I'll provide the answers to the questions based on the provided images.

SECTION A
QUESTION 1
a) Briefly explain two track chain inspections. (2 marks) * Visual inspection: Checking for
obvious damage like cracks, wear, loose bolts, and missing components. * Dimensional
inspection: Measuring components like pin and bush wear, track shoe height, and link pitch to
assess wear limits.
b) During a test run of the undercarriage give any four checks that are to be checked. (2 marks)
* Smoothness of operation (no excessive noise or vibration) * Proper track tension * No
abnormal heating of components * Steering and braking performance
c) Explain how one can inspect the following ground engaging equipment: i) Ripper (2 marks) *
Check for bent or broken shanks, worn or missing teeth, and cracks in the frame. ii) Mould
board (2 marks) * Inspect for wear on the cutting edge, cracks in the mouldboard, and loose or
damaged bolts. iii) Bucket tips (2 marks) * Examine for excessive wear, cracks, or breakage.
Check for secure attachment. iv) Cutting edge (2 marks) * Look for wear, chipping, or bending.
Ensure it is securely fastened.
d) State two important factors of keeping written logs for service schedule on ground engaging
equipment. (2 marks) * Tracking maintenance history: Provides a record of all services
performed, aiding in troubleshooting and predicting future maintenance needs. * Compliance
with warranty and regulations: Essential for maintaining warranty validity and adhering to
safety and operational regulations.
e) Give two precautions to be observed before carrying out arc welding on an excavator. (2
marks) * Disconnect the battery: Prevents damage to electrical components and systems from
welding currents. * Ensure proper ventilation: Protects against harmful fumes generated
during welding.
f) State two advantages of using a Segmented Sprocket. (2 marks) * Easier and quicker
replacement of worn segments, reducing downtime. * Lower replacement cost as only worn
segments need to be replaced, not the entire sprocket.
QUESTION 2
a) State five components of the Undercarriage of a bulldozer with an elevated sprocket. (5
marks) * Track chain (links, pins, bushes) * Track shoes * Idlers (front and rear) * Track rollers
(carrier and track rollers) * Sprocket (elevated drive sprocket)
b) Give the function of the equalizer bar. (2 marks) * Distributes the weight of the machine
evenly across the track frames, allowing the tracks to conform to uneven terrain and maintain
traction.
c) How does a grader achieve sharp turns? (2 marks) * A grader achieves sharp turns primarily
through its articulated frame steering combined with front wheel lean and sometimes
tandem drive differential lock/unlock.
d) Give four reasons why track chains are adjusted. (4 marks) * To prevent excessive wear on
components (pins, bushes, sprockets, idlers). * To maintain proper engagement between the
sprocket and track chain. * To improve traction and stability. * To reduce noise and vibration.
e) State four advantages of track chains over tyres. (4 marks) * Superior traction and flotation on
soft or uneven terrain. * Better weight distribution, reducing ground pressure. * More durable
and resistant to punctures and damage. * Enables operation on steep slopes and difficult
terrain.
f) Give the function of tandem chains on a grader. (2 marks) * Tandem chains on a grader drive
the tandem bogies, which provide power to the rear wheels, enhancing traction and allowing for
independent movement of the wheels over uneven ground.
g) List one merit of tempering a metal. (1 mark) * Increases toughness and ductility, reducing
brittleness after hardening.
SECTION B
QUESTION 3
a) Define the following Undercarriage terms. i) Link pitch. (2 marks) * The distance between the
centers of two consecutive track pins in a track chain. ii) Track pitch. (2 marks) * The distance
from the center of one pin to the center of the next pin on a track chain. (Essentially the same as
link pitch, often used interchangeably in this context). iii) Sprocket pitch. (2 marks) * The
distance between the centers of two consecutive teeth on a sprocket, measured along the pitch
circle. It must match the track pitch for proper engagement.
b) Give four advantages of rubber suspension over leaf spring suspension system. (4 marks) *
Smoother ride and better shock absorption. * Reduced noise and vibration. * Less maintenance
compared to leaf springs. * Longer lifespan of components due to reduced stress.
QUESTION 4
a) List five symptoms which indicates that the track needs adjustment. (5 marks) * Excessive
sag in the track. * Track coming off the idler or sprocket. * Excessive noise or vibration from the
tracks. * Steering difficulties or machine pulling to one side. * Accelerated wear on track
components.
b) Give three possible reasons of a bulldozer pulling to one side while being driven. (3 marks) i)
In a straight ahead position. * Uneven track tension. * One track motor or final drive delivering
less power. * Worn or damaged steering clutches/brakes on one side. ii) One reason why a
swinging bearing on an excavator needs continuous greasing. (2 marks) * The swinging bearing
(or swing bearing/slewing ring) is subjected to continuous rotational movement and significant
loads, requiring constant lubrication to reduce friction, prevent wear, and extend its lifespan.
QUESTION 5
In a logical sequence describe the procedure of installing a new track chain on a bulldozer. (10
marks)
1.​ Prepare the machine: Park the bulldozer on level ground, engage the parking brake, and
block the tracks to prevent movement.
2.​ Loosen track tension: Release the track tension by loosening the grease fitting on the
idler recoil spring assembly to allow the idler to retract.
3.​ Break the old track chain: Locate the master pin or master link of the old track chain.
Use a track press or specialized tools to remove the master pin/link and separate the
track.
4.​ Remove the old track chain: Carefully remove the old track chain from the machine,
using lifting equipment if necessary due to its weight.
5.​ Position the new track chain: Guide the new track chain around the idler, track rollers,
and sprocket. Ensure the direction of the chain is correct if it is directional.
6.​ Connect the new track chain: Bring the ends of the new track chain together. Insert the
master pin/link and secure it using the appropriate fasteners or by pressing it into place
with a track press.
7.​ Adjust track tension: Gradually tighten the track tensioning mechanism (by adding
grease to the idler cylinder) until the correct track sag/tension is achieved according to the
manufacturer's specifications.
8.​ Inspect and test: Conduct a visual inspection to ensure all components are properly
seated and secured. Run the machine slowly forward and backward to check for proper
operation and recheck track tension after a short run.
QUESTION 6
Explain the operation of hydraulic applied steering clutches during: a) Cornering (5 marks) *
When cornering, the operator engages a steering lever or pedal that directs hydraulic pressure
to disengage the clutch on the side toward the desired turn. This reduces or stops power to that
track, causing the machine to pivot around the stationary or slower track. The other track
continues to receive full power, facilitating the turn.
b) Straight ahead position. (5 marks) * In a straight-ahead position, hydraulic pressure is applied
equally to both steering clutches, ensuring both tracks receive full and equal power from the
final drives. This maintains a straight trajectory for the bulldozer.
QUESTION 7
a) List the materials used in the manufacture of the following components: i) Track chain (2
marks) * High-strength alloy steel (e.g., manganese steel, boron steel) ii) Excavator bucket. (2
marks) * High-strength steel, abrasion-resistant steel (e.g., Hardox, Manganese steel for wear
parts) iii) Bucket tips. (2 marks) * High-strength, wear-resistant alloy steels iv) Rippers. (2
marks) * High-strength alloy steel, often with wear-resistant tips/shanks
PAPER NO: 319/22/M04 - UNDERCARRIAGE AND GROUND ENGAGING EQUIPMENT
MAINTENANCE
SECTION A
QUESTION 1
a) List (or) Give (4) causes of noise from track chains. (4 marks) * Improper track tension (too
tight or too loose). * Worn or damaged pins and bushes. * Worn sprocket teeth. * Lack of
lubrication on track components. * Build-up of dirt or debris in the track system.
b) Give the meaning of undercarriage. (3 marks) * The undercarriage refers to the entire drive
train system of a track-type machine, including the tracks, rollers, idlers, sprockets, and frames,
that supports the machine and provides traction and mobility.
c) State any five components of the undercarriage. (5 marks) * Track links * Track shoes *
Sprockets * Idlers * Track rollers (lower and upper/carrier)
d) State one (1) function of each component stated in c). (5 marks) * Track links: Form the
main body of the track chain, providing connection points for pins and bushes and track shoes. *
Track shoes: Provide flotation and traction, distributing the machine's weight over a larger area.
* Sprockets: Drive the track chain, transmitting power from the final drive to the tracks. * Idlers:
Guide the track chain around the ends of the track frame and maintain track tension. * Track
rollers: Support the weight of the machine on the track chain and guide the chain along the
track frame.
e) List three (3) effects of too tightly adjusted track chains. (3 marks) * Increased wear on pins,
bushes, sprocket teeth, and idlers. * Higher fuel consumption due to increased friction. *
Reduced machine performance and power. * Increased stress on final drives and other
powertrain components.
QUESTION 2
a) State two (2) advantages of an elevated sprocket undercarriage machine over the
conventional type. (8 marks) * Isolation of final drive: The elevated sprocket isolates the final
drive from ground-induced shock loads, reducing wear and prolonging its life. * Easier
maintenance: Components like the final drive are more accessible for service and repair as
they are not integrated into the track frame. * Improved ride comfort: The design can absorb
more impact, leading to a smoother ride for the operator. * Modular design: Allows for easier
replacement of major components.
b) State the four (4) clearance measurements performed in a motorised grader mould board and
scarifier. (8 marks) * Mouldboard float: The vertical movement of the mouldboard when it's in
the float position. * Mouldboard side shift: The horizontal movement of the mouldboard. *
Scarifier tooth wear: Measurement of the length of the scarifier teeth to determine wear. *
Scarifier shank clearance: The clearance between the scarifier shanks and their mounts.
c) Give four (4) critical areas to be checked during routine maintenance of the undercarriage. (4
marks) * Track pin and bush wear (elongation) * Sprocket tooth wear * Idler wear (flange wear,
tread wear) * Track roller wear (flange wear, tread wear)
d) Give two (2) functions of track rollers. (4 marks) * Support the weight of the machine on the
track chain. * Guide the track chain along the track frame, preventing it from derailing.
SECTION B
QUESTION 3
Describe the procedure of tensioning track chains. (10 marks)
1.​ Position the machine: Park the machine on a flat, level surface.
2.​ Clean the track: Remove any excessive mud, dirt, or debris from the track chain and
undercarriage components, as this can affect tension measurement.
3.​ Determine sag specification: Refer to the manufacturer's service manual for the specific
track sag or tension specification for your machine model. This is usually a measurement
of vertical sag between the track roller and the track shoe.
4.​ Locate tensioning mechanism: Identify the track tensioning mechanism, which is
typically a grease fitting (nipple) on the idler cylinder or a mechanical adjuster.
5.​ Adjust tension:
○​ To increase tension: Add grease to the grease fitting using a grease gun. As
grease is pumped in, the idler will move forward, increasing tension.
○​ To decrease tension: Loosen the relief valve or release the grease through the
tensioning mechanism (often by loosening the grease fitting a small amount) until
the desired sag is achieved. Caution: Grease can be under high pressure;
release slowly and carefully.
6.​ Measure sag: After adjusting, measure the track sag at the specified point (e.g., midpoint
between the carrier roller and the front idler, or between the first and second track rollers).
Ensure it falls within the manufacturer's recommended range.
7.​ Recheck and repeat: Cycle the machine forward and backward a few times to allow the
track to settle, then recheck the tension. Readjust if necessary.
8.​ Secure adjustment: If there's a lock nut or cap, tighten it after adjustment.
QUESTION 4
a) State two (2) types of master links used on track chains. (2 marks) * Split master link (with
bolts and nuts) * Pressed-in master pin (requires special tooling to remove and install)
b) What do you understand by the term 'hunting' in connection with track chain. (2 marks) *
"Hunting" in track chains refers to the uneven wear pattern that can occur on the track links and
sprocket teeth due to slight differences in pitch or manufacturing tolerances. It leads to the
sprocket teeth contacting different links at different points, causing accelerated and uneven
wear.
c) Give the component which is responsible for floatation on the bull dozer track chain. (2
marks) * Track shoes (or grousers)
d) Give the function of the grouser teeth on track chain. (2 marks) * Grouser teeth (or simply
grousers) are the cleats on the track shoes that project outwards to provide traction and grip
with the ground.
e) State two (2) types of sprockets used on a conventional undercarriage. (2 marks) * Integral
sprocket (fixed, single piece) * Segmented sprocket (bolted-on segments)
QUESTION 5
Explain the operation of spring applied hydraulic release steering clutches during: a) During
straight ahead operation (5 marks) * In straight-ahead operation, the steering clutches are
engaged. This means hydraulic pressure is applied to release the spring force that would
normally disengage the clutches. When hydraulic pressure is maintained, the clutches are held
engaged, transmitting power to both tracks equally, allowing the machine to move straight.
b) During cornering (5 marks) * When cornering, the operator actuates a steering control that
reduces or releases hydraulic pressure to the clutch on the side of the desired turn. The spring
force then overcomes the reduced hydraulic pressure, causing that clutch to engage and
effectively disengage the power to that track. This allows the machine to pivot or turn, with the
other track continuing to receive power.
QUESTION 6
a) State four (4) purposes of undercarriage inspection. (4 marks) * To identify worn or damaged
components before they fail. * To plan and schedule maintenance and repairs. * To extend the
lifespan of undercarriage components. * To optimize machine performance and reduce
operating costs. * To ensure safe operation.
b) A light vehicle tyre is written 215/70/16/R. Give the meaning of each number and letter. (4
marks) * 215: Tread width in millimeters (215 mm). * 70: Aspect ratio (sidewall height is 70% of
the tread width). * 16: Rim diameter in inches (16 inches). * R: Radial construction of the tyre.
c) Differentiate between a cross ply and radial ply tyre. (3 marks) * Cross-ply (Bias-ply) Tyre:
The plies (fabric layers) are laid diagonally across the tyre from bead to bead, forming a
criss-cross pattern. This construction results in a stiffer sidewall and tread. * Radial-ply Tyre:
The body plies are laid radially (at 90 degrees) to the direction of travel, running from bead to
bead. The tread is then stabilized by separate belt layers that run circumferentially. This
construction allows the sidewall and tread to operate more independently, providing better
flexibility, ride comfort, and often better traction and fuel efficiency.
QUESTION 7
Explain the procedure of removing track chain from a bulldozer. (10 marks)
1.​ Prepare the machine: Park the bulldozer on a firm, level surface. Lower the blade or
attachment to the ground. Engage the parking brake and block the tracks to prevent
accidental movement.
2.​ Loosen track tension: Locate the grease fitting for the track tensioning cylinder on the
idler assembly. Slowly and carefully loosen the relief valve or fitting to release the grease
and allow the idler to retract fully. This will slacken the track chain. Be extremely
cautious as grease is under high pressure.
3.​ Locate and prepare master link/pin: Identify the master link or master pin in the track
chain. This is the link that connects the two ends of the chain. Clean the area around the
master link/pin.
4.​ Break the master link/pin:
○​ For bolted master links: Use appropriate wrenches to unbolt and remove the
master link components.
○​ For pressed-in master pins: This typically requires a specialized track press
(either portable or workshop-based) to press out the master pin. This is a critical
step and often requires heavy-duty equipment.
5.​ Separate the track chain: Once the master link/pin is removed, the track chain will
separate.
6.​ Remove the track chain: Carefully guide the separated track chain off the idler, track
rollers, and sprocket. Due to the significant weight of a track chain, it is often necessary to
use a crane, forklift, or other lifting equipment to safely remove it from under the machine.
7.​ Inspect and clean: After removal, inspect the undercarriage components (rollers, idlers,
 sprocket) for wear or damage. Clean any debris or build-up.
QUESTION 8
a) List three (3) advantages of employing rubber tracks on some earth moving equipment. (3
marks) * Reduced ground damage (e.g., on turf or paved surfaces). * Quieter operation
compared to steel tracks. * Smoother ride and reduced vibration for the operator. * Lighter
weight, potentially leading to better fuel efficiency. * Higher travel speeds possible on certain
terrains.
b) Give two (2) advantages tubeless tyre over a tubed tyre. (2 marks) * Better heat dissipation,
reducing the risk of blowouts. * Slower air loss in case of a puncture, allowing for safer stops or
repairs. * Lighter weight (no inner tube). * Easier to repair small punctures (plugging).
c) Give five (5) varieties of excavator buckets. (5 marks) * Standard (general purpose) bucket *
Heavy-duty bucket * Rock bucket * Ditching/grading bucket * Clean-up bucket * Skeleton bucket
* V-ditching bucket