Automobile Engineering (22656) Practical No. 5 : n Iv VI VIL antle, inspect and reassemble the Synchromesh Gear Box. Practical Significance Gear box is an important part in automobiles, It transmits power from the engine crankshaft to the rear wheels, Now a day, in most of the automobiles synchromesh gear box is used for power transmission purpose, To understand the probable faults that may occur in the gear b ential to identify the various components of the synchromesh gear box. This task includes the assembly , disassembly and inspection of different clements of synchromesh gear box. Relevant Program Outcomes (POs) POI - Basic knowledge: Apply knowledge of basic mathematics, sciences and basic Engineering to solve the broad-based Mechanical Engineering problems. PO2 - Discipline knowledge: Apply mechanical engineering knowledge to solve broad-based mechanical engineering related problems. PO3 - Experiments and practice: Plan to perform experiments and practices touse the results to solve broad-based Mechanical Engineering problems. PO8 -Individual and team work: Function effectively as a leader and team member in diverse/ multidisciplinary teams Competency and Skills One of the main competency that a mechanical engineering student should posses is “Perform the job of Mechanical supervisor in Automobile Industry’ . To inculcate this competency following skills are developed in the student after conducting the- practical of this laboratory manual 1. Use relevant tools and equipments for dismantling and assembly of various automobile system components. 2. Inspect given component /assembly of the given vehicle. Relevant Course Outcome(s) * Select service tools for relevant service operation in automobile shops Practical Outcome © Dismantle, inspect and reassemble the Synchro Mesh Gear Box. Relative Affective Dom: © Follow the road and workshop safety practices, © Maintain tools, equipment and service records Minimum Theoretical Background . In the Synchromesh gearbox, provision of synchromesh device avoids the necessity of double declutching. These synchromesh devices work on the principle that the two 3 Maharashtra State Board of Technical Education‘Automobile Engineering (22656) 5. Remove the main shaft gears, dog clutch, sliding sleeve, synchromesh unit, bearings and arrange these in the order of their fitment on the main shaft. 6. Remove the reverse idler gear shaft and the idler gear, Remove the lay shaft gear set with washers. Remove the lay shaft bearings. * Inspection : Inspect the transmission ease for era threads. Check each synchronizer sleeve for free movement on its hub. Check the amount of synchronizer ring wear by placing the ring on its gear cone. Inspect the shift fork and groove in the synchronizer sleeve for wear or damage. Check all bushings and bearings Inspect all gears for crack or worn out excessively. ind! worn or damaged bearing bores and ave Assembling : Place all seats in the cover. Fit the counter shaft bearing. Clamp the counter shaft in its position. Fix the reverse idler along with its shaft and lock it. Assemble the gears, bushes, dog clutches, synchromesh units on the main shaft. Place the plot bearing on the main shaft. Lift the main shaft & place it in the gearbox casing. Fit the main shaft rear end bearing ifiside the casing. 6. Fix the bearing on clutch shaft & fit d circlip. Place the clutch shaft in the casing. Place the bearing housing along with the gasket on gear casing. 7. Place the speedometer drive gear on the main shaft. Fit all the bearing covers along with the gasket. 8. Place the drive flange on main shaft. Keep the main shaft in neutral position. Keep all the forks in neutral position. 9. Mount the selector assembly on gearbox. 10. Engage each gear and check the rotation by hand XIL_ Resources Used S. | Name of Broad Specifications ‘Quantity | Remarks No. | Resource | Make Details (fany) 1 [anersen Working medel of Venicle| ef 2. [Tools 4 Gauges Wernler caliper [Feelerseud ol XI Actual Procedure Followed A.Me meuot. the whele assembly oo work stand, leek mein shake 2. 3. Thenwe chek dine, ach, Park PF ASAE SERN. + assemble the whole Maharashtra State Board of Technical Education zi 2Automobile Engineering (22656) XIV Precautions Followed j XV Observations and Calculations + | | a a a) Note: Identify the driver and driven gears for different gear ratios F & dismantling and count the number of tecth on respective gears. Calculate the tios. Sr. r Gear No. of tecth on Gear Ratio No. | __ position Driven gear _| Driver gear 1__| First 2_| Second 3__| Third 4_[Forth 3_| Fifth 6 _| Reverse ») i) Observe the Synchromesh unit and state whether they are single / double/é stage Synchromesh unit ii) The gears on the layshaft are —C1xe4. Aol a nnnnnnn-—--— (fixed / movable) iii) The gears on the Main shaft are “2veble ___ (ixed / movable) XVI Results Gear ratio obtained for a given vehicle 1. Fist gear = 2. 3. 4. 5. Fifth gear =, 6. Reverse gears, XVIL_ Interpretation of ResultsAutomobile Engincering (22656) XVIII Conclusions XIX Practical Related Questions . Note: Below given are few sample questions for reference. Teachers must design more such questions so as to ensure the achievement of identified CO. |. What is the purpose of gear box? .. Describe principle of Synchromesh gear box. = Describe the constant mesh gear box with the help of sketch. |. What are the advantages ofa synchronizing mechanism? . What are the possible éauses and remedies of hard gear? Pepe [Space for Answer] ata. Slower 204¢...thenn....opat Short + This ‘Maharashtra State Board of Technical EducationAutomobile Engineering (22656) Maharashor State Board of Technical EducationAuomobile Engincering (22656) xeplacs replace. XX __ References / Suggestions for Further Reading 1. hittps:/Avww.youtube.com/watch?v=VeFQZ8NiF40 2. hitps://www.youtube.comvwatch?v=0Bqs-oHBBQk XXI_ Assessment Scheme Performance Indicators Weightage Process Related (15 Marks) (60%) T | Handling of service tool carefully 20% 7 Select the sequence of operation of dismantle and 20% assembly 3 | Safety measures and standard practices 20% Product Related (10 Marks) (40%) J | interpretation of result , Conclusion 20% 6 Practical related questions 20% Total (25 Marks) 100% Names of Student Team Members fie : 2. 3. 4. Marks Obtalned J Dated signature of Teacher Product | Total Process Related(15) Related(10) (25)Practic 1 Ti Relevant Program Outcomes (POs) 1 No. 6: Dismantle, inspect al . : . " Assembly- and reasers-—— : the rear axle, accommodayg, Procite Se ail power from the gearbox to ‘The propeller sha Ss “angles. It is connected between the i fh, and transmits motion at varying a phivedal joist Hexos 4 ae versal joint and differential unit si ropoller shaft and uni aries saat the constructions! see ite Ae eae cami : significant 10° Ss its working for fi : AUS. joint ass: emonstrate its wo tnt d-usiversal ia a set ae actual working unit of propeller shaft ani j for this practical w' ie ef Sisiuntng, inspection and assembling purpose. POI - Basic knowledge: Apply knowledge of basic roaihemalles, and basic ‘ineering to solve the broad-based Mechanical Engineering pro ; ot Pon ~ Discipline, knowledge: Apply mechanical engineering knowledge to sol anical engineering related problems. proad-based mechanical engineering rel ; i PO3 - Experiments and practice: Plan to perform experiments and practices to use the results to solve broad-based Mechanical Engineering problems. PO8 -Individual and team work: Function effectively as a leader and team member in diverse/ multidisciplinary teams MIL Competency and Skills One of the main competency that a mechanical engineering student should posses is ‘Perform the job of Mechanical supervisor in Automobile Industry” . To inculcate this competency following skills are developed in the student after conducting the practical of this laboratory manual. 1, Use relevant tools and equipments for dismantling and assembly of various automobile system components. 2. Inspect given component /assembly of the given vehicle. IV Relevant Course Outcome(s) * Inspect given component assembly of the given vehicle v Practical Outcome * Pismantl, inspect and reassemble the Propeller shat Assembly VI Relative Affective Domain- * Follow the road and worksho, Maintain tools, . P safety practices, equipment and service recordsssemwuute Engineering (22656) * Inspection ; spect the bearing, joumal trunnions and the splines of sliding joint for wear, If there is sign of wear or excessive looseness found replace the different parts, Assembling: + Grease the various rollers an . Replace the gaskets |. Install the circlips, } Screw the dust cover and slide in the slip joint. - Lubricate the various joints with specified lubri + Place the reassembled propeller shaft in position fa the chassis, insert the bolts in the flanges and tighten them assemble the needle bearings, And fit the journal und bearing trunnions to the yokes, AVAUpoe XII Resources Used S. [Name of Broad Specifications Quantity | Remarks No. _| Resource Make Details (fany) 1 Prepetien ey car hole propane | _e1 2. Roses ot leress € Yoke dype el XII Actual Procedure Followed needed. de. Fellese bly. as ff Propeller shaft assemt eaten sould inspect all the components 0 The student shot a a = } te re obse Remark / Fun: = (SH | communes drive Bhatt assembly Te Ft r a fhe required apphication: Et runs on necdle roller b eripy te puss - 7 deer Spider ru eases z Slipjoint [EF used te. isae Toa censideabi 3 lof pro} + 7] Bearing [E+ s“pros? IT? allows ihe Fricflon. lr sitp within shaftTn hol of Front fone, when The fis unseres ADS figd fone a z 1 Tor pransenitting Teryuc er XVII Interpretation of Results XVIII Conclusions XIX Practical Related Questions Note: Below given are fow more such questions so as fo ensure the achievement of identified CO. 1, Whatis the function of universal joints to power transmission? 2, What is the purpose of slip joint? 3, Why are two universal joints required? 4, Name the two types of propeller shaft and describe one type in detail. sample questions for reference. Teachers must desisf E F B E E pvommbleapbecing 268) [Space for Answer} ropleay js a large axial mavement mevement are, the Propeller a Maharashtra State Board of Technical Education0 m VI vir ‘Maharashtra State Board of Technical Eauca Practical No, 7: Dismantle, inspect and reassemble the Differentig, Assembly Practical Significance | ee ‘The purpose of final drive is to provide a permanent speed hen a ss oy the drive through 90°, Differential mechanism alsa cs he Pa re ae | it is significant to us the vehicle to take a tum safely. Hence itis signifi : details of differential and rear axle-for finding the faults and identify te causes fr same. In this practical we use actual working unit or cut-section working my differential ear axle for dismantling, inspection and assembly purpose. Relevant Program Outcomes (POs) ; ; POI - Basic knowledge: Apply knowledge of basic mathematics, sciences and Engineering to solve the broad-based Mechanical Engineering problems. PO2 - Discipline knowledge: Apply mechanical engineering knowledge to s3 broad-based mechanical engineering related problems. POS - Experiments and practice: Plan to perform experiments and practices tom the results to solve broad-based Mechanical Engineering problems. POS -Individual and team work: Function effectively as a leader and team in diverse/ multidisciplinary teams Competency and Skills One of the main competency that a mechanical engineering student should ‘Perform the job of Mechanical this competency following skills practical of this laboratory manual 1. Use relevant tools and equipment ‘automobile system components, Inspect given component assembly of the given vehicle. supervisor in Automobile Industry" . To are developed in the student after cond for dismantling and assembly of various 2. Relevant Course Outcome(s) Select servic cl i ee ools for relevant service operation in automobile shops Practical Outcome * Dismantle, inspect and reas emble the Differential Assembly Relative Affective Domain. Follow the road and workshop safety practices, * Maintain tools, equipment and Service records Minimum Theoretical Background It is a geared mechanism loca22656) Automobile Engineering ( XIL__ Resources Used [s] 7 XV Observations : 1, The differential is a mechanism fitted afer 2.924 (Propellet/gearbox) 2. Differential transmit power at right angle to 2 cc) s 3. The speed of inner and outer wheels is differentiated while 72kins..2. (Moving straighvtaking a tum). 4. In the differential the crown wheel is meshed to .... shaft). 5. The axle half shaft js splined to the. wheel& pinion gear) « (drive pinion / Components of differential SN._| Components Write Location and iy 1 | Bevel pinion | Location function of the These ave weunte Bhar . Punction-these ro] Bowes tian fiom components Von differentta Pinion acts ae idtens Fol ater: 4 esa 2 | Sun gear Function. y Oped setative yy Me Tuva" |___1_____lepeed setae yf he 2 1 rolaye Tate Board of Technical Education &3 | Cage Location= Function. 4 | Bearing Location. J Is placed after nnn. Function. 8 ¢a11 n; 14 Used to veduce the Friction 4a Sandie 5 | Rear axle-halt ] Location= T¥Treepepeeee shaft alFerendial Geary a ving wheel & the Function- Tt transmit power fom dhe di FFerenival io the eit wheels. Location- 11 is mounted on BAF axle shaft 4 IP mesh uslth driving’ pinion « Funetion- 74 35 ¢. i 1 19 equally split: engine torque 4 fed it _ 40 wheels 4 allow ine onea ae ey sHeesea, 7 [Pinion gear | Location- Tis mounied oa Pinion shaft tn a Mesh with rin eae. Funetion- 74 jsonsenit Power to both Gresexles tmoggh another set of Gears ! 6 Crown wheel XVI Results inal Drive ratio = Noofteeth on crown wheel Final Drive ratio = No.of teeth on bevel pinion XVIL_ Interpretation of Results XIX Practical Related Questions Note: Below given are few sample such questions so as to ensure the achie 1, State the function of differential unit. 2. List the components of differential. questions for reference, Teachers must design more hievement of identified CO. Maharashtra State Board of Technical Educationzdesign cel Eellewetey. DriveBa per esac ismanth e le, inspect and reassemble the Drum/Dise Brake. Practical Significance : The purpose of the . ; vehicle is staioeary at is to stow down or stop the vehicle and when the + f0 bold the vehiele in the chosen Position.In this practical we use actual working unit or cut 7 a section working el of " " inspection and assembly pag NE Model OF drm / dss brake for dismanting Relevant Program Outcomes (POs) POI - Basi : Entree nuetedge: Apply knowledge of basie mathematis, sciences and basic pens ering to solve the broad-based Mechanical Engineering problems. 2 ~ Discipline knowledge: Apply mechanical engineering knowledge to solve broad-based mechanical engineering related problems, POS - Experiments and practice: Plan to perform experiments and practices to use the results to solve broad-based Mechanical Engineering problems POS -Individual and team work: Function effectively as a Jeader and team member in diverse’ multidisciplinary teams Competency and Skills One of the main competency that a mecl “Perform the job of Mechanical supervisor in Automobile Industry’ . To inculcate this competency following skills are developed in the student after conducting the. practical of this laboratory manual 1. Use relevant tools and equipments for dismantling and assembly of various automobile system components. Inspect given component /assembly of the given vehicle. Relevant Course Outcome(s) : © Select service tools for relevant service operation in automobile shops Practical Outcome beg © Dismantle, inspect and reassemble the drum / dise brake, Relative Affective Domain- © Follow the road and workshop safely p Maintain tools, cquipment and service records ractices. mam tains energy of motion (kinetic energy) and the avert this kinetic energy into heat energy. It rake drum, or the brake pads VIL Minimum Theoretical Backgroun When a vehiele is moving it contain’ ion of the braking system 15 et h foe tad the frition at the brake Linings and the re i se on vehic Tae ee of friction brakes are in common use 1, Drum brake ;Practical Related Questions Note: Below given are few sample questions for reference, Teachers must design more such questions so as to ensure the achievement of identified CO. - What is the principle of automotive brakes? . What are the important differences between mechanical and hydraulic Brakes? Compare disc and drum brake. . Name important components of brake drum. . Out of disc and drum brakes, which have better anti-fade characteristics? wwe [Space for Answer] vVelstele wheels 4 Ak Often acegaiplist Maharashtra State Board of Technical EdvcanionAutomobile Engineering (22686) ‘Maharashtra State Board of Technical Educationcharacter,m1 VI Vi — * ASsmantie, 5 6 ee Rack RPinig net a d reasse reuta mle the Steering Gear Box, iat Sinica ng Type orm And Wheel) Steering System steered man, ae le is a ; Pally. the dive vine System of vehicle, Vantage of th S all the steer h he steerine © steering force, i right or left as desired by then a Bear and linkage, the front tecring syst i or _ 8 system SPerALION enables Q driv ection and Maintenance ego contol vehi 1B Bear box jg essential, » When a vehicle is - Then through the Wheels are steered to Of Steetin, icle direction and Motion, Relevant Program Outcomes (POs) role Basie knowledge: Apply knowledge of bas Sincering to solve the bong. ical Engi Discipline ees BOarbased Mechenien Engineering problems, * Apply mechanical enginess broad-Based mechanical engineering related problems ae POS - Experiments and practice: Plan to ic mathematics, Sciences and basic Perform experiments and practices to use Competency and Skills One of the main competency that a mechanical engi ‘Perform the job of Mechanical supervisor in Aut this competency following skills are developed Practical of this laboratory manual 1. Use relevant tools and cquipments for dismantlin; i ‘Mm components. AS an neering student should posses is lomobile Industry’ . To inculcate in the student after conducting the iB and assembly of various ‘se Outcome(s) | if eee braking and stecring systems for different applications, ° Sel ese picts and renssemble the Steering Gear box. (Rack & Pinion’ Re- © Dismantle, insp circulating Type/Worm and Wheel) Relative Affective Domain d © Practice good housekeeping. round . ere ieee on Ldgaaheiae ame the mechanical aavantge oles nig te ry The Siesta Be zi to linear motion. The steeri i ie te tn motion of steering wheel nee rackeand-inion steering arms: motion to the EE harashara State Board of Technical Fatucation ira StaXVE Results XVI Interpretation of Results XVIII Conclusions XIX Practical Related Questions Note: Below given are few such questions 50 as 10 ens 1. Describe bearing pre: 2. Justify the need of ste sample questions Sor reference. Teachers must design ure the achievement of identified CO. ad procedure and its necessi ty. ‘ering whee} locking in Place_ during service. 'Space for Answer] Maharashira State Board of Technical Educapsoas (22656) ee er ee Pxsl nperature depends poss Qalar contact ball By “4 roller ce an. interne!XX References / Suggestions for Further Reading 1. hitps:/Avww.youtube.com/watch?v=vawb-2xM8Ik Replace steering gear box 2. hps:fAvwww youtube.com/watch?v=B4CIKSESLnA how to replace a steering eo ‘box 3. https://www.youtube.com/watch?v=CSSibRicoiY how to adjust a steering geo box. XXL Assessment Scheme Performance Indicators Weightage Process Related (10 Marks) (4026) T | Handling of tools and special tools 20% 2 [Observations 20% Product Related (15 Marks) Gor) 3 [Interpretation of result es sore 4 | Conclusions 0% 5 | Practical related questions 30% ‘Total (25 Marks) ea Names of Student Team Members 2. 3. 4 Marks Obtained Dated Signature of Process] Product | Total Related(10) | Related(15) | (25)asgomablle 22656) practical No. 10 : Dismantle, ins Si Pect and reasse stem. (Hydrautiey Hlestoue Tang Lee 1 Practical Significance Power steering is very important for sa that transmits Quid to the fe driving, Power stecring has a hydraulic pump ste wheel easily. Without the q ering System to assist driver in turing vehide steering hs power assistance system it would be very difficult to tur the vehicle. Over time, Nuid bre . meaks down due ne . the rubber and nylon o-ring, m duc (0 heat and contamination which can cause One should check the powersteeri « proper amount and that the power-steering system isn't leaking. Reservoirs on many vehicles are the see-through plastic type, so you don’t even have to remove a cap to check the level. Refer owner's manual for the location of the reservoir in the engine compartment for help. One also should check the manual for the type of power- steering fluid that is required. . I Relevant Program Outcomes (POs) POI - Basic knowledge: Apply knowledge of basic mathematics, sciences and basicEnginceringto solve the broad-based Mechanical Engineering problems. PO 2Discipline knowledge: Apply mechanical engineering knowledge 10 solvebroad- basedmechanicalenginecring related problems P03 - Experiments and practice:Plan to perform experiments and practices to use the results to solve broad-based Mechanical Engineering problems. PO4 -Discipline knowledge: Apply, mechanical engincering knowledge to solve broad-basedmechanicalengineering related problems 11 Competency and Skills : ; One of the main competency that a mechanical engineering student should posses is ‘Perform the job of Mechanical supervisor in Automobile Industry’ . To inculcate this competency following skills are developed in the student after conducting the practical of this laboratory manual a ; 1. Use relevant tools and equipments for dismantling and assembly of various automobile system components. a 2 Inspect given componenl/ assembly of the given vehicle »’ me(s) aes, v La reliceeeearees 2 scring ystems for ferent applications © Se . V Practical Cuca “ 1 Power Steering system, (Hydraulic’ © Dismantle, inspec! Electronic Type) 1d reassemble th VI Relative Affective Domaln- «Practice good housekeeping: fee energy conservation. = / 5 Practice ene ent ana serve rmsIv VI _—_—— I-ngineering : eaf Sprin al No. 11 : Dismantle, inspect and reassemble the Li spring : ‘Assembly. Se ave several moving parts, Th Practa Signin ey psa they have several moving Par, They bo cloned and inspected at intervals specified by the pa very 20000K0 Sawn maintenance / Failure of Feat spring during @ Journey te 2 cay, soa a ss to a transport organization, It causes a lot of inconvenience 1g Relevant Program Outcomes (POs) eyisaat oh trast aie & PO! - Basic knowledge: Apply kn f mathe basicEnginceringto solve the broad-based Mechanical Engineering problems. PO 2-Discipline knowledge: Apply mechanical engineering knowledge to sole broad- basedmechanicalengineering related problems ; s PO3 - Experiments and practice:Plan to perform experiments and practices tp usethe results to solve broad-based Mechanical Engineering problems. PO4 -Discipline knowledge: Apply mechanical engineering knowledge to sobe broad-engineering related problems Competency andSkills One of the main competency that a mechanical engineering student should posses is ‘Perform the job of Mechanical supervisor in Automobile Industry’ . To inculoae _ this competency following skills are developed in the student after conducting te practical of this laboratory manual ; 1. Use relevant tools and equipments for dismantling and assembly of various automobile system components, 2. Inspect given component/ assembly of the given vehicle 3. Maintain given automobile componenY assembly. Relevant Course Outcome(s) * Select suspension system for different applications, Practical Outcome * Dismantle, inspect and reassemble the Leaf Spring assembly. Relative Affective Domain. * Follow the road and workshop safety practices, «Practice good housekeeping, . ¢ Demonstrate working as a leader/a team member, ¢ Maintain tools, equipment and service records, :XVIL_ Interpretation of Results XVII Conclusions XIX Practical Related Questions Noie: Below given are few sample questions for reference. Teachers must design such questionsso as to ensure the achievement of identified CO. 1. Describe concept of ‘Nipping in leaf spring’. 2. Describe the leaf spring lubrication process. 3. Describe the inspection procedure for leaf spring assembly. [Space for Answer] ‘Maharashtra State Board of Technical Fluesee anssble! Engincering (22656) mecider ch... were Laden ipractical No. 12: Remoy ce ih ae 'e, inspect a 1 Practical Signig Nd refit the Snificance Wheel And Tyres heed to Fespond a and cope with the stresseq qeey to Hl tyres ., Steetin, onions rae SP Vehicles atte OM braking they need to roll smoothly sondions including when dy, a Seely on gee td Szleratig, Abe . slippery or co) pcrating surface in different ered in snow and ice, ‘Tyre Assembly. mT Relevant Program 0; ny POI - Baste knowledge mao Engineer ve the. PPly knowledg, ‘ PO ea .O Solve the broad-bised Medien ERIN, sienes and bs 03 + periments and practice: Plas ical Engineering problems. the results to solve broad: inical eee emcee ase nginecring problems, IM Competency and Skills One of the main competency that a “Perform the job of Mechanical su this competency following skills mechanical engineering student should posses is ipervisor in Automobile Industry’ . To inculcate ‘ are developed in the stu x practical of this laboratory manual me dent after conducting the se relevant tools and equipment for dismantling and assembly of various automobile system components. 2. Inspect given component assembly of the given vehicle. Maintain given automobile component’ assembly. v Vv Relevant Course Outcome(s) | «Select suspension system for different applications. v Practical Outcome . , Remove, inspect and refit the Wheel and Tyre assembly VI Relative Affective Domain- Follow the road and works! d housekeeping. conservation. equipment and se hop safety practices © Practice goo © Practice enerBy «Maintain tools, P Follow ethical Practices. vice records. round ; YA stn Thor DS ae pressure in your DTS (tang our ESSURE F int of air PT ing performance ant ek ae Keep the HEME OTT are opin eared handling and fuel tis impo! P ie ressure "ures 380 spare), Correct PFS oe p i at. minimization ©! economy- a WHEEL NUTS ae Ngee reps naan< Practical Related Questions XIX Note: Below given are few Sample WMestions fp refere 1 ‘ wie. Teachers must design more such questionsso as fo ensure the ach ment Sldeniified co, * 1. List six dos and don'ts for Wheels, und tyres, 2. Deseribe inspection Procedure for wheely nd tyres, 3. State tightening torque for a car Wheel fug/ nyt by referting service manual, sWer] [Space for An,———_---—-—. wbile Engineering (22686) Delo, dent of Maharashura State Bosal of Technical Education ie re —— nocts: SCE n. stone, fe las iol You .cam. alae is SPO. ty¢..0n, Jour Apr departing on Mh. Pou. hat z DY se b.t0, aye Oe eho dost AGH, LOLs, JOOF 4 pend aes den! Is a bul. just because yx _ References / Suggestions for Further Read : mn hips: www -youtube.com/wat s . tch?v=VBNOY_{U mas cabs com thon Stole pecon Pa bps outube.com/watch’v=cYReHemu Vhs Simple Tyre Peston Pa 4 hneps:/ www.youtube.com Wwateh?v=Vzee-SDNRN 4. : z =Vzee-9DXRNS How to check fe bent Ehuips:, woww.youtube.com watchiv=LNJIBSITPGI How fo ice Wp ea ih torque wrench NXT Assessment Scheme Performance Indicators [Weightage | Process Related (10 Marks) (40%) mis [7 Tiandling of the tools and equine Observations Product Related (15 Marks 0 ; 20% 3 | Interpretation of result 4 | Conclusions questions, 5 | Practical related. t Total 25 Marks) »mbers ae of Student Team M Pro Process cl | | Related(!'on. al No. 13: Test a fead acid battery for Open V Gravity Practical Significance Battery testing is an inp. understand the state of charge of” battery, and the also the energy that can be battery. Battery testing enables us to decide if the battery can be or not, Battery tests help 4S important aspect of bi cadlights ary Some of the signs that indicate a weak or discharged battery, Lack of leads to premature failure: of battery. Testing avoids Premature failure of | Relevant Program Oute POL - Baste knowledge: Engineering to solve the br PO3 - Experiments and the results to solve broads I Competency and Skills Mechanical supervisor in this competency following skil Practical of this laboratory man 1. Inspect given comp. 2. Test given battery of an automobile, IV Practical Outcome VI * Follow the road and * Practice energy con, * Maintain tools, + equim VIL Minimum Theoret jonenl/ assembly Relevant Course Outcome(s) Prepare simple clectrical-clectronic Circuits for a Testa Lead Acid Battery for Open v oltage and Specitig: 5 ortant part of electrical system service. It helps a "echnician ty 7 i F in Put into use in yep: tery. Visual inspec: cranking and diny hy us to locate weak cells and faults in bat atlery testing, Slow engine maintenance battery, omes (POs) Apply knowledge of basic mathemat tics, sciences and basic Problems. periments and Practices to use ig problems. oad-based Mechanical Engineering Practice: Plan to perform ex based Mechanical Engincerin ‘obile Industry’ . To Toculen: lls are developed in the Student after conducting the ual - of the given vehicle utomobile systems. oltage and Specific Gravity Relative Affective Domain. . Workshop safety pretices, Practice good housekeeping, SerVAiON, ent and service Tecords, cal Backpround Depending on the constr determined in the followin, 1. Specific gravity test 2, Visual Inspection of ba 3. Open circuit voltage test ‘Maharashera Sate Dodnd of Technical ba fal Eom OF the battery, state of charge of battery ean MF 8 Ways; With builtin hydrometer ad a lucationeS ISMOVE the iy float. Be sure the fh S fe © cell Read the > Note down the Feadings 2 Specific Bravity indicated on the Table-t lists specific prose TPT the st : * Bry reading | NPS for remaining cells, battery's ability to crank '& iN Various MARES Of charge with te ; ge with respect eNBiNe at a temperature Of 26.7% c. e Open Circuit v, Procedure: lage Tes Remove the surface hay ary StEPS 10 TeMoOVe surface applied to remove the sur ® Connect the digital Vvolim » Note down the vw Be from, battery, if any, Refer precautions section for the charge, If vehicle jy Nol available, certain load may be fave charge, Neter across the battery terminals, voltmeter Teading of a 12 battery, Use the following table-2 to interpret the results, / open circuit voltage can i Minor changes in the batery indicate major changes in the fe state of charge. * XM Resourees Used Name of | ‘Quantity Remaris Details ic 2 apecifie baitety of cor| © sey mea i Plosemedd welde sical _©2 Yettage 1B = Goo voll oot Sancle es atibday t | [eniete compat RasSenges . d ure Followet Se eae ea aien XIVTest an ae Gravity Open Cirenit Voltage Test St. No. | Voltmeter Reading in Volts | State of Charge of Battery | XVIII Conclusions XIX Practical Related Questions: 1 4 Note: Below given are few sample questions, for reference, Teachers must design more such questions so as to ensure the achlevement of identified CO. 1, State the significance of Open Voltage test and specific gravity test, 2. Enlist the precautions while handling hydrometer. State the effect of temperature on the specific gravity reading, 3. List precaution to be taken before conducting Open circuit voltage test an battery: 4, List precaution should be taken before conducting Specific Gravity test. . increased fuel C01 Rh rnin, increase a eed By at ete pvition system e can be light or even a non-starting engine © ‘ siicie inopenblera te a ar improperly set distributor can render a vehicle inoperable, and there tre A worn-out 0 s 1 you can tell if your distributor that needs replacing several ways YW intain distri ed in ignition system, Therefore it is essential to maintain distributor used in ignition sy: Relevant Program Outcomes (POs) PO} - Baste knowledge: Apply knowledge 0 Engineering to solve the broad-based Mechanical Enginee : PO3 - Experiments and practice: Plan to perform experiments and practices to use the results to solve broad-based Mechanical Engineering problems. {basic mathematics, sciences and basic gineering problems. Competency and Skills One of the main competency that a mechanical engineering student should posses is “Perform the job of Mechanical supervisor in Automobile Industry” . To incalee: this competency following skills are developed in the student after conducting the practical of this laboratory manual 1. Inspect given component/ assembly of the given vehicle Relevant Course Outcome(s) * Prepare simple electrical-clectronic circuits for automobile systems. Practical Outcome + Dismantle, inspect and reassemble the Distributor used in Battery lenition System. F Relative Affective Domain- * Follow the road and workshop safety practices, * Practice good housekeeping, * Practice energy conser ion. Maintain tools, equipment and service records, Minimum Theoretical Background Modern S.L, engines use electro voltage pulses to spark plugs in used firing order for four ¢) nic ignition system, The distributor provides bis engine cylinders as per firing order, Most commonly vlinder engine is 1-3-4-2Most electronic ignitio® distributors use a pickup coil to sense trig pickup coil sends small electrical pulses 4 these electrical pulses properly, the ign pickup coil will produce a wide range ition system can stop functioning. A fal of engine troubles, such as stalling. ss11 Actual pists age. al wt fe. dhe, 4 feast, webtete XIV. Precautions Followed s mupolng NV _Observations Sr.No. | Parameter Obsened paneer | “ ‘ 1 | Distributor pulse coil and reluctor | | gap (in mm) using plastic feeler gauge 2 | Distributor Pulse coil resistance XVI Results nition. systemWuee sre erway 1. Stute the reason for using plastic feeler BAN coil and reluctor gap. ey ‘ . Describe the procedure to check the ignition pulse coil vee Deséribe the effects of fault ignition system on engine functioning. . Describe the procedure to advance / retard static ignition timing of un engine. Bon {Space for Answer] Them as needed Maharashtra State Board of Technical Educationre wn + peel ar anbucerd chaege nese SPS ; pis, ict the sme _of Fyrivien stony — ity ef cambustien gherfere— or of the petiufants from the ererere, the wets ign teh oe 1¢ _perrermenss L dxbocilitz- /