QUESTIONS & ANSWERS STUDY GUIDE: HEAVY
VEHICLE SYSTEMS
SUSPENSION SYSTEMS OF HEAVY VEHICLES
Q: Name any 4 types of suspensions that you know
A: Leaf spring, Coil spring, Torsion bar, Air suspension
Q: What's the need for suspension systems on machines or vehicles?
A: Provide comfort, stability, traction, safety, and protect chassis.
Q: What is the purpose of helper spring?
A: Supports main spring under heavy loads and prevents sagging.
Q: Identify tangential, flat end & pigtail coil springs
A: Tangential: cut at angle; Flat: ground flat; Pigtail: tapered circle end.
Q: Arrange laminated leaf springs in their order
A: Master leaf → Graduated leaves → Helper leaves.
Q: Are torsion bars used on independent or non-independent suspension designs?
A: Independent suspension.
Q: Describe Air suspension system and how it works
A: Uses compressed air in bellows with compressor and valves to regulate ride height.
Q: What are the functions of torque arms (tubes), stabilizers and trailing arms?
A: Torque arms: transmit torque; Stabilizers: reduce roll; Trailing arms: control wheel movement.
Q: Measure camber, caster and kingpin inclination (KPI) angles
A: Camber: wheel tilt; Caster: steering pivot tilt; KPI: kingpin inward tilt.
Q: Identify reversed Elliot and Elliot a designs
A: Elliot: yoke on axle; Reversed Elliot: yoke on stub axle.
Q: What's the difference between toe in and toe out?? Do the measurements
A: Toe-in: wheels closer at front; Toe-out: wheels farther apart.
Q: Describe 2 methods for carrying out wheel alignments
A: Optical/laser alignment, Mechanical/trammel bar method.
Q: What is oversteer and understeer and their causes
A: Oversteer: rear slips more; Understeer: front slips more.
PNEUMATIC SYSTEMS
Q: Identify components of the pneumatics
A: Compressor, reservoir, regulator, valves, actuators, pipelines, air dryer.
Q: Tell any circuit of pneumatic system that you know
A: Brake system: Compressor → reservoir → brake valve → brake chambers.
Q: Identify the types of valves and their functions
A: Check valve: one-way; Relief valve: overpressure; Directional: control air path; Quick release:
exhaust air.
Q: Name 2 types of compressors
A: Reciprocating, Rotary screw.
Q: Name 2 types of braking systems of pneumatics
A: Service brake, Parking/emergency brake.
Q: How do we adjust pressure in this system?
A: By regulator or governor valve.
Q: What's the function of an air dryer?
A: Removes moisture and oil from compressed air.
Q: A DAF truck has oil leaks on its pressure tanks, what is the main cause of it.
A: Faulty compressor passing oil.
Q: How do we adjust pressures in pneumatic system?
A: Adjust regulator or governor settings.
HYDRAULICS
Q: Name 2 types of hydraulic systems
A: Open loop and Closed loop systems.
Q: Identify & state the functions of hydraulic pumps and motors
A: Pump: mechanical to hydraulic energy; Motor: hydraulic to mechanical energy.
Q: 2 types of hydraulic cooling systems
A: Air-cooled and Water-cooled.
Q: What's the difference between a cylinder and a ram?
A: Cylinder: fluid acts both sides; Ram: fluid acts one side only.
Q: 3 functions of hydraulic fluid
A: Transmit power, Lubricate, Cool/seal.
Q: Types of hydraulic lines and how to fit hoses
A: Pressure, return, suction lines; hoses fitted with couplings/clamps.
Q: How do we measure and adjust pressures in a hydraulic system?
A: Connect pressure gauge and adjust relief valve.
Q: Identify types of pickings (sealing)
A: O-rings, Lip seals, V-packings.
Q: Trace a hydraulic circuit on a certain machine and identify components
A: Excavator: Pump → Control valve → Actuator → Reservoir.
Q: Types of actuators and their tests
A: Cylinders (linear), Motors (rotary); tests include leakage, stroke, pressure.
Q: The difference between cracking and pilot pressure and their circuits
A: Cracking: pressure to open relief; Pilot: pressure to control another valve.
Q: What is the method and procedure for doing cylinder testing?
A: Disconnect, connect to test bench, pressurize, check leakage/stroke.
Q: Differentiate Relief valve and Unloader valve
A: Relief: limits pressure; Unloader: unloads pump when idle.
Q: Describe swinging of an excavator
A: Swing motor drives pinion which rotates swing gear on turntable.
UNDERCARRIAGE
Q: Name 2 types of undercarriages
A: Crawler, Wheel undercarriages.
Q: Tell and identify 2 types of track linkages
A: Sealed & lubricated (SALT), Dry track linkages.
Q: All the measurements on tracks and the necessary tools needed
A: Track pitch, link height, bushing wear; Tools: caliper, gauge, tape.
Q: Name 2 types of sprockets
A: Segmental, Solid sprockets.
Q: Identify the sprocket segment
A: Replaceable outer part engaging track links.
Q: Describe the proper procedure for carrying out track adjustments (tensioning or loosening)
A: Measure sag; add/remove grease in track adjuster cylinder.
Q: Describe 2 typical types of power train of Bull Dozers
A: Mechanical drive (torque converter), Hydrostatic drive.
Q: Describe how a dozer turns (steering and braking system)
A: Clutch/brake steering or hydrostatic differential speed.
Q: How do we adjust brakes?
A: Turn adjuster bolt to set clearance.
Q: Know how to change tracks
A: Release tension, remove master pin, reassemble track.
Q: Describe tilting and lowering of moldboard and ripping on a Dozer
A: Hydraulic cylinders tilt/lower moldboard; ripper breaks soil.
Q: Describe Excavator swinging on a turn table
A: Swing motor rotates pinion engaging swing gear on turntable.
