THE GARAGE INDEX 1. INRODUCTION.

CHAPTER 1 INTRODUCTION With increasing population, the standard of living of people is also increasing. This has lead to an increase in car population on the roads steadily. This rise has necessitated the availability of garages and service station for carrying out repair work and providing maintenance services for different types of vehicles. Many vehicle manufacturers have setup their own authorized garages in every big city and towns in different locations to provide servicing and maintenance of their vehicles. The scope of garage is influenced by the availability of repair work and number of vehicles running on the road. There are generally two different types of garages, the general repair workshops owned by mechanic turned businessmen person. This general repair shop works on all different makes and models of automobiles and repairing all the different parts from engine to rear axles. The second types of garages are of those working on any one kind of vehicle such as Maruti or Honda. These workshops may also be specialized in working on specific repairs such as engine rebuilding, tune ups, transmission etc. These shops are run by businessmen who employ several mechanics.

GARAGE A garage is a place or area where repair and maintenance work for an automobile take place which is important for trouble free and prompt operation of automobiles. There are three main different types of garages: 1. Small garages : They replace and adjust some major components of a particular range of vehicles and stock a large range of tools, parts and accessories. 2. Medium garages : They provide all types of routine service and repair work including tune up and brake testing with parking facilities and reception area for customers. 3. Large garages : they have a well trained and qualified staff who carry out thorough analysis of each system of automobiles and generate a test report indicating the condition of each components and how soon they will be repaired. They deal with urgent repairs without even advance booking. They also provide adequate parking and waiting facilities for the customers. SERVICE STATION

A Service station is a place where regular and periodical maintenance work takes place. They include facilities for providing from care of motor vehicles by mechanical servicing to minor servicing such as providing petrol and lubricating oils. LOCATION A garage/ service station should be strategically sited near to markets and highways for its successful running. Since a garage or service station may provide work for a large number of people hence it should be located where labour is easily available. They should be located on busy roads where all kinds of transport can be flown, particularly in highway junctions. They should be placed in a region where spare parts and lubricating oil is easily available and in sufficient quantity. A sufficient flow of vehicular traffic should be present in that area for profitable operation of the garage.

LAYOUT OF GARAGE The layout of a garage also plays a crucial role in determining the successful running of a garage. The internal layout of the garage should be as such to provide ample space for space for bench work, tool storage and repair work. Sufficient lighting and ventilation should be provided for the work benches. The garage should have simple facilities such as cleaning, washing, checking of air pressure, petrol pump and sales of spare parts etc. as a part of its layout. Narrow entrance should be avoided at it may result in damaging the customers vehicle while shunting it in and out. The layout of a garage mainly depends on the size of work done by it. If it is a small garage then it will have one bench at the closed end of the garage and a pit or a small lift in front to lift the vehicle and carry out the work underneath it. A large garage should have a number of repair bays wherein each bay is provided with a lift, a separate drawer belonging to the mechanic with all the tools necessary to carry out the repair work. The repair bays should be placed properly in the garage so as they do not provide inconvenience in taking the vehicle out of the garage after repair. This speeds up the repair work and gains in profit by facilitating quick servicing. A warm front office should also be provided with waiting areas for the customers.

VARIOUS SERVICES AT A GARAGE A garage is divided into different divisions to carry out repair works on different parts of the vehicle. The vehicle drawn in to the garage should be checked in all respects before delivering it to the customer. Such type servicing helps in bringing good name to servicing center for providing best servicing. The vehicle is handed over to technical supervisors in the garage wherein he notes down the faults needed to be rectified in the vehicle on a job card. Now the supervisor hands the vehicle along with the job card to the repair bay wherein a mechanic further inspects the vehicle thoroughly. The mechanic carries out a standard procedure for servicing the vehicle. He then removes different parts of the vehicle and sends it to their specific divisions in the garage for further servicing. Like this all different parts of the vehicle are properly serviced. This reduces the chances of future breakdown of the vehicle and increases its life. Important service divisions that should be made in a garage are as follows:

1) Brake service division where operations such as Brake drum turning, Brake relining, Brake riveting, Brake bleeding, servicing brake shoes are carried out. 2) Wheel alignment and balancing division. 3) Battery servicing which includes battery testing thru hydrometer, voltmeter and high rate discharge tester. Battery charging unit and analyzers. 4) Tuning of the engine, carburetor, fuel pump, etc. with the help of fuel pump calibration machine, timing light, spark plug cleaner and tester. 5) Reconditioning of engine by overhauling equipments such as cylinder boring machine, valve seat cutter and grinder, connecting rod aligner and other such tools. 6) Welding and cutting using oxyacetylene and metallic arc welding equipments. 7) Body repairing divisions which carry out denting and repainting jobs on the vehicles.

TOOLS AND EQUIPMENTS USED IN A GARAGE In a garage various types of tools and equipments are required to carry out different types of repair work. They vary from hand operated tools, power tools, measuring tools and others equipments meant for specific parts of vehicles and perform a specific task. All the mechanics should be well trained to operate the tools and regular servicing of the equipments should be done to ensure safety, speed and efficiency. Hand tools for which energy supplied by the hand is sufficient for its operation, are kept in stores or steel racks within the vicinity of the mechanics work area. These tools include all the tools used for striking, turning, gripping, cutting, bending and flaring tools. The list of hand tools required in a garage by the mechanic is given below. 1. Hammers

2. Screwdrivers 3. Wrenches 4. Spanners 5. Sockets 6. Feeler gauge 7. scrappers 8. Pliers 9. Pullers 10. Chisels 11. Hacksaw 12. Files 13. Punches 14. Twist drills 15. Taps and dies. Power tools are the tools that are driven with the aid of electricity, compressed air or hydraulic pressure. They are used in cases where manual power in not sufficient to do the job such as holding fixtures, work benches, lifting heavy parts and cleaning. This saves time and increases productivity. Various power tools that are used in a garage are enlisted below. 1. Bench vise 2. Electric drill 3. Drill press 4. Grinding wheels 5. Air hammers, drills and wrenches 6. Soldering gun 7. Hydraulic jacks 8. Shop crane

9. Press 10. Car washer 11. Tyre changer In addition to these above mentioned general tools various other equipments are necessary to carry out tasks like measuring, repairing and tuning up of engine, electrical repairs and reconditioning of a vehicle. These equipments are listed as below. Measuring and precision tools 1. Inside and outside micrometers 2. Dial micrometer 3. Cylinder dial gauge 4. Wheel alignment equipments Engine repairing and tune up equipments 1. Piston ring compressor and expander 2. Piston ring files and groove cleaners 3. Valve lifter and valve spring tester 4. Vacuum gauge 5. Compression gauge 6. Dwell angle tester 7. Battery tester 8. Spark plug cleaner and tester 9. Ignition timing light 10. Fuel injector tester 11. Fuel consumption tester 12. Cylinder leakage tester 13. Exhaust gas analyzer 14. Smoke tester

15. Tech II Reconditioning equipments 1. Brake drum lathe 2. Cylinder boring and honing machine 3. Crankshaft and camshaft grinding machine 4. Connecting rod aligner 5. Line boring machine 6. Arbor press 7. Nozzle grinding and lapping machine 8. Fuel injection pump calibration machine 9. Valve refacer and valve seat grinding machine 10. Radiator tester 11. Tyre retreading equipments 12. Cylinder head refacer 13. Brake efficiency tester 14. Paint spray gun and paint drying equipments 15. Brake line riveters 16. Wheel balancing machine Electrical repair equipments 1. Multimeter 2. Growler 3. Electrical test bench 4. Battery charger 5. Head light beam analyzer

All these tools and equipments mentioned above are necessary in a garage. These provide speed, reliability and productive work. All the mechanics should be properly trained to handle these equipments to ensure customer safety and satisfaction. Proper servicing of all these equipments should be done periodically to ensure its longer and economical life. All these equipments will be discussed in detail in this book.

Chapter 2 GENERAL GARAGE TOOLS AND EQUIPMENTS An automotive service workshop requires a great variety of tools and equipments which will help in doing a repair job

HAND TOOLS n

CHAPTER 3 SERVICE STATION EQUIPMENTS 1. AIR COMPRESSOR SPECIFICATION : MOTOR 5 H.P., 3PHASE, 440 VOLTS TANK CAPACITY- 250 LITRES SPEED- 1440 R.P.M. PISTON DISPLACEMENT- 20 CUBIC FEET/MM. PRESSURE-12 KG/CM. APPLICATION :

The air compressor compresses the air which is further used on various other purposes in a garage, like