motor?

A.) Add additional weight to the Motor so it can develop more torque.

B.) Provides bearing housings for Armature bearings or bushings.

C.) Provides a low reluctance (low resistance) for the Magnetic Flux provided by theField Coil Windings.


234.) The Drawing shown in Figure #27, to the right of

this question is an Electrical Schematic of a:A.) Series Motor.

B.) Separately Excited Field Motor.

C.) AC Motor that is Delta Wound.

D.) AC Motor that is Wye Wound.


Meter in Figure #28 shown to the right of this question?A.) 87,900 Ohms.B.) 87.9 Amps.C.) 87.9 Ohms.D.) 87.9 Volts.

TOTAL POSSIBLE FOR ELECTRICAL IS 25.


FIGURE #26

FIGURE #28

FIGURE #27


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SECTION 12:

Cooling System

236.) An engine has a large amount of silicon and calcium buildup in the cooling system. Technician Astates the silicon is there because of the high quality of the antifreeze. Technician B states the

calcium is there to lubricate the aluminum cylinder block. Which Technician is correct?

A.) A Only.B.) B Only.

C.) Both A and B.


237.) Technician A states that when water is heated it contracts. Technician B states that rust in theCooling System is usually formed by the iron, water, and oxygen in the Cooling System. Which

Technician is correct?A.) A only.

B.) B only.


238.) Which system will produce more rust and corrosion in a Cooling System?

A.) A Cooling System without an Expansion Tank.B.) A Cooling System with an Expansion Tank.

C.) A Cooling System without a Cross-Flow Radiator.D.) A Cooling System with a malfunctioning Thermostat.

239.) Technician A states that most Water Pumps have permanently Sealed Type Bearings. Technician

B states that the inlet of the Water Pump is connected to the lower Radiator connection. WhichTechnician is correct?


240.) Technician A states that a Radiator Pressure Cap with a 13 P.S.I. rating will increase the EngineCoolants Boiling Point to approximately 250 Fahrenheit. Technician B states that the Water

Pump part that rotates to cause the water circulation between the Radiator and the Engine Water

Jackets is called the Rotor. Which Technician is correct?A.) A only.B.) B only.C.) Both A and B.D.) Neither A nor B.


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241.) Technician A states that a Cooling System that continuously keeps the Engine at a low Operating

Temperature will cause Crankcase Oil Sludge build up and corrosion of the Engines internal parts.

Technician B states that most Lift Trucks use a Puller Type Fan. Which Technician is correct?A.) A only.B.) B only.C.) Both A and B.D.) Neither A nor B.

242.) On a Lift Truck that has a Shroud attached to the Radiator:

A.) All of the Fan Blades protected widths should be inside the Fan Shroud.

B.) One-Half of the Fan Blades protected widths should be inside the Fan Shroud.C.) One-Third of the Fan Blades protected widths should be inside the Fan Shroud.

D.) One-Fourth of the Fan Blades protected widths should be inside the Fan Shroud.

243.) Generally, ________, ________, or ________ type materials are used for the Core on a Radiator.

A.) Platinum, Palladium, Titanium.B.) Steel, Aluminum, Iron.

C.) Brass, Copper, Aluminum.D.) Copper, Teflon, Magnesium.

244.) What happens to the Freezing Point of Engine Coolant if the percentage of Anti-Freeze is to high?A.) It decreases.

B.) It increases.

C.) It gels together.


245.) When an Expansion Tank is used on the Engine Cooling System:A.) Overflow Coolant from the Pressure Cap enters the Expansion Tank.B.) Coolant is drawn back into the Radiator when the Engine cools down.

C.) Coolant can be added to the Expansion Tank.


246.) On an Engines Cooling System, a Fan Shroud is used:

A.) To reduce any hot spots in the corners of the Radiator.B.) To protect the Radiator from damage.

C.) To protect the Radiator Hoses from damage.


247.) Technician A states that when two different metals are immersed in Engine Coolant, at the same

time, the metals may set up an Electrical Current flow in the Engine Coolant. Technician B

states that the standard Radiator used with Internal Combustion Engines today is considered aLiquid to Air Type of Heat Exchanger. Which Technician is correct?



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248.) Which two deposits build up inside the Engines Cooling System?A.) Calcium and water.

B.) Silicate and rust.

C.) Calcium and silicate.D.) Water and rust.

249.) When installing a Thermostat into an Engines Cooling System, the Temperature-Sensitive Valveon a Thermostat should always be placed toward the _______________ side of the Engine.

A.) Hot side.B.) Right Side.

C.) Left Side.

D.) Cold side.

250.) Technician A states the Thermostat can be checked only by keeping it in antifreeze. Technician B

states in order to check the Thermostat, remove it , and suspend it in water with a Thermometer

while heating up the water. Which Technician is correct?

A.) A Only .B.) B Only .


TOTAL POSSIBLE FOR COOLING SYSTEM IS 15.



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SECTION 13:

Lubrication

251.) A Lift Truck must be put in storage for four months. Technician A states that the oil should bechanged before storage because of acid buildup in the oil. Technician B states that the old oilshould be kept in the Engine and then changed after the Lift Truck is taken out of storage. Which

Technician is correct ?A.) A only.

B.) B only.


252.) Extreme Pressure, or Hypoid Gear Oils are compounded with additives:

A.) To increase viscosity.

B.) To provide anti-score protection.C.) To make them water repellant.

D.) To provide lubrication.

253.) When hydrocarbons combine with oxygen in the oil, the process is called _________________ .

A.) Oil Oxidation.B.) Organic Acid Oxidation

C.) Oxidation Inhibitor.


254.) Technician A states that the Viscosity Rating of an oil is a measurement of the oils lubricating

quality. Technician B states that Detergent Oil cleans an Engine more efficiently by carryingforeign material in suspension. Which Technician is correct?


255.) What lubricant should be used to service Wheel Bearings?A.) Regular Chassis Grease.

B.) 90 Weight Gear Oil.

C.) Silicon Grease.

D.) None off the above.

256.) Technician A states that the advantage of a Detergent Oils is its ability to clean. Technician B

states that when servicing an Engine the Crankcase Oils should be drained when the Oil is hot.Which Technician is correct?



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257.) Technician A states that the American Petroleum Institute (API) Gear Oil Lubricant Designationsare designed to help in the selection of the correct Gear Oil Lubricants. Technician B states that

an Engines Oil Level should be checked immediately after stopping the Engine. Which

Technician is correct?A.) A only.B.) B only.C.) Both A and B.D.) Neither A nor B.

258.) An SAE 90 Gear Oil is:

A.) Less viscous than SAE 50 Motor Oil.

B.) More viscous than SAE 50 Motor Oil.C.) More viscous than SAE 140 Gear Oil.

D.) Less viscous than SAE 30 Motor Oil.

259.) Technician A states that Synthetic Oil should never be used as a Break-In Oil. Technician B

states that Synthetic Oil should never be used in an old Engine. Which Technician is correct?A.) A only.



260.) The additive put into oil to help polish moving parts is called a/an ________________ additive.

A.) Anti-Scuff.

B.) Anti-Dispersant.

C.) Anti-Wear.D.) Anti-Oxidation.

261.) Which device controls the pressure of the oil directly from the Oil Pump?A.) Oil Relief Valve.

B.) Oil Regulator Valve.

C.) Oil By-Pass Valve.D.) Oil Pump Control Valve.

262.) Fuel has been found in the Engine Oil. Technician A states it could be because of too rich of aCarburetor Mixture. Technician B states it could be caused by a bad Diaphragm in the

Mechanical Fuel Pump. Which Technician is correct ?

A.) A only.


D.) Neither A nor B

263.) Two common problems that cause an Engine to experience an Oil Pressure drop are a

damaged ________________ and ________________ .

A.) Dipstick Tube & worn Main Bearing.B.) Faulty Sending Unit & low Engine Coolant.

C.) Main Seal & improper Inspections.

D.) Faulty Sending Unit & bad Rod Bearings.


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264.) Chemicals added to oil to keep small particles of dirt separated from each other are called:

A.) Detergents.

B.) Dispersants.C.) Viscosity Index Improvers.

D.) Separators.

265.) An oil with a 10W30 label means the oil has a/an ________________ at 0 Fahrenheit.

A.) API 30 rating.B.) SAE rating of 10.

C.) SAE rating of 30.

D.) API SD rating.

TOTAL POSSIBLE FOR LUBRICATION IS 15.



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SECTION 14:

Safety

266.) If a Technician we must work under a Lift Truck, such as pulling down an Oil Pan on an Engine,the Technician should:

A.) Suspend the Lift Truck from an Overhead Chain Hoist so there is no chance of it

falling on the Technician.B.) Support the Lift Truck in the air with Wheel Cradles, or with Blocking under the

Frame Prop Points.

C.) Never work under a suspended Lift Truck.


267.) Technician A states that gases exhausted from an Internal Combustion Engine during Repair and

Tune-Up will rise to the roof of the building and will create no problems. Technician B statesthat when Parking a Lift Tuck the Forks must always be lowered to the Floor Surface. Which



C.) Both A and B.


268.) The Stability is a measure of the Lift Trucks resistance to:

A.) Lubrication.B.) Travel.C.) Maintenance.

D.) Overturning.

269.) Technician A states that it is OK to use Gasoline to clean Greasy Parts as long as we do it outside

in the fresh air. Technician B states that Horseplay or Practical Jokes are an acceptable practice

on the Shop Floor as along as they are conducted in a safe manner. Which Technician is correct?A.) A only.

B.) B only.

C.) Both A and B.


270.) When using a Cutting Torch:

A.) Light the Torch with a Friction Lighter.B.) Shut off the Gas to change the Torches by Crimping the Hoses.

C.) No Eye Protection is necessary.

D.) There is no Danger of Fire.


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271.) Technician A states that when using a Portable Grinder always check the spray of sparks you are

creating. Do not direct them at another worker, and be careful of open solvent cans, Gasoline orLP Gas Leaks, Greasy Rags, or any other Flammable Material. Technician B states that you

should never push a Lift Truck with the Forks of another Lift Truck, always push Lift Trucks

Counterweight to Counterweight. Which Technician is correct?A.) A only.B.) B only.C.) Both A and B.D.) Neither A nor B.

272.) When removing a Radiator Cap while the Engine is Hot:

A.) Twist the Cap quickly and jump back out of the way.

B.) Never remove the Radiator Cap while the Engine is Hot always wait until theEngine cools below 80 Fahrenheit.

C.) Cover the Radiator Cap with cloth and turn it gradually to allow the Pressure to be

reduced slowly, until the Cap can be safely removed.

D.) There is no need to worry just remove the Radiator Cap in a normal Manner.

273.) Technician B states that when using a Hydraulic or Mechanical Jack make certain that it is on a

firm-flat footing, such as a concrete floor, when jacking against an asphalt surface, care must betaken so that the Jack Base does no sink in, allowing the Jack to work at an angle, this same

condition exists in dirt or gravel yard conditions also. Technician B states that when handling

Regular Automotive Type Batteries you should always wear Work Gloves and lift and carry theBatteries with you hands in order to avoid the possibility of dropping the Battery. Which



274.) A Technician servicing a Lift Truck on the Customers Premises;

A.) May assume that all Safety Precautions will be observed.

B.) Should exercise extreme Caution because of an Unsafe Environment.C.) May assume that Customer Personnel will help him.

D.) Is permitted in any location in the Plant.

275.) When a Technician is required to lift Heavy Parts:

A.) Use any Hoisting Equipment that may be available.

B.) Ask for help.

C.) Use a Lift Truck, if available.D.) All of the above.

276.) When Handling Industrial Batteries with a Lift Truck and Battery Bar:A.) Use both Forks set close together with a Cross Bar of Steel and the Battery Bar

Sling draped over the Steel Bar in order to lift the Battery.

B.) Make sure the Lift Truck has enough Capacity to safely lift the Battery.C.) Cover the Battery with a non-conductive material, such as plywood, in order to

prevent short circuits and sparks across an open Battery top.



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277.) In the event of a minor Injury while working on a Lift Truck in the Shop:

A.) Immediately tell a fellow Employee.B.) Use a Band-Aid.

C.) Report the Injury immediately to the First Aid Personnel.D.) Just ignore the Injury.

278.) Which of the following, under normal conditions, is notconsidered Safety Attire for aLift Truck Technician?

A.) Safety Shoes.B.) Safety Glasses.C.) Long Sleeve Shirt.D.) Work Gloves.

279.) When using a Lift Truck to Lift a second Lift Truck off of the floor:

A.) Use only one Fork in order to maneuver the Lift Truck easier.B.) Drive under the Lift Truck as far as practical so that the Load is carried as

close to the Fork Heel as possible.C.) There is no need to secure the Lift Truck on the Forks, the Lift Trucks own weight

will prevent it from moving or sliding on the Forks.


280.) Certain types of Shop Injuries may be avoided by:

A.) Assuming all Safety Rules are being practiced.

B.) Always maintaining a Clean and Orderly Work Area.C.) Working alone.

D.) Wearing Leather Soled Shoes.

TOTAL POSSIBLE FOR SAFETY IS 15.



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SECTION 15:

Welding

281.) Tinning a Soldering Copper consists of:A.) Heating until Rainbow Colors appear.

B.) Cleaning and Coating with Solder.C.) Keeping the Soldering Tip Bright and Clean.

D.) Filing.

282.) Generally speaking, when making a Fillet Weld, the Electrode should be held as in figure:

283.) An Example of using too slow of a Welding Speed in which figure:

284.) A cracked Weld, as shown in Figure #29 to the rightof this question, could be caused by:

A.) Welding Speed too slow.B.) Uneven Heating.C.) Wrong Electrode.D.) Poor Appearance.

285.) When Welding,

Mechanical Aptitude Test 080609

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