2 & 3 Manual

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 Accessories unit.
o Electrical systems.
o Controls and instruments.
o 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.

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 cross-
pieces. 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 front-
wheel 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 cross-
members 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.
Grade obtained:-
PRACTICAL NO: - 03
TRANSMISSION SYSTEMS OF AN AUTOMOBILE
AIM: To study about different transmission systems of an automobile.

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.
Grade obtained:-
PRACTICAL NO: - 04
SUSPENSION SYSTEMS OF AN AUTOMOBILE
AIM: To study about different suspension systems of an automobile.

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.
Grade obtained:-
PRACTICAL NO: - 05
ELECTRICAL SYSTEMS IN AN AUTOMOBILE
AIM: To study about the electrical systems in an automobile.

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. Charging circuit.
2. Starting circuit.
3. Ignition circuit.
4. Lighting circuit.
5. 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.
Grade obtained:-
PRACTICAL NO: - 06
DIFFERENT TYPES OF BRAKES
AIM: To study about different types of automobile brakes.
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 day-
to-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.
Grade obtained:-
PRACTICAL NO: - 07
DIFFERENT TYPES OF WHEELS AND TYRES
AIM: To study about the different types of automobile wheels and tyres.
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.
Grade obtained:-
PRACTICAL NO: - 08
DIFFERENT GARAGE TOOLS
AIM: To study about the different automobile garage tools.
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. Auto service unit
2. Car washing machine
3. Hydraulic lift
4. Greasing equipment
5. Lubricating equipment
6. Crane
7. 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. Hammers
2. Chisels
3. Screw drivers
4. Pliers
5. Spanners
6. 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
Grade obtained:-
PRACTICAL NO: - 09
DIFFERENT AUTOMOBILE LAWS
AIM: To study about the different automobile laws.
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 follows-

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

automobiles.
Grade obtained:-

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L. J.

INSTITUTE ENGINEERING AND TECHNOLOGY

AIM: To study about the basics of an automobile.

Figure 1.0 Anatomy of an automobile

On the basis of Prime mover used

On the basis of Weight of the vehicle

On the basis of Purpose served

On the basis of Wheel drive system

1. Define Automobile. Give the classification of automobiles.

AIM: To study about the automobile classis, frame and body.

Classification of Chassis with respect to engine fitting

Figure 1.0 Photo of an automobile chassis and body.

Figure 2.0 Components of a typical frame design

1. Write a brief note on Automobile Chassis. Also sketch the

AIM: To study about different transmission systems of an automobile.

Figure 1.0 Transmission system of an automobile.

FUNCTIONS OF A GEAR BOX

TYPES OF TRANSMISSIONS (GEAR BOXES)

Figure 2.0 Electrical type continuously variable

Figure 3.0 Five speed manual transmission in cars.

GEAR SELECTOR MECHANISM

1. Define Transmission system. State the requirements of transmission

3. State the requirements of a good clutch.

5. State the advantages of Epicyclic Gear Box.

AIM: To study about different suspension systems of an automobile.

Figure 1.0 Basic components of a suspension system.

TYPES OF SUSPENSION SPRINGS

Figure 2.0 Double Wishbone suspension.

1. State the functions of a suspension system.

AIM: To study about the electrical systems in an automobile.

To accomplish these functions, several systems are contained in

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

Figure 1.0 Circuits of an automobile,

1. Lead acid battery

3. Non conventional battery

4. Dry charge battery

Figure 2.0 Cross section of a typical storage battery.

CHARGING SYSTEM IN AN AUTOMOBILE

1. Generator (dynamo) or alternator

1. State the main components of an automotive electrical system.

AIM: To study about different types of automobile brakes.

To understand the basics of automobile brakes.

Figure 1.0 Braking system of an automobile.

Figure 2.0 Typical Drum and Disc Brake.

1. State the requirements of a good braking system.

4. Wheels should be balanced, both statically and dynamically.

TYPES OFAUTOMOBILE WHEELS

2. Wire wheel: - This type of wheel consists of a separate hub

AUTOMOBILE TYRE CONSTRUCTION

Figure 1.0 Design of Diagonal Ply Tyres.

AIM: To study about the different automobile garage tools.

Figure 1.0 General Automobile Garage tools.

Reconditioning machine tools

General purpose machine tools

Measuring instruments and gauges

Figure 2.0 Special Purpose Automobile Garage tools.

Repairing accessories and equipments

Portable power tools

Servicing and repairing tools

Special purpose tools, instruments and systems

GARAGE TESTING EQUIPMENTS

This 4-plate system offers advanced electronics, strong sensors;

COMPUTER AIDED WHEEL BALANCINIG EQUIPMENT

The wheel alignment refers to the positioning of the front wheels

2 & 3 Manual

2 & 3 Manual