Description:
Automotive technology is emerging as a potential sector for employment. Technicians in this sector need to be trained about the standard operation procedures of the two wheeler, its preventive maintenance and breakdown maintenance. Diagnosis of the fault and rectifying it is the need of the hour.
Course Objectives:
-
Would be able to understand each individual parts working mechanism
-
Able to find out the problems and solve the issue.
-
Would be able to guide the technicians for standard operating procedures to resolve fault
-
To empower the students through projects, internships leading to development of creativity, self-confidence and team spirit.
-
To create the ambience with scope for developing communication and life skills so as to meet the needs of the society in the globalized environment
-
Dismantles partially or completely defective unit or parts of vehicle such as engine, gear box, wheel disassembly & assembly etc. according to nature of repairs to be done, using hoist, jack, pullers, hand tools and other devices.
Learning Outcomes:
-
It is applicable in both your personal and professional lives.
-
Can be self-employed.
-
Explain personnel finance, entrepreneurship and manage/organize related task in day to-day work for personal & societal growth.
-
Overhaul, service and testing Diesel Engine, its parts and check functionality.
-
Evaluate the information gathered from the customer report/job card /technician notes
-
warranty claim and maintenance details and take appropriate action to ensure maximum customer
Course Syllabus
Module I
Introduction to an Automobile
Two wheelers auto Industry in India - leading manufacturers, new product. Introduction to Engine: Description of internal & external combustion engines, Classification of IC engines, Principle & working of 2&4- stroke diesel engine (Compression ignition Engine (C.I), Principle of Spark Ignition Engine(SI), differentiate between 2-stroke and 4 stroke, C.I engine and S.I Engine, Direct injection and Indirect injection, Technical terms used in engine, Engine specification
Module 2
Basic engine components Engine cams & Description & functions of pistons, piston rings, connecting rod and piston pins and materials. Used recommended clearances for the rings and its necessity, precautions while fitting rings, common troubles and remedies of piston. Description and function of Crank shaft, Engine bearings.
Module 3
Valves & Valve Trains Function of Engine Valves, different types, materials, Type of valve operating mechanism, Importance of Valve seats, Valve-timing setting. Description of Camshafts & drives, importance of Cam lobes, Timing belts & chains. Trouble shooting procedure for Excessive smoke, overheating, knocking or abnormal noise. Troubleshooting procedure for cam chain noise, and cam chain slack excessively
Module 4
Intake & exhaust systems - Carbureted systems, Principle of Carburetor, type of carburetor -working of constant velocity, type carburetor, Carburetor operation Carburetion, Carburetor systems, Metering jets, Accelerating, Carburetor barrels , Carburetor filters Diesel fuel Injection system, Tanks & lines, Fuel lines idle speed circuit, slow speed circuit, high speed circuit, air cleaners, Intake manifolds
Module 5
Gasoline /Diesel Fuel Systems: Gasoline fuel characteristics, Diesel fuel characteristics, Difference between Gasoline and diesel fuel. Controlling fuel burn, Stoichiometric ratio (air-fuel ratio), Air density, Fuel supply system, Pressure & vacuum.
Module 6
Introduction to steering Principles of steering, Description of different types of steering & handle, fork mounted over races. Description, construction and function of steering stem. Troubleshooting Procedure for Hard steering Steers to one side or does not track strain, front wheel wobbling, Soft suspension, Hard suspension, Front suspension noise.
Module 7
Suspension Systems- Principles of suspension, Suspension force, Description, location, suspension description, construction and working principle of telescopic front suspension, suspension oil, oil seal installation, Shock absorber types Hydraulic shock absorbers, Gas pressurized shock absorbers, Load adjustable shock absorbers, Manual adjustable-rate shock absorbers, Electronic adjustable-rate shock absorbers, Automatic load-adjustable shock absorbers
Module 8
Wheels & Tyres-Function of wheel and construction, Wheel types-spoke, cast wheel & sizes, Wheel balancing, Rim sizes & designations, Tyre function and structure, size and designation, Radial ply tyres, Tubeless tyre, Relation between tyre pressure and life, Tube size, TUFFUP tube. Aspect ratio of tyre, Puncture procedure, Repair of TUFFUP tube, Tyre construction type of tyre construction, Tyre materials, Tyre sizes & designations, Tyre information, Tyre tread designs, Effects of air pressure and uneven wear pattern
Module 9
Braking Systems - Braking fundamentals Principles of braking, description, construction and operation of Drum & disc brakes, advantage over drum brake, Description and working principle of master cylinder, Hydraulic pressure & force, Brake fade. Braking system components- Brake pedal/lever, Brake fluid hose, Brake fluid, Bleeding, Applying brakes, Brake force, Brake light switch
Module 10
Clutches & Transmission:- Clutch principles, Wet & dry clutches Single-plate clutches, Multi-plate clutches, Operating mechanisms, Description of cam chain mechanism. Automatic clutch Gearbox layout & operation Gearbox layouts, description of gear shift mechanism, gear ratio, Gearbox operation, Gear drive position - Neutral, 1 st to 5th position. Trouble shooting procedure for Clutch slip when accelerating, clutch will not disengage, motor cycle creeps with clutch disengaged.
Module 11
Auto electrical Thermistor, Description and function of ignition switch, alternator, Regulator/rectifier, Ignition, principles, Ignition components, Battery power source, Ignition coil, DC/AC CDI, TCI Contact breaker, capacitor / condenser, Distributors, Distributor types, High-tension leads, Spark plugs, Spark plug components, Principal of electronic ignition, advantage of electronic ignition
Project List:
Two seated electric vehicle
Solar power electric vehicle (two seated vehicle)
Chassis design for an Electric vehicle
Design a battery operated go kart.
Disassembling and assembling a Vehicle engine
References:
Automobile Engineering K K Jain & R B Asthana
Automobile Engineering Vol-2 Dr. kirpal singh
Session Plan
Session 1
Two wheelers auto Industry in India - leading manufacturers, new product. Introduction to Engine: Description of internal & external combustion engines, Classification of IC engines, Principle & working of 2&4- stroke diesel engine (Compression ignition Engine (C.I)
Video link: https://www.youtube.com/watch?v=ukifXPZx-4Y
Practice – Practice Health & Safety – select, use, maintain & store tools, equipment’s & clothing safely
Session 2
Principle of Spark Ignition Engine(SI), differentiate between 2-stroke and 4 stroke, C.I engine and S.I Engine, Direct injection and Indirect injection, Technical terms used in engine, Engine specification
Video link: https://www.youtube.com/watch?v=kU5G20s4ILA
Video link: https://www.youtube.com/watch?v=Pu7g3uIG6Zo
Practice – Practice 5S technic
Session 3
Basic engine components Engine cams & Description & functions of pistons, piston rings, connecting rod and piston pins and materials.
Video link: https://www.youtube.com/watch?v=u5lL074hLlI
Video link: https://www.youtube.com/watch?v=j5pk2mwnUO8
Practice – Identify / familiarize with the tools & equipment’s
Session 4
Used recommended clearances for the rings and its necessity, precautions while fitting rings, common troubles and remedies of piston. Description and function of Crank shaft, Engine bearings
Video link: https://www.youtube.com/watch?v=JASHFJFxaeE
Practice – Clean / replace – air filter & Apply Grease to parts / through greasing points
Session 5
Valves & Valve Trains Function of Engine Valves, different types, materials, Type of valve operating mechanism, Importance of Valve seats, Valve-timing setting. Description of Camshafts & drives, importance of Cam lobes
Video link: https://www.youtube.com/watch?v=om32-xSKw4s
Video link: https://www.youtube.com/watch?v=MnJWmo5CjAs
Practice – Remove and refit head lamp assembly
Session 6
Timing belts & chains. Trouble shooting procedure for Excessive smoke, overheating, knocking or abnormal noise. Troubleshooting procedure for cam chain noise, and cam chain slack excessively
Video link: https://www.youtube.com/watch?v=W9TUNvy30dc
Video link: https://www.youtube.com/watch?v=XPvg-q3xa4w
Practice – Clean, Check and Adjust spark plug
Practice – Check Tyre pressure & for defects, tread depth, inflate, rotate the tyres
Session 7
Intake & exhaust systems - Carbureted systems, Principle of Carburetor, type of carburetor -working of constant velocity, type carburetor, Carburetor operation Carburetion, Carburetor systems, Metering jets
Video link: https://www.youtube.com/watch?v=Gkhd-eJk234
Practice – Adjust Hand brake and replace hand brake cable & Adjust clutch and brake pedal plays
Session 8
Accelerating, Carburetor barrels , Carburetor filters Diesel fuel Injection system, Tanks & lines, Fuel lines idle speed circuit, slow speed circuit, high speed circuit, air cleaners, Intake manifolds
Video link: https://www.youtube.com/watch?v=0VDIV-A-Y7A
Video link: https://www.youtube.com/watch?v=_CpYmNRTsMw
Practice – Remove tyre from vehicle & Check tyre & rim and also check for run out
Session 9
Gasoline /Diesel Fuel Systems: Gasoline fuel characteristics, Diesel fuel characteristics
Video link: https://www.youtube.com/watch?v=HGEsF9qIIic
Practice – Practice on Dismantling two wheeler engine and inspection of cylinder head, piston, piston ring, connecting rod Practice on measurement of piston ring gap, the piston ring to groove clearance, piston OD, cylinder -to-piston clearance, piston pin OD.
Session 10
Difference between Gasoline and diesel fuel. Controlling fuel burn, Stoichiometric ratio (air-fuel ratio), Air density, Fuel supply system, Pressure & vacuum.
Video link: https://www.youtube.com/watch?v=CNK2hVmmcA8
Video link: https://www.youtube.com/watch?v=RLS6TW9Oelo
Video link: https://www.youtube.com/watch?v=OOMzrlZeWCI
Practice – Identify valves and condition of valve and seat. Inspection of rocker arm and rocker arm shaft, camshaft, valve spring, valve guide, valve guide replacement, valve seat inspection and replacing.
Session 11
Introduction to steering Principles of steering, Description of different types of steering & handle, fork mounted over races. Description, construction and function of steering system
Video link: https://www.youtube.com/watch?v=wOOxMp5X0o8
Practice – Inspection of valve clearance and Ignition timing and setting.
Session 12
Troubleshooting Procedure for Hard steering Steers to one side or does not track strain, front wheel wobbling, soft suspension, hard suspension, Front suspension noise.
Video link: https://www.youtube.com/watch?v=OIBzSLKPDOk
https://www.youtube.com/watch?v=AzI2IEns3WY
Practice – Cylinder head assembly
Session 13
Suspension Systems- Principles of suspension, Suspension force, Description, location, suspension description, construction and working principle of telescopic front suspension
Video link: https://www.youtube.com/watch?v=Fhc2KgDoSxQ
Video link: https://www.youtube.com/watch?v=sZ-g5i_hmMI
Video link: https://www.youtube.com/watch?v=zxsb2NZ3peU
Video link: https://www.youtube.com/watch?v=DeI4N71Ref0
Practice – Check the carburetor idle speed and adjust as per manual
Session 14
Suspension oil, oil seal installation, Shock absorber types Hydraulic shock absorbers, Gas pressurized shock absorbers, Load adjustable shock absorbers
Video link: https://www.youtube.com/watch?v=1IVjhvvmTEE
Video link: https://www.youtube.com/watch?v=3TngwuHIeto
Practice – Practice on throttle valve disassembly, check the throttle valve and jet needle surfaces for presence of dirt, scratches or wear and assemble the throttle valve
Session 15
Manual adjustable-rate shock absorbers, Electronic adjustable-rate shock absorbers, Automatic load-adjustable shock absorbers
Video link: https://www.youtube.com/watch?v=MfDdlJ9wS9w
Practice – Perform removal of fuel tank; check that fuel flow freely from the petrol tap. Practice on removal of petrol tap and clean the strainer and assemble.
Session 16
Wheels & Tyres-Function of wheel and construction, Wheel types-spoke, cast wheel & sizes, Wheel balancing, Rim sizes & designations
Video link: https://www.youtube.com/watch?v=qvfjkN4INus
Practice – Diagnose - causes and remedy for engine not starting, high fuel consumption, Practice on engine tune.
Session 17
Tyre function and structure, size and designation, Radial ply tyres, Tubeless tyre, Relation between tyre pressure and life, Tube size, TUFFUP tube
Video link: https://www.youtube.com/watch?v=xAPllrcBcJI
Video link: https://www.youtube.com/watch?v=3pb9U21OJls
Practice – Identify steering system components in two wheelers, Practice on handle bar removal, inspection and assembling of handle bar.
Session 18
Aspect ratio of tyre, Puncture procedure, Repair of TUFFUP tube, tyre construction, Tyre materials, Tyre sizes & designations, Tyre information, Tyre tread designs, Effects of air pressure and uneven wear pattern
Video link: https://www.youtube.com/watch?v=ovl6QqHDFj8
Practice – Practice on removal of front fork, inspection of front fork spring, fork tube, piston, slider and assembling of front fork.
Session 19
Braking Systems - Braking fundamentals Principles of braking, description, construction and operation of Drum & disc brakes
Video link: https://www.youtube.com/watch?v=6c4deRAhqcA
Video link: https://www.youtube.com/watch?v=MAuVDB-G-HQ
Practice – Identify suspension system components in two and three wheelers, Practice on rear shock absorber removal, inspection of shock absorber spring and assembling of shock absorber.
Session 20
Advantage over drum brake, Description and working principle of master cylinder, Hydraulic pressure & force, Brake fade.
Video link: https://www.youtube.com/watch?v=g5n8OqS1Fow
Video link: https://www.youtube.com/watch?v=mfcwQlnhKnI
https://www.youtube.com/watch?v=bGKJOICWmFQ
Practice – Practice on removal of swing arm, inspection of pivot bolt, swing arm Inspection of condition of shock absorbers. Servicing of suspension, changing bush.
Session 21
Braking system components- Brake pedal/lever, Brake fluid hose, Brake fluid, Bleeding, Applying brakes, Brake force, Brake light switch
Video link: https://www.youtube.com/watch?v=aGvFMjxPaWo
Practice – Practice on removing front wheel from vehicle, inspection of front wheel axle , front wheel bearing inspection, front wheel rim run out, brake drum inspection, and assembling of front wheel.
Session 22
Clutches & Transmission:- Clutch principles, Wet & dry clutches Single-plate clutches, Multi-plate clutches, Operating mechanisms,
Video link: https://www.youtube.com/watch?v=JhTf7cBeGcs
Practice – Practice on removing rear wheel from vehicle, inspection of rear wheel & assembling of rear wheel.
Session 23
Description of cam chain mechanism. Automatic clutch Gearbox layout & operation Gearbox layouts, description of gear shift mechanism, gear ratio
Video link: https://www.youtube.com/watch?v=9cKbzUgFdS0
Practice – Adjust as per manual, servicing the brake system, Cleaning, checking, greasing and assembling
Session 24
Gearbox operation, Gear drive position - Neutral, 1 st to 5th position. Trouble shooting procedure for Clutch slip when accelerating, clutch will not disengage, motor cycle creeps with clutch disengaged.
Video link: https://www.youtube.com/watch?v=g8xnIFf4id4
Practice – Practice on A.C. Generator removal, inspection and installation.
Session 25
Auto electrical Thermistor, Description and function of ignition switch, alternator, Regulator/rectifier, Ignition, principles, Ignition components, Battery power source,
Video link: https://www.youtube.com/watch?v=ci0Ab2GlhpM
Video link: https://www.youtube.com/watch?v=n2dErdiB7m8
Practice – Practice on removal of battery, specific gravity test, and practice on battery charging, practice on removal of regulator/rectifier, inspection, and assembling.
Session 26
Ignition coil, DC/AC CDI, TCI Contact breaker, capacitor / condenser, Distributors, Distributor types, High-tension leads, Spark plugs, Spark plug components, Principal of electronic ignition, advantage of electronic ignition
Video link: https://www.youtube.com/watch?v=dea07uYGkps