RAJALAKSHMIENGINEERINGCOLLEGE
THANDALAM, CHENNAI – 602 105.
DEPARTMENT OF AUTOMOBILE ENGINEERING
VEHICLE MAINTENANCE AND RECONDITIONING LAB
LABORATORY MANUAL
RAJALAKSHMIENGINEERINGCOLLEGE
THANDALAM, CHENNAI – 602 105.
LABORATORY RECORD
200 - 200
Name of lab:
Department :
Certify that this is a bonafide record of work done by …………… of …………………………… class in the ………………….. Laboratory during the year
200 -200 .
Signature Of Lab In Charge Head Of The Dept
Submitted for the practical examination held on …………………………..
INTERNAL EXAMINER EXTERNAL EXAMINER
AT2405 VEHICLE MAINTENANCE AND RECONDITIONING LAB
0 0 3 2
LIST OF EXPERIMENTS
- Study and layout of an automobile repair, service and maintenance shop.
- Study and preparation of different statements/records required for the repair and maintenance works.
- Cylinder reboring – checking the cylinder bore, Setting the tool and reboring.
- Valve grinding, valve lapping - Setting the valve angle, grinding and lapping and checking for valve leakage
- Calibration of fuel injection pump
- Minor and major tune up of gasoline and diesel engines.
- Study and checking of wheel alignment - testing of camber, caster.
- Testing kingpin inclination, toe-in and toe-out
- Brake adjustment and Brake bleeding.
- Simple tinkering, soldering works of body panels, study of door lock and window glass rising mechanisms.
- Battery testing and maintenance.
- Practice the following:
- Adjustment of pedal play in clutch, brake, hand brake lever and steering wheel play
- Air bleeding from hydraulic brakes, air bleeding of diesel fuel system
- Wheel bearings tightening and adjustment
- Adjustment of head lights beam
- Removal and fitting of tyre and tube
STUDY AND LAYOUT OF AN AUTOMOBILE REPAIR, SERVICE AND MAINTENANCE SHOP.
Ex No :1
Date :
AIM :
To draw the layout of an automobile repair, service and maintenance shop and study the different sections of the layout.
DESCRIPTION :
SERVICE STATION :
A service is a place where in addition to care of the motor vehicle like mechanical service and minor repairs, petrol is supplied, cars are lubricated, cleaned, washed and other types pf simpler services that are required daily are performed. In general it includes a number of sections like garage general services, mechanical service, major repair shop, tyre shop, paint shop, body shop etc.
A service station is addition to the equipment available is garage is usually run in conjuction with a sales agency for a particular type of motor vehicle to provide comprehensive repair service for that particular vehicle.
The equipment available, in general garage will be added with specialized equipment like lifting tackle, and different types of jigs, fixtures and tools specially designed for checking, adjusting and repair of particular type and make of vehicle. A service station may consist of a machine shop having a lathe, drilling machine etc.
In case of big service station special types of machines like crankshaft grinding machine, valve refacer, surface grinder, reboring and boring machine, brake drum lathe also will be used. In service station fuel filling and water servicing facilities are available. It has a small workshop to provide repair for particular make of vehicle. It may have sales agency for a particular type of vehicle. All the equipment in the garage plus small workshop tools: viz, lathe, drilling machine, jigs, fixtures are available.
LAYOUT OF GARAGES AND SERVICE STATION :
The internal layout of a garage should be such as to make it water proof, clean and spacious to provide sufficient space for small workbenches to storage and repair benches. Following considerations should be made in the layout of garage and service stations:
To provide light to the workbenches, openings the windows should be provided at the proper place.
To keep the floor cleanable, it should be a smooth concrete floor with a surface-scaling compound.
The doors are provided as many members as required for easy flow of men and materials.
The electrical control should be accessible to the operators.
To form a neat storage for hanging tools, hooks or screw eyes should be provided on the pegboards.
To provide a deposit of waste material.
CONCLUSION :
Thus, the general layout of an automobile repair, service and maintenance shop was drawn and the functions of the different sections of the layout were studied.
Table No. 2.1 Periodic Maintenance Check Sheet
Dealer:Place:
Date of Sale:
SERVICE TYPE / Ro No:
Mileage: Kms: / Ro Date:
Engine No.
Fraame No:
Mileage(Kms) / 10000 / 30000 / 50000 / 70000 / 90000 / 110000 / 130000 / 150000
Service type
Mileage(Kms) / 170000 / 190000 / 210000 / 230000 / 250000 / 270000 / 290000 / 310000
Service type
Mileage(Kms) / 330000 / 350000 / 370000 / 390000 / 410000 / 430000 / 450000 / 470000
Service type
Mileage(Kms) / 490000 / 510000 / 530000 / 550000 / 570000 / 590000 / 610000 / 630000
Service type
S. No / CHECK ITEM / CHECK / STATUS / REMARKS
1 / BASIC ENGINE COMPONENETS
Engine Oil
Engine oil filter / R
R
2 / IGNITION SYSTEM
Battery / T
3 / FUEL AND EMISSION CONTROL
Pre-filter
Water sediment filter
Air cleaner filter / R
CA
C
4 / CHASSIS AND BODY
Brake pedal, Parking brake
Brake pads and discs
Brake linings and Brake drums
Brake line pipes and hoses
Brake fluid
Clutch
Power steering fluid
Ball Joints and dust covers
Tyres and inflation pressures
Lights, horns, wipers
Steering wheel linkage and gear box oil
Front and rear suspension
Tightening of bolts and nuts / CA
CA
CA
CR
R
CA
CR
CR
CA
CA
CA
CA
T
5 / AC / Cooler Refrigerant / NA
C Clean; R Replace; CA Check& Adjust; CR Check & Replace; T Tighten
ADDITIONAL JOB:
MILEAGE / 1.50,000 / 4,50,000
TIMING BELT / Replace / Replace
Name of the Inspector / Signature
STUDY AND PREPARATION OF DIFFERENT STATEMENTS AND RECORDS REQUIRED FOR THE REPAIR AND MAINTENANCE SHOP.
Ex No : 2
Date :
AIM :
To prepare and study the different statements and records required for the repair and maintenance shop.
TYPES OF RECORDS :
1)Periodic maintenance check sheet.
2)Maintenance schedule sheet.
3)Trip sheet
4)Log book etc.
DESCRIPTION :
Periodic maintenance check sheet
The periodic maintenance check sheet is used to record the inspection status made during the maintenance check operation. It contains various details such as the dealer name, place, date of sale, manufacturers name, mileage, frame number, chassis number etc. the mileage and service type are indicated in the various cells of the check sheet. The check sheet also contains the check item name, status and remarks.
The check items include the following:
Basic engine components.
Engine oil
Engine oil filter
Ignition system
Battery
Fuel and Emission Control
Pre- Filter
Water sediment filter
Air cleaner filter
Chassis and Body
Brake pedal, parking brake
Brake pads and discs
Brake linings & brake drums
Clutch
Power steering fluid
Ball joints and dust covers
Tyres and inflation pressures
Lights, horns, wipers
Steering wheel linkage & gear box oil etc.
The status and remarks for all the items mentioned above are indicated on the check sheet during the maintenance operation.
Vehicle Reg No:Job No :
Chassis No :Date :
Table 2.2 Road Test Report
S.No / Parameter to check / Before work / After work1 / Front side abnormal noise
2 / Rear side abnormal noise
3 / Front/rear suspension noise
4 / Steering noise
5 / Brake caliper noise
6 / Misfiring / starting
7 / Hunting problems / Stopping problems
8 / Underbody noise
9 / Abnormal noise from doors / glasses and body
10 / Overheating of engine on AC and Non AC operation
11 / Brakes poor / Weak line effective / noisy
12 / Wheel bearings noisy
13 / Drive shaft noise / vibration
14 / Vehicle pulling to one side
15 / Poor pick up of vehicle (with AAAC and without AC)
Table 2.3 TRIP SHEET
Name and Address of the Agency / REPORT TOMr. / Mrs. ------
Engaged by Arranged by ------No. ------Date: ------
Vehicle Number ------Driver Name ------
Closing Time ------
Starting Time ------
TOTAL Time ------
Signature of the Customer / Hire Charges
Charge Per km
Driver Batta
Excess Hours
Excess Kms
Service Tax
Permit Charges / Rupees / Paise
Advance Rs. ------TOTAL
Driver’s Signature
For Agency
ROAD TEST REPORT:
- The road test inspector or the machine makes the road test report after the completion of the maintenance operation.
- This report contains the vehicle reg number, chassis number, job no, date of test etc.
- The parameters to be checked include the following:
Front side and rear side abnormal noise.
Steering and brake caliper noise.
Ilunting, misfiring, sudden stoppage of vehicle.
Brake condition.
Wheel and bearing check.
Pick up of the vehicle.
Mileage of the vehicle etc.
The road test report gives a fare idea of the condition of the vehicle before and after the maintenance operation.
TRIP SHEET :
The trip sheet gives the entire details of the vehicle before and after a trip. The starting km and ending km, time of start and closing of the journey time and the charges per km and also the overall cost of trip is described in the trip sheet.
LOGBOOK :
The logbook of a vehicle gives the details of the vehicle, which will be useful not only for the owner of the vehicle but also to the mechanic who might take the job of vehicle maintenance latter.
The logbook contains the following details:
Distance covered
Fuel consumption
Average fuel consumption
Best and worst mileage
Total maintenance cost
Running costs
Faults in the vehicle
Likes and dislikes
Date of the previous maintenance report
CONCLUSION :
The different statements and records required for the repair and maintenance works were prepared and the uses of records were studied.
CYLINDER REBORING-CHECKING THE CYLINDER BORE, SETTING THE TOOLS AND REBORING
Ex.No:3
Date:
AIM:
Checking the cylinder bore, measurement setting and rebore the worn out cylinder
bore of an IC engine and set the tools and rebore the given cylinder
TOOLS REQUIRED:
Telescopic bore gauge, Vernier gauge,Micrometer,Test lamp,Machine clamping tool, bore clamp, telescopic gauge, vernier calipers, ferler gauge, u- clamp and Allen key setting micrometer.
CYLINDER SURFACE:
Normally in the IC engine cylinder wear at the top is maximum and impact scoring mark either thrust axis or crank pin axis to eliminate the scoring required by boring. The measurement of the cylinder wears, taper and ovality by using telescopic gauge. These gauge and vernier callipers can be used to measure the worn out bore.The cylinder ovality and taper should not exceed 0.050mm otherwise u.s.p and blow by will occur Bore dial gauge with setting ring is also used to measure the cylinder taper is high diffcult for the rings to control by blow gases. The recondining that have excessive tapper or out of cylindricity is done by boring or reboring.Generally a cylinder greater than 0.006inches must be rebored and boring is done.
REBORING:
A cylinder that can not be cleaned by boring and it must be done by reboring process boring which rotates a cutting tool in the cylinder to remove the metals.These operation increase the cylinders bore diameter.
PROCEDURE:
- Initially measure the cylinder bore size at 3 points like top, middle and bottom using telescopic bore gauge or vernier caliper.
- Set the cylinder bore centre and the font mounted spindle centre by using spring loaded pin arrangement.
- After ensuring the boring part is rotated at the exact centre of bore , tight the clamp giving more toque.
- Sides should be bored.
- Set the depth of stopper upto b.d.c.
- Rebore , then clean the ovality, taper , scoring marks e.t.c
- The vertical boring machine is placed on the engine, after it is fixed to the stand.
- Boring machine is fixed to the engine clamp and machine clamp.
- The spindle is lifted and to centered to the cylinder which is to be measured and machines using the pin and spring.
- The centering pins are introduced into their respective holes and the spring is introduced over them.
- The spindle is lowered into the bore and the centering pins are extended by turning the expander knob.
- Machine position is adjusted and the centre pins are extended and brought in such that the gap between the pins and the cylinders walls are same.
- After fixing the spindle is lifted and the centre pin spring are removed.
- The boring tool is now placed in the holder and the nut above the holder is adjusted using Allen key to move the boring tool. Its distance from the centre is measured by tool setting micrometer.
- Tool is set the required length according to the next specified bore diameter and tool adjusting nut.
- The tool position is fixed using the locker nut on one side, now the motor is started and the gear is engaged for automatic movement of spindle.
Result:
The IC engine cylinder reboring machine setting and machined to exact size of cylinder bore and tolls are set and cylinder of the given engine is rebored to the next standard size.
VALVE GRINDING AND VALVE LAPPING,SETTING THE VALVE ANGLE AND CHECKING FOR VALVE LEAKAGE
Ex.No:4
Date:
AIM:
To perform the grinding , lapping ,valve setting and valve leakagein the given valve
TOOLS REQUIRED:
Valve grinding machine,Spanner,Lapping paste
Lapping stick,Cutter seat, compressed air,water and Lathe machine
PROECDURE:
- At first the valve is taken out the valve assembly. Check the valve head for cranking, valve seat for radial run out in the given valve.
- If there is a good margin still left over it can refaced and reused thus the correct of proper valve seat cutter assembly with point.
- This assembly is placed on the valve seat which is rotated in the cloakwise4 direction. The carbon of dust and radial run out on the valve head is grinded and cleaned by using the valve grinding machine.
- Then the lapping paste is applied over the valve face.
- To rotate valve and lift it during the lapping, suction cup is attached to the stick is used.
- When the lapping seat is important to give a valve reciprocating under a racking motion not continuously rotary movement. Then the valve is removed in the head and paste is applied, thus the process is done.
To check up the valve seat and its setting following methods can be employed
- Checking with petrol
- Selection on cup method
- Compressed test
- By blowing compressed air
Compressed test: compression test method is used where the air is pumped with help of rubber and the whole unit is kept light over cylinder head. After building of pressure at(15 lbs square inch) wait for a few minutes, there should be no drop in pressure.
Blowing water and compressed air: in this method compressed air is blown through suitable adapted filtered on manifold.
- Chamber is fitted with water
- On blowing the air. No air bubble should be sealing the water
RESULT:
Thus grinding, lapping ,setting the valve angle and checking the valve leakage is done
CALIBRATION OF FUEL INJECTION PUMP
Ex.No:5
Date:
AIM:
To study the calibration of fuel injection pump for a ulticylinder diesel engine.
TOOLS REQUIRED: fuel injection test bench, micro pump.
PROECDURE:
- The calibration test is usually carried to check connect quality of fuel is injected for various load and speed condition. the rack of the fuel ump under test should be in no load position when the test bench is started speed is controlled by hand wheel.
- Fit the correct rack setting device4 to the injection pump, remove the tapped inspection cover gauge restriction wheel cock is kept closed to avoid the damage to pressure gauge set the rack setting device to zero then connect the flexible supply line to the supply connection build up the required pressure.
- By closing the valves, inspect for leakage the pump housing around discharge union, air vents and locking screw. When the counter knob is engaged and start button one electronic tachometer is pressed fuel will cut off the fuel to the test tub. Then the speed of the varied for varying load condition and the corresponding fuel quantity injected is noted and the readings are tabulated.
RESULT: Thus the calibration of fuel injection pump for a multicylinder diesel engine is carried out and tabulated.
MINOR AND MAJOR TUNE-UP OF GASOLINE AND DIESEL ENGINES.
Ex No: 6
Date :
AIM :
To perform the major and minor tune-up of gasoline and diesel engines>
TOOLS AND INSTRUMENTS REQUIRED :
Cell tester, Double end spanner, Screw driver, Battery charger, Feeler guage, Pliers, Ball-peen hammers, socket spanner, Wrenches, Dial indicators, Hydrometer, Files, Piston ring expander, Piston ring compressor, Valve spring compressor, Spark plug spanner, Grinding machine etc.
PROCEDURE :
PETROL ENGINE TUNE-UP :
Ridge in cylinder liner:
The wear starts in the linear from the height of ring travel i.e., on top of liner; there is practically no wear. Since this portion does not come in contact with the rings. In worn out engine you can feel this area by your finger running up and down in the liner. In case with worn out liner when rings have to be changed to check up this ridge, in case it is prominent it should be cut with ridge cutter. Then only new set of rings can be placed, otherwise there are chances of new rings being thicker in width then the used worn out rings may strike the ridge and break. Secondly, the piston assembly can easily slide in Boring and honing of cylinder liners.