Engine Fundamentals

1. In a 4-cycle diesel engine, which of the following strokes would be occurring if

both valves are closed and the piston is moving downward?

a. Intake.
b. Compression.
► c. Expansion.
d. Exhaust.

2. Which statement is true regarding the operating principle of a 2-cycle diesel

engine?

► a. One crankshaft revolution is required for each power cycle.

b. Two crankshaft revolutions are required for each power cycle.
c. The exhaust valve or port is closed when the intake port is open.
d. Intake and exhaust occur during separate strokes.

3. Which type of combustion chamber is the most widely adopted?

a. Side valve type.

► b. Overhead valve type.
c. F - head type.
d. T - head type.

4. Which of the following statements is true when comparing the characteristics

of a pre-combustion chamber type engine with a direct injection type?

a. The fuel consumption rate is lower than that of direct injection engines.
b. There is less thermal loss than that of direct injection engines.
c. It is easier to increase the temperature of the intake air in a pre-combustion
chamber
type engine.
► d. Engines with the pre-combustion chamber design have the ability to burn
lowgrade fuels.

5. Which of the following firing orders is most common for 6 cylinder engines
found in Komatsu products?

a. 1-4-2-6-3-5.
► b. 1-5-3-6-2-4.
c. 1-2-5-6-3-4.
d. 1-3-6-4-5-2.
6. At sea level, about how much of the composition of air is oxygen?

► a. 20%.
b. 30%.
c. 40%.
d. 50%.

7. What is the maximum percentage of horsepower increase that is possible by

supercharging and adding fuel to an engine?

a. 10%.
b. 20%.
► c. 30%.
d. 40%.

8. Which statement is true regarding the fuel used in a diesel engine?

a. The spray mist can never be too fine.

b. The larger the fuel globules, the faster the fuel will burn.
c. Advancing fuel injection timing increases horsepower and therefore has no
adverse
effects.
► d. Many factors affect the burning of fuel, particularly correct spray pattern,
injection pressure, and injection timing.

9. Which of the following best describes compression ratio?

► a. The volume in a cylinder with the piston at bottom dead center divided by the
volume with the piston at top dead center.
b. The volume in a cylinder figured by multiplying the length of the stroke by the
area of a circle having the diameter of the cylinder bore.
c. The amount of pressure felt on the human body at sea level.
d. The ratio between the air fuel mixture that actually enters a cylinder compared
to the amount that could enter under ideal conditions.

10. Which of the following is the best description of one horsepower?

a. A horse lifting a weight of 550 pounds a distance of one foot in 1 second.

b. A horse lifting a weight of 75 kilograms a distance of one meter in 1 second.
c. A horse lifting a weight of 1,100 pounds a distance of two feet in 2 seconds.
► d. All of the above.
11. Which of the following statements best describes “rated speed“?

a. The highest speed the engine can achieve.

b. High free idle speed.
► c. The speed at which the governor is set.
d. The speed which SAE rates the engine commercially.

12. Why is no engine 100% efficient?

a. Friction occurs at all moving parts.

b. Brake horsepower is always less than indicated horsepower.
c. Only a small part of the heat in the burning fuel can contribute anything toward
pushing down on the piston and thereby causing the engine to produce power.
► d. All of the above are contributing factors.

Engine Fundamentals
1. Which of the following is added to cylinder head molten iron to give the
finished casting increased toughness?

a. Carbon.
b. Silicon.
c. Manganese.
► d. All of the above.

2. Which of the parts listed below is subjected to the greatest combustion heat?

a. Piston pin.
► b. Valve.
c. Turbocharger.
d. Exhaust manifold.

3. Why is there a clearance between the rocker arm and the valve stem?

a. To protect against thermal expansion.

b. To prevent the entire movement transmitting mechanism from being subjected
to excessive force.
c. To prevent the valve from being kept open.
► d. All of the above.
4. Why do most diesel engines have wet type cylinder liners?

► a. They have high cooling efficiency and can be replaced should the piston sliding
surface become worn.
b. Wet liners are subjected to less combustion temperatures than dry liners or
piston bores machined into the block.
c. They are subjected to less friction than dry liners or piston bores machined into
the cylinder block.
d. No special seals are needed between a wet liner and the block.

5. A "mid-fit" cylinder liner uses which of the following to prevent leaking?

a. A press fit surface at the top and a clevis seal plus two o-rings at the bottom.
b. A press fit surface at the top and three o-rings at the bottom.
► c. A press fit surface at the top and a single o-ring near the middle.
d. Two press fit surfaces, one at the top and one at the bottom, plus a single o-
ring in the
middle.

6. Which of the following is the most important function of the piston?

a. Compressing the air so combustion can occur.

► b. To transfer the pressure of combustion to the crankshaft to turn the shaft.
c. To rapidly pass heat to the rings and out through the liner to the coolant.
d. All of the above.

7. Main bearings have a tin plating (overlay). What is its purpose?

► a. It provides initial run-in protection.

b. It adds hardness to the bearing, thereby increasing its life.
c. It transfers heat rapidly which allows the bearing to run cooler.
d. It protects the bearing from rough handling during packaging and shipping.

8. Which of the following parts govern the opening and closing of the valves?

a. Rocker arm.
b. Push rod.
► c. Camshaft.
d. Crankshaft.

9. What is the purpose of a damper?

a. To balance the crankshaft at the front end.

► b. To counteract torsional vibrations.
c. To counteract secondary vibrations
d. Absorbs unevenness of torque and makes power transmission smooth.

10. Which of the following may be used to control the thrust of a rotating shaft?

a. Thrust plate.
b. Thrust washers.
c. An end plate with adjustable shim pack.
► d. All of the above.

Air Intake and Exhaust Systems

1. Which of the following best describes an engine whose intake manifold air
pressure never exceeds atmospheric pressure?
► a. Naturally aspirated engine.
b. Turbocharged engine.
c. Turbocharged and after cooled engine.
d. Supercharged with a belt driven blower and inter cooled engine.

2. What is the function (s) of a turbocharger?

a. Increase horsepower.
b. Cool the intake air.
► c. Increase the quantity of intake air and minimize the amount of unburned fuel in
the exhaust.
d. All of the above.

3. Paper air filter elements are designed to block passage of all dust particles
larger than........?

a. 3 microns.
► b. 5 microns.
c. 8 microns.
d. 10 microns.

4. At what point does the electronic type dust indicator activate?

a. When the weight of the intake air filter element reaches 10 pounds.
b. When positive pressure in the intake manifold reaches 5 kg/cm².
c. When negative pressure in the intake manifold reaches 635mm Ag.
► d. When negative pressure in the air inlet pipe reaches 635mm Ag.
5. How much does an after cooler cool the intake air?

a. 10o to 20o C.
► b. 20o to 30o C.
c. 30o to 40o C.
d. 40o to 50o C.

Lubrication Systems
1. How is oil classified?
a. By its weight.
b. By its SAE viscosity number.
c. By its service classification.
► d. Both answers b and c above.

2. Assuming that the service classification is CC, CD, or CE, which of the
following types of engine oil is suitable for use in Komatsu manufactured engines
found in Komatsu products?

a. SAE 30.
b. SAE 15W-40.
c. SAE 10W-30.
► d. Any of the above is possible depending upon the ambient
temperature and the recommendation in the Operation and Maintenance
manual.

3. Which of the following components is used for reducing the load of the oil
pump when running at high speed?

a. Main pressure regulator valve.

► b. Oil pump relief valve.
c. Scavenging oil pump.
d. Filter by-pass valve.

4. An oil filter is designed to filter out undesirable elements circulating in the oil
system. Which of the following is the micron rating of the full-flow oil filters used
in Komatsu engines?

a. 5 micron absolute.
b. 10 micron absolute.
► c. 40 micron absolute.
d. 45.8 micron absolute.

5. The external appearance of the new style spin-on canister type by-pass filter is
identical to the appearance of the full-flow filter. If the customer paints over the
labels on the filters, how could you identify the by-pass filter?

a. The size of the by-pass filter is larger than the full-flow filter.
► b. Viewed from the top, the full-flow filter has more holes than the by-
pass filter.
c. Viewed from the top, the by-pass filter has more holes than the full-flow filter.
d. This is no problem because by-pass filters are never used in construction
equipment.

Fuel Systems
1. Who originally designed the High Pressure Fuel System found on some Komatsu
products?

a. Diesel Kiki of Japan.

b. Nippon Denso of Japan.
► c. Robert Bosch of Germany.
d. International Harvester of the United States.

2. The High Pressure Fuel Systems found on some Komatsu products are equipped
with a pump that takes fuel from the tank and delivers it under pressure to the
multi-pump (injection pump). What is its name?

a. Feed pump.
b. Transfer pump.
c. Lift pump.
► d. Depending upon the text, any of the above names could be correct.

3. Which of the following is most likely to happen when the fuel pressure between
the fuel transfer pump and main injection multi-pump assembly reaches a
pressure greater than 3 kg/cm² (43 psi)?
► a. The transfer pump will stop pumping.
b. The transfer pump inlet valve will open and the outlet valve will close.
c. The transfer pump outlet valve will open and the inlet valve will close.
d. Both lift pump valves will be open.

4. Which of the following statements is true regarding the Komatsu engine stop
motor?

a. Current only flows through it when the ignition key is in the "ON" position.
b. The motor turns in one (clockwise) direction.
► c. The motor works like a windshield wiper motor. It turns a specified amount in
one direction when the ignition key is turned on and turns an equal distance in the
opposite direction when the key is turned off.
d. The motor turns in one (counter-clockwise) direction.

5. Which of the following fuel systems supplies fuel to its injectors at all times if
the engine is running?

a. The Robert Bosch system.

► b. The Cummins Pressure-Time (PT) system.
c. The Rotary Distribution system.
d. None of the above.

6. Multi-pumps have individual plungers and barrels for each cylinder. Which of
the following best describes when injection begins for each cylinder?

a. When the inlet/outlet port opens.

► b. When the inlet/outlet port closes.
c. When the plunger is at its lowest point in the barrel.
d. When the plunger is at its highest point in the barrel.

7. Where does the metering of fuel take place in a high-pressure fuel system?

a. Injector.
b. Nozzle.
► c. Injection multi-pump.
d. PT pump.

8. Where does the metering of fuel take place in a low-pressure fuel system?

► a. Injector.
b. Nozzle.
c. Injection multi-pump.
d. PT pump.
9. Which of the following statements is true regarding injection timing in the PT
system?

► a. Injection occurs when the cam follower roller rolls over the part of the camshaft
surface called the "injection ramp."
b. Injection occurs when the cam follower roller rolls over the part of the camshaft
surface called the "retraction ramp."
c. Injection occurs when the cam follower roller rolls over the part of the camshaft
surface called the "outer base circle."
d. Injection occurs when the cam follower roller rolls over the part of the camshaft
surface called the "inner base circle."

10. Which component listed below needs to be adjusted using a dial indicator
when reinstalling on the engine?

a. Injection nozzle.
► b. PTD type injector.
c. PTD Top Stop injector.
d. Both a. and c. above.

Cooling Systems
1. Which of the following best describes the flow of coolant during normal engine
operation?

a. From the water pump, through the engine passages, to the thermostat, and
back to
the pump.
b. From the water pump, through the engine passages, to the thermostat, to the
radiator,
and back to the pump.
► c. From the water pump, through the engine passages, to the thermostat
where part of the flow goes to the radiator and the remainder goes to the
pump.
d. From the water pump, to the radiator, to the thermostat, through the engine
passages,
and back to the pump.
2. What is the ideal pH level for the source water used in the coolant mix?

a. Between 2 and 4.
b. Between 5 and 7.
► c. Between 8 and 10.
d. Any tap or drinking water source is good.

3. What causes pitting of cylinder liners?

a. Aeration.
b. Electrolysis.
c. Air bubbles.
► d. Imploding vapor voids.

4. Which of the following is the correct freezing protection point the diesel engine
technician should use when adding antifreeze to the coolant?

► a. Provide freezing protection to 10°F lower than the lowest recorded

temperature in the area of operation.
b. Provide freezing protection to -37°C (-34°F), which is obtained with a solution
of 50%
water and 50% antifreeze.
c. Provide freezing protection to -58°C (-50°F), which is obtained with a solution
of 32%
water and 68% antifreeze.
d. Provide freezing protection to -82°C (-68°F), which is coolant consisting of
straight antifreeze.

5. What is/are the reason(s) for pressurizing the cooling system?

a. To control the boiling point of the coolant.

b. To assure solid coolant flow into the extreme reaches of the system.
c. By maintaining a positive pressure in the system, most leaks will be obvious to
the outside and easier to detect.
► d. All of the above are reasons.

6. In an engine operating at sea level, each psi of pressure above atmospheric

pressure will raise the coolant boiling point by how much?

a. 1°F.
► b. 3°F.
c. 3°C.
d. 1°C.

7. How many different types of radiator core tube arrangements are found in
Komatsu products?
a. One.
b. Two.
► c. Three.
d. Four.

8. What component of a thermostat causes it to open and allow coolant to flow

through the thermostat?

a. A heat sensitive spring.

b. Expansive wax.
c. A heat sensitive thermostat housing.
d. All of the above.

9. Which of the following is the purpose of an after cooler mounted on a

turbocharged engine?

a. To heat the coolant.

b. To heat the inlet air during engine warm-up.
c. To cool the inlet air during normal engine operation.
► d. Both answers b and c above are correct.

10. Which of the following types of cooling fans are the most effective when
considering the transference of heat from the coolant to the atmosphere?

► a. Suction.
b. Blower.
c. Reversible.
d. Multi-blade.