DPF

Theory trade test

Questions and Answers

By MR STG
 THEORY TRADE TESTS
QUESTIONS AND ANSWERS

SECTION A
1. What is the function and operation of shift valves in a transmission? [3]
To control the upshift by receiving line pressure from the governor valve to change one gear to the
other.

2. With the two stroke piston at TDC. What is taking place in the crankcase? [3]
Air and fuel mixture entering the crankcase

3. State advantages of integral valve guides compared to detachable ones. [3]

Less machining
Provides a better cooling
Less maintenance
Do not come to loose and service

4. What is a turbo charge? [2]

An exhaust gas driven pressure charging unit.

5. What are the three function of piston rings? [3]

To prevent the passage of lubrication oil into the combustion chamber
To transfer heat from a piston crown to the cooled cylinder walls
To maintain a gas tight seal between the piston and cylinder and all normal temperature pressure and
piston speeds

6. Define Ductility. [2]

The ability of a material to be rolled into wire

7. Define Elasticity. [2]

It can be stretched or deformed but it will return to its original shape

8. Give any three causes of engine overheating. [3]

Defective water pump
Defective thermostat
Damaged fan
Clogged fins

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 9. What valves on a 4 stroke are said to be rocking, what does it mean? [3]
Exhaust valve closing at the end of the exhaust stroke and inlet valve opening and the beginning of the
induction stroke

10. Give any three purpose of engine oil.[3]

Cooling agent
Cleansing agent
For lubrication to reduce friction

11. Why is the combustion chamber design important to the performance of an engine? [3]
For thorough combustion
Move complete combustion
It gives controlled and efficiency combustion

12. What is crankshaft bearing nip? [3]

Is the amount the bearing protrudes above the joint faces of the cap

13. Describe valve bounce and explain its effects. [3]

The vibration of the valve at high speed
It can affects air supply, combustion, the time of cooling the valve and seating of the valve

14. Describe the delay period. [2]

The period between injection and self-ignition.

15. Give four (4) types of file. [2]

Flat file
Half round file
Round file
Triangle file

16. Why is a work rule to remove the residual flux after the brazing or soldering is completed?
[2]
To check the quality of weld
For good looking of object

17. Fuel is supplied to the system in two major way. [2]

Pump supply
Gravity force

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 18. What is the purpose of an injector leak off? [2]
To get read of the excess fuel from the injectors

19. Why is a metal incorporated in the shirt of an aluminum alloy piston? [5]
Allows a slower controlled expansion rate.

20. Give any 5 causes of whitish blue smoke. [5]

0Worn valve guides/stem seals
Worn piston rings
Too advanced ignition timing
Worn engine cylinder walls
Lean mixture
Oil leaking in combustion chamber
Bad exhaust manifold
Bad head gasket

21. Name any 4 types of master cylinders. [4]

Lockheed
Tandem lockheed
Girling
Tandem girling
Girling compression barrel.

22. Give three advantages of air-cooling. [3]

Less bulk and mass
No freezing
No leaking
High thermal efficiency

23. Name three benefits of the turbo-charger to an engine. [3]

More power
Less fuel consumption
Cleaner exhaust
Less noise

24. What replace clutch assembly on an automatic transmission system? [2]

Torque converter

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 25. State any seven factors affecting tyre life. [7]
Road surface
High speed
Hard driving
Under inflation
Over inflation
Toe in
Toe out
Excessive load

26. What advantages can be gained by using double valve springs? [2]
If one fails the other one remains functional
To prevent the vibration of valve bounce

27. Why is full flow filtration system commonly used? [3]

It filters all the oil therefore is very safe and reliable
Also incorporate by-pass valve which insure that if oil is dirty they allow the unfiltered to circulate in
the system

28. List any five problem which associated with uncontrolled engine temperature. [5]
High fuel consumption
Loss of power
Cylinder bore wear
Oil dilution
Sludge formation

29. What is the purpose of wheel balancing? [2]

To prevent wheel shimmy

30. What is the function of a steering system? [2]

To control the direction of the vehicle

31. What is the purpose of interlocking plunger into the gearbox? [2]
To prevent two gears from being engaged at the same time

32. Explain the purpose of double declutch on a sliding mesh gearbox. [4]
To synchronize the speed of the layshaft and the main shaft
Making the speed of the layshaft and mainshaft nearly the same

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 33. Name 3 factors affecting the ignition delay in the diesel engine. [3]
Quality of fuel
Degree of atomization
Turbulence
Air supply
Temperature
Pressure

34. Define Cranking resistance. [2]

Force that act against torque required to start an engine

35. Why the battery be kept dry?

To prevent sulphates

36. After a power shift transmission has been bench tested it is fitted into the machine but does
not drive. State two likely causes.
Fault torque converter
Torque converter not engaging the transmission pump
Torque converter is not connected to the engine

37. What three factors that affect the torque that required to start an engine? [3]
Defective starter motor
Poor of battery
Thick of oil
Too many cylinders
High compression ratio

38. Why is fuel introduced in the cylinder in, sequence which is term the firing order? [3]
For smoother running and the better balance reduction of velocity changes in the distribution of gases.
This gives a better engine breathing and smoother running

39. State the disadvantage of very little or no valve clearance. [3]

The valve opens early and closes late
Valve will not seat properly
It will affect the time when the valve it will going to be cooled

40. What is the purpose of a modulation valve in a transmission? [3]

To make sure that the torque converter receive oil before transmission

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 41. What the advantage of hydraulic governor as compared of mechanical governor?
Smooth operation (smoother in operation)
Less moving components
Small and compact (light weight)
Fuel used as a lubricant

42. What is a hydraulic motor?

A rotary actuator that converts hydraulic pressure/energy into mechanical power

43. Why is turbulence of the air/fuel mixture in the combustion chamber important? [2]
Turbulence is the controlled air movements in the combustion chamber which causes the fuel and air to
mix thoroughly and complete to give controlled efficient in combustion

44. Name 4 factors that determine the torque transmitted by a dry friction clutch. [4]
Material used (coefficient of friction)
Number of friction surface
Surface area of lining
Pressure applied

45. Explain what effects brake surface area has on friction. [3]
The bigger the area the less the friction, the smaller the area the more the friction, the more the heat
generated

46. What is Pre-ignition? (Detonation)

When fuel burns earlier than wanted/uncontrolled burning

47. When dealing with a fire caused by thinners give three correct fire extinguishers to use?
Foam
Dry powder
Carbon dioxide

48. Give 2 purpose of cushion springs fitted between clutch friction linings. [2]
Provide for a smooth take up of drive.
The cushion the clutch engagement
They dampen vibration during drive take up

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 49. Give two types of HT cables used in the ignition system. [2]
Copper stranded
Carbon graphite

50. What tools would you use to accurately measure the following:

1. Cylinder head warpage >

Straight edge rule and filler gauge

2. Liner protrusion >

Dial test indicator gauge (DTI)

3. Bearing shell thickness >

Outside micrometer

4. Crankshaft end float >

DTI

5. Valve guide bore >

Small hole gauge

51. Give 5 functions of a clutch. [5]

To assist in gear changing
To provide temporary neutral position
To provide gradual take off
To allow smooth engagement and disengagement of gears
Helps to transmit drive from the engine to the gearbox

52. Why is the cutting edge of a cold chisel hardened and the top part left soft? [2]
To increase strength and top part left soft to prevent cracking under the impact of the hummer

53. Name 2 metals that constitute brass. [2]

Copper
Zinc

54. Give 4 main parts of an epicyclic gear train. [4]

Annular/ring gear/ internal gear
Planet gears
Planet carrier
Sun gear

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 55. Define the term clutch drag. [2]
When the clutch is not fully disengages

56. State 2 disadvantages of a wire spoked wheel. [2]

Too expensive
Difficult to maintain

57. Give 3 advantages of wet liners. [3]

Easy to fit
Direct contact with water
Improved heat conduction

58. Give 3 main types of universal joints used in motor vehicle construction. [3]
Constant velocity
Layrub type
Cross type

59. Identify 3 types of manual gearbox. [3]

Sliding mesh
Constant mesh
Synchro-mesh

60. Name any 5 types of injector nozzles

Single hole
Multi hole
Pintle
Pintaux

61. What type of crankshaft cannot be straightened, and how would you tell the difference
between the two shafts just by looking at them? [5]
Cast iron is naturally brittle
Noted with a thin joint or seam which is overflow from casting

62. State 2 precautions you must take when starting and shutting off an engine with a turbo-
charge. [3]
When staring allow the engine to idling for 5 minutes before take off
When shutting off allow the engine for 5 minutes before shutting off

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 63. Give three effects of detonation describing each. [2]
Loss of engine power inside the cylinder wall
Causes of wear inside the cylinder wall
Noise (pinking) when the engine is running

64. What is

a). crankshaft ovality?

When the crankshaft is out of round measure two points at 90 degrees apart

b). crankshaft taper?

When the crankshaft is out of round and measure at 180 degrees apart

c). name the instrument used to measure both taper and ovality
Outside micrometer

65. Give 5 advantages of electronic fuel injection system. [10]

Low fuel consumption
More power
Enhanced reliability
Excellent starting (cold or hot)
Needs less maintenance

66. Disadvantages of the sliding gearbox. [2]

It requires expertise in changing gears
Its noisy in operation

67. State the purpose of the well on the wheel base rim. [2]
Enables the tyre to be pressed into the recess for easy fitting and removing

68. What factors that govern the torque to require the engine?
Compression ratio
Size of battery
Type of oil

69. What three types of governors may be fitted to diesel injection pumps? [3]
Hydraulic governor
Mechanical governor
Pneumatic governor

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 70. Name two types of oil pump. [2]
Gear type (external and internal gear pump)
Eccentric vane pump
Eccentric rotor pump

71. When testing for satisfactory clutch operation, what checks should be made? [4]
Fluid level
Leaks
Pedal free play
Actuation of clutch fork

72. Give 2 functions of residual pressure in the braking system. [2]

Prevent the entry of air
Assure a solid column of fluid so that movement of the master cylinder piston is immediately reflected
by movement of the wheel cylinder.

73. A delivery valve has two functions [4]

a. List the two

Prevent a reverse flow of fuel
Controls fuel residual pressure (prevents fuel dribbling)

b. Define dribbling with reference to injectors

This is when fuel drips out of the nozzle after injection.

74. Give any two types of wheel bearings. [2]

Ball bearings
Taper roller bearings

75. Name any two types of oil flow found within a torque converter. [2]
Vortex flow
Rotary flow

76. Name three moving parts of the gear type pump. [3]
Dive Shaft
Drive gear
Driven gear

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 77. Give four reasons which cause a hydraulic pump to make noise. [4]
Restriction inlet line
Air leaks at inlet line
Air in system due to low fluid
Fluid viscosity too high
Pump speed too fast
Sticking internal pump parts

78. What advantages can be gained by using double valve spring? [2]
If one fails the other remain factional
To prevent the vibration of the valve bounce

79. State five reasons why hydraulic motor not given actual power. [5]
No/less oil
Defective connection from the motor to the sprocket
Blocked pipe/hoses
No/less fuel
Incorrect oil from the pump

80. Define the following;

(A) A lubricant

Any fluid that is used to lubricate parts

(B) Viscosity
The measure of the resistance of a fluid to flow

(C) Viscosity index

A measure of the rate at which temperature changes causes a change in viscosity.

81. What is the purpose of masked inlet valve? [2]

To produce/induce horizontal or rotary (air) swirl

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SECTION (B&C)

1. (A)Give three type of diesel engine sensors for each of the following. [20].

(i) Position sensors

Throttle position sensor
Exhaust gas recirculating (EGR) sensor
Crankshaft position sensor
Camshaft position sensor

(ii) Pressure sensor

Turbocharging pressure sensor
Vapor pressure sensor
Engine oil pressure sensor
Barometric pressure sensor
Fuel pressure sensor
Cylinder pressure sensor

(iii) Speed/ Timing sensors

Air flow meter
Engine speed sensor
Air fuel ratio meter
Camshaft speed sensor
Turbocharger speed sensor

(iv) Temperature sensors

Engine coolant temperature sensor
Cylinder head temperature gauge
Exhaust gas temperature sensor
Engine oil temperature sensor

2. How is the torque divider coupled to the engine? Briefly explain how it operates. [10].
It connects the engine to the planetary transmission. This connection is both a hydraulic and a
mechanical connection. The hydraulic connection is through a torque converter. The mechanical
connection is through a planetary gear set. At low engine speed no torque multiplication on both
hydraulic and mechanical. At high speeds engine put hydraulic torque converter and the planetary
gear set multiplies torque

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 3. (a) Give and draw three types of accumulator. [20].
1) Compressed-gas accumulator
a. Diaphragm type accumulator
b. Piston type accumulator
c. Bladder type accumulator
2) Tower type accumulator
3) Raised weight accumulator
4) Spring accumulator

(b) Briefly describe the charging procedure of accumulators.

Install the hose end of the gauging/charging assembly onto the nitrogen gas bottle.

Verity the gas chuck is backed all the way out on the gauging assembly.

Make sure the bleed valve is closed.

Once steps #2 and # are verified, begin installing the gas chuck onto the gas valve.

Turn the gas chuck in until pressure is indicated on the gauge. Do not turn the gas chuck all the way in,
as this will damage the gas valve.

Slowly crack open the nitrogen bottle valve; let the accumulator slowly fill until the gauge displays the
desired pre-charge pressure.

Shut off the valve on the nitrogen bottle.

Let the pre-charge set for 10 to 15 minutes. If after this time, the pre-charge is too high, slowly open the
valve

4. Give four types of engineering fits and give an example of each as found on a motor vehicle
engine. [8].
Interference fit- Dry liners
Slip fit/push fit- con rod and gudgeon pin
Step fit- Dry liner
Clearance fit- Journal bearings
Running fit/spline fit-
Screw fit- Bolt and nuts
Transitional fit- Welsh plugs

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 5. Explain in detail the following hydraulic terms [10].

A. Displacement
The volume of oil displaced by one complete stroke/rev of the pump/cylinder.

B. Hydraulic balance
A condition where equal opposed hydraulic force at on a part in a hydraulic components.

C. Relief valve
A valve which limits the maximum pressure in the system.

D. Variable displacement pump

Pump which the output cycle may be varied.

E. Open centre valve

Which the inlet and outlet ports are open in the neutral position allowing continues flow of oil from the
pump.

6. Explain in full the following technical terms. [10].

a. Final drive
A combination of the crown wheel and pinion which gives final ratio and also converts drive at 90
degrees

b. Viscosity of oil
Resistance of flow or flow rate

c. Bearing nip
Amount of the bearing protrudes above the joint faces of the cap.

d. Brake fade
Loss of brake efficient caused by heat generated by continues braking.

e. Engine capacity
Volume one cylinder multiply by all the cylinders.

7. Describe why shock absorbers are necessary on a vehicle. [10].

Their actual name is called dampers.
When a spring hurts a bump it has got a tendency to bounce like a ball or oscillate. To limits those
oscillation, a dumber is fitted in between a chassis and the spring. The dumper has got a housing,
piston and con rod which as it hurts a bump oil is forced through small orifices from one camber to the
other thereby limiting piston movement. Thus a dumping those oscillation

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 8. A. Explain how one can ”spill timing” a diesel engine with an inline injector pump. [20].
Turn engine in direction of rotation (DOR) until cylinder 1 is on TDC compression. Remove timing
rocker cover to valves of 6 cylinder. Align point of flywheel housing to the stipulated mark on the
flywheel for example 15 degree before TDC
Remove inspection cover on pump, turn pump in DOR until number plunger just starts to rise
Fit the pump on the engine leaving coupling bolts loose. Connect fuel system and bed the system
Remove number 1 injector pipe connection. Remove delivery valve and spring. Fit number 1
connection back one pump and also fit spill pipe one the connection
Prime pump so that fuel is issued fuel flows from the spill pipe. Advance pump until a drop of fuel
hands on the spill pipe. Lock that pump on the connection that is the point of spill cut off

B. Give 5 advantages of hydraulics on heavy equipment.

Transmission of large forces using small component, i.e. great power intensity

Start-up under heavy load

Smooth operation and reversal

Favourable heat dissipation

Good control and regulation

Precise positioning

9. Describe how one check track tension on a track type machine and how the track are
adjusted. [10].
Run the engine at low idle, then move the machine forward for a distance equal to the track length on
ground and slowly stop the machine.
Put on the track shoe a straight edge which stretches from idle to upper carrier roller.
Measure the maximum deflection between the bottom surface of the straight edge and top surface of
the track shoe………deflection should be 10-30mm
If the tension is not at the standard value adjust as follow:
a. Pump in grease through grease fitting with a grease pump.
b. Check tension again.
If tension is too much
a. Loosen the plug on grease fitting
b. When loosening the plug, turn it a max of one turn.

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 10. Explain the operation of power shift transmission and how we get speeds. [10].
It’s a gearbox in constant mesh by multidisc clutches which are actuated by hydraulic pressure and
released by a spring force. The gears are engaged manually. The transmission has 2 directional
clutches, forward and reverse and also has speed clutches to engage 1, 2, 3 etc. For the machine to move
a directional clutch and speed clutch should be selected.
Therefore selection of the speed are the same for forward and reverse.

11. A. Give advantages of aluminum pistons over cast iron pistons. [10].
Easy to machine
Light in weight
Good heat dissipates
Low vibration of engine

B. Give advantages of cast iron pistons over aluminum pistons

Very strong material
Dump mechanical noise
Resist wear
High coefficient of thermal expansion

C. Which metal is used to manufacture piston for high rated engines and moderate rated
engines.
Cast iron.

12. State 5 adjustments carried out on a differential. (2 marks per adjustment) [10].
Pinion bearing pre-load
Pinion height/depth
Carrier bearing pre-load
Tooth contact pattern
Backlash
Radial runout
Lateral runout

13. Describe the operating principle of a fluid coupling. [10].

A unit which have a housing, impeller and turbine. The engine rotates with housing and impeller. Oil
inside the impeller is drone out by the centrifugal force to strike the vanes of the turbine. The vanes will
turns with gear input shaft of the gearbox because of the gear input located into the splines of the
turbine.

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 14. Give three probable causes of the following torque converter problems. [20].

A. (i) Low stall speed.

Engine performances is not correct.

(ii) High stall speed in both directions.

Air in the oil
Low oil level
Torque converter slipping

(iii) High stall speed in one gear or in one direction.

A leakage of oil.
A failure of the clutch in gear or direction.

(iv)There is high torque converter pressure

Restriction of the oil flow through lines
Over speed of the transmission pump
Excessive transmission pump lift

(v) There is low torque converter pressure.

Low viscosity of oil
Damaged of turbine vanes

B. Give five probable things which causes the torque converter to get too hot during operation.
Clogged oil filter
Cracked suction lines
Too low fluid level
Failure of charging pump
Leakage of oil
Malfunctioning solenoid

15. Explain in a logical sequence how you would carry out a pressure test on a power shift
transmission. [10].
Run the engine to warm it up to a normal operating temperature
Raised the machine and place it on modern blocks
Connect the gauge which are attached to the transmission
Run the engine and engage a specific gear at a given rpm then check the pressure recorded at particular
point on the transmission. The results may inculcate the defective pump

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 16. Briefly explain the 3 phases of combustion in the C.I engine. [15].
With an added diagram….

Ignition delay
Near the end of the compression stroke, fuel injection begins, but does not begins immediately.
Flame spread
The flame spread causes a shape rise in cylinder pressure due to the sudden combustion of the fuel that
was injected in phase one
Direct burning
The fuel burns as it enters the chamber, giving a more gradual rise in cylinder pressure.

17. Explain briefly what you understand about the open centre and the closed centre hydraulic
systems. [10].
In an open centre valve system, the pump runs constantly and oil flows through the circuit continuous.
A fixed displacement pump is used. A valve is used which when it is in neutral/open position it allows
fluid to flow back to the reservoir
In a closed center system, the pump can be rested during operation whenever flow is not required to
operate an actual. This means that the control valve blocks flow from the pump when it is in
closed/neutral position.

18. Briefly explain how you adjust the governor shift valve for the torque divider. [10].
The shift valve controls upshift in an automatic transmission by receiving line pressure from the
governor valve. The two units can be adjusted to get early or late upshifting. Adjustment of governor
weights and a governor springs can be achieved by altering the size of the weights or the tension of the
spring. The spring on the shifter valve can also be changed to achieve late or early upshift. The
clearance between the throttles valve and the regulator plug behind the shifter valve, can also be
altered to achieve the same.

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 19. Draw and label a bladder type accumulator and explain how if functions. [15].

In this type of accumulator, gas is used to load a volume oil under pressure. The gas usually nitrogen
and hydraulic oil occupy the same chamber but are separated by a (pistons) bladder. When circuit
pressure rises, incoming oil to the chamber compresses the gas, when circuit pressure drops off, the gas
in the chamber expands, forcing oil out into the circuit.

20. Give 10 steps to be taken on battery maintenance. [10].

Ensure the electrolyte is on right level
Keep it dry
Avoid short circuiting
Do not put directly to the flow
Avoid leakages
Always clean the deposit on the terminals
Coat each terminal with grease to reduce corrosion
Keep the top lead closed
Do not overcharge as it will damage the battery
Do not over tighten the mounting brackets as it can damage the casing and leads plates.

21. Give five factors which promote detonation and explain briefly how each affect detonation.
[10].
Temperature inside the cylinder-if the temperature low they delay period is prolonged
Fuel quality- fuel with low ignition temperature leads to detonation
Combustion chamber design- some combustion chamber promotes swirl and swish
Turbulence- it determine the degree of atomization
Degree of atomization- it determine the final compression pressure

22. With the aid of diagram explain the difference between a single acting hydraulic cylinder
and a double acting hydraulic cylinder. [10].
Single acting cylinder Double acting cylinder

In a single acting cylinder oil pressure will raise the load but on the return stroke it is either spring
force pressure or weight of the loading components.
On a double acting cylinder release oil pressure to lower the load.

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 23. Name and describe the moving components on an undercarriage of a track type machine
and give the purpose of each components. [10].
Carrier rollers- to support the tracks
Track rollers- to support the tracks
Sprocket- to rotates the track chain
Track chain- provide traction and motion
Idlers and tension group- to support and guide the tracks

24. Explain why it is critical to have crown wheel and pinion backlash in a differential unit and
briefly explain the adjusting procedure. [10],
Backlash is the clearance between the crown wheel and pinion, that clearance allow the unit to turn and
also for lubrication to get smooth take off and smooth slows down. Too much clearance causes a jack
take off.
So after carrying out the following adjustments; pinion bearing pre-load, pinion depth, carrier bearing
pre-load and tooth contact pattern.
The mount a dial gauge (DTI) with a magnetic stand at a convenient place on the housing. Then adjust
the pointer to the tip of teeth of a crown wheel. Hold the pinion and move the crown wheel forward
and zero the DTI, moving backward the amount it reads is the backlash.
It can be adjusted as follows; if there is more clearance, loosen nut and on the opposite adjusting the
nut on the opposite side to the crown wheel slide closer to the pinion or opposite if it is too much.

25. Draw hydraulic symbols for [10].

1. Oil cool 2. Pump

3. Filter 4. Check valve 5. Hydraulic cylinder

26. State and describe any three tests to be done on fuel injectors. Seat tightness (front leak):
this ensure that the nozzle valve seat is sound when the pressure is behind the opening
pressure. [10].
Needle wear (back leakage): this indicates the amount of fuel that is passing from the needle or
pressure faces to the leak off pipe.
Pressure setting (pop test): the opening pressure (breaking point) must be checked, if incorrect, reset to
the recommended value.
Spray pattern: the pattern should be observed when it is operating under its working pressure. A
poorly atomized spray of streaky appearance indicates that the nozzle orifice is partially blocked.

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 27. Explain the following technical terms [10].

Power to weight ratio

Comparison weight of the engine by the power output

Volumetric efficiency
Actual volume of air induced by weight to theoretical volume

Brake power
Actual power available on the crankshaft

Indicated power
Actual power produced by the burning fuel/gasses

Thermal efficiency
Conversion of the potential heat energy in the fuel to a mechanical force

28. Explain how you would adjust a mouldboard circle. [10].

The circle must be kept properly adjusted for smooth operation.
1. Preparation
Loosen all jam nuts securing the guide plate setscrews.
Loosen the front guide plate set screws approximately 6mm to allow the circle to move freely. Use a
safe method to move the circle teeth away from the drive pinion. Measure the distance from the inside
edge of the circle to the side of the drawbar on both side of the machine.
Tighten the front setscrews on the rear guide plates to adjust the circle from side unit the distance is
approximately equal on both side.
2. Centering circle to pinion
Measure the backlash between each drive pinion and the circle teeth. If the backlash for each pinion the
same, tighten the front setscrews of the rear guide plates to adjust circle until the backlash
measurement is equal.
3. Setting pinion backlash
The front guide plate should always be in contact with circle at both ends. Tighten the setscrews of the
front guide plate to pull the circle closer to the drive pinion. The backlash to the face of each pinion is
set at 2mm. when you have obtained the correct backlash at both finally tighten the jam nuts securing
the front guide plate setscrews
4. Setting guide plate clearance
Measure the clearance between the rear guide plates and the circle inside edge. Adjust each rear plate
to have a clearance of 1.0mm plus 1.0

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 29. How do you carry out oil pump overhaul? [15]
Clean the pump and mark mating surfaces
Remove bolts clamping front and back plates to housing
Remove thrust plates, seals, bushes, bearings, and gears
Clear, dry and inspect components;
Measure the bushes for wear against specifications
Measure the clearance between housing and gear against manufacturer’s specification
Measure the clearance between driving and driven gear against manufacturer’s specification
Check the clearance between shaft and bushes against specifications
Replace defective components
Fit bushes/bearings, gears to back plate, thrust plate
Fit gear housing and other thrust and front plate
Then test the pump

30. Outline the installation procedure of tracks on the track frame. [20]
Place the machine in the correct service position of installing the tracks, on a level surface with
adequate space for rolling out the tracks.
Raise the undercarriage to barely take the machine weight off the track using the equipment
Position tracks under machine with sprocket side raised on block or roller
Lower the machine onto tracks
Connect one track link into sprocket tooth
Use machine drive to pick and up and move tracks into position
Fit master link/pin into place
Fit track in correct way
Tension the track by pumping grease through the grease nipple on the tension cylinder to
manufacturer’s specification
Test track operation

31. Briefly describe the operation of steering clutches. [10]

This incorporate multidisc clutch which hydraulically operated and spring released. The frictional disc
are splined to the half shaft and reaction member /disc are splined to the non-rotating half shaft casing.
Hydraulic pressure is used to clamp the clutches so as to brake the half shaft. When the half shaft is
brake the sprocket will not receive drive. When one once to turn the right will operate a lever to brake
the right side half shaft and maintain drive on the left drive half shaft. Therefore the machine will turn
to the right side.

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 32. A. Give two types of rack and pinion steering system. [20]
End take-off
Centre take-off

B. Outline the construction and operating mechanism of re-circulating ball steering box.
Construction
The steering wheel is fixed to the steering shaft, which has a threaded rod at the end. The threaded rod
is fixed, unlike in the rack and pinion type.
The block has gear teeth machined ON its surface.
The threads in the rod are filled with ball bearings.
These ball bearings have two functions: To reduce friction and wear in the gear;
Fixing the teeth of the gear to prevent the former from breaking contact with each other when the
steering wheel changes direction.
Mechanism
When the steering wheel is rotated, the rod turns.
When the wheel spins, the block moves.
The block moves another gear that in turn moves the Pitman’s arm.
The ball bearings in the threads re-circulate through the gear as it turns

33. In few point describe how you would adjust valve clearance give all the equipment? [10]
Turn the right direction of crankshaft.
Established that cylinder one is on TDC compression by rocking cylinder number four (4) and six (6).
Take a spanner and loosening the lock nut on the inlet valve rocker and put a filler gauge in between
and adjust that to get a magnetic feel between the valve foot and the rocker.
Then do for the exhaust, then from there turn the engine, rock number two and seat five, rock four and
seat three, rock one and seat six and rock five and seat two, rock three and seat four

34. Describe how one would carry out headlight beam alignment using the wall. [10]
Position car ten metres from aiming wall
Ensure that tyre pressure are correct
Bounce car to settle suspension
Mark out aiming wall dependence on the car
Mark centre of front windscreen and rear window with wax crayon and position car so that it is
aligned with the centre line of the aiming wall.
Switch on dipped beam and cover one lamp.
Adjust horizontal and vertical alignment to give light pattern

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 35. (A) Give eight probable causes as to why the transmission does not operate in any gear. [20]
Low oil level
Failure of the oil pump or the pump drive
Air leaks on inlet side of the pump
Clutch disc and plate are worn
Leakage at the seals
Forward and reverse clutch components are damaged

(B) Give four probable causes as to why the transmission slips in all gears.
Failure of the reduction gears (if applicable), check the rotation of transmission output shaft.
Failure of the bevel pinion or the ring gear, check the rotation of transmission output shaft
Mechanical failure in transmission
Low pressure caused by leakage inside the transmission

C) Give eight probable causes as to why the transmission gets hot during operations.
Bad temperature.
High oil level.
Too much slipping in the clutch.
Core of the oil cooler not completely open.
Damaged clutch.
Air mixed in the oil. Air leaks on the inlet side of the pump.
Low pressure due to hydraulic pressure tests are not correct.
Low oil flow through converter caused by a stuck converter relief valve.

36. State five pre-checks you would undertake before setting wheel alignment of a vehicle.
[10]
All tyre pressure to specifications
Tread depth and evidence of wear due faulty wheel alignment
Bearings for correct clearance [free play]
Kingpins and bushes for excessive free play lift
Ball joints for excessive free play, locking and rod lift
Swivel points of suspension unit for excessive free play
Shackle pins and bushes for excessive wear and side movement
Spring ‘U’ blots for tightness and plate security
Steering gearbox for excessive wear/free play and security on chassis

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 37. Define the following differential terminology.

a. Pitch line
Is a frictive line running through the length of the tooth at the centre.

b. Tooth root

c. Tooth face
Is a gear tooth area above the pitch line

d. Tooth flank
Is a gear tooth area below the pitch line

e. Tooth heel
Is the larger section of the gear tooth, which is farthest from the centre of the ring gear

f. Tooth toe
Is the smallest section of the gear, which is nearest the centre of the ring gear

g. Drive side of crown wheel tooth

Is curved outwards, or the convex that is driving forward

h. Coast side of crown wheel tooth

Is the side of tooth curved inward or the concave

38. List the components of a pneumatic braking system outlining how it operates. [20]
Air compressor
Air compressor governor
Safety valve
Supply pressure gauge
Air storage tank
Brake valve or Triple valve
Brake drums
Brake cylinder or Brake chamber
Brake pedal

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Operation
It consists of service brakes, parking brakes, a control pedal, and an air storage tank.
Parking breaks consist of a set of disc or drum brakes held in lock position by a spring mechanism.
Air pressure is required to release the parking brake and set the vehicle in motion. In case of service
brakes which are used for the regular operation of the vehicle, a pedal is pushed for stopping or
engaging and disengaging the brake.
Generally, a pressure of 6.8 to 8.2 bars is used for this kind of application
A majority of heavy commercial vehicles use drums with pneumatic brake systems although now the
usage of disc brakes are also catching up. Every vehicle fitted with air brakes has a pressure gauge
mounted on the dashboard and in clear line of view of the driver, this enables the driver or the operator
of the vehicle to be completely aware of the operational pressure in the compressor.
As an emergency fail-safe mechanism in case of an extreme sudden drop in the air pressure, the spring-
operated parking brakes are immediately engaged putting the vehicle to a safe stop.
(The basic principle of pneumatic brake system is similar to any other type of braking system, the only
differentiating factor being the use of compressed air in place of hydraulic fluids. So in principle, it’s
just a conventional braking system.)

39. Outline the design and operating principle of a limited slip differential system. [20]
Design
Viscous limited slip differential
Mechanical clutch type limited slip differential
Operation
Limited slip differential transmit equal torque to both wheels when driven straight.
When one wheel spins due to loss of traction, patch of ice, mud, too much throttle etc, then the unit
automatically provides more power to the wheel that has traction.
In situations where absolute lockup is need, a limited slip is not the best choice due to the fact that
limited slips do slip in some situations. An example of it slipping would be with one tire in the air.
Limited slips generally are a driven by a series of clutch disc located behind the side gears.
The different disc are held under tension with springs.
As the slip increases the tension increases between the different layers of disc and provides resistance
to limit the slip between the wheels.
A draw back to this is that they need to be rebuilt as they do wear and their effectiveness diminishes
over time.
A special additive is also needed for the differential fluid to enable the clutches to work properly and
to keep them from chattering during normal turns.

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 40. Describe the differential action [10]

a. In straight ahead position

The pinion drives the crown wheel rotates with differential cage and the sun gears, the half shaft and
the wheel at the same speed.

b. When cornering

The inner wheel slows down because it is meeting more resistances to turning. The planet gears walk
around and they slows down sun gear thereby speeding up the other sun gear, half shaft and the wheel

41. Draw the open centre and closed centre hydraulic system giving a brief description of how
each system operates. [20]
OPEN CENTRE

Within an open centre system, as the pump turns flow is generated and then directed back to the tank
through a central passage within the directional control valve. When one of the directional control
valve’s spools id stroked, the flow is focused towards a load and pressure is created. Once the pressure
exceeds the load, the moves and the hydraulic work is executed.
CLOSED CENTRE

Flow within a closed centre system is also created with the turning of the pump; however, only enough
flow is being produced to keep the pump lubricated and to achieve a standby pressure at the
directional control valve. In the closed centre system, when a spool is stroked a passage is exposed for
the flow to enter while a pressure signal is sent from the directional control valve to the pump. This
pressure signal informs the pump to then produce the flow needed to complete the hydraulic work.

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 42. Outline in sequence the operating of steering hydraulic control valve for steering clutches
and brake valve.
CLUTCHES
On a straight ahead oil is sent to the piston through rotating seal from spool valve. Oil pressure is
normally present at the clutch to provide drive torque to the final drive
When turning either side the spool valve is moved and oil is drained from the clutches. With the clutch
released the machine make a gradual turn.

BRAKE VALVE
When the brake pedal is pushed, mechanical linkage moves piston in the hydraulic control mechanism.
The movement in the hydraulic controls through the mechanical linkage moves struts towards each
other thereby pushing the ends of the brake band and this causes the band to come into contact with
steering clutch drum. Movement of the machine is stopped or slows it down.
When the brake pedal is released, the spring in the hydraulic controls move the mechanical linkage and
brake pedal. The struts move away from each other and the brake band is not in contact with clutch
drum

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