SM2B: NQF 2 SERVICE AND MAINTENANCE

INSTRUCTOR COPY
Pass mark: 60% Possible points: 65 Time allowed: 1 Hour 15 Min

These comprehensive exams are the questions for the Service and Maintenance course.
The exams are organized by topic. Some or all of the questions can be used as a
knowledge assessment after the relevant learning has been completed, or as a “test-out” if
the individual has demonstrated knowledge of the topics.
Tests:
1. General Machine Maintenance 35 points possible
2. Schedule oil sampling 18 points possible
3. Remove, dismantle and assemble components 12 points possible

1. GENERAL MACHINE MAINTENANCE

Answer the following questions or circle true or false:
1. Give a short description of what Preventative maintenance is and what is (3)
most important part of preventative maintenance.
Preventative maintenance refer to daily maintenance carried out on a machine
in order to keep the machine operating as efficiently as possible. The most
important part is the machine inspection
2. Write down 4 personal protective requirements for a safe machine inspection (4)
• Overalls / dustcoat
• Safety shoes
• A do not start tag
• Clean rags / mutton cloth
• Leather gloves
• Goggles
3. Write down three factors responsible for tire damage (3)
• Specific inflation pressure
• Specific load (over loading)
• Specific vehicle speed
• Vehicle maintenance (wheel alignment)
• Haul road and terrain condition
4. Write down the 4 things you must check / hear / feel / smell during a machine (4)
inspection when the engine is running.
• Smoke colour
• Unusual noise
• Vibration
• General performance

SM2B_Instructor -1- SERV 3700

 SM2B: NQF 2 SERVICE AND MAINTENANCE

5. Write down the two configurations batteries can be connected together (4)
and write down the voltage of each connection.
• Parallel connection - 12 volts
• Series connection - 24 volts

6. Diesel fuel tanks should be topped up in the morning before a shift (1)
False

7. Battery acid must never be mix into water (1)

False

8. One of the advantages of SOS is to detect foreign matter in oil (1)

True

9. Oils become thinner with heat but also expand more (1)
True
10. Diesel has the same density as water. (1)
True
11. A machine must be thoroughly cleaned before a machine inspection. (1)
False
12. Write down the 8 points you must make sure of before any inspection on (8)
• The machine is out of the way of traffic
• The machine is on level ground
• The transmission is in neutral
• The park brake is engaged
• All implements are lowered / supported
• The engine has been turned off
• The main disconnect switch is off and the key removed
• A "do not start" tag is placed in the cab
13. Write down 3 points of why maintenance is so important. (3)
• Reduce repair cost (overall operating cost) of machine
• Increased machine availability (lesser machine down time)
• Extend the life of the machine

2. SCHEDULED OIL SAMPLING

1. Name the functions of oil. (5)
• Reduction of Wear
• Removal of Heat
• Removal of Contaminants
• Corrosion Protection
• Sealing

SM2B_Instructor -2- SERV 3700

 SM2B: NQF 2 SERVICE AND MAINTENANCE

2. Name the four types of analysis that are carried out in the laboratory (4)
• Wear Rate
• Oil Condition
• Oil Cleanliness
• Additional Tests to detect water, coolant or fuel in oil

3. Give four reasons for scheduled oil sampling (1)

• Detects problems early, so they can be repaired before they become
major failures.
• Helps customers schedule downtime to fit their workloads.
• Monitors positives as well as negatives, so that customer will not have to
pay for repairs of components that are not worn out.

4. What is the Wear Rate Analysis used for? (1)

Ware rate analysis detects tiny metal particles caused by component wear.

5. What is Trend Analysis used for? (1)

Trending is an essential part of wear rate analysis. After three samples have
been taken from a particular compartment, a trend for each wear metal is
established.

6. What is soot and where is it found in a machine? (1)

Soot is found only in engine oil.

7. If the results of a Wear Analysis indicates high iron concentration in the final (2)
drive. What would the probable problem area be?
Gears, Bearings

8. What is formed when water and oil mixes and what is the resulting effect? (3)
When water combines with oil it forms sludge that reduces the oil’s ability to
lubricate and it plugs filters.

3. REMOVE, DISMANTLE AND ASSEMBLE COMPONENTS

9. Why is it important that all parts be thoroughly cleaned before measuring the (1)
part for serviceability?
Dirt and grime on the parts may affect the readings taken when the parts are
measured

10. Give 3 reasons why bearings are pre-loaded. (3)

• To improve running accuracy by reducing the run-out of the shaft.
• To improve gear engagement accuracy by increasing bearing rigidity.
• To reduce smearing by eliminating sliding and irregular rotation.
• To minimise abnormal noise due to vibration or resonance.
• To keep rolling elements in the right position relative to the raceway.

SM2B_Instructor -3- SERV 3700

 SM2B: NQF 2 SERVICE AND MAINTENANCE

11. How should bearing be stored and handled? (3)

• Bearings should only be removed from their protective packaging at the
assembly site just before they are mounted
• Any bearings that are to be stored for long periods of time must be left in
their original packaging
• Large bearings with thin walled rings should be stored in a flat position
and must be supported over the whole circumference of the bearing.

12. Why is it important to mark the position of parts before dismantling? (1)
Marking the parts before dismantling the component is an ideal way of
insuring that all the parts will later be assembled in the correct position.

13. Why should you never spin a bearing with compressed air? (1)
The rollers may be forced out of the bearing causing serious injury to
bystanders.

14. What three important points you should keep in mind when ordering new (3)
parts?
• Order the required parts as soon as possible thereby reducing the
possibility of time wastage.
• Make sure you have the correct description and serial or model number
of the part you require. This is extremely important to prevent the
ordering of incorrect parts.
• Ensure that you order the correct quantities of the parts that you require.

SM2B_Instructor -4- SERV 3700