Certificate Course in Two Wheeler Technician

Teacher

A Avinash

Category

Certificate Courses

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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

Our Main Teachers

A Avinash

Asst Professor
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A.Avinash working as Assistant Professor, Dept of CSE, Centurion University of Technology and Management, Andhra Pradesh . Interested to work on Machine learning,Natural Language Processing,Problem Solving Methodologies , and ChatBot. Programming Skill: C Programming Data Structure Object Oriented Programming using C++ Formal Language Automata Theory Python Web Development(HTML,CSS,PHP) Database Management Systems Compilers