Auto Manual 2011 LJIET

L. J.
INSTITUTE ENGINEERING AND TECHNOLOGY

MECHANICAL ENGINEERING DEPARTMENT
AUTOMOBILE ENGINEERING LAB MANUAL
PRACTICAL NO: - 01
AUTOMOBILE BASICS
AIM: To study about the basics of an automobile. LEARNING OBJECTIVES: To understand the basics of an automobile. To understand the classification of automobiles. To understand the functions of the different automobile systems. THEORY: INTRODUCTION TO AUTOMOBILE In todays world, transportation has become an inevitable means for a compact and cohesive society. All sorts of things: goods, animals and mankind need to be transported from one place to another place with the help of an automobile. The automobile transportation on roads is comparatively cheaper. It accounts for about 70%out of all modes of transports available. Auto vehicles (or automobiles) are unguided ground vehicles propelled by a prime mover. Wide range of auto vehicles serves some specific purposes. Mopeds, scooters, motorcycles etc. are meant for individual uses while cars and jeeps are supposed to be family vehicles. A mini bus serves the need of society by transporting people while trucks are required for carrying goods. COMPONENTS OF AN AUTOMOBILE An automobile consists of two main assemblies viz. Chassis and Body. The chassis is a complete combination of various systems that enable it to run on the road. It is, in fact an auto vehicle minus the body. The chassis comprises of basic structure, prime mover, transmission system, auxiliaries and controls, and the wheels with inflated tyres. A suitably shaped body mounted on the chassis makes the complete auto vehicle which may be in the form of a mini bus, bus, truck, deluxe coach, goods carrier, etc. In its general construction, the chassis comprises of the following main details:o Basic structure. o Power unit. o Transmission unit
L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

o o o o
Accessories unit. Electrical systems. Controls and instruments. Body (or super structure).
Figure 1.0 Anatomy of an automobile CLASSIFICATION OF AUTOMOBILES The classification of automobile is as follows: On the basis of Number of wheels 1. Two wheelers 2. Three wheelers 3. Four wheelers 4. Six wheelers 5. Eight or more wheelers On the basis of Prime mover used 1. Steam engine driven automobiles 2. I. C. engine driven automobiles 3. Gas turbine driven automobiles 4. Electric power driven automobiles 5. Solar energy driven automobiles 6. Hydrogen propelled automobiles

On the basis of Weight of the vehicle 1. Light weight or light duty vehicles 2. Medium weight or medium duty vehicles 3. Heavy weight or heavy duty vehicles 4. Extra heavy duty vehicles 5. Special purpose (load) vehicles On the basis of Purpose served 1. On the road vehicles 2. Off the road vehicles 3. On the road and off the road vehicles On the basis of Wheel drive system 1. Single wheel drive (1 wd) 2. Two wheel drive (2 wd) 3. Four wheel drive (4 wd) 4. All wheel drive (6 wd or more) REVIEW QUESTIONS: 1. Define Automobile. Give the classification of automobiles. 2. Write a brief note on components of an automobile. 3. State the functions of the following Suspension system Steering system Drive line system Braking system 4. State the advantages and disadvantages of Front Wheel Drive. 5. Write a brief note on Articulated vehicles.
Grade obtained:Date & Signature of Faculty:-

PRACTICAL NO: - 02
AUTOMOBILE CHASSIS, FRAME AND BODY
AIM: To study about the automobile classis, frame and body. LEARNING OBJECTIVES: To understand the basic concepts of automobile chassis. To understand the functions of an automobile frame. To understand the construction of an automobile frame. To understand the basics of the body of an automobile.
THEORY: AUTOMOBILE CHASSIS A vehicle without body is called a chassis. It is the backbone of the vehicle. All moving parts of the vehicle are fitted to it. It is made of steel. To give it extra strength, it is provided with bolted, riveted or welded crosspieces. The chassis in general is a equipped with a I beam construction front axles. For a god chassis design and for its good performance it must have fast pick up, strength, safety, durability, dependability, ease of control, quietness, speed, economy of operation, low centre of gravity, stability, load clearance, braking ability, simplicity of lubrication, etc. the chassis frame and front and rear suspension systems without abnormally raising the frame or transmitting shock to the frame due to road irregularities. Types of chassis Classification of Chassis with respect to its controls 1. Conventional control chassis 2. Semi-forward control chassis 3. Full forward control chassis Classification of Chassis with respect to engine fitting 1. Engine at front 2. Bus chassis 3. Engine fitted at back 4. Engine fitted in front but cross wise 5. Semi-forward chassis 6. Engine fitted at the centre of the chassis

Figure 1.0 Photo of an automobile chassis and body. AUTOMOBILE FRAME The frames in auto vehicle having independent front-wheel suspension are heavier in front than those having conventional (or rigid axle) suspension. It is because there is no rigid front axle in independent frontwheel suspension vehicles. The side members of the frame are generally made of steel pressings of channel section. The members have variable depth so that the beam may be made of uniform strength. The crossmembers are generally riveted or welded to the side members and the longitudinal members. Functions of Frame 1. To support the load of body, engine, gearbox and radiator. 2. To provide the connecting link for front and rear axles. 3. To carry load of the passengers or goods carried in the body. 4. To withstand stresses caused due to bad road conditions. 5. To withstand forces caused due to a sudden braking or acceleration. 6. To withstand load / force caused due to turning of vehicle.

Figure 2.0 Components of a typical frame design AUTOMOBILE BODY The body is a superstructure of the vehicle. The chassis and the body make the complete vehicle. In larger and heavier vehicles, the chassis and the body are each made as a separate unit and then bolted together. The body is usually made from a large number of steel pressings which are welded together. The body is bolted to the chassis at numerous points. The rubber or felt-strips being interposed to damp-down (reduce) the vibrations and noise. REVIEW QUESTIONS: 1. Write a brief note on Automobile Chassis. Also sketch the layout of an automobile chassis. 2. State the functions of an automobile frame. 3. Explain with a neat sketch, the construction of a frame. 4. Write a brief note on Integral Frame Chassis. 5. Explain the defects in the chassis frame. 6. Enlist the basic requirements of an automobile body.

PRACTICAL NO: - 03
TRANSMISSION SYSTEMS OF AN AUTOMOBILE
AIM: To study about different transmission systems of an automobile. LEARNING OBJECTIVES: To understand the objectives of a transmission system. To understand the working of different types of clutches. To understand the construction and working of different types of gear boxes. To understand the different rear axle drives. THEORY: INTRODUCTION TO TRANSMISSION SYSTEM The mechanism that transmits engine power to the rear wheels (in case of rear wheel driven vehicles) or to the front wheels (in front wheel driven vehicles), or to all the four wheels (in four wheel driven vehicles) is known as a transmission system. It comprises of the following main units. 1. Clutch 2. Gear box (manual or automatic) 3. Overdrive (on many recent vehicles) 4. Transfer box (in four wheel driven vehicles) 5. Propeller shaft 6. Universal shaft 7. Final drive 8. Differential gear assembly 9. Rear axles

Figure 1.0 Transmission system of an automobile. FUNCTIONS OF A GEAR BOX The gear box and its associated units perform the following functions. 1) A gear box assists in variation of torque or tractive effort produced by the engine in accordance with the driving conditions. 2) It helps in smooth running of the vehicle at different speeds since variation in torque induces variation in speed. 3) It provides a means to vary the torque ratio between the engine and the road wheels. 4) A gear box reverses the direction of rotation of drive output by use of a back gear, thereby causing back motion to the vehicle. 5) An overdrive provides a super top gear. The ratio of engine crankshaft speed to road wheel speed is unity in top gear but in super top gear it is less than one. TYPES OF TRANSMISSIONS (GEAR BOXES) Several kinds of transmissions are employed on auto vehicles. These can be classified as follows:1. Manual transmission i. Sliding mesh gear box. ii. Constant mesh gear box iii. Synchromesh gear box without overdrive. iv. Synchromesh gear box with overdrive.

2. Semi-automatic transmission i. Electric controlled with a fluid drive. ii. Electric controlled with overdrive. iii. Fluid torque drive. 3. Automatic transmission i. Hydramatic drive. ii. Torque-converter drive.
Figure 2.0 Electrical type continuously variable transmission. MANUAL GEARBOXES Different types of manual gear boxes have been used on automobiles. The sliding mesh type was the earliest gear box in which the gear engagement was accomplished by sliding the desired gear. The engagement during gear change required greater driving skill, introduced considerable noise and provided lower mechanical efficiency. Only spur gears were installed on them.
Figure 3.0 Five speed manual transmission in cars.

GEAR SELECTOR MECHANISM The gear selector mechanism is used to select the appropriate gear on the output shaft so that it may be engaged with the corresponding gear on the lay shaft. The choice of engaging a particular gear depends on the driving environment and is based on drivers judgment. Several kinds of selector mechanisms have been used on numerous vehicles, which are actuated by a gear shift lever through the external linkage. Based on the location of gear shift lever, the selector mechanism can be one of the following types:1. Floor mounted selector mechanism 2. Steering column mounted selector mechanism 3. Remote controlled selector mechanism REVIEW QUESTIONS: 1. Define Transmission system. State the requirements of transmission system. 2. Explain with a neat sketch the following clutches (a) Single plate clutch. (b) Centrifugal clutch (c) Cone clutch (d) Multi plate clutch. 3. State the requirements of a good clutch. 4. Explain with a neat sketch the following (a) The Constant Mesh Gear Box (b) The Sliding Mesh Gear Box (c) The Synchromesh Unit. 5. State the advantages of Epicyclic Gear Box. 6. Explain with a neat sketch, Hotchkiss Drive and Torque Tube Drive. 7. Explain with a neat sketch, the working of a Differential. 8. State the different types of Rear axle. Explain any one type with a neat sketch.

PRACTICAL NO: - 04
SUSPENSION SYSTEMS OF AN AUTOMOBILE
AIM: To study about different suspension systems of an automobile. LEARNING OBJECTIVES: To understand the basic requirements of a suspension system. To understand the different types of suspension springs. To understand about the shock absorbers. To understand about the different types of suspension systems.
THEORY: OBJECTIVES OF SUSPENSION SYSTEM 1. It provides comfortable riding by minimizing road shocks. 2. It reduces the stresses and strains on various components. 3. It enhances the life of vehicles components. 4. It maintains stability in the moving vehicle by absorbing road shocks. 5. It damps down the amplitude of vibratory oscillations caused due to road undulations.
Figure 1.0 Basic components of a suspension system.

TYPES OF SUSPENSION SPRINGS Various types of suspension springs may be categorized as follows:(a) On the basis of shape and construction 1. Coiled (helical) spring 2. Leaf spring 3. Torsion bar (b) On the basis of spring material 1. Steel spring 2. Rubber spring 3. Plastic spring 4. Composite materials spring (c) On the basis of fluid used 1. Hydraulic spring 2. Air spring (d) On the basis of specialized considerations 1. Taper spring 2. Helper or progressive spring 3. Spiral spring (e) On the basis of load-deflection behavior 1. Soft and hard springs 2. High and low frequency springs 3. Constant rate and variable rate springs
Figure 2.0 Double Wishbone suspension.

SHOCK ABSORBERS The shock absorber is a damping device and is used to damp the springs vibrations. By doing so, it prevents excessive flexing of the spring and enhances riding comfort. A shock absorber works in conjunction with a spring. On experiencing the road shock, the spring starts vibrating at varying amplitude and frequency depending upon the intensity of road bump. This vibration is then damped down by a shock absorber. Types of Shock Absorbers: - Several kinds of shock absorbers have been used on automobiles. These can be classified as below. (a) Based on principle of working 1. Friction type (or mechanical) shock absorber 2. Hydraulic shock absorber (b) Based on the type of fluid used 1. Liquid (oil) filled shock absorber 2. Gas filled shock absorber (c) Based on damping action cycle 1. Single acting shock absorber 2. Double acting shock absorber (d) Based on location on 2-wheeler 1. Front fork shock absorber 2. Rear fork shock absorber REVIEW QUESTIONS: 1. State the functions of a suspension system. 2. Explain with a neat sketch, Rear leaf spring. 3. State the different types of Independent Front suspension. Explain anyone with a neat sketch. 4. Enlist the advantages and disadvantages of Independent suspension systems. 5. Write a brief note on Telescopic Shock Absorber. Also draw a neat sketch of the same. 6. Explain with a neat sketch, Air Suspension.

PRACTICAL NO: - 05
ELECTRICAL SYSTEMS IN AN AUTOMOBILE
AIM: To study about the electrical systems in an automobile. LEARNING OBJECTIVES: To understand the different electrical systems in an automobile. To understand the different lighting systems in an automobile. To understand the different automobile accessories. THEORY: INTRODUCTION One of the important and essential group of systems belong to the area of auto electrical. The electrical systems of an automobile are meant to serve the following purposes:1. To generate electricity for charging of the battery. 2. To store electricity in the battery and then supply the same to various units. 3. To supply current to starting motor for cranking. 4. To supply current to ignition coil for producing spark in petrol and gas engines. 5. To supply current to the lighting system. 6. To supply current to the horn, dashboard instruments and the control gauges. 7. To supply power to various other electrical accessories. To accomplish these functions, several systems are contained in automotive electrical line up. These are as follows: 1. 2. 3. 4. 5. Charging circuit. Starting circuit. Ignition circuit. Lighting circuit. Accessory circuit.

The important circuits in an automobile are shown in the figure 1.0.
Figure 1.0 Circuits of an automobile, AUTOMOTIVE BATTERIES A battery is an accumulator or storage cell that possesses the capacity of accumulating and storing the electrochemical; source of current and supplying it as electrical energy. It serves as a power station for the vehicle and supplies D.C. to various destinations. The batteries for automobile uses are available in numerous models and in 6V, 12V and 24V range. The batteries may be connected in series to obtain a battery of higher voltage if so required. A battery is composed of several cells in series. The electromotive force (emf) of a cell in lead-acid battery is 2V and in alkaline battery is 1.2V; therefore a 12V lead-acid battery consists of 6 cells (6 x 2 = 12). Types of batteries Several kinds of batteries are employed on different makes and models of automobiles. Depending upon the electrolyte and the materials used for the plates, the batteries may be classified into different types.

1. Lead acid battery 2. Alkaline battery (a) Nickel iron battery (b) Nickel cadmium battery (c) Silver zinc battery 3. Non conventional battery (a) Sodium sulphur battery (b) Zinc air battery (c) Lithium chloride battery 4. Dry charge battery
Figure 2.0 Cross section of a typical storage battery. CHARGING SYSTEM IN AN AUTOMOBILE The purpose of charging system in an automobile is to generate electricity to cater the needs of all the load demands at proper voltage. The name charging system comes from the fact that the generated electricity is first used to charge a battery which then supplies current to various loads. The main parts of a charging system are as follows-

1. Generator (dynamo) or alternator 2. Voltage and current regulators 3. Cut-out relay 4. Ammeter 5. Battery 6. Indicator lamp REVIEW QUESTIONS: 1. State the main components of an automotive electrical system. 2. Draw only a neat sketch of Lead Acid Battery. Explain the different components of the battery. 3. Explain with a neat sketch, the Cut out Relay. 4. Write a brief note on Current Regulator and Voltage Regulator. 5. Give the classification of Automotive Bulbs. 6. Sketch and explain, the electrically operated Windshield Wiper. 7. Explain in brief, the main components of an Automobile Air Conditioning system.

PRACTICAL NO: - 06
DIFFERENT TYPES OF BRAKES
AIM: To study about different types of automobile brakes. LEARNING OBJECTIVES: To understand the basics of automobile brakes. To understand about the construction and working of different brakes. To understand the trouble shooting in brakes. THEORY: INTRODUCTION Brakes are employed to stop or slow down the speed of a vehicle depending upon the driving needs. When braked, each wheel of the vehicle builds-up a certain braking force. For this reason, greater the number of wheels braked, greater will be the braking effort and sooner will the vehicle come to halt. Modern vehicles are therefore equipped with brakes on all the wheels.
Figure 1.0 Braking system of an automobile.

Types of brakes. Different types of brakes are sued on various categories of vehicles. These can be classified according to following considerations. 1. On the basis of purpose served (a) Main (service or primary) operational brakes (b) Parking (secondary) brakes 2. On the basis of drivers ergonomics (a) Foot brakes (b) Hand brakes 3. On the basis of actuating method (a) Mechanical brakes (b) Hydraulic brakes (c) Pneumatic (air) brakes (d) Electric brakes 4. On the basis of construction (a) Drum brakes (b) Disc brakes (c) Band brakes 5. On the basis of application of braking effort (a) Manual brakes (b) Servo (power assisted) brakes (c) Power brakes DRUM BRAKES Drum brakes work the opposite way from disc brakes. Instead of squeezing in on a disc to slow your vehicle, drum brakes push brake shoes outwards against the inner surface of a drum. The resulting friction brings your vehicle to a stop. When you release the brake pedal, internal springs return the shoes to their original position. Just like the pads in disc brakes, the shoes in drum brakes also wear away over time and must be replaced to prevent severe damage to your braking assembly. DISC BRAKES Because a disc brake assembly can absorb more heat than a drum brake assembly, most cars use disc brakes for their front brake systems. When the brake pedal is pushed, brake fluid from the master cylinder compresses the brake pads against the rotors attached to the vehicle's front wheels. The friction between the stationary pads and the revolving rotors causes the rotors and wheel to slow and stop. In dayto-day driving, these rotors and pads are subject to much abuse, and

should be checked periodically for wear. Faulty disc brakes can cause excessive pedal travel, pumping or fighting pedal, vibration during braking action, and brake failure.
Figure 2.0 Typical Drum and Disc Brake. REVIEW QUESTIONS: 1. State the requirements of a good braking system. 2. Give the classification of Automobile Brakes. 3. Explain with a neat sketch, the construction and working of a Disc Brake. 4. State the advantages and disadvantages of Hydraulic Brakes. 5. Explain with a neat sketch, the Engine Exhaust gas operated brakes. 6. Write a brief note on ABS. 7. Give the comparison between Drum Brakes and Disc Brakes.

PRACTICAL NO: - 07
DIFFERENT TYPES OF WHEELS AND TYRES
AIM: To study about the different types of automobile wheels and tyres. LEARNING OBJECTIVES: To understand the classification of automobile wheels and tyres. To understand about the tyre construction. To understand the tyre properties. To understand about the tyre maintenance.
THEORY: INTRODUCTION The power developed by the engine is transferred through the clutch, gear box, propeller shaft and differential to the rear axles. Wheels are connected to the rear axles. As the rear axle turns, wheels also turn and the vehicle moves on the road. The ultimate purpose of the power developed by the engine is to turn the wheels so that the vehicle moves on the road. A wheel tyre assembly is an essential device (system) in imparting rolling motion to the vehicle. It is mounted on the rear axle and the front axle. It always remains in contact with the road. AUTOMOBILE WHEELS The wheel is an assembly of the hub, disc (body), rim and spokes. Besides supporting the vehicles weight and protecting it from the road shocks, they also transmit power and are steered. The wheels are subjected to braking stresses and side thrusts during their motion. They are therefore required to be strong enough. Presently the trend is towards the use of light-alloy wheels made of aluminum and magnesium alloys. These are light weight, almost corrosion free, casted wheels. Requirements of a Good Wheel To accomplish different purposes, the automobile wheels should possess the following requirements. 1. They must be structurally strong. 2. To keep the unsprung weight to a minimum, they should be as light as possible. 3. The material of the wheel should be anti corrosive and weather resisting.

4. Wheels should be balanced, both statically and dynamically. 5. They should be easily and quickly attachable and detachable. TYPES OFAUTOMOBILE WHEELS Different types of wheels used on various auto vehicles are as follows:1. Disc wheel: - This type of wheel consists of a steel rim and a pressed steel disc. The rim is rolled section, sometimes riveted but usually welded to the flange of the disc. The disc performs the function of spokes. A hole in the rim serves to accommodate tube valve. This type of wheel is simple, cheap and robust in construction. It is most commonly used in heavy motor vehicles buses, cars, trucks, tractors, etc. 2. Wire wheel: - This type of wheel consists of a separate hub connected to the rim with a number of wires or spokes. The headed inner ends of the spokes fit in the hub holes and the threaded outer ends fit in the rim holes. The spokes do not stick straight out as radii from the hub, but alternate spokes are screwed to slope forwards and backwards towards the rim. This arrangement or spokes serve special purpose of the wheel. 3. Split wheels: - The split wheel is made in the form of two dishes which fit back to back and are clamped by a separate outer ring of studs and nuts. The flanges of the discs thus give a seating for the type and clamp on the beads. The main advantage of the split wheel is that the tyre may be easily taken out of the wheel by unscrewing the nuts and separating the two discs. 4. Heavy vehicle wheels: - they are made in the same way as the disc wheels but much thicker plate is used. To lighten the wheel and also to increase air flow to the brake drum, large holes are made around the disc. The wheel nut recesses are usually machined instead of being embossed. AUTOMOBILE TYRE CONSTRUCTION A tyre is made of three basic elements viz. thread, body and beads. These elements are composed of three incompatible materials rubber, fabric and steel. The tread is meant to take load, the beads provide a firm footing for the tyre ove, the rim and the body is a joining link between tread and the beads. The constructional details of a typical

heavy duty tyre are shown in fig. different elements are indicated therein. Each of these elements serves some specific purpose.
Figure 1.0 Design of Diagonal Ply Tyres. REVIEW QUESTIONS: 1. State the different types of wheels. Explain any one type with a neat sketch. 2. State the requirements of a good automobile tyre. 3. Give the classification of automobile tyres. 4. Explain with a neat sketch, Captive Air Tyres. 5. Enlist the effects of Over Inflation and Under Inflation. 6. Give the comparison between Radial tyres and Bias-Ply tyres.

PRACTICAL NO: - 08
DIFFERENT GARAGE TOOLS
AIM: To study about the different automobile garage tools. LEARNING OBJECTIVES: To understand the classification of tools and equipments used in an automobile garage. To understand about the auto service unit. To understand the concept of lifting jacks. To understand about the garage testing equipments. THEORY: INTRODUCTION Breakdown of vehicles can occur due to accidents, loss of strength in components material and several other unforeseen reasons. Such vehicles are then brought back to automobile garages (workshops) for repairing. Modern auto garages are capable of undertaking all sorts of repairs. For that they need to be equipped with trained technicians, varieties of tools and equipments. The tools may be hand operated or mechanized. The mechanized (or power) tools may be operated electrically, hydraulically, pneumatically or by their combinations. They are therefore known as electrical tools, hydraulic tools, pneumatic tools, hydro-pneumatic tools etc. CLASSIFICATION OF TOOLS AND EQUIPMENTS Depending upon the type of services performed, the kind of energy used in operation and several other basis; the auto garage tools and equipments can be put under different categories. These also include the tools and equipments used in workshop which may be or may not be the part of the garage. Garage servicing equipments 1. 2. 3. 4. 5. 6. 7. Auto service unit Car washing machine Hydraulic lift Greasing equipment Lubricating equipment Crane Ramp

Figure 1.0 General Automobile Garage tools. Reconditioning machine tools 1. Crankshaft grinder 2. Brake drum lathe 3. Cylinder boring machine 4. Valve refacing machine 5. Chassis alignment equipment 6. Battery charger 7. Wheel balancing machine Ultramodern machines 1. Car disk brake lathe 2. Ultrasonic cleaning and degreasing machine 3. Ultrasonic plastic welding machine 4. Ultrasonic riveting machine 5. Ultrasonic spot welder Testing equipments 1. Remote controlled brake, suspension, side-slip and weight testing 2. Diesel fuel pump testing machine 3. Diesel fuel injection nozzle testing machine 4. Engine analyzer

General purpose machine tools 1. Centre lathe 2. Bench drilling machine 3. Radial drilling machine 4. Pedestal grinding machine Measuring instruments and gauges 1. Vernier caliper 2. Micrometer 3. Dial bore gauge 4. Vernier height gauge 5. Vernier depth gauge
Figure 2.0 Special Purpose Automobile Garage tools. Repairing accessories and equipments 1. Engine repairing stand 2. Mechanical press 3. Hydraulic press 4. Hydraulic pump 5. Bench vice

Portable power tools 1. Pneumatic nut and bolt tightener 2. Portable drilling machine 3. Sanding and polishing machine Servicing and repairing tools 1. Piston and piston ring servicing tools 2. Pullers 3. Handles and extension rods 4. Tyre removers Hand tools 1. 2. 3. 4. 5. 6.
Hammers Chisels Screw drivers Pliers Spanners Wrenches
Special purpose tools, instruments and systems 1. Electronic controlled screw driver 2. Laser based measuring system 3. Digital sensors and instruments 4. Infrared rays based testing system Miscellaneous 1. Fire extinguisher 2. Multi-jet parts cleaner 3. Engineers stethoscope TYRE INFLATORS With the help of tyre inflators, the inflation, checking- up and deflation can be done by means of thumb pressure only. To check the pressure in tyres, the dual foot connector is pressed on to the tyre valve and immediately the pressure in the tyre will be indicated by the gauge. If the tyre pressure is lower than the recommended rating we press the remote control valve knob fully for inflation. When the tyre has excess pressure, deflation of the tyre can be done by pressing the control valve knob slightly. The tyre inflators are available in two distinct models viz. Wall mounted model and Portable model

GARAGE TESTING EQUIPMENTS Advanced vehicle technology required test methods and advanced test devices and a modern auto garage should be equipped with them. These test methods may be an improvement over the conventional tests or other incorporating recent developments of electronics and computers. INFRARED RAYS BASED COMPUTERISED TESTING This 4-plate system offers advanced electronics, strong sensors; colored monitor, and computerized test results, supported by infrared remote controls. The salient features of this testing equipment are as follows: The brake force and the post oscillations of all four wheels are recorded precisely at the time of testing. The test method makes it possible to provide a comprehensive evaluation of brake force difference, weight of the vehicle and deceleration. The efficient infrared remote control makes easy and quick operation of the test system. During the test all the test results as shown on LED or on the computer monitor. A graphical color printer is able to show the test results clearly. COMPUTER AIDED WHEEL BALANCINIG EQUIPMENT The wheel alignment refers to the positioning of the front wheels and the steering mechanism for having ease of steering, reducing tyre wear as well as to provide the directional stability to the vehicle. For proper wheel alignment, it is necessary that camber, caster, toe-in and king-pin inclination must be properly set. For making wheel alignment, the following checking, inspection and adjustments should be made. Hence now in most of the modern automobile garages such, type of computer aided wheel balancing equipments are used for better results. 1. Wheel bearing adjustment should be check and made if required according to specifications. 2. The king pins and their bushing be checked and made if required according to specifications. 3. The springs are to be checked for breaks or any damage.

4. Checking factors like frame alignment, spring conditions, position of the rear axle, the condition of the shock absorbers, etc.
Figure 3.0 Computer Aided Wheel Balancing Equipment REVIEW QUESTIONS: 1. Explain the different types of Automobile garages. 2. State the classification of tools and equipments used in an automobile garage. 3. Explain any one type of a Lifting Jack with a neat sketch. 4. Enlist the advantages of Ultrasonic Plastic Welding system. 5. Write a brief note on different Power tools. 6. Explain in brief the following types of Spanners Open ended spanner Ring spanner Socket spanner

PRACTICAL NO: - 09
DIFFERENT AUTOMOBILE LAWS
AIM: To study about the different automobile laws. LEARNING OBJECTIVES: To understand the Motor Vehicle Act. To understand about the registration of motor vehicles. To understand about the Insurance against third party. THEORY: MOTOR VEHICLE ACT The motor vehicles act of 1977 is applicable and extends to the whole of India. It was first framed in 1939 and amended time to time according to the requirements and necessities of roads and vehicles. This act as amended up to 1977 has 10 chapters, 135 sections and 12 schedules. The 10 chapters are as follows Chapter I: Preliminary Chapter II: Licensing of driver of motor vehicles. Chapter III: Licensing of conductors of state carriages. Chapter IV: Control of transport vehicles. Chapter V: Construction, equipment and maintenance of motor vehicles. Chapter VI: Control of traffic. Chapter VII: Motor vehicles temporarily leaving or visiting India. Chapter VIII: Insurance of motor vehicles against third party risks. Chapter IX: Offences, penalties and procedure. Chapter X: Miscellaneous.

The schedules are as followsFirst schedule: - Forms. Second schedule: - Diseases and disabilities absolutely disqualify a person for obtaining a license to drive a motor vehicle. Third schedule: - Test of competence to drive. Fourth schedule: - Authorities entitled to grant licenses to drive and to register motor vehicles, the temporary or the time being under the exclusive control of central Govt. and Registration makes for such vehicles. Fifth schedule: - Offence on conviction of an endorsement shall be made on the license of the person affected. Sixth schedule: - Registration marks. Seventh schedule: - Omitted Eight schedule: - Limits of speed for motor vehicles. Ninth schedule: - Traffic signs. Tenth schedule: - Driving Regulation. Eleventh schedule: - Signals. Twelfth schedule: - Repeat of certain endorsements. TERMS DEFINED IN MOTOR VEHICLE ACT Some important definitions, words and terms used in the Motor Vehicle Act are briefly explained as below: Articulated vehicle means a tractor to which a trailer is attached in such a manner that a part of trailer is superimposed on and the part of the weight of the trailer is borne by the trailer. Axle weight means the total weight transmitted by several wheels attached to the axle at the surface whereon the vehicle rests. Certificate of registration means the certificate issued by a competent authority to the effect that a motor vehicle has been duly registered in accordance with the provisions of chapter IV. Driver means that person as well as any other person engaged in driving of the vehicle.

Goods it includes live-stock and anything carried by a vehicle except living persons, but does not include luggage or personal effects carried in a motor car or a trailer attached to a motor car or the personal luggage of passengers travelling in the vehicle. Light motor vehicle means a transport vehicle or omnibus, the gross vehicle weight of either of which or motor car or tractor or road roller the unladen weight of any of which does not exceed 6000 kilograms. Motor cycle means a two-wheeled motor vehicle inclusive of any detachable side car having an extra wheel, attached to the motor vehicle. Transport vehicle means a public service vehicle, a goods carriage, an educational institutional bus or a private service vehicle. REVIEW QUESTIONS: 1. State the overview of the Motor Vehicle Act 1988. 2. Define the following terms Articulated vehicle Driver Private service vehicle Public service vehicle 3. Explain Learners Driving License and Permanent Driving License. 4. State the necessary regulations for the construction of Motor vehicles. 5. Enlist the duties of Chief Motor Vehicle Inspector.

PRACTICAL NO: - 10
MODERN AUTOMOBILES
AIM: To study about the different modern automobiles. LEARNING OBJECTIVES: To understand about chassis. To understand about transmission systems. To understand about steering systems. To understand about brakes. To understand about wheels and tyres. REVIEW QUESTIONS: 1. Every student must prepare a report regarding the modern automobiles. the modern developments in automobile the modern developments in automobile the modern developments in automobile the modern developments in automobile the modern developments in automobile

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L. J.

INSTITUTE ENGINEERING AND TECHNOLOGY

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

Grade obtained:Date & Signature of Faculty:-

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

Grade obtained:Date & Signature of Faculty:-

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

Figure 3.0 Five speed manual transmission in cars.

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

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L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

Figure 1.0 Basic components of a suspension system.

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

Figure 2.0 Double Wishbone suspension.

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

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L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

The important circuits in an automobile are shown in the figure 1.0.

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

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L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

Figure 1.0 Braking system of an automobile.

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

Grade obtained:Date & Signature of Faculty:-

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

Grade obtained:Date & Signature of Faculty:-

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

Hammers Chisels Screw drivers Pliers Spanners Wrenches

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

Grade obtained:Date & Signature of Faculty:-

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

Grade obtained:Date & Signature of Faculty:-

L. J. INSTITUTE ENGINEERING AND TECHNOLOGY

Grade obtained:Date & Signature of Faculty:-

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