WORKSHOP NOTES

C T T I Islamabad

Prepared By
Mr. Shahzaib Farooq
Table of Contents
EGR ....................................................................................................................................................... 2
Main Parts: ......................................................................................................................................... 2
Thermic Switch: ................................................................................................................................. 2
Vacuum Control Solenoid: ................................................................................................................ 2
Service Schedule ................................................................................................................................... 3
Lubrication Chart & Lubrication System: ......................................................................................... 3
Lubricant base (grease): ..................................................................................................................... 3
Engine lubrication system: (oil pressure or indicate) ........................................................................ 3
Daily Inspection ................................................................................................................................. 4
Car A / C system .................................................................................................................................. 4
How Car AC WORKS ....................................................................................................................... 5
Trouble shooting ................................................................................................................................ 5
Tuning of an engine ............................................................................................................................. 6
Visual Inspection ............................................................................................................................... 7
Performance testing and charging ...................................................................................................... 7
BRAKE PAD INSPECTION ............................................................................................................. 9
Checking Fuel Spray .......................................................................................................................... 9
Fuel System Inspection. ................................................................................................................... 10
Cleaning Equipment......................................................................................................................... 12
Battery Charger ................................................................................................................................. 15
Jacks .................................................................................................................................................... 19
Car Lift ............................................................................................................................................... 22
Layout of Garage ............................................................................................................................... 24
Automotive Faults Diagnostic Scanner ............................................................................................ 26
Positive Crankcase Ventilation System: .......................................................................................... 28
PRINCIPLE OF RECORD KEEPING: .......................................................................................... 33
Engine overhaul ................................................................................................................................. 35
Main service station Eqpt .................................................................................................................. 38

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EGR
Function:
The EGR valve helps to control the oxides of nitrogen by recirculating a portion of the exhaust
gases back into the combustion chamber recirculation into cooler temperature.

Main Parts:

Vacuum operated controls the flow of exhaust flow into the intake, exhaust flow will occur whenever
vacuum is applied.
EGR should not operation before operating temperature.
EGR valve should not operate during heavy load.

EGR valve & application of vacuum:

As the throttle opens, vacuum is applied to EGR valve. The EGR is operated up to half throttle. EGR
closes at full throttle.

Thermic Switch:
Is used to select the way of incoming vacuum & is also called ported vacuum switch, temperature
vacuum valve. It is heat sensitive thermic switch screws into intake manifold its heat sensing element
is in contact with the engine coolant.
A wax plug inside the switch pushes a slide plunger to uncover or block vacuum part in the switch the
engine heat expands the wax thug’s plunger is raised & the rising plunger uncovers or block the engine
(carburetor) venturi line.

Vacuum Control Solenoid:

Solenoid is a magnetic coil that uncovers or block a vacuum part. Voltage to solenoid may be routed
through a relay or timer & is controlled by the ECU. The engine computer gets the information of
engine temperature via the temperature sensor fitted in the cooling system & gives information to the
solenoid via, the electric wires to electric choke & delay timer. Modulator system is enclosed in dashed
lines on the solenoid valve is normally open allowing intake manifold vacuum to pass through it. When
engine temperature is high enough to open the thermal switch & the throttle valve is partially opened,
intake manifold can have operated the EGR valve, EGR results. When car speed reaches a certain
level, the speed sensor sends signals to the electronic amplifier. This causes the electronic amplifier to
close the solenoid valve. Now the vacuum line is closed & EGR stops. A different arrangement uses a
vacuum amplifier to increase the vacuum enough to operate the EGR valve. At wide open throttle a
dump diaphragm inside the amplifier eliminate recirculation. Amplifier continually compares the
vacuum signal going to the EGR VALVE & the vacuum in the intake manifold. When the comparison
shows that the throttle valve is wide open, the amplifier stops amplification of vacuum signal. Now it
is not great enough to hold the EGR valve open it closes holding recirculation. The EGR delay timer
& EGR delay solenoid delay EGR action for 35 seconds after starting a cold engine. This assure
reliable starting & initial operations of the engine after the engine has begun to warm-up, can begin
without upsetting the operation.

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System uses a vacuum part into the carburetor throat located just above the throttle plate. As the throttle
plate begins to open , vacuum will begin to applied to the port & operate the EGR valve. The valve
will continuously operated until approximately half throttle is reached. As the throttle opened past the
half way point, EGR will gradually diminish to zero as the throttle approaches the fully opened
position.

Service Schedule
Introduction:
An efficient lubrication system requires maintenance of service schedule. It is either based on time or
on usage of Automobiles.

Lubrication Chart & Lubrication System:

Proper lubricant at appropriate intervals is the requirement of an efficient lubrication system. Correct
grade of lubricant & correct amount of lubricant can make the system efficient. Do not thrush the
engine with k-2 oil, petrol or detergent or gasoline.
Engine Oil specifications:
▪ ML Light & favorable service condition
▪ MM Moderate to severe service condition
▪ MS Most severe service condition
▪ API American petroleum institute
▪ SAE Society of automotive engineers
MIL Grading Specification, Japanese Grading Specification
ACEA Associate Des Contractors Europeans
Short trips, come & go driving is serve constant speed driving is least serve.
10 w 40, 5 w 30 is engine oil
80 w 90, 75 w 90 is gear oil
𝑆𝐴𝐸 20 𝑊 − 𝑆𝑢𝑚𝑚𝑒𝑟
𝐼𝑛𝑡𝑖𝑎𝑙 500 𝑚𝑖𝑙𝑒𝑠 {
𝑆𝐴𝐸 𝑂 𝑊 − 𝑊𝑖𝑛𝑡𝑒𝑟
General lubrication chart book pg56-57

Lubricant base (grease):

{graphite base lubrication}
Sodium base lubricants are used for initial fill mixing of sodium & lithium based lubricants results in
tinned out mixture.

Engine lubrication system: (oil pressure or indicate)

Check through oil pressure gauge on instrument panel or through dip stick, the quality & quantity
both. Red light appearance for insuffienat quantity in the oil sump when ignition switch is turned on.
Failure of the gauge or connection can result in improper information engine must stopped. Engine is
lubricated by an oil pump; the strainer will avoid the sediments. Oil pressure is maintained through
relief valve.
Initial lubrication:
In new vehicle or overhauled engine, replace oil filter 500km. SAW 20 W for summer & SAW 0W
for winter for first 500km. Engine crankcase is cleaned after its gets heated for cleaning sediments.

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 Lubrication Filling (1000miles):
▪ Tie Rod filling.
▪ Drag link clutch master kit operating device.
▪ Clutch & Brake pedals.
▪ Steering bell crank grease.
▪ King pin filling (RD spring, clutch pin, brake master cylinder)
▪ Transfer case shift leaver shaft.
▪ Spring shackles & pivot balls.
▪ Propeller shaft universal joints.
▪ Rear wheel bearing.

Daily Inspection
Power unit
Transmission
Body
Check before & after operations:
FOWA
Tires & Tracks
How to undertake operation (Drill as in technical)?
Specific checks:
Noise, Steering, Clutch, Brakes, Gear shifting
Lubrication:
Tire or brake drums
Compress air cylinders
Long Maintenance Day:
▪ Stabilizers oil
▪ Winches
▪ Vision devices
▪ Shutter control linkage
▪ Turret traverse mechanism
▪ Dozer blades
▪ ARY Booms
▪ Computer/ Range Finder
▪ Fifth wheel bad plates

Car A / C system
The principles of evaporation & condensation is utilized in car A/C.
6 X basic components:
Compressor, Condenser, Receiver drier, Thermostatic expansion valve, Evaporator & Refrigerant.
Refrigerant is a liquid capable of vaporizing at low R-12(CFC)chloroforo carbon was used. Now R-
134 is used.

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How Car AC WORKS
Step one:
The compressor is the power unit of the AC system. It is powered by a driver belt connected to the
engine crankshaft. When the C system is turned on then the compressor pumps out refrigerant vapor
under high pressure and high heat to the condenser.
Step two:
The condenser is a device used to change the high pressure refrigerant vapor to a liquid. It is mounted
ahead of the engine radiator & it looks very similar to a radiator with it parallel tubing’s and tiny
cooling tins if you look through the grille of a car and see what you think is a radiator it is most likely
the condenser. As the car moves air flowing through the condenser remove heat from the refrigerant
changing it to a liquid state.
Step three:
Refrigerant moves to the receiver drier, this is the storage tank for the liquid refrigerant, it is also
removing moisture from the refrigerant. Moisture in the system can freeze and then act similarly to
cholesterol in the human blood stream, causing blockage.
Step four:
As the compressor continues to pressurize the system, liquid refrigerant under high pressure is circulate
from the receiver –drier to the thermostatic expansion valve. The valve removes pressure from the
liquid refrigerant so that it can expand & becomes refrigerant vapor in the evaporator.
Step five:
The evaporator is very similar to the condenser. It consists of tubes & fins and is usually mounted
inside the passenger compartment. As the cold low-pressure refrigerant is released into the evaporator
vaporizes & absorb heat from the air in the passenger compartment. As the heat is absorbed cool air
will available for occupants of the vehicle. A blower fan inside the passenger compartment helps to
distribute the cool air.
Step six:
The heat loaded low pressure refrigerant vapor is then drawn into the compressor to start another
refrigerant cycle

Trouble shooting
• Loosen/ broken drive belt
• In operative compressor or slipping compressor clutch
• Defective expansion valve
• Dogged expansion valve receiver drier or liquid refrigerant line
• Blown fins
• Leaking in refrigerant/ air line
• Insufficient cool air
• Low refrigerant charge
• Loose drive belt
• Slipping compress or clutch
• Clogged condenser
• Clogged evaporator
• Slow leak in system

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 • Partially clogged filter or expansion valve
• Cautions:
• Run the car AC for 10 min/ month
• Engage the compressor defort mode.

Tuning of an engine

Tune-ups may include the following:

• Check Engine Oil
• Inspection & service of Battery
• Replacement of the air filter and other filters
• Inspection & service of Spark Plug
• Inspection & service of Fuel System
• Inspection & service of Brake System
• Adjustment of the carburetor idle speed and the air-fuel mixture
• Inspection and possible replacement of ignition system components like spark plugs, contact
breaker points, distributor cap and distributor rotor
• Inspection of emission controls
• Valvetrain adjustment

Steps

1.Inspection of engine oil

Viscosity, colour, mixed water, k2 etc

A great way to keep track of what’s going on under the hood of your vehicle is to change your own
oil. For some owners, the only time they pop their hood is when they are changing their oil.

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2. Inspection of battery

Specific gravity 1.25 to 1.27 at 20°C, fully charged

Electrolyte quantity of each cells, if low fil with distill H2O.
Battery terminals. (not loose and corroded)
If the electrolyte solution has been adjusted during the visualinspection, charge the battery for 15
minutes at 15 to 25 amps. Charge the battery to obtain at least 12.6 volts (full charge). After
charging the battery apply a 150 amp load for 10 to 15 seconds to remove any surface charge.

Visual Inspection

Performance testing and charging

Before performance testing can take place on the battery, a visual check must be done to determine if
the battery’s physical condition is adequate for proper operation.
1. If the electrolyte solution has been adjusted during the visual inspection, charge the battery
for 15 minutes at 15 to 25 amps.

2. Charge the battery to obtain at least 12.6 volts (full charge). After charging the battery apply a
150 amp load for 10 to 15 seconds to remove any surface charge. Check the open circuit voltage. If
12.6 volts or above is not measured, replace the battery and continue to evaluate the charging system.

3. If the open circuit voltage is 12.6 volts or above, load-test the battery. A good battery will be
capable of producing one-half of its CCA rating for 15 seconds and maintain a voltage reading of 9.6
volts (adjusted at 70º F) or above (Table 1). Perform the load test twice, waiting approximately 30
seconds between tests.

4. Check for parasitic loads at the battery. An excessive parasitic load can drain the battery in a
short period of time. Draws in excess of 0.35 amps should be investigated. Refer to the Original
Equipment Manufacturer’s service manual for the parasitic load specification for your vehicle.

3 Air filter
Clean with compressed air
Channing of oil bath type air filter
Wash the oil pan
Wipe the oil case and air filter with Cleans rag
Place the oil case on a level work stand. Pour oil up to the mask
Place air filter on a try

4.Changing spark plugs

Changing spark plugs is a great way to freshen up a motor. Depending on the type of plugs your
vehicle runs will depend on the maintenance schedule of replacing the plugs. Copper plugs usually
need to be replaced every 20k-30k miles or every 4-6 years. Iridium plugs are very different. They

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have a life of up to 100k and only need to be checked for replacement between 10-15 years. While it
is arguable if there are any performance gains between different types of plugs, certainly staying on
top of the maintenance of your spark plugs will keep your engine

5.Checking your distributor Cap and Wires

This step is slowly getting faced out as most manufactures are turning now to Coil on Plug ( COP )
set-ups. For those of us still driving a vehicle with a distributor and spark plug wires, checking these
items for wear, and replacing them every 50k or so miles will help our vehicle to stay in top-notch
shape.
Upgrading to a premium performance based spark plug wire has shown improvements in spark
performance offering a better burn in the engine. This results in more horsepower and improved fuel
economy.

6.High tension cards,

C.B point, condenser and spark plug.
Check resistance of H. T lead card with multimeter
Chan spark plug with cleaners
Check the spark plug for electrode, wear, and thread damage
Check electrode gap

7.C.B-point gap
Adjustment of alternative desire belt
Check alignment and bolt flexibility

8.Adjustment of valve clearance

Remove the acyl head cover, set No. 1 cylinder at TDC/compression

Align timing mark of flywheel or timing prelley with the timing pointer by turning the crank shaft in
direction of rotation with wrench

9.Check rocker arm as per firing order and adjust as per user manual.

Measure and adjust the clearence of the intake and exhaust valves as per manual.
Using a feeler gauge measure the valve clearence between the valvue stem and rocker arm. Loose the
lock nut and turn adjusting screw in position and tighten the lock nut.
Ro check clearence valence. The feelet gauge should slide with slight drag.
Turn the crank shaft keen revolution and align the mark as above. Adjust the left over valves.
Install cylinder head cover.

10.Toping off fluids

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Part of the maintenance and repair of your vehicle should be to make sure that all fluids in the vehicle
stay clean and are full. This goes for transmission fluid, Engine Oil, Power steering fluid, Brake fluid,
window washing fluid, and coolant overflow
11.Fuel Filter Replacement Installation
Fuel filters are located outside the gas tank – to combat pollutants from reaching vital parts of your
engine.
What happens when your Fuel Filter clogs?
• Dirt can prevent gas from reaching the engine, resulting in declining performance and poor gas
mileage.
• Fuel filters require routine maintenance and should be serviced regularly.
Pep Boys will check and replace your fuel filter to keep your fuel system delivering optimal results.

12.BRAKE INSPECTION
Brake problems often start out little but can become increasingly bigger and more costly. Jiffy Lube®
technicians can detect most brake problems big or small. They start by inspecting all major brake
components: discs, brake pads and shoes and brake lines. After a thorough inspection, they can make
brake repair suggestions based on wear and your vehicle manufacturer’s recommendations.

BRAKE PAD INSPECTION

When you step on the brake pedal, brake pads on each side of the disc or rotor apply pressure against
it to slow your vehicle or bring it to a stop. During a brake inspection, pads will be measured by a Jiffy
Lube® technician. Brake Service replacement is recommended based on the results of a complete
brake inspection using vehicle manufacturer’s recommendations for disc pad/drum shoe minimum
thickness and actual measurements.

Testing TBI Injectors

You can visually inspect the fuel spray on TBI system injectors. Fuel flow spray is readily accessible,
making it fast to check for potential problems.

Checking Fuel Spray

1. Remove the cover off the air cleaner housing (where the air filter lives).

2. Ask an assistant to start (or crank the engine, if it doesn't start).

3. Check the spray pattern coming our of the injector.

* Fuel should come out partially atomized in an inverted V pattern. A single, solid spray or irregular
pattern means the injector needs cleaning, or that an internal part wore out or broke.

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You can try to fix an irregular fuel spray pattern by adding a quality cleaning fuel system additive to
the fuel tank. Or take your car to the service shop and have them clean the system.

* On the other hand, if you don't see fuel coming out, there may be several reasons for this:

Blocked fuel injector

Bad injector
Injector not receiving power
Bad fuel pressure regulator
Fuel filter clogged
Bad fuel pump
To troubleshoot the injector, apply the tests described in the following section Testing EFI Injectors.

3.Fuel System Inspection.

remain free of any buildup in debris and water contamination.

The various elements of the low-pressure system are, in order:
a. FUEL TANK:
Your fuel tank should ideally be placed above the engine level, where the head of the fuel will provide
a positive pressure force throughout the system. In the case of a leak, the fuel will seep out rather than
air ingestion into the fuel system.
If your tank is alongside or lower than your engine, then any leaks that develop air can be drawn into
the system when the engine is stopped. A small header tank will be enough to provide positive pressure,
but must also be vented to fresh air outside to allow flow into the engine fuel system.
NB: This is not necessary if your engine has a self-air bleed fuel filter fitted to the engine.
A fuel tank can be made of various materials including, but not limited to:
Stainless steel: strong and corrosion resistant.
Mild steel: coated inside and out with a paint system to protect against corrosion.

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Plastic: normally translucent so that the fuel level can be seen and offers less condensation and no risk
of rust forming.
Heavy-duty tanks: flexible and ideal for temporary tanks to endure a long journey.
b. SUPPLY LINE:
Your engine will vibrate relative to your boat, so it is only logical that a fuel system composed entirely
of solid pipe will fracture. A section of the pipework between the tank and the engine must be flexible,
such as a purpose-made diesel fuel hose with a protective wire mesh cover.
This will usually be placed next to the engine between your water separator and the lift pump, allowing
for the rest of the fuel line to be made of solid pipe and securely attached to your vessel.
Solid piping can be made of anything from thick-walled copper to stainless steel. All sealing joints
should be metal-to-metal. A sealing compound or PTFE tape should never be used in this situation as
you can run the risk of particles entering the fuel system.

c. FUEL PRE-FILTER
Most systems will have a separate water trap maintained between the fuel tank and the mechanical or
electric fuel lift pump for the water to settle out of the fuel and be drained off routinely. Fuel passes
through the internal passages which allow water and debris to settle out.
If there are more than a few drops of water settled or a small amount of debris, inspect the tank and, if
possible, clean it out immediately. The water trap will not need any maintenance but the cylindrical
container should also be removed and cleaned if it is badly affected.
Most water separating filters will consist of a disposable element filter, fitted above a clear plastic cup
as a water trap. This way you are able to see if there is any water or dirt on the bottom. Give this a
routine check over and be prepared to drain out if necessary.
d. FUEL LIFT PUMP
The mechanical lift pump is operated continuously from the engine camshaft and offers a consistent
supply of fuel at a low-pressure to the injector pump, keeping things topped up nicely. Many pumps
also have internal mesh screens to filter out debris and prevent non-return valves from staying open.
Two non-return valves flow inward and outward of the chamber above the oscillating diaphragm. Once
the pressure in the injector pump body is established, the spring becomes compressed and the
displacement reaches an optimal level to maintain pressure.
The Electric type pump is operated via the ignition switch once the key is turned to the on position.
e. FINE FUEL FILTER
The last line of defense for the high-pressure pump is the fine filter, which works to trap debris before
it is able to clog either the pumps or injectors. Considered by many to be something of a throwaway

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item, your filter should actually be changed every 250 to 300 hours. Always refer to the maintenance
guide in your engine operations manual.
Frequency will depend on the standard of fuel used and the effectiveness of the filter. If in doubt, best
practice is to change the fine fuel filter when the oil filter is changed. Take care to ensure that the seals
and the holding bolts are in good condition and correctly placed.

Cleaning Equipment

Types:
1.Sand Blasting
2.Glass Bead
3.Steam Cleaner
4.Salvage Tank
5.Air Gun

1.Sand Blasting
All sandblasters work on roughly the same principles: finely ground silica sand is used to clean and
abrade a surface, typically metal, of any rust, paint or other unwanted surface materials. This is done
by means of an air-powered pressure gun that fires out the sand at high velocity to impact with the
intended surface. All sandblasters use said pressurized gun, which has a ceramic barrel or interior
coating to prevent the sand from eroding it over time. The exact process by which the sand is
introduced to the gun differs. Basically speaking, there are three types of sandblaster.

The first of the three types of sandblaster is the gravity-fed model. There are three basic parts
to this model: an air compressor or pressurized air tank, a hand-held pressure gun with air hose and a
hopper on top of the gun. The hose connects to the air tank, and the hopper is filled with silica sand.
When the trigger of the gun is depressed two things happen. First, compressed air fires through the
gun as long as the trigger is held down. Second, an opening at the top of the gun into which the hopper
is connected opens. The air flowing through the gun and the force of gravity pulls the sand down
through the gun and out the barrel.

2.Glass Bead
Blasting is a common procedure use to treat the surfaces of many different kinds of objects. There are
several different types of blasting, and they can be compared most easily to sandpaper. Some types of
blasting are done using large blasts that are made to wear away large portions of material. Other types
use very small materials that are designed to wearing away small patches with much more attention to
detail. Glass bead blasting is a method using one of the largest types of blast media.

3.Steam Cleaner

Comforday Pressurized Handheld Steam Cleaner

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 The Comforday is a true handheld device that comes with a 9 piece accessories kit and targeted
towards those on a budget. For quickly going around the car without carrying a large steam cleaner,
this is the best buy.
In terms of the specification of this cheap handheld steam cleaner, it includes:
• 1050 watts of power
• Up to 270 degrees Fahrenheit of steam
• 20 minutes of operating time
• 9 piece accessory kit
It is an all in one steamer that will work with all surface to cut through dirt effortlessly. It is the cheapest
steam cleaner for cars that wont fall apart the moment you use it and will actually remove stains and
odors.
Procedure:
1) Inspect parts, equipment, and vehicles for cleanliness, damage, and compliance with standards
or regulations.
2) Scrub, scrape, or spray machine parts, equipment, or vehicles, using scrapers, brushes, clothes,
cleaners, disinfectants, insecticides, acid, abrasives, vacuums, and hoses.
3) Mix cleaning solutions, abrasive compositions, and other compounds, according to formulas.

4) Press buttons to activate cleaning equipment or machines.

5) Clean and polish vehicle windows.

6) Rinse objects and place them on drying racks; or use cloth, squeegees, or air compressors to dry
surfaces.

7) Drive vehicles to and from workshops and/or customers' workplaces or homes.

8) Turn valves or handles on equipment in order to regulate pressure and flow of water, air, steam, or
abrasives from sprayer nozzles.
9) Pre-soak or rinse machine parts, equipment, or vehicles by immersing objects in cleaning solutions
or water, manually or using hoists.

10) Lubricate machinery, vehicles, and equipment, and perform minor repairs and adjustments, using
hand tools.

11) Monitor operation of cleaning machines, and stop machines or notify supervisors when
malfunctions occur.
12) Disassemble and reassemble machines or equipment; or remove and reattach vehicle parts and
trim, using hand tools.

13) Connect hoses and lines to pumps and other equipment.

14) Maintain inventories of supplies.

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15) Apply paints, dyes, polishes, reconditioners, waxes, and masking materials to vehicles in order to
preserve, protect, or restore color and condition.

16) Turn valves or disconnect hoses in order to eliminate water, cleaning solutions, or vapors from
machinery or tanks.

17) Sweep, shovel, or vacuum loose debris and salvageable scrap into containers; and remove
containers from work areas.

18) Transport materials, equipment, or supplies to and from work areas, using carts or hoists.

19) Collect and test samples of cleaning solutions and vapors.

20) Clean the plastic work inside cars, using paintbrushes.

21) Fit boot spoilers, side skirts, and mud flaps to cars

Compressor

The basic working principle of an air compressor is to compress atmospheric air, which is then used
as per the requirements. In the process, atmospheric airis drawn in through an intake valve; more and
moreair is pulled inside a limited space mechanically by means of piston, impeller, or vane.

Types

1. Reciprocating type,
2. Rotary type

• An air compressor is a versatile device used for supplying compressed at required pressure.

for starting main engine of the ship, compressed air is required at 30 bar
-workshop purposes for removing dust
-spray paint
1. Reciprocating (Piston) Air Compressor:-
A reciprocating air compressor makes use of piston(s) to compress air and store it in a storage tank(or
reservoir) .
• Based on the number of compression stages, reciprocating compressor can be a single-stage or
double-stage configuration.
• In the single-stage unit, only one piston is used to compress air, whereas there are two pistons
for air compression in the double-stage air compressor.
• Double - stage compressor are used to compress air at higher pressure. As in double stage the
air which is compressed in primary stage is input for the secondary stage.
• For marine purpose multistage compressor is used along with inter-coolers at every stage of
compression and aftercooler (for maintaining the final temperature)

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2.Rotary Screw Air Compressor
• These are either vane or screw type.
• Each stage pressure rise is limited to 7 bar only.
• It requires a high speed drive.
(a) screw type
• Over here, two spinning helical screws or rotors are involved for compressing air (instead of
using pistons), hence the name.
• As the screws mesh towards each other, air is compressed and pushed inside a storage tank.

(b) vane type

A centrifugal air compressor is also called a dynamic compressor.
• It is applicable when the demand for compressed air is high.
• In this unit, a high-speed rotating impeller increases velocity of air, which is directed towards
a diffuser that converts the velocity of air into pressure.
• A centrifugal air compressor requires more energy to operate than the other two air
compressors.
Air Compressor: Working Mechanism
• In an air compressor, there are two major parts - a compressing system and a power source.
• The compressing mechanism can be a piston, rotating impeller, or vane depending upon which
type of compressor you are referring to.
• As for the power, it is supplied by an electric motor or other energy sources.
• The compressing mechanism, as the name suggests, helps in compressing atmospheric air by
using energy from the power source.
• The basic working principle of an air compressor is to compress atmospheric air, which is then
used as per the requirements. In the process, atmospheric air is drawn in through an intake valve; more
and more air is pulled inside a limited space mechanically by means of piston, impeller, or vane. Since
the amount of pulled atmospheric air is increased in the receiver or storage tank, volume is reduced
and pressure is raised automatically. In simpler terms, free or atmospheric air is compressed after
reducing its volume and at the same time, increasing its pressure.

Battery Charger

Battery charger working

A battery charger, or recharger, is a device used to put energy into a secondary cell or
rechargeable battery by forcing an electric current through it. ... A trickle charger provides a relatively
small amount of current, only enough to counteract self-discharge of a battery that is idle for a long
time.

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 Working Procedure
A battery charger is basically a DC power supply source. Here a transformer is used to step down the
AC mains input voltage to the required level as per the rating of the transformer.
This transformer is always a high power type and is able to produce a high current output as required
by most lead-acid batteries.
A bridge rectifier configuration is used to rectify the low voltage AC into DC and is further smoothed
by a high value electrolytic capacitor.
This DC is fed to an electronic circuit which regulates the voltage into a constant level and is applied
to the battery under charge, where the energy is stored through an internal process of chemical reaction.
In automatic battery chargers a voltage sensor circuit is incorporated to sense the voltage of the battery
under charge. The charger is automatically switched OFF when the battery voltage reaches the required
optimum level.

PERIODIC MAINTENANCE AND LUBRICATION CHART

The annual check must be performed every year, except if a kilometer-based maintenance is performed instead.
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
Items marked with an asterisk(*) should be performed by a Yamaha dealer as they require special tools, data
and technical skill.

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 ODOMETER
READING(x10
NO. ITEM CHECK OR MAINTENANCE JOB Annual check
00 km)
1 10 20 30 40
Check fuel hoses and vacuum hose for cracks
1 * Fuel line + + + + +
or damage.
2 * Fuel filter Check condition. + +
Check condition.
+ +
3 Spark plugs Clean and regap.
Replace + +
Check valve clearance.
4 * Valves Every 20,000 km
Adjust.
Clean. + +
5 Air filter element
Repalce. + +
Check operation.
6 Clutch + + + + +
Adjust.
Check operation, fluid level and vehicle for
+ + + + + +
7 * Front brake fluid leakage.
Repalce brake pads. Whenever worn to the limit
Check operation, fluid level and vehicle for
+ + + + + +
8 * Rear brake fluid leakage.
Repalce brake pads. Whenever worn to the limit
Check for cracks or damage. + + + + +
9 * Brake hoses
Repalce. Every 4 years
10 * Wheels Checkrunout and for damage. + + + +
Check tread depth and for damage.
Replace if necessary.
11 * Tires + + + + +
Check air pressure.
Correct if necessary.
12 * Wheel bearings Check bearing for looseness or damage. + + + +
Check operation and for excessive play. + + + +
13 * Swingarm
Lubricate with lithium-soap-based grease. Every 50,000 km
Check chain slack.
Every 1,000 km and after
Make sure that the rear wheel is properly
14 Drive chain washing the motocycle or riding
aligned.
in the rain.
Clean and lubricate.
Check bearing play and steering for roughness. + + + + +
15 * Steering bearings
Lubricate with lithium-soap-based grease. Every 20,000 km

Workshop practice III 17

 Make sure that all nuts, bolts and screws are
16 * Chassis fasteners + + + + +
properly tightened.
Sidestand/centersta Checkopertaion.
17 + + + + +
nd Lubricate.
18 * Sidestand switch Checkopertaion. + + + + + +
19 Front fork Checkopertaion and for oil leakage. + + + +
Shock absorber Checkopertaion and shock absorber for oil
20 + + + +
assembly leakage.
Rear suspension Check operation. + + + +
relay arm and
21 *
connecting arm Lubricate with lithium-soap-based grease. + +
pivoting points
Check starter(choke) opertaion.
22 * Carburetors Adjust engine idling speed and + + + + + +
synchronization.
Change. + + + + + +
23 Engine oil
Check oil level and vehicle for oil leakage. + + + + + +
Engine oil filter
24 Replace. + + +
cartridge
Front and rear brake
25 * Checkopertaion. + + + + + +
switches
Moving parts and
26 Lubricate. + + + + +
cables.
Lights, signals and Check operation.
27 * + + + + + +
switches Adjust headlight beam.
The air filter need more frequent service if you are riding in unusually wet or dusty areas.
2001 and earlyer models - maintenance period: every 6,000 km.

Workshop practice III 18

Jacks
A jack, screwjack or jackscrew is a mechanical device used as a lifting device to lift heavy loads or to
apply great forces. ... A hydraulic jack uses hydraulic power. The most common form is a car jack,
floor jack or garage jack, which lifts vehicles so that maintenance can be performed.
Different types of jacks
Floor Jack:
A floor jack is the most common type of jack used for maintenance and repairs. They are easy to move
around and position in the exact spot that needs to be lifted. A floor
jack consists of a low to the ground unit with four wheels and a long
handle that the user pumps to operate the hydraulic lift portion of
the jack. The jack saddle is a round disk that makes contact with the
vehicle.
The low profile of the base unit allows it to be easily maneuvered.
The handle must be turned clockwise which closes the valve before
pumping the handle to raise the jack. The handle is turned counter
clockwise to open the valve and lower the jack saddle.

Floor jacks are the workhorses of the jack community and they are extremely helpful when performing
work that requires the mechanic to get underneath the vehicle.

Scissor Jack:
A scissor jack is the type of jack that most people have in the trunk of their car. It uses a screw
mechanism to produce the lifting power. The main advantage of this type of jack is its small size and
portability.
The jack is placed underneath the spot to be lifted and the screw is turned using a handle to raise or
lower the vehicle. In many cases the handle will be the tire iron that is included with the car.
In most cases the jack that is included with the vehicle is designed to fit the specific lifting spots on

the car. If a replacement is needed, verify that it will fit the car and has a lifting capacity that is
appropriate for the vehicle.

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Hydraulic Bottle Jack:
This bottle shaped jack uses hydraulic pressure to lift heavy vehicles and other large equipment. These
jacks have a high lifting capacity and must be used on a hard and level surface. A lever is inserted and
pumped to lift the vehicle.
While bottle jacks are high capacity and are quite portable, they lack the mobility of a floor jack and
are not stable enough to be used on the side of a road, making them less than ideal for changing a tire.

As with all jacks, check the lifting capacity of a bottle jack against the weight of the vehicle before
using it.
Hi-Lift Jack:
This is a specialty jack that is used with lifted or off-road vehicles. These jacks are mainly used in off
road situations or where rugged terrain limits the use of other types of jacks.
Hi-lift jacks are often high capacity, rated up to 7,000 pounds and can lift a vehicle up to five feet.
They are usually 3 to 5 feet long and can weigh up to 30 pounds making them unsuitable for carrying
around in a typical car.
Basic parts of every hydraulic truck crane:

Boom
Jib
Rotex gear
Outriggers
Counterweights
Reinforced-steel cable
Hook

Workshop practice III 20

Boom
The most recognizable part of any crane is the boom. This is the steel arm of the crane that holds the
load. Rising up from just behind the operator's cab, the boom is the essential piece of a crane, allowing
the machine to raise loads to heights of several dozen feet.
Most hydraulic truck cranes have a boom that has several telescoping sections. For instance, a 70-ton
Link-Belt hydraulic truck crane has a boom with three telescoping sections.
Jib
This particular boom has a length of 127 feet (38.7 meters). Some booms are equipped with a jib,
which is the lattice structure attached to the end of the boom. On the 70-ton hydraulic truck crane, the
jib is 67 feet (20.4 meters) long, giving the crane a total length of 194 feet (59.1 meters). As the load
is lifted, the sections telescope out to the desired height.
Reinforced-steel cable
Reinforced-steel cable lines run from a winch just behind the operator's cab, extending up and over the
the boom and jib. Each line is capable of holding a maximum load of 14,000 pounds (6,350 kilograms).
So, a 70-ton hydraulic truck can use up to 10 cable lines for a total of 140,000 pounds (63,503
kilograms), or 70 tons. The lines run up the boom and jib and attach to a 285-pound (129 kilograms)
metal ball that keeps the lines pulled taut when no load is attached to the hook.
Rotex gear
To maneuver the load, the boom has to be able to move right and left, as well as up and down.
Underneath the operator's cab is a Rotex gear on a turntable bearing that turns at 2 revolutions per
minute (rpm). It is driven by a bidirectional, hydraulic motor mounted on the cab and housed in a metal
cover to prevent injuries. The rotation is controlled by a foot-operated, hydraulic pedal in the cab.

Outriggers:
Hydraulic truck cranes are used to lift heavy loads to tall heights, and it's important that the truck be
completely stable during the lifting operation. The tires don't offer the stability needed, so the truck
employs outriggers that act as balances to keep the crane from leaning too much to one side or the
other. The outriggers use hydraulics to lift the entire truck, tires and all, off the ground. The outriggers
are comprised of the beam, which is the leg of the outrigger, and the pad, which is the foot. Sometimes,
"floats" are placed under the pad to dissipate the force of the crane and the load over concrete or
pavement. Floats are usually wood planks that are lined up to create a base that is larger than the pad
itself.

Workshop practice III 21

The outriggers are only one mechanism used to balance the crane during lifting operations. There are
also detachable counterweights that can be placed on the back of the crane on the underside of the cab.
These counterweights prevent the crane from tipping forward during operation. The amount of
counterweight needed for a particular lift is determined by the weight of the load, the radius of the
boom and the boom's angle during operation. The 70-ton Link-Belt truck crane has counterweights
that come in 4,000-pound (1,814-kilogram) sections. Counterweights are only used during lifts; they
have to be removed before the truck can be driven.

Car Lift
A car lift, also called a car lift, is a forklift that specializes in the vertical movement of vehicles. They
are used to transport these vehicles from one height to another with or without an occupant. For this

Workshop practice III 22

purpose, its design is generally robust and simple, so that it can withstand the blows well and facilitate
the entry and exit of vehicles. Its technology can be more or less elaborated in its presentation and in
the handling devices, but in general it uses the same basic physical principles.
How do they work?
The most efficient and most widespread car lifts are the hydraulic ones that work by the Pascal
principle. This one that affirms that, when exerting pressure on a liquid body, it is transmitted to the
entire container of the liquid without diminishing its volume. In a container that has non-deformable
retaining walls, these will direct all this pressure towards the only point that is free to release it.

In the case of a hydraulic lift, an actuator piston is available, that is, the place where the inlet pressure
is exerted, which is of a smaller size compared to the executing piston. The pressure is lower at the
point of action, although the distance traveled during it increases with respect to that obtained in the
executing piston. In this way, a high pressure can be generated to lift a very heavy element by exerting
a small pressure for a long stroke.
Types of auto lifts
Depending on the type of work to be done, there are several types of car hires. The two-post lift is
often used to lift light or medium-sized cars. The four-post lift is more versatile and has the possibility
of lifting heavier loads. The parking lifts allow you to stack vehicles that will not have to move for
extended periods of time or in a way that makes the parking space more efficient.

For other needs, such as wheel alignment services, there are elevators specially designed for this. You
can also find mobile elevators, more powerful than a simple hydraulic jack but not necessarily installed
on the ground in a fixed manner. In addition to these elevators, there are a large number of designs for

Workshop practice III 23

 special jobs: scissor lifts, low-rise elevators, mobile column elevators, elevators designed for small
workshops and a long catalog. Astarlifts has a long history in the manufacture, installation and
maintenance of all these equipment although it stands out for its extensive experience in larger
elevators.

Layout of Garage

Introduction: It facilitates function; include system for record keeping, registrations. Layout means laying down
of various machines, equipment’s in various locations so that their availability, accessibility and functionality
facilitates managers, mechanics, and functionality facilitates managers, mechanics, store men and customer’s
satisfaction is achieved.

Important shops/offices (see chart)

1. Auto machines and plants. Jacks lifting mechanisms, cranes.
2. Battery Service. Bty testers, rechargers, distilled water plants, funnels.
3. Body and fended service. Body straitening tool, hand tools, power tools, sanders, spray guns, flux, solder,
paints, upholstering

4. Brake service. Brake fluid, special tools, honing sets, plug gauges, brake master cylinder relining, brake shoes
riveting relining rivets.
5. Carburetor, fuel pump, ignition service.
Carburetor OIH kit, fuel pump is calibrated in FIP labs.
6. Engine tune-up svc. Spark plug cleaners, engine analyzer, diagnostic sets, V.C micrometer, feeler gauge,
timing light dies, petrol, wrenches set, compression, vac gauges.

7. Engine tune-up service

Compression and vacuum gauges, gas analyzers, timing lights, spark plug cleaners, tools for adjusting valves,
wrenches for spark plug, torque wrenches, ring expanders, measurement tools, power tools, pneumatic wrenches,
data charts for wiring, measurements.

8. Engine Re boring Re conditioning service.

Cylinder rebooting and honing equipment’s. Piston and connecting rod aligners, piston pin hole hones, valve
lapping, valve lapping, valve seat regrinding, engine stand, micrometer, Vernier calipers, cylinder gauges.

9. Engine Reconditioning
Engine stand, ring expander, VC, m.m. mercer gauge

10. Gasoline service

11. Lub service

Workshop practice III 24

12. Painting service. Spray guns, paint mixing m/c, compressors, Air handling unit, paint, thinner, separate booth
or room for painting

13. Radiator service. Solders, radiator leak tester, flushing equipment’s.

14. Tools. Special and common use tools, wrenches, pliers, screwdrivers, hammers.

15. Testing equipment’s. Engine, transmission, light, diagnostic sets, soft wares.

16. Tow equipment’s (service, car) used old cars, 1/4 ton vehicle in good condition.

17. Welding and cutting. Oxyacetylene, elect welding tig, MiG plants.

18. Wheel Alignment wheel balancer, aligners. Generally this type of work is done in separate shops

19. Layout of garage.

It should be systematic, facilitating, smooth in functioning easiest in accessibility, more economical in handling
and in managerial issues.

20. A NINE-car garage.

60× 40 feet and 14 ft in height.

Workshop practice III 25

Automotive Faults Diagnostic Scanner

Procedure to use Diagnostic Scanner

The OBD scan tool set up process is not a uniform process and it depends on the type and brand of
car. While the use of onboard diagnostic scans is desirable, the process of setting one up may be quite
involved. When a new tool is bought, some of the things to be done in the course of its setup include;

1.Download the necessary applications

Different OBD 2 scan tools may require a number of applications to be able to work effectively. While
this may be so, there are other applications which only work well with the PC.
These applications require proper installations before the OBD scan tool can be connected to the areas
where it is connected to the PC. The applications are also important in making the several other areas
of the OBD scan tool work well.
In addition, you may include the addition of the several other software programs depending on which
OBD you are using. For instance, Bluetooth wireless devices may need the inclusion of the several
wireless applications.

2.The use of the data link connector

In most of the OBD scan tools, this is where the car engine is connected to the car. It is comprised of
the 16 pin connection points which are usually marked with different colors.

The DLC, as it is popularly known, is the most vital part of the OBD set up process and is usually
conveniently placed for instance on the dashboard for older cars and near the car driver, below the seat
to be precise. Connecting each pin to the various areas of connection, like the battery, is important.
3.Connect the OBD
The OBD 2 requires the connection using one pin among several pins. This is because most of them
are considered standalone, as they have their own power sources. The OBD pins are classified to suit
the diverse areas.

These 16 pins include:

1. Manufacturer reserved pin
2. The J1850

Workshop practice III 26

3. Manufacturer reserved pin
4. The chassis ground connector
5. The signal ground
6. The CAN high, J-2284
7. The k line, ISO9141-2/DIS 14230-4connector port
8. Manufacturer reserved pin
9. Manufacturer reserved pin
10. J1850 Bus
11. Manufacturer reserved port
12. Manufacturer reserved port
13. Manufacturer reserved port
14. CAN, J2284 PORT
15. The L line, ISO 9141 and ISO/ DIS 14230-4
16. The battery power connection

4. Check when the system is fully set up

The user needs to know how to navigate the aspects of the tool. Some of which include:
• Keypad– this helps in navigating the tool features by scrolling up and down. The keypad also
helps in enabling some of the features of the OBD scan tool.
• Display– depending on which type of display, this is where the data information is shown. You
can read the data here.
• Power– though most of the OBD 2 scan tools are standalone, they need the use of car engine
power at a given time and so the power connection pin has to be working.
5.Use the OBD Scan
The ultimate aim of setting up the OBD scan tool is to be used for scanning the car. As long as the
OBD scan is compatible with the car, it will work with the car computer system.
With this, you are all set for some great scanning experience.

Workshop practice III 27

Positive Crankcase Ventilation System:

Workshop practice III 28

Workshop practice III 29
Workshop practice III 30
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Workshop practice III 32
PRINCIPLE OF RECORD KEEPING:
Introduction
It comprises of record of maintenance system of repair and accounts which inventories stock registers
consumption register the job costs the timer sheets analysis of pre operational diagnosis
Garage records
A garage is a place where cars are storage and cared for
Thus forms are main trained
monthly checking sheet
repair card
inspection form in ins and out
wash order

Following dues are maintained in workshop

day book…it gives an idea of leading of various secs

master job folder…it is a file having master numbers it contains all inspection, reports, job cards, work
orders
Lubrication system
In the lubrication system following are inspected
1 engine oil
2 oil pump
3 transmission oil
4 oil level
5 oil condition
6 oil leakage
Other inspection
• electric wiring
• electrical connections
• head lights
• gauges
• fuse
• horns
• vipers
• repair / maintenance record cards
• It gives a record of periodic maintenance of vehicle/equipment’s
• principle of record keeping
• Equipment’s which record will be maintained i.e. tires, cars, earthmoving equipment
• Customer wise number of vehicle /plant will be show customize
System of repair and account
• sequence of work is determined by i/c section
• 2* men team is detailed 1* shilled and another are under training
• essential space is made avail before commitments of wash

Workshop practice III 33

 • local contact experienced is done if wash is beyond the repair
• deposit repair of major repairs is regular, if spares are unveiling or repair work is beyond the
scope of wash
• if spares are avail repair is under taken
• liavon of various sections of art experience
• Estimation of repairs costs
• Computer cost of repair from job card and time sheets
• cost of spares
• cost if mechanic
• System of account
• provision of spares
• receipt issue
• accounts
• direct exchange pool
• Stock of first moving stock item
• collection and return stores
Workshop inventories
Stock register and consumption register
Following are maintained’
receipt control
expense control
issue control
daily lean
permanent lean
test equipment
inspect record register
indent control
Inventory control
Job card and time sheet
1 concerned mech allocation
2 optimum utilization of man powers
3 apparels equipment’s of spares id washed out
4 costumer bill can be easily prepared
5 future records

Time sheet
1 date and time
2 judicial equipment’s
3 costumer bill

Perform a one-pre-operational inspection

In pre-ops inspection following sys of vehicle are inspected
cooling sys

Workshop practice III 34

fuel sys
electric and ignition sys

Engine overhaul

1) In class rebuild
2) Major overhaul
3) Blue printing an engine
An engine overhaul is a comprehensive engine tune up that involves removing and dis assembling a
vehicles engine, testing all the components, cleaning and replacing parts as necessary and then re
assembling the engine.
The restoration of an item to a completely serviceable condition as prescribed by stds.

Basic requirements
Infra structure
Man power
Tools gauges
Spares
Machining facility
Infrastructure
Shed/garage
Water
Electricity
Assembly tables
Test benches
Dynamometers
Portable crane
Solvent tank
Spray washers
Tool cabinets
Pneumatic tools
Skilled manpower

Tools and gauges

. Vernier, micro, mercer gauges
. Torque wrench
. Socket set
. Puller set
. Ring expander
. V block
. Grinding machines (Crankshaft) etc.

Workshop practice III 35

Disassembly sequence
Cam shaft
Fly wheel
Fly wheel hosing
Piston and connecting rod
Crank shaft
Tappet
Cylinder block
Piston
Measurement

Determine overhaul reasons

Top overhaul
Major overhaul

Parts remove sequence

Engine on stand. Injection nozzle
Starter motor. Injection pump
Alternator. Intake manifold
Exhaust manifold. Head cover
Injection pipes. Rocker Arm
Thermostate. Push rod
Water pump/ fan. Cylinder head
Fuel filter. Oil pan
Oil filter. Oil suction pipe
Glow plugs. Crank pulley

Re- assy. Sequence

Cylinder block
Tappet
Crankshaft
Main cap
Piston sub assy i.e piston and connecting rod
Fly wheel housing
Fly wheel
Cam shaft
Oil sumo
Idler gear
Fuel injection pump
Front cover
Crank pulley gear
Oil suction pipe
Oil pan

Workshop practice III 36

Fuel pump oil sub assy
Cylinder head
Push rods
Rocker arm
Valve clearance
Head cover

Functions of rings
Sealing mixture
Scraping oil during down stroke
Prevent excessive oil flow into C.C
cool the piston
Prevention of blow by

Types
Compression rings:
Cast iron, excellent wearing qualities tapered, chambered, counter bored, scraper, plain, Centre
grooved.
Oil rings

Re assy sequence
• Exhaust manifold
• Intake manifold
• Injection nozzle
• Glow plugs
• Fuel injection pipe
• Water pump
• Fuel filter
• Starting motor
• Fan pulley
• Alternator
• Finish engine
• Engine assy to stand
• Rings counter board, twists, stops engine oil to flow into C. C
• Scraper type, scrapes the oil

Rings coating
Phosphate, Graphite, Iron oxide, Molybdenum, Chromium.

Rings wear
Scuff wear. Extra power demand at very high temperature
Abrasive wear. Dust wear.

Workshop practice III 37

Main service station Eqpt

Intro: Cranes, Jacks, lifters

Main:
Jacks convert fluid energy into linear mech: energy

Working

Single acting: pressure fluid of a pump or compressor moves a load in opposite direction.
Double Acting: the pressure fluid extends or retracts the cylinder.

Double end rod:

The cylinder allows work to be performed at both ends, if desirable,
Work speed is same.

Cushion
It reduces piston speed at the end of its stroke

Intensifier:
It produces the secondary pressure higher than the available primary pressure. Intensifiers have large
and small pistons, each piston connected to a single rod.
The sizes of large and small pistons provide a degree of pressure increase, and in some cases the highest
pressure is achieved by putting values to facilitate the increase of pressure in the system.

Single Acting Hydraulic cylinder

Hydraulic fluid is pushed into the cylinder. The piston is raised up and on operation of cylinders’
piston, the load is picked up. There is only one way to pass the fluid.

Double acting
There are two connections. The fluid can be pumped into the cylinders, both ways

Workshop practice III 38