HMT ENTRANCE EXAMINATION QUESTION AND ANSWER

Q.1 Duty Ring Of Kraz Veh 255b :- [Ref O/M Page No 70 To 82]

(A) The lower cylinder of the brake valve is fitted with duty ring which may be set in
one of the three positions designated by letters P , H and TT , depending on
loading of trailer.

(i) When towing empty trailer the duty ring must set in the TT position. In
this case the valve of advance action of the trailer brakes relative to the truck
will be minimum.

(ii) When towing heavily loaded trailers and when the weight of the truck
train is great the duty ring must be set in `H` position. This will cause maximum
advanced braking of the trailer and will prevent the latter from running in to
towing truck.

(iii) The `P` position corresponds to the normal adjustment of the valves and
provides stable operation of the brakes under normal conditions.

Q.2 Centrifugal Oil Filter Of Kraz Veh

1. It is main component of KRAZ lubrication system. It is located at No 5 cylinder in

front of the engine. It is functioned due to the back pressure at the oil. After 1.6 Kg cm2 of
oil pressure the PRV in the centrifugal is opened and allowed the oil in to the rotor
assembly, but the outlet of the filter is a small orifice so the oil comes under back pressure
and the same back pressure falls on the rotor body, which comes to rotate at a speed of
5000 RPM.

Therefore the dust particles or the foreign materials in the oil is attached to the
inside the rotor wall. The clean oil is going to the sump.

(i) The centrifugal oil filter is responsible for filtering only 10% of the out put of
the pump and the remaining 90% is goes to the system.

(ii) Its components

(a) Outer body

(b) Rotor Body
(c) Shaft
(d) Strainer
(e) Spray nozzles

Q. 3 Spool valve of Kraz 255B :-

1. Spool valve is one of the component of the steering booster of KRAZ veh, which
serve for neutral , left and right turn of the vehicle.

2. It is seated on its seat if there is no force on steering wheel for either left side or
right side.

3. It has two groves for right and left chambers of steering booster. When start the
engine the steering pump sucks the oil from fluid container and delivers it up to spool
valve is on its seat, the fluid goes to the front and rear chambers of the steering booster
and also returns the excessive fluid to steering oil container.
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4. Unless we take right or left turn the spool will not move from it seat.

Q. 4 Hydraulic Booster

Hydraulic booster is one of the main component of the KRAZ vehs steering system,
which is fitted at right side on the veh chassis.

The steering booster is consisted of

(a) Right chamber

(b) Front chamber
(c) Ball joint
(d) Drag link

The front and right chamber serve for left and right turn respectively. The steering
booster has functioned three position.

 Left turn
 Right turn
 Neutral

Neutral

The hydraulic steering booster is in the neutral position when no force is applied to
the steering wheel. When the automobile runs along a straight line or along a curve with
the steering wheel no longer being turned, In this case the slide valve (Spool valve) is in
the neutral position the oil flowing in to the hydraulic booster distributor through supply
tube. When it passes into front and rear reaction chamber of distributor body through tube,
there by ensuring stable operation of the slide valve.

Left Turns

During the left turn pitman arm moves forward and acts upon ball pin, this
movement being transmitted through ball socket and sleeve slide valve connected to the
sleeve by bolt.

When slide valve moves 0.4 to 0.6 mm forward and its tugs close the return
chamber Circuit grooves oil flows into the cylinder front chamber presses against the
piston crown to shift the hydraulic booster forward along with piston rod together with ball
pin and drag link connected there. Thus the hydraulic booster contributes to the force
applied by the steering link to the wheel as the automatic turns. The oil in the rear
chamber is returned to the oil reservoir through return line.

Right Turn

During a right turn pitman arm moves backward to shift ball pin which
displace ball socket and spring and limit stop to pressure against the wall of sleeve and
moves the latter backward together with the slide valve. When the slides valve moves
back and its tugs close the return chamber circular grooves oil passes into the hydraulic
booster rear chamber through supply time. The oil passing into the cylinder rear cover to
shift the hydraulic booster along rod together with ball pin and drag link connected there
to.
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Thus the hydraulic booster contributes to the force applied by the steering linkage
to the wheels on the automobile turns with the action oil is forced by piston from the
cylinder front chamber into distributor return chamber when it returns into the oil reservoir
through line.

Q. 5 Clutch Adjustments Of Kraz 255B

(a) Size `A` adjustment

(b) Size `B` adjustment
(c) Withdrawal lever height adjustment.

Size `A` Adjustment

(i) Put the gear shift lever to the neutral position.

(ii) Remove the covers of the clutch and flywheel housing hatches.
(iii) Turn the flywheel with cranking device. Turn the adjusting screw all the way
in the middle driving plate, having previously unscrew the lock nuts.
(iv) Rotate the flywheel turn out all the adjust screw one revolution with lock
nuts and tighten it without disturbing the adjusted clearance of 1mm
between the adjusting screw tip and the middle driving plate. This ensures
the guaranteed clearance of the flywheel.

Size `B` Adjustment

(i) Disconnect fork of draw rod from clutch release bearing fork shaft.
(ii) Loosen the lock nut and turn the fork off or adjust the length of the draw rod.
So that pedal free travel is from 32 to 40 mm between the thrust ring and
release bearing.
(iii) Connect the fork with lever lock the pin with a collar and tighten up check nut
of the draw rod fork.

Withdrawal Lever Height Adjustment

This adjustment should be made with the help of special device which provides a
setting of 64+-5 mm.

(i) Fix the pressure plate on the special device and fasten the clutch cover
attachment bolts.
(ii) With the help of a height gauge measure the distance between special
device surface to the top of the thrust ring. Adjust the finger height by means
of finger adjusting nut.
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Q. 6 Special Features Of Kraz 255B

(i) Engine 4 stroke , 8 cylinder `V` shape 90. diesel engine.

(ii) Radiator shutters provided.
(iii) Copper sleeve is provided in cylinder head around the injector.
(iv) Engine exhaust brake is provided
(v) Cooling fan gets drive from timing gear.
(vi) Centrifugal oil filter is provided.
(vii) Clutch friction type double plate with cylindrical spring.
(viii) Gear box synchromesh type no 5th gear over drive and gear type oil pump is
provided for lubrication.
(ix) PTO gear is provided in gear box.
(x) Double reduction type differential is fitted.
(xi) Provision of towing valve.
(xii) Provision of towing valve.
(xiii) Provision of trailer brake system.
(xiv) Centralized tyre inflation system.
(xv) Hydraulic steering.
(xvi) Water pump drive belt deflection adjusted by shims.

Q. 7 Radiator Shutter Of Kraz Veh

It is fitted in front of the radiator. The function of the shutter is to control the water
temperature areas. The three section flap shutters are composed of steel plates
horizontally arranged on the front side of the radiator for quick warming up. The shutters
can be operated by a control linkage handle located under dash board.
During the winter season the shutters should be closed so that the water can be
brought normal temperature quickly.
During the summer season we have to open the shutters, So that the air can hit the
shutters and the engine temperature can be maintained.

Q.8 Differential Adjustment

Bevel Pinion Adjustment

1. The axial play to bevel pinion should not exceed 1 mm.

2. The checking is done by removing the axle to work table and measurement taken
by a dial gauge.
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3. The pre –tightening can be achieved by reducing the shims by 0.03 to 0.05 mm or
by grinding the adjusting washer in emergency. The turning movement should then be
checked with the help of spring balance and should rotate with a weight of 0.65 to 2.15 kg
corresponding to a movement of 0.06 kgm to 0.2 kgm.

Bevel Pinion Bearing Adjustment

Shims are fitted on both sides of the shaft play can be removed by removing shims
and seeing that the shaft rotates with a movement of 0.2 to 0.4 kgm. The quality of
meshing of the driving and driven bevel gear should be checked by the gear back lash
and by the gear tooth contact.

The backlash in new gear should be with in 0.24 to 0.52 mm in used great it should
be up to 0.70 mm is permissible.
The area of the contact pattern on the teeth of new gear should be about to 50%-
60% of the teeth surface for used gears increase in the area of the contact pattern is
permissible. Adjustment of the gear backlash and gear teeth contact in the meshing is
performed by the relative displacement of the driving spur gear complete with driven bevel
gear and the driving bevel complete with the housing.

Q. 9 Exhaust Brake Of Kraz Veh

Engine exhaust brake is an auxiliary brake. It is a compression type device used for
braking the truck by increasing the back pressure in the exhaust line of the engine.
It is used under the following circumstances.
(a) While traveling on long down hill gradient.
(b) In traffic situations demanding slowing down over a long stretch of road.
(c) IE slipping and muddy roads

Main components

(a) Exhaust brake pedal

(b) Air distributor valve
(c) Engine shutdown pneumatic cylinder
(d) Pneumatic cylinder for cast iron housing flapper.
(e) Cast iron housing with flap.

Operations

The system operation can be described in three portions.

(a) Normal position

(b) Apply position
(c) Release position
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NORMAL POSITION

In normal position air distributor check valve remains on its seat. Air pressure from
air tank always acts under the air distributor check valve.

APPLY POSITION

The engine exhaust brake is operated by pedal of the air distributor valve found on
the toe board cab. Pressure one exhaust brake pedal opens air passes into engine
shutdown pneumatic cylinder and pneumatic cylinder of flapper valve.

In the engine shutdown pneumatic cylinder piston moves forward with piston rod.
Piston rod is connected by a cable with FIP rack and FIP rack control comes in less fuel
position causing to slow down. Simultaneously pneumatic cylinder piston with rod also
moves forward against tension of spring. Piston rod is connected with flapper valve which
is located in cast iron is connected with flapper valve which is located in cast iron housing
and it closes flapper valve. Out coming exhaust is restricted and it exerts back pressure
on pistons and hence engine slow down.

RELEASE POSITION

When exhaust pedal is released air distributor check valve is closes the air passage
from air tank. Both cylinders piston comes to its original position with the help of piston
returning spring and air is released into atmosphere through tubular valve of air distributor.

ADVANTAGES

(i) It increases the life of tyres, brakes lining and drum and eliminates brake
fade.
(ii) It improves the life of service brake.
(iii) It also reduce driver fatigue.

(Ref 01 manual page No 107,108.)

Q. 10 Centarlised Tyre Inflation System

The tyre inflation control system serves fro increasing the cross country capacity of
the truck on heavy section of the road by decreasing the tyre pressure. In case of a tube
got puncture the system permits the truck to proceed with the movement as far as the
garage without changing the wheel , provided the compressor capacity is able to
compensate for air leakage from the damaged tyre.

The system is controlled from the driver cabin and it is possible for the driver to
constantly check the tyre inflation pressure by pressure gauge and maintained the
pressure within specified limits.
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Components

(i) Air pressure control valve

(ii) Limiter valve
(iii) Tyre pressure gauge
(iv) Wheel valves
(v) Wheel hub sealing device
(vi) Air pipes and hoses

Air Pressure Control Valve

The valve is a plunger type and consists of a body with holes for delivering
compressed air to the and into the atmosphere. Limiter valve is fitted in the front of air
valve is fitted in the front of air pressure control valve. The cut off valve permits the
delivery of air for inflating the tyre only in case the pressure in the air tank is 4.5 kg/cm2
and higher.

If the air pressure is less pumping of the tyres in the centralized tyre inflation
system is not possible. The valve is adjusted for the above air pressure by adjusting bolt
which additionally compress spring.

Position Of Air Control Valve

(i) Pumping position

(ii) Neutral position
(iii) Release position

Pumping Position

Air in tyres can be inflated only when pressure in truck pneumatic system is 4.5 kg
cm2 or more then diaphragm of limiter valve permits air entrance in pressure control
valve. When valve rod handle is pushed in valve spool lifts from its seat and air from air
tank through sides of spool valve goes to the wheel.

Neutral Position

In this position spool valve remains on its seat and air coming from tank acts on
spool valve only.

Release Position

In this position air has to be pumped out of tyres and valve rod is pulled out fully.
Air from tyres through sides of spool valve is connected to atmosphere. Amount of air
released from tyres can be seen from pressure gauge of centralized tyre inflation control
system, which is located on dash board.

Q. 11 Function Of Steering Pumps

The vane type steering pump is one of component of this veh steering system,
which is takes drive from crank shaft pulley through belt.
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When we start the engine the also comes to rotate and takes the hydraulic fluid
from container and delivers it up to the steering booster.

Its components

(i) Pulley
(ii) Pump housing
(iii) Vanes
(iv) Rotor
(v) Pump cover
(vi) Adjusting screw

The vane pump is able to deliver 55 kg/cm2 at 500 RPM and delivered 9.5 ltrs in
one minute and its maximum pressure is 70 kg/cm2.

Q. 12 Preventive Maint Of Kraz Veh

Preventive maint is such a maint which ensure equipment availability and increase
the life of the veh.

Preventive maintenance of cool system

(1) Fill the system with clean sift water.

(2) Pour water through a funnel having strainer using clean containers.
(3) After every two years remove and flush out radiator and complete cooling
sys.
(4) After every 12,000 kms grease water pump (bearing) with grease XC-271.
(5) After every 1000 kms or 6 months check all `V` bolts of generator
compressor engine water pump and hydraulic servo pump drive. For
tension the belts are checked by applying 3 kg pressure in the middle of the
belt branch. There should be a sag of 10 to 15 mm. For compressor belt the
sag is 5 to 8mm.
(6) To avoid deformation of the cylinder heads and cylinder blocks, water
jackets fresh water should be added on to the cooling system of hot engine
very slowly and only with the engine running.
(Refer EMER NO VW/H 481 No 1 ISSUE 1 dt July 77)

Preventive Lubrication System

(i) Type of oil used - OMD 110 or HD 50

(ii) Initial oil change - 1000 kms after

(iii) Clean primary oil filter element and secondary centrifugal oil filter with petrol
first
- 1000 kms

(iv) Second oil change after every - 2000 kms

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(v) Subsequent engine oil change - 2000 kms

(vi) Clean primary and secondary centrifugal oil filter with every engine oil
change with petrol

(vii) Air cleaner oil change with every engine oil change.

Preventive Maintenance Of Steering System

(i) Change initial hydraulic fluid after 1000 km or 6 months.

(ii) Subsequent change after 6000 km or 24 month
(iii) Change steering gear oil after 6000 kms/24 month.
(iv) Adjust `V` belt deflection 10-15 mm aat 3 kg load.

Preventive Maintenance Of Brake System

(i) Drain air tank weekly

(ii) Lubricate brake pedal shaft and brake expansion cam shaft after every 1000
km.
(iii) Brake shoe clearance adjust 0.2 to 0.9 mm after 3000 kms.

Q. 13 Fine Setting Of FIP

(i) remove the high pressure line of No 1 as injector order.

(ii) Install the momento scope of the No 1 high pressure union.
(iii) Set the governor shackle to cut in position.
(iv) Keep priming the fuel system and build up pressure in FIP main gallery.
After priming screw in the pump handle.
(v) Turn the engine crankshaft in DOR using cranking device until the fuel
appears in glass tube.
(vi) Turn the crankshaft in anticlockwise about 450 then slowly turn the
crankshaft clockwise. Watch alternatively the fuel level in the glass tube. The
moment up the fuel start moving in the tube , stop the crankshaft rotation
and check the alignment of the mark. The mark on the crankshaft pulley
should be aligned with 20 on the timing gear cover. As n alternative
numerical 20 on the flywheel should coin side with pointed of the flywheel
housing.
(vii) If the marks have not get come to face each other at the movement the fuel
start moving in the glass tube. Then loosen the attachment both in FIP
coupling and turn the coupling of the drive shaft against the rotation the
tighten the attachment bolt. Recheck the injection advance angle. If
misalignment of the mark has already passed the aligned position dive shaft
coupling must be turned towards its DOR displacement of the coupling with
respect to its flange through out division corresponds to four on thr fly wheel
on timing gear cover.
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Q. 14 Adjustment Of Hand Brake Of Kraz 255B

Tech Data

Clearance between drum & shoe - .7 to 1 mm

(adjusting by bolt)

Inner dia of brake drum - 380 mm

Width of shoe lining - 80 mm

Adjustments

(a) Apply brake with the hand lever fully.

(b) Loosen the lock nut of thrust screw and turn the screw in. A djust the
clearance between the screw and outer shoe to 0.5 to .75 mm.

(c) Release brake and loosen the lock nut of the brake shoe lever and the
eccentric pins and set the clearance to 0.70 – 1 mm between the shoes and the
drum sand lock the lock nut. Rest the adjustment can be done by yoke rod, so
that brake is engaged by moving lever by 5 to 6 matches.

Note :

(a) After adjustment the spring height is 48 mm.

(b) Hand brake lever is connected to the trailer brake which is operated
pneumatically released.

Q. 15 Bleeding Procedure Of Power Steering Of Kraz

Jack up the both front wheels. Remove the filler cap of the reservoir. Disconnect
the inlet and outlet pipe lines from spool valve and drain oil from pump and reservoir. Start
the engine. Turn the steering wheel to left and right. Drain oil from the power cylinder.
Clean reservoir tank and filter element separately in kerosene. Pour one litre fresh fluid if
reservoir and wait till it flows out through the pipe.

Connect the pipes on the spool valve. Pour fresh oil to the reservoir. Start the
engine at idle speed slowly turn the steering right to left. Built up the pressure in the
hydraulic system and air in the system will escape through filler cap. Shut off the engine.
Top up reservoir tank 40-50 mm below the upper edge of the filler neck.

Change initial oil after 1000 kms or 6 months, subsequently after 6000 kms or 2
years which ever is earlier.

Q. 16 Function Of Air Compressor

The compressor is a single stage two cylinder water cooled and gets drive from the
fan belt. After the system has been adjusted and there is no leakages it should be filled in
3-1/2 minute The air governor maintains the pressure with in limits. The compressor must
be overhauled after 50,000 km.