AT2403 Vehicle Maintenance

Unit 1 MAINTENANCE RECORDS AND SCHEDULE

Maintenance is the routine repairing wor! re"uire# to eep the $ehic%e in goo# con#ition so
that it can &e
Uti%i'e# (or #esigne# capacit) an# e((icienc)*
Repair is the restoration o( the $ehic%e to a con#ition su&stantia%%) e"ua% to its origina%
con#ition &) changing
+arts ,or- &) recon#itioning it*
O&.ecti$es o( /aintenance s)ste/
0 To eep the $ehic%e a$ai%a&%e (or protecti$e wor (or /a1i/u/ perio#*
0 To e1tract opti/u/ %i(e (or the $ehic%e*
0 To get /a1i/u/ uti%i'ation o( $ehic%e at /ini/u/ cost*
T)pes o( /aintenance s)ste/23
Sche#u%e# /aintenance,pre$enti$e /aintenance-
Un Sche#u%e# /aintenance, 4rea#own /aintenance-
Sche#u%e# /aintenance s)ste/23
In this s)ste/! ser$icing o( the $ehic%e is #one at pre #eter/ine# ti/e inter$a%! inor#er
to a$oi# &rea#own o( the $ehic%e
Un Sche#u%e# /aintenance23
In this s)ste/! ser$icing or repairing wor is #one on%) a(ter the $ehic%e &rea#own*
A#$antages o( sche#u%e# /aintenance23
It re#uces cost o( operation
It ren#ers wor sche#u%ing eas)*
It re#uces starting pro&%e/*
Contro% o( store in$entor) eas)*
LA5OUT O6 AN AUTOMO4ILE RE+AIR! SER7ICE AND MAINTENANCE SHO+*
SER7ICE STATION 2
A ser$ice is a p%ace where in a##ition to care o( the /otor $ehic%e %ie /echanica% ser$ice
an# /inor repairs! petro% is supp%ie#! cars are %u&ricate#! c%eane#! washe# an# other t)pes p( si/p%er
ser$ices that are re"uire# #ai%) are per(or/e#* In genera% it inc%u#es a nu/&er o( sections %ie garage
genera% ser$ices! /echanica% ser$ice! /a.or repair shop! t)re shop! paint shop! &o#) shop etc*
A ser$ice station is a##ition to the e"uip/ent a$ai%a&%e is garage is usua%%) run in con.uction with a sa%es
agenc) (or a particu%ar t)pe o( /otor $ehic%e to pro$i#e co/prehensi$e repair ser$ice (or that particu%ar
$ehic%e*
The e"uip/ent a$ai%a&%e! in genera% garage wi%% &e a##e# with specia%i'e# e"uip/ent %ie %i(ting
tac%e! an# #i((erent t)pes o( .igs! (i1tures an# too%s specia%%) #esigne# (or checing! a#.usting an# repair
o( particu%ar t)pe an# /ae o( $ehic%e* A ser$ice station /a) consist o( a /achine shop ha$ing a %athe!
#ri%%ing /achine etc*
In case o( &ig ser$ice station specia% t)pes o( /achines %ie cransha(t grin#ing /achine! $a%$e
re(acer! sur(ace grin#er! re&oring an# &oring /achine! &rae #ru/ %athe a%so wi%% &e use#* In ser$ice
station (ue% (i%%ing an# water ser$icing (aci%ities are a$ai%a&%e* It has a s/a%% worshop to pro$i#e repair (or
particu%ar /ae o( $ehic%e* It /a) ha$e sa%es agenc) (or a particu%ar t)pe o( $ehic%e* A%% the e"uip/ent in
the garage p%us s/a%% worshop too%s2 $i'! %athe! #ri%%ing /achine! .igs! (i1tures are a$ai%a&%e*
LA5OUT O6 8ARA8ES AND SER7ICE STATION 2
The interna% %a)out o( a garage shou%# &e such as to /ae it water proo(! c%ean an# spacious to pro$i#e
su((icient space (or s/a%% wor&enches to storage an# repair &enches* 6o%%owing consi#erations shou%# &e
/a#e in the %a)out o( garage an# ser$ice stations2
To pro$i#e %ight to the wor&enches! openings the win#ows shou%# &e pro$i#e# at the proper
p%ace*
To eep the (%oor c%eana&%e! it shou%# &e a s/ooth concrete (%oor with a sur(ace3sca%ing co/poun#*
The #oors are pro$i#e# as /an) /e/&ers as re"uire# (or eas) (%ow o( /en an# /ateria%s*
The e%ectrica% contro% shou%# &e accessi&%e to the operators*
To (or/ a neat storage (or hanging too%s! hoos or screw e)es shou%# &e pro$i#e# on the
peg&oar#s*
To pro$i#e a #eposit o( waste /ateria%*


9hee%s
an# T)res
Repairs
Trans/ission
Repairs
4o#)
Repairs
Main
Rep%ace/ents
Super$isor Ca&in 9aiting Roo/


Air
Supp%)
Lu&rication +etro%
Supp%)
Diese%
Supp%)

+ainting
Section
Tinering
Section
Inspection
Section
Layout of Automobile Service Station
Log book:-
7ehic%e no 2
Date 2
Starting :/ 2
En#ing :/ 2
Dri$er Na/e 2
6ue% (i%%ing at 2
Detai% o( Maintenance 2
Repair 2
Engine oi% change# at 2
8ear &o1 o$erhau%e# at 2
Maintenance Chec%ist23
1* Chec the oi% %e$e% in the su/p
;* Chec the rep%ace/ent o( engine oi% perio#
<* Chec the oi% %e$e% in the (ue% in.ection pu/p
=* Chec the steering gear &o1*
>* Chec the con#ition o( the ru&&er s%ee$e on c)%in#er hea# co$er*
?* Chec the &e%t tension o( the coo%ing (an*
@* Chec an# a#.ust c%utch (ree pe#a% p%a)*
A* Chec the whee% a%ign/ent para/eters*
B* Chec the %e$e% o( &atter) e%ectro%)te %e$e%*
1C* Chec a%% the %ighting s)ste/*
11* Chec the soc o&ser$ers*
1;* Chec the &rae shoe pins an# ho%es*
1<* Chec the t)re in(%ation pressure*
1=* Chec the %e$e% o( (%ui# in (%ui# coup%ing*
1>* Chec a%% the instru/ents woring in #ash&oar#*
GENERAL LUBRIATI!N "ERVIE
It is reco//en#e# that genera% %u&rication ser$ice is ren#ere# at an in re$e% o( >CCC/*
1* 6ue% in.ection pu/p*
;* 8ear &o1
<* Steering gear &o1*
=* 6ront an# rear whee% &earing*
>* Steering %inage*
?* Lu&ricants use# Engine oi%! Trans/ission oi%! 8enera% grease! 4earing grease*
#e$io%ic Maintenance heck "heet
Dea%er2
+%ace2
Date o( Sa%e2
SER7ICE T5+E
Ro No2
Mi%eage2 :/s2
Ro Date2
Engine No*
6raa/e No2
Mi%eage,:/s- 1CCCC <CCCC >CCCC @CCCC BCCCC 11CCC
C
1<CCC
C
1>CCCC
Ser$ice t)pe
Mi%eage,:/s- 1@CCC
C
1BCCC
C
;1CCC
C
;<CCC
C
;>CCC
C
;@CCC
C
;BCCC
C
<1CCCC
Ser$ice t)pe
Mi%eage,:/s- <<CCC
C
<>CCC
C
<@CCC
C
<BCCC
C
=1CCC
C
=<CCC
C
=>CCC
C
=@CCCC
Ser$ice t)pe
Mi%eage,:/s- =BCCC
C
>1CCC
C
><CCC
C
>>CCC
C
>@CCC
C
>BCCC
C
?1CCC
C
?<CCCC
Ser$ice t)pe
S* No CHEC: ITEM CHEC: STATUS REMAR:S
1 4ASIC EN8INE COM+ONENETS
Engine Oi%
Engine oi% (i%ter
R
R
; I8NITION S5STEM
4atter) T
< 6UEL AND EMISSION CONTROL
+re3(i%ter
9ater se#i/ent (i%ter
Air c%eaner (i%ter
R
CA
C
= CHASSIS AND 4OD5
4rae pe#a%! +aring &rae
4rae pa#s an# #iscs
4rae %inings an# 4rae #ru/s
4rae %ine pipes an# hoses
4rae (%ui#
C%utch
+ower steering (%ui#
4a%% Doints an# #ust co$ers
T)res an# in(%ation pressures
Lights! horns! wipers
Steering whee% %inage an# gear &o1 oi%
6ront an# rear suspension
Tightening o( &o%ts an# nuts
CA
CA
CA
CR
R
CA
CR
CR
CA
CA
CA
CA
T
> AC E Coo%er Re(rigerant NA
C C%eanF R Rep%aceF CA ChecG A#.ustF CR Chec G Rep%aceF T Tighten
ADDITIONAL DO42
MILEA8E 1*>C!CCC =!>C!CCC
TIMIN8 4ELT Rep%ace Rep%ace
Na/e o( the Inspector Signature
+erio#ic /aintenance chec sheet
The perio#ic /aintenance chec sheet is use# to recor# the inspection status /a#e #uring
the /aintenance chec operation* It contains $arious #etai%s such as the #ea%er na/e! p%ace! #ate o( sa%e!
/anu(acturers na/e! /i%eage! (ra/e nu/&er! chassis nu/&er etc* the /i%eage an# ser$ice t)pe are
in#icate# in the $arious ce%%s o( the chec sheet* The chec sheet a%so contains the chec ite/ na/e! status
an# re/ars*
The chec ite/s inc%u#e the (o%%owing2
4asic engine co/ponents*
Engine oi%
Engine oi% (i%ter
Ignition s)ste/
4atter)
6ue% an# E/ission Contro%
+re3 6i%ter
9ater se#i/ent (i%ter
Air c%eaner (i%ter
Chassis an# 4o#)
4rae pe#a%! paring &rae
4rae pa#s an# #iscs
4rae %inings G &rae #ru/s
C%utch
+ower steering (%ui#
4a%% .oints an# #ust co$ers
T)res an# in(%ation pressures
Lights! horns! wipers
Steering whee% %inage G gear &o1 oi% etc*
The status an# re/ars (or a%% the ite/s /entione# a&o$e are in#icate# on the chec sheet #uring
the /aintenance operation*
7ehic%e Reg No2 Do& No 2
Chassis No 2 Date 2
Ta&%e ;*; Roa# Test Report
S*No +ara/eter to chec 4e(ore wor A(ter wor
1 6ront si#e a&nor/a% noise
; Rear si#e a&nor/a% noise
< 6rontErear suspension noise
= Steering noise
> 4rae ca%iper noise
? Mis(iring E starting
@ Hunting pro&%e/s E Stopping pro&%e/s
A Un#er&o#) noise
B A&nor/a% noise (ro/ #oors E g%asses an# &o#)
1C O$erheating o( engine on AC an# Non AC
operation
11 4raes poor E 9ea %ine e((ecti$e E nois)
1; 9hee% &earings nois)
1< Dri$e sha(t noise E $i&ration
1= 7ehic%e pu%%ing to one si#e
1> +oor pic up o( $ehic%e ,with AAAC an#
without AC-
Table 2.3 TRIP SHEET
Na/e an# A##ress o( the Agenc) RE+ORT TO
Mr* E Mrs*
3333333333333333333333333333333333333333333333333333
3333333333333333333333333333333333333333333333333333
333333333333333333333333333333333333333
Engage# &) Arrange# &) 333333333333333333333 No* 333333333333333 Date2 333333333333333333
7ehic%e Nu/&er 3333333333333333333333333333333 Dri$er Na/e 333333333333333333333333333333333333
C%osing Ti/e 33333333333333333
Starting Ti/e 33333333333333333
TOTAL Ti/e 33333333333333333
Signature o( the Custo/er
Hire Charges
Charge +er /
Dri$er 4atta
E1cess Hours
E1cess :/s
Ser$ice Ta1
+er/it Charges
Rupees +aise
A#$ance Rs* 333333333333333 TOTAL
Dri$erHs Signature 6or Agenc)
ROAD TEST RE+ORT2
1* The roa# test inspector or the /achine /aes the roa# test report a(ter the co/p%etion o( the
/aintenance operation*
;* This report contains the $ehic%e reg nu/&er! chassis nu/&er! .o& no! #ate o( test etc*
<* The para/eters to &e chece# inc%u#e the (o%%owing2
6ront si#e an# rear si#e a&nor/a% noise*
Steering an# &rae ca%iper noise*
I%unting! /is(iring! su##en stoppage o( $ehic%e*
4rae con#ition*
9hee% an# &earing chec*
+ic up o( the $ehic%e*
Mi%eage o( the $ehic%e etc*
The roa# test report gi$es a (are i#ea o( the con#ition o( the $ehic%e &e(ore an# a(ter the
/aintenance operation*
TRI+ SHEET 2
The trip sheet gi$es the entire #etai%s o( the $ehic%e &e(ore an# a(ter a trip* The starting / an#
en#ing /! ti/e o( start an# c%osing o( the .ourne) ti/e an# the charges per / an# a%so the
o$era%% cost o( trip is #escri&e# in the trip sheet*
LO84OO: 2
The %og&oo o( a $ehic%e gi$es the #etai%s o( the $ehic%e! which wi%% &e use(u% not on%) (or the
owner o( the $ehic%e &ut a%so to the /echanic who /ight tae the .o& o( $ehic%e /aintenance %atter*
The %og&oo contains the (o%%owing #etai%s2
Distance co$ere#
6ue% consu/ption
A$erage (ue% consu/ption
4est an# worst /i%eage
Tota% /aintenance cost
Running costs
6au%ts in the $ehic%e
Lies an# #is%ies
Date o( the pre$ious /aintenance report
UNIT & II' ENGINE MAINTENANE - RE#AIR AN( !VER)AULING
TOOLS AND S+ECIAL INSTRUMENTS REIUIRED 2
1* Dou&%e spanner B* Ce%% tester
;* 4a%%3peen ha//er 1C* 9renches
<* +%iers 11* Screw#ri$er
=* 6ee%er guage 1;* Dia% in#icator
>* H)#ro/eter 1<* +iston ring e1pan#er
?* 4atter) charger 1=* +iston ring co/pressor
@* 6i%es 1>* 7a%$e spring co/pressor
A* Socet Spanner 1?* +u%%er
DESCRI+TION 2
Dou&%e en# spanner
These are the /ost co//on%) use# t)pes o( spanner* The opening shou%# &e the right si'e to (it the
nut or &o%t* I( the spanner opening is too %arge it cou%# roun# o(( the corners o( the he1* This /aes the use
o( the proper spanner /ore #i((icu%t* These spanners are a$ai%a&%e in #i((erent si'e ranging (ro/ ? to <;
//*
Ha//ers
The &a%%3peen ha//er shou%# &e grippe# on the en# o( the han#%e* 9hen )ou swing the ha//er
the (ace shou%# strie the o&.ect s"uare%)! an# not at an ang%e* Rawhi#e! p%astic3tip! &rass an# ru&&er
ha//ers are use# to strie easi%) /arre# sur(aces*
+%iers
+%iers are specia% t)pes o( a#.usta&%e wrench* The two %egs /o$e on a pi$ot so that ite/ o( $arious
si'es can &e grippe#* There are two &asic t)pes! gripping p%iers an# cutting p%iers*
6ee%er gauge
Thicness gauges or J(ee%erK gauges are strips or &%a#es o( /eta% o( $arious thicnesses* Man)
thicness gauges are #ua%3#i/ensione#* 6or e1a/p%e! the < an# C*CA// on the (irst &%a#e /eans it is
C*CC< inch ,or C*CA//- thic* So/e thicness gauges are steppe#* The tip is thinner than the rest o( the
&%a#e* Thicness gauges are use# to /easure s/a%% #istance such as the c%earance





&etween two parts* It is use# to chec the c%earance &etween the rocer ar/ an# $a%$e ste/ in an engine*
H)#ro/eter
The (%oat3t)pe h)#ro/eter has a (%oat with a ste/ that stics up a&o$e the e%ectro%)te %e$e% in the
tu&e* The (%oat ste/ is /are# to in#icate the speci(ic gra$it) o( the e%ectro%)te* The height o( the ste/
a&o$e the e%ectro%)te in#icates the &atter) state o( the charge* It $aries (ro/ a high 1!;AC in a (u%%) charge#
,goo# con#ition- &atter) to a %ow 1*1;> in a co/p%ete%) #ischarge# ,&a# con#ition- &atter)*
Socet spanners
These t)pes o( spanners are use(u% in restricte# spaces where co//on t)pes o( spanners cannot &e
use#* The) consist o( socets o( #i((erent si'es! which can &e use# with $arious t)pes o( han#%es* The
han#%e has pro.ections at one en# aroun# which the socets (it*
9renches
The wrenches are use# to (it nut or &o%t* The co/&ination wrench has a &o1 on one en# an# an
open en# on the other*
Screw#ri$ers
It is use# to #ri$e! or turn screws* The /ost co//on t)pe has a sing%e (%at &%a#e (or #ri$ing screws
with s%otte# hea#s*
Dia% in#icator
It is a guage that uses a #ia% (ace an# a nee#%e to register /easure/ents* It can &e use# to /easure
the en#p%a) in sha(ts or gears* A%so! it can &e use# to /easure taper in engine c)%in#ers*
+u%%ers
+u%%ers are use# to re/o$e the whee%s! gears an# &earing (ro/ sha(ts or to re/o$e sha(ts (ro/
housings*
Tor"ue wrench
It is a specia%i'e# (or/ o( socet spanners* I/portant nuts an# &o%ts in auto/o&i%e wor ha$e to &e
tightene# with a speci(ie# a/ount o( tor"ue! &ecause e1cessi$e tor"ue /a) resu%t in their &reaage whi%e
%ess tor"ue! the) wi%% re/ain %oose* This is /a#e possi&%e &) tor"ue wrench*
+iston ring e1pan#er
It is genera%%) use# to e1pan# an# re/o$e the piston rings (ro/ their groo$es without &reaing it*
+iston ring co/pressor
+iston ring co/pressors are p%aces aroun# the piston co$ering the rings* As the co/pressor is
tightene#! it co/presses the piston rings into their groo$es on the piston* Then the piston an# ro# asse/&%)
is insta%%e# into the c)%in#er*
7a%$e spring co/pressor
7a%$e spring co/pressor or %i(ters are use# to co/press the $a%$e spring to (aci%itate the re/o$a%
o( the $a%$e retain %oc or eeper (ro/ the $a%$e ste/*
A""EMBL* !+ ENGINE +R!M VE)ILE & RE#AIR AN( !VER)AULING
+ETROL EN8INE TUNE3U+ 2
Ri#ge in c)%in#er %iner2
The wear starts in the %inear (ro/ the height o( ring tra$e% i*e*! on top o( %inerF there is practica%%)
no wear* Since this portion #oes not co/e in contact with the rings* In worn out engine )ou can (ee% this
area &) )our (inger running up an# #own in the %iner* In case with worn out %iner when rings ha$e to &e
change# to chec up this ri#ge! in case it is pro/inent it shou%# &e cut with ri#ge cutter* Then on%) new set
o( rings can &e p%ace#! otherwise there are chances o( new rings &eing thicer in wi#th then the use# worn
out rings /a) strie the ri#ge an# &rea* Secon#%)! the piston asse/&%) can easi%) s%i#e in 4oring an#
honing o( c)%in#er %iners*
The c)%in#er &ores #o wear out a(ter so/e use* The a/ount o( wear can &e contro%%e# to so/e
e1tent &) c%eaning the air c%eaner! eeping watch on proper woring o( coo%ing s)ste/ an# %u&rication
s)ste/! in spite o( a%% this care a(ter =C to >C thousan# /s in #iese% engine an# in petro% engine ?C to @C
thousan# /s wear is pre#o/inant in the %iner which )ou can see when )ou #is/ant%e the engine (or
o$erhau%ing* 6ro/ the worn out c)%in#er &ores (ew /ore %i(e can &e taen &) &oring the sa/e with &oring
/achine* 9hen using the &oring /achine! the &oring too% wi%% %ea$e $er) (ine %ine on the &ore! which
cannot &e seen &) nae# e)es* +resence o( these %ines o( honing is not #esira&%e* To ru& these %ines! &ores
are hone#! i*e*! po%ishe# with the he%p o( honing stone (i1e# in the c)%in#er hone hea#* These hones are
#ri$en with porta&%e e%ectric han# #ri%% an# whi%e woring "uic%) up an# #own /otion are gi$en*
Maintenance o( (%)whee% 2
6%)whee% #oes not re"uire /uch /aintenance e1cept that is /ounting &o%ts with cransha(t
shou%# &e tightene# with proper tor"ue! the (ace where the c%utch p%ate is (i1e# so/eti/es gets score#
&ecause o( %oose ri$a%s or ri$ets touching the (ace when %ining is worn out* Un#er such circu/stances the
(ace o( (%)whee% shou%# &e got si//e#* The (ace o( (%)whee% shou%# &e e1a/ine# at each o$erhau% an#
whi%e changing c%utch p%ates this (ace shou%# &e ru&&e# with e/er) paper to re/o$e the g%a'e* The
(%)whee% a(ter (itting shou%# &e chece# that it is running true* 6or checing run out! p%ace the cransha(t
with the (%)whee% /ounte# on 73&%oc to a$oi# scoring o( cransha(t /ain .ourna% p%ace paper in the 7 o(
7 &%oc* 6i1 up #ia% guage* 9ith its point resting on c%utch p%ate /ating sur(ace! re/o$e the cransha(t
an# note the run out* It shou%# not &e /ore than C*; //*
7AL7E SER7ICIN8 2
The $a%$e is su&.ecte# to $er) high te/perature! runs at high spee# an# is one o( the critica% part
which re"uires care(u% e1a/ination at the ti/e o( o$erhau% whi%e inspecting the $a%$e! tae care o( the
(o%%owing points2
Hea# 2
Chec the hea# (or crac! &urning! $a%$e seat an# ra#ia% run out* It shou%# not ha$e ni(e e#ge
warpe# an# shou%# ha$e goo# /argin* 6or checing ra#ia% runs out p%ace the $a%$e in 7 &%oc! (i1 up the
pointer o( #ia% guage on e#ge o( $a%$e hea#* Re$o%$e the $a%$e an# note the rea#ing i( run out is /ore than
C*<< //* Discor# the $a%$e*
7a%$e s)ste/ 2
7a%$e s)ste/ shou%# &e straight without scoring* I( it is s%ight%) &ent it can &e straightene#! &ut in
case it is &ent too /uch! $a%$e shou%# &e rep%ace#*
Re(acing o( $a%$e 2
7a%$e a(ter #is/ant%ing (ro/ the hea# shou%# &e e1a/ine#! i( there is a goo# /argin sti%% %e(t o$er!
it can &e re(ace# an# reuse#* It is #esira&%e to /ar each $a%$e as it is re/o$e# (ro/ the gui#e so that it
/a) &e put &ac to its origina% position* This /a) sa$e "uite a %ot o( ti/e in a#.usting tappet c%earance
when the engine is reasse/&%e#* Moreo$er! (itting $a%$e &ac to its own3gui#e wi%% ensure proper woring
c%earance* 6or re(acing $a%$e! re(acing /achine is use#* It has a grin#ing whee% an# a re$o%$ing chuc to
ho%# the $a%$e* The post on which re$o%$ing chuc is (i1e# is /o$a&%e! ang%e o( which can &e set an#
%oce# in an) speci(ic ang%e*
4e(ore starting grin#ing! chec up that $a%$e hea# is running true an# $a%$e hea# is not protru#ing
out /uch (ro/ the chuc* Otherwise it wi%% not gi$e #esire# (inish! then start the coo%ant supp%) #irecting
it .et on grin#ing stone! &ring the $a%$e c%oser to the regu%ar ha//ering action! the tip o( the $a%$e a%so
gets #a/age#! pro$ision is a%so /a#e in the $a%$e3re(acing /achine to re(ace*
8ASOLINE EN8INE TUNE U+ 2
4ATTER5
C%ean the &atter) ter/ina%s
Chec the %oose connections*
Chec the &atter) (or (i1ing in &o1 or cra#%e*
Chec up e%ectro%)te %e$e% in the &atter)*
Chec up the capacit) o( &atter)*
CHAR8IN8 S5STEM
7isua%%) inspect the #)na/o (or an) wear
Chec up (or an) %oose connections
Chec the &e%t (ro/ which #)na/o gets power
Chec the charging rate*
STARTIN8 S5STEM
7isua%%) inspect the se%(3starter! ca&%e an# switch
Chec the woring switch (or an) %oose connections
Chec the consu/ption o( current &) starter /otor*
I8NITION S5STEM
Chec the ca&%e connections (ro/ #istri&utor to spar p%ugs
Chec the #istri&utor sha(t &ushes (or an) %ooseness
Chec the contact &reaer point
Chec the wear on #istri&utor ca/*
Chec the wear in #istri&utor cap
Chec the ignition s)ste/ with osci%%oscope
6UEL S5STEM
7isua%%) inspect (or an) %ea
C%ean the air c%eaner
Chec the (unctioning o( choe
Chec the (ue% pu/p pressure
Chec the p%unger asse/&%)
CAR4URETTOR
Chec the (ue% %ine (ro/ (ue% pu/p to (%oat cha/&er
Chec the &utter(%) o( the car&uretor
A#.ust the height o( the (%oat
A#.ust the .et nee#%e an# nee#%e .et
A(ter asse/&%ing! a#.ust the i#%e an# high3spee# a#.ust/ents
LU4RICATION S5STEM
Chec the %e$e% o( %u&rication oi% in the crancase
Chec the %u&rication oi% (i%ter! i( c%ogge# rep%ace it with new one
I( the oi% is &a#! re/o$e the oi% an# intro#uce new oi% o( the correct gra#e
COOLIN8 S5STEM
Chec the ra#iator (or an) #a/age an# &%ocs
Chec the hoses that connect ra#iator an# engine
Chec (or an) %eaage
Chec the (an &e%t
Use c%ean water in the ra#iation
TRANSMISSION LINE
7isua%%) inspect the trans/ission %ine (or #a/ages! cracs etc*
Chec the prope%%er sha(t
Chec the #i((erentia% asse/&%)
Chec the state o( %u&rication oi% in the #i((erentia% asse/&%)
DIESEL EN8INE TUNE U+ 2
6UEL INDECTION +UM+
7isua%%) inspect the (%ow %ines (ro/ tan to pu/p an# to in.ector
Chec the in.ection pressure
Chec (or an) wear an# tear in the (ue% in.ection pu/p
Chec the entire co/ponents o( the (ue% pu/p
6UEL INDECTOR
Chec the in.ector no''%e (or an) &%oc an# c%ean it thorough%)
Chec the pressure at which the no''%e spra)s the (ue% #rop%ets
A#.ust the screw (or correct pressure
HEATER +LU8
Chec the heater p%ug &) connecting it with &atter) ter/ina%
Chec the heater p%ug (or an) #irt #eposition
Rep%ace it a(ter c%eaning ii thorough%)
A%so chec the air in#uction s)ste/! (ue% (ee# s)ste/ an# other i/portant co/ponents ha$e
to &e chece# (or per(or/ing the tune up operations*
ELETRIAL IGNITI!N "*"TEM
The (unction o( ignition s)ste/ is to pro#uce a spar in the engine c)%in#er towar#s the en# o( the
co/pression stroe* In =3S engine a spar shou%# occur in each c)%in#er a(ter two re$o%utions o( the
cransha(t whereas in a ;3S engine a spar in each c)%in#er is re"uire# e$er) re$o%ution o( the cransha(t*
Spar at the p%ug e%ectro#es /ust &e regu%ar%) ti/e# with respect to the c)%in#er piston position at
a%% spee#s an# %oa#s*
The spar shou%# &e su((icient%) strong so as to start ignition o( the charge*
It shou%# &e %ight an# co/pact
The s)ste/ /ust &e eas) to /aintain
It shou%# not cause ra#io inter(erence*
GA"!LINE +UEL "*"TEM
The &asic (ue% supp%) s)ste/ in an auto/o&i%e with petro% engine consists o( a (ue% tan! (ue% %ines!
(ue% pu/p! (ue% (i%ters! air c%eaners! car&uretor! in%et /ani(o%#! an# supp%) an# return %ines*
+,el tank
It is /a#e o( stee% or a%u/iniu/ a%%o) stee%* The tan is usua%%) coate# on the insi#e with a %ea#3tin
a%%o) to protect against corrosion* It is p%ace# in the $ehic%e at an) suita&%e %ocation* The (ue% tan is
#i$i#e# into co/part/ents &) /eans o( &a((%e p%ates to re#uce surging o( (ue% #uring su##en &raing or
acce%eration*
+,el -,.-
The (ue% pu/p is use# to #e%i$er the (ue% at the correct o( pressure to the car&uretor*
+,el /ilte$0
6ue% (i%ters are usua%%) use# to (i%ter the (ue% &e(ore it enters the (ue% pu/p* It /a) &e a p%astic or
cera/ic (ue% (i%ter*
Ai$ cleane$0
The air c%eaners are usua%%) use# to re/o$e the #ust partic%es that enter into the co/&ustion
cha/&er* It is connecte# to the intae /ani(o%#*
Ta&%e >*; Trou&%e shooting o( gaso%ine (ue% s)ste/
S*No Trou&%es Causes Re/e#ies
1* High (ue% consu/ption Air c%eaner /a) &e choe#
6ue% /a) &e %eaing
9rong i#%e a#.ust/ent
C%ean
Inspect the p%ug an# the
%ea
A#.ust
; Di((icu%t starting Car&uretor .et /a) &e
c%ogge#
6ue% (i%ter c%ogge#
6ue% pu/p pressure not
constant
Ser$ice car&uretor
C%ean the (i%ter
Chec the pressure an#
recti() the #e(ect
<* +oor acce%eration 6ue% %ine c%ogge#
6ue% (i%ter c%ogge#
Chec the (ue% %ine
C%ean the (i%ter
=* Lac o( power Incorrect car&uretor setting
6au%t) in%et /ani(o%#
A#.ust
Rep%ace
Table 5.3
Trouble shooting of diesel fuel ignition system
S*No Trou&%es Causes Re/e#ies
1* Engine crans nor/a%%)
&ut wi%% not start
Incorrect or #irt) (ue%
No (ue% to no''%e or
in.ection pu/p
+%ugge# (ue% return
6%ush s)ste/ use
correct (ue%
Chec (or (ue% to
no''%es
;* Rough i#%e with a&nor/a%
noise an# s/oe
In.ection pu/p ti/ing o((
No''%e trou&%e
Chec return! c%ean
Reti/e
Chec in se"uence
< I#%e correct! &ut /is(ires as
thrott%e opens
+%ugge# (ue% (i%ter
In.ection3pu/p ti/ing o((
Incorrect or #irt) (ue%
Rep%ace (i%ter
Reti/e
6%ush s)ste/3use
correct (ue%
= Co/&ustion noise with
e1cessi$e &%ac s/oe
Ti/ing o((
In.ection3pu/p trou&%e
No''%e sticing open
Interna% engine pro&%e/s
Reset
Rep%ace the pu/p
C%ean or rep%ace
DIESEL 6UEL S5STEM 2
6ue% supp%) s)ste/ in a #iese% engine has to per(or/ certain (unctions* These (unctions a%ong with
the na/es o( the co/ponents! which per(or/ the sa/e! are gi$en*
6i%tering
9ater an# #irt /ust &e re/o$e# (ro/ #iese% (or which two (i%ters are e/p%o)e#* +ri/ar) (i%ter is
usua%%) in the (or/ o( coarse wire gauge* It pre$ents %arge so%i# partic%es an# water* The secon#ar) (i%ter is
use# a(ter the (ue% (ee# pu/p an# is /eant to re/o$e (ine partic%es o( #ust! #irt! etc*
De%i$er) o( (ue% to in.ection pu/p
6ro/ the (ue% tan the (ue% is #e%i$ere# to the (ue% in.ection pu/p &) /eans o( (ue% (ee# pu/p* The
rate o( (ue% #e%i$er) #epen#s upon the engine re"uire/ents*
Contro%%ing the spee#2
Diese% engine spee#s ten# to o$ershoot to #angerous $a%ues on re#uction o( %oa#* This is contro%%e#
&) /eans o( a go$ernor! which &esi#es %i/iting the /a1i/u/ spee#! a%so regu%ate the (ue% supp%) un#er
a%% con#itions*
UNIT-III' )A""I" MAINTANENE & RE#AIR AN( !VER)AULING
,i- A#.ust/ent o( pe#a% p%a)
C%utch pe#a% p%a) a#.ust/ent
C%utch pe#a% (ree p%a) ,; to = //- is a#.uste# (ro/ c%utch re%ease ar/ with c%utch operating
(%e1i&%e ca&%e co/ing (ro/ c%utch pe#a%*
9hi%e (itting c%utch re%ease ar/ on the c%utch re%ease sha(t! (i1 up the ar/ such that the punche#
/ar on the c%utch re%ease is shi(te# towar#s the (ront si#e &ut one notch (ro/ the punche# /ar on the
c%utch re%ease sha(t! a(ter tightening the ar/ (i1 up the ca&%e an# a#.ust c%utch pe#a% (ree p%a) through
a#.uster nut 1* It is not possi&%e to get the #esire# p%a) then a#.ust with a#.uster nut ;*
C%utch Repairs an# Inspection
1* C%utch (acing an# ser$ice %i/it
;* Loose ho%#ing #own ri$ets
<* Chec up the tor"ue spring
=* Chec (or #istortion or crac on c%utch
>* Chec (or (%at run out ,LC*= //-
?* Chec (or %atera% run out ,LC*@ //-
4rae pe#a% p%a) a#.ust/ent
The (ree pe#a% p%a) shou%# &e at%east 1;*@ // or as reco//en#e# &) the co/pan)* The proce#ure (or
&rae pe#a% p%a) a#.ust/ent is as (o%%ows
Raise the $ehic%e unti% the whee%s are o(( the roa#*
9ith a wrench %oosen the %ocnut (or the (orwar# &rae shoe an# ho%# it*
9ith another wrench turn the eccentric towar#s the (ront o( the $ehic%e unti% &rae shoe strie the
#ru/*
9hi%e turning the whee% with one han#! re%ease the eccentric unti% the whee% turn (ree%)*
6ig B*1 C%utch Linage
6ig B*; C%utch +e#a% +%a) A#.ust/ent
6ig B*<
Ho%# the eccentric in position an# (asten the %ocnut*
Repeat this proce#ure to a#.ust the re$erse shoe* 4ut! turn the eccentric towar#s the &ac o( the
$ehic%e*
Repeat this on a%% the (our &raes*
Chec the (%ui# %e$e% in the /aster c)%in#er*
A#.ust/ent o( Han# &rae %e$er p%a)
1* +u%% up the paring %e$er a%% the wa) with one han# to app%) &rae (u%%) an# see how /an)
notches o( ratchet the %e$er has tra$erse#*
;* I( the nu/&er o( tra$erse# notches is /ore than eight! then the paring &rae ca&%e has to &e
a#.uste#*
<* A%so! chec the tooth tip o( each notch (or #a/age or wear* I( an) #a/age or wear is (oun#
rep%ace the paring %e$er*
6ig B*=
Steering p%a) a#.ust/ent
To chec the a/ount o( p%a) in the steering s)ste/ on $ehic%es with power steering! chec the
con#ition an# tension o( the #ri$e &e%t (ro/ the power steering pu/p* Then chec the (%ui# %e$e% in the
pu/p reser$oir* Start the engine* Ne1t! with the (ront whee%s in the straight3ahea# position! turn the
steering whee% with a /ar on a ru%er or sca%e* Now s%ow%) turn the steering whee% in the opposite
#irection unti% the (ront whee%s start to /o$e again* The #istance that the steering whee% re(erence /ar
ahs /o$e# a%ong the ru%er is the a/ount o( (ree p%a) in the steering s)ste/* I( the steering whee% ri/
/o$es too /uch &e(ore the (ront whee%s &egin to /o$e! there is e1cessi$e p%a)*
Air 4%ee#ing
The purpose o( air &%ee#ing is to re/o$e the air &u&&%es*
The air &%ee#ing is #one &) the (o%%owing the proce#ure gi$en &e%ow2
4e(ore &rae &%ee#ing! ensure su((icient oi% is present in /aster c)%in#er*
Start the process with the 9hee% c)%in#er! which is (ar o(( (ro/ the /aster c)%in#er*
6irst! (i1 up &%ee#er pipe in $ent screw pro$i#e# in the whee% c)%in#er*
:eep the other en# o( pipe in g%ass &ott%e*
+ress the &rae pe#a% = or > ti/es an# eep it presse# the %ast ti/e*
Now unscrew the $ent screw o( whee% c)%in#er*
4rae oi% an# air &u&&%es co/e out in the g%ass &ott%e*
9hen the pe#a% goes #own! c%ose the $ent screw*
Again repeat the proce#ure unti% a%% the &u&&%es are re/o$e#*
9hee% 4earing Tightening an# A#.ust/ent
Hoist the $ehic%e an# re/o$e the rear whee%*
Re/o$e spin#%e cap &) ha//ering at < or = %ocations*
Re/o$e the sp%it pin! cast%e nut an# washer*
Chec to ensure that the paring &rae %e$er is not pu%%e# up*
Re/o$e the &ac p%ate p%ug attache# to the &acsi#e o( &rae p%ate! so as to increase c%earance
&etween &rae shoe an# &rae #ru/*
Re/o$e the whee% &earings*
Insert the new stu# in #ru/ ho%e a(ter rotating the stu# s%ow%) to assure the serrations are a%igne#
with these /a#e &) origina% &o%t*
Ensure that a%% the nuts are tightene# proper%)*
DESCRI+TION 2
The whee% a%ign/ent re(ers to the positioning o( the (ront whee%s an# steering /echanis/ that
gi$es the $ehic%e #irectiona% sta&i%it)! pro/otes case o( steering an# re#uces t)re wear to a /ini/u/* A
$ehic%e is sai# to ha$e #irectiona% sta&i%it) or contro% i( it can run straight #own a roa#! enter an# %ea$e a
turn easi%) an# resist roa# shocs* The (ront whee% a%ign/ent #epen#s upon the (o%%owing ter/s Ca/&er!
Caster! :ingpin inc%ination! toe3in an# toe3out on turns* The (ront whee% geo/etr) or steering geo/etr)
re(ers to the angu%ar re%ationship &etween the (ront whee%s! the (ront whee% attaching parts an# the $ehic%e
(ra/e* A%% the a&o$e ter/s are inc%u#e# in the (ront whee% geo/etr)* The $arious (actors that a((ect the
whee% a%ign/ent o( the $ehic%es are gi$en &e%ow
1* 6actors pertaining to whee%
a* 4a%ance o( whee%s
&* In(%ation o( t)res
c* 4rae a#.ust/ent
;* Steering 8eo/etr)
a* Ca/&er
&* Caster
c* :ingpin inc%ination
#* Toe3in an# Toe3out
<* Steering %inages
=* Suspension S)ste/
Ca/&er
The ang%e &etween the center%ine o( the t)re an# the $ertica% %ine when $iewe# (ro/ the (ront o( the
$ehic%e is nown as ca/&er* 9hen the ang%e is turne# outwar#! so that the whee%s are (arther apart at the
top than at the &otto/! the ca/&er is positi$e* 9hen the ang%e is inwar#! so that the whee%s are c%oser
together at the top than at the &otto/! the ca/&er is negati$e* An) a/ount o( ca/&er! positi$e or negati$e!
ten#s to cause une$en or /ore t)re wear on one si#e that on the other si#e* Ca/&er shou%# not
E1cee# ;
C*
6ig @*1
+roce#ure
,i- Turn the whee% to <C
C
LHS
,ii- A#.ust the sprit %e$e% such that the &u&&%e occupies the center
position*
,iii- Note the rea#ing o( the ?C
C
sca%e*
,i$- Turn the whee% to <C
C
RHS an# the a&o$e proce#ure is repeate# an# the $a%ue is
note#*
,$- The #i((erence &etween the two rea#ings gi$es the ca/&er ang%e*
Caster
The ang%e &etween the $ertica% %ine an# the ingpin center%ine in the p%ane o( the whee% ,when
$iewe# (ro/ the si#e- is ca%%e# the Caster ang%e* 9hen the top o( the ing pin is &acwar#! the caster
ang%e is positi$e an# when it is (orwar# the caster ang%e is negati$e* The caster ang%e in /o#ern $ehic%es
range (ro/ ; to A #egrees*
+roce#ure
,i- +ar the car on the turning ta&%e
,ii- Turn the whee% a%ign/ent gauge to BC
C
*
,iii- 6i1 the whee% a%ign/ent gauge on the whee%*
,i$- Turn the whee% to ;>
C
in RHS*
6ig @*;
,$- A#.ust the &u&&%e to its origina% position
,$i- Note the rea#ing on the >C
3#egree
sca%e an# the note# $a%ue wi%% gi$e the caster ang%e*
:ingpin inc%ination
The ang%e &etween the $ertica% %ine an# center o( the ingpin or steering a1%e! when $iewe# (ro/
the (ront o( the $ehic%e is nown as ingpin inc%ination or steering a1%e inc%ination* The ingpin inc%ination
in co/&ination with caster is use# to pro$i#e #irectiona% sta&i%it) in /o#ern cars! &) ten#ing to return the
whee%s to the straight3ahea# position a(ter an) turn* It a%so re#uces steering e((ort particu%ar%) when the
$ehic%e is stationar)* It re#uces t)re wear a%so* The ingpin inc%ination in /o#ern $ehic%es range (ro/ = to
A #egrees*
+roce#ure
,i- +ar the car on the turnta&%e*
,ii- 6i1 the whee% a%ign/ent gauge on the whee%s*
,iii- Turn the whee% to <C
C
RHS an# a#.ust the spirit %e$e% such that the
&u&&%e occupies center position*
,i$- Note the $a%ue on the ?C
C
sca%e an# the $a%ue gi$es the ingpin
inc%ination*
Toe3in an# Toe3out
The (ront whee%s are usua%%) turne# in s%ight%) in (ront so that the #istance &etween the (ront en#s
,A- is s%ight%) %ess than the #i((erence &etween the &ac en#s ,4-! when $iewe# (ro/ the top* The
#i((erence &etween these #istances is ca%%e# toe3in* The a/ount o( toe3in usua%%) < to > //* The toe3in is
pro$i#e# to ensure para%%e% ro%%ing o( the (ront whee%s! to sta&i%i'e steering an# pre$ent si#e s%ipping an#
e1cessi$e t)re wear*
Toe3out is the #i((erence in ang%e &etween the two (ront whee%s an# the car (ra/e #uring turns* The
steering s)ste/ is #esigne# to turn the insi#e whee% through a %arger ang%e than the outsi#e whee% when
/aing a turn* The con#ition causes the whee%s to toe3out on turns! #ue to #i((erence in their turning
ang%es* The toe3out is secure# &) pro$i#ing the proper re%ationship &etween the steering nuc%e! tie3ro#s
an# pit/an ar/*
+roce#ure
,i- The toe3out &ar is positione# (ro/ the (ront o( the $ehic%e such that the
pointer touches the whee% an# the #istance &etween the whee%s is (oun#
(ro/ the sca%e on the &ar* :eep is as ,A-*
,ii- Si/i%ar%) the #istance &etween the (ront whee%s on the rear si#e is
note#* :eep it as ,4-*
,iii- 6ro/ the rea#ings we can (in# out toe3in or toe3out*
I( A M 4! then it is toe3out an# i( 4 M A! then it is toe3in*

Toe3out on turns
,i- +ar the car on the turn ta&%e*
,ii- Turn the whee% to e1tre/e %e(t*
,iii- The rea#ings in &oth the turnta&%e are note#* The #i((erence in the
rea#ing wi%% gi$e the toe3out on %e(t turn*
,i$- Si/i%ar%) the $a%ues are ca%cu%ate# (or the right turn*
UNIT & IV' ELETRIAL "*"TEM MAINTANANE & "ERVEIE AN( RE#AIR
4ATTERIES23
4ATTER5
C%ean the &atter) ter/ina%s
Chec the %oose connections*
Chec the &atter) (or (i1ing in &o1 or cra#%e*
Chec up e%ectro%)te %e$e% in the &atter)*
Chec up the capacit) o( &atter)*
CHAR8IN8 S5STEM
7isua%%) inspect the #)na/o (or an) wear
Chec up (or an) %oose connections
Chec the &e%t (ro/ which #)na/o gets power
Chec the charging rate*
STARTIN8 S5STEM
7isua%%) inspect the se%(3starter! ca&%e an# switch
Chec the woring switch (or an) %oose connections
Chec the consu/ption o( current &) starter /otor*
Test con#ucte# on &atteries23
H)#rau%ic test To /easure speci(ic gra$it) o( e%ectro%)te*
High #ischarge test 3 To /easure #ischarging current*
In#i$i#ua% ce%% test Ce%% $o%tage can &e /easure#*
Ca#/iu/ test 3 Ce%% $o%tage can &e /easure#*
Hea#%ights! Tra((icator %ights an# +aring %ights
The re"uire/ents o( hea#%ights (or auto/o&i%e are that this shou%# i%%u/inate the roa# ahea# at the
reasona&%e #istance with su((icient intensit)*
The tra((icator are shown in the #iagra/* A so%enoi# contains a p%unger! which is (urther connecte#
with the pi$ote# in#icator ar/* 9hen the $ehic%e has to tae a turn! the #ri$er operates the tra((icator
switch* This energies the so%enoi# which pu%%s the p%unger #own so that the in#icating ar/ is %i(te# up to
the hori'onta% position* The #irection o( the $ehic%e a&out to turn is in#icate# &) it*
9in#screen wiper
9in#screen wiper is operate# &) /eans o( a s/a%% /otor* The /otor #ri$es the wor/ NAH which
rotates the whee% N4H! the sector NEH reciprocates a&out the (u%cru/H8H*
This /otion is then i/parte# to a si/i%ar sector N6H on the spin#%e on which it is /ounte# the wiper ar/*
9iper &%a#e is attache# to the wiper ar/ &) /eans o( a spring %oc* A ru&&er3wiping e%e/ent is he%# in
p%ace in the wiper &%a#e* 9hen the /otor rotates the wiper &%a#e wipes o(( the g%ass*
Horn s)ste/
The e%ectrica%%) operate# horn s)ste/ consists o( a #iaphrag/ an# an ar/ature insi#e a (ie%# coi%*
The contacts are shown c%ose#! which is the position when the horn switch is in the o(( position* 9hen the
#ri$er pushes the horn switch the circuit is co/p%ete# an# the (ie%# coi% pro#uces an e/(! which causes the
ar/ature a%ong with it the #iaphrag/ too /o$e #own! the contacts separate opening the e%ectrica% circuit*
The (ie%# coi% is then #e energi'e# an# again the ar/ature /o$es up on account o( the (orce o( a
/echanica% spring! which eeps it into the upper /ost position* This /otion causes the #iaphrag/ to
$i&rate in up an# #own /otion causing the $i&rations o( air co%u/n &e%ow it* These $i&rations o( air
co%u/n su&se"uent%) pro#uce the horn soun#! which #epen#s upon the (re"uenc) o( #iaphrag/* The horn
s)ste/ is use# to a%ert the pass=ngers on the roa# or the other $ehic%es to /o$e awa)*
6ig ?*1
6ig ?*;
6ig ?*<

6ig ?*=
Charging s)ste/
The (unction o( the charging s)ste/ in an auto/o&i%e is to generate! regu%ate an# supp%) the
e%ectrica% energ) (or charging the &atter)* The charging s)ste/ consists o( a generator (or con$erting
/echanica% energ) (ro/ the engine to e%ectrica% energ)! a regu%ator to contro% the a/ount o( e%ectrica%
energ) so pro#uce#! a re%a) to regu%ate the (%ow o( the charging current (ro/ the generator to the &atter)
re%e$ant to the state o( the charge o( the &atter) an# an a//eter or in#icating %a/p to in#icate whether the
s)ste/ is operating or not*
STARTIN8 S5STEM 2
Testing o( starter /otor
There are two /etho#s o( testing a starter /otor*
No %oa# test
Mount the starter /otor in a (i1ture or $ice*
The &atter)! a//eter! car&on pi%e rheostat! starter /otor are connecte# in series*
The $o%t/eter is connecte# in para%%e% an# groun#*
A#.ust the car&on pi%e rheostat to o&tain the speci(ie# $o%tage as reco//en#e# &) the
/anu(acturer*
Note the a//eter rea#ing
+%ace the tacho/eter against the #ri$e en# o( the ar/ature sha(t to now the running spee# at no
%oa# con#itions*
Sta%% tor"ue test
The o&.ecti$e o( this test to now the o$era%% e%ectrica% con#itions o( the /otor*
A tor"ue &ar is use# to %oc the pinion gear an# spring sca%e connecte# to the &ar*
A#.ust the car&on pi%e rheostat to o&tain the speci(ie# $o%tage*
Note the correct $a%ue an# the spring sca%e rea#ing*
Sta%% tor"ue spring rea#ing 1 %ength o( the tor"ue ar/*
UNIT IV & MAITANENE !+ +UEL "*"TEM' !!LING "*"TEM' LUBRIATIN "*"TEM
AN( VE)ILE B!(*1
Coo%ing s)ste/3
The /ain purpose o( coo%ing s)ste/ is to eep the engine at its /ost e((icient operating te/perature at a%%
spee# an# un#er a%% operating con#ition*
T)pes o( coo%ing23
1* Air coo%ing Here there are /eta% (ins on the hea#s an# c)%in#er to #issipate heat (ro/ the engine*
E$en (ans are use# on so/e air coo%e# engine to i/pro$e air circu%ation aroun# the c)%in#er an#
hea#s*
;* Li"ui# coo%ing Here the %i"ui# is circu%ate# aroun# the c)%in#er to o&ser$e (ro/ the c)%in#er
wa%%s* The %i"ui# use# is water! &ut e$en anti(ree'e so%utions are use# as coo%ant to pre$ent
(ree'ing is coo%e# weather*
COOLIN8 S5STEM
Chec the ra#iator (or an) #a/age an# &%ocs
Chec the hoses that connect ra#iator an# engine
Chec (or an) %eaage
Chec the (an &e%t
Use c%ean water in the ra#iation
LU4RICATION S5STEM
Chec the %e$e% o( %u&rication oi% in the crancase
Chec the %u&rication oi% (i%ter! i( c%ogge# rep%ace it with new one
I( the oi% is &a#! re/o$e the oi% an# intro#uce new oi% o( the correct gra#e
Description 2
So%#ering
So%#ering is the process o( .oining two or /ore pieces o( /eta% &) /eans o( (usi&%e a%%o) or /eta% ca%%e#
so%#er! app%ie# in the /o%ten state*
So%#ering is &asica%%) o( two t)pes*
1* So(t so%#ering
;* Har# so%#ering
So(t so%#ering
It is use# e1tensi$e%) in sheet /eta% wor (or .oining parts that are not e1pose# to the action o( high
te/peratures an# are not su&.ecte# to e1c%usi$e %oa#s an# (orce#*
Har# so%#ering
It e/p%o)s so%#ers which /e%t at high te/peratures an# are stronger than those use# in so(t so%#ering*
Si%$er so%#ering is har# so%#ering /etho# an# si%$er a%%o)e# either tin uses a so%#er* The te/perature o(
$arious har# so%#ers $aries (ro/ ?CC to BCC #egrees* The (%u1es are /ost%) in the (or/ o( paste an# are
app%ie# to .oint with a &rush &e(ore heating*
Denting
The process o( &o#) repairing an# re(inishing is ca%%e# #enting* It /ain%) in$o%$es sheet /eta% wors in
which the #a/age# &o#) pane%s an# (en#ers are straightene# or gi$en pro(i%es to /ae the/ %oo %ie the
origina% ite/*
The nee# (or #enting o( a $ehic%e arises when!
The (en#ers! #oors or pane%s are .une#*
+ane%s are twiste# a(ter co%%ision*
A series o( ri#ges are seen on certain area*
A #a/age# wrin%e# pane% is to &e straightene#*
A protru#ing sheet /eta% is to &e presse# &ac into position*
The patches or scratches ha$e co/e up an# the origina% co%our has (a#e#*
The #enting is a%so ca%%e# as #inging process which in$o%$es nu/&er o( processes such as &en#ing!
(%attening! shearing! (i%%ing! painting! co%our /atching etc* These processes are per(or/e# with the he%p
o( /o#ern too%s are e"uip/ents /ost o( which are #escri&e#* So/e too%s are $er) co//on an#
essentia% (or the #enting an# are genera%%) re(erre# as #enting too%s* These are (en#er3straightening
han# too%s! center punches! /eta% shears! pu%% ro#s! #o%%) &%ocs! #inging ha//ers et*
9in#ow rising /echanis/
9in#ows are pro$i#e# in the upper part o( the #oors* The) are use# to a#/it natura% %ight when c%ose# an#
a%%ow in(%ow o( air when open* To pro$i#e a##itiona% passenger space without increasing the o$era%%
$ehic%e wi#th! the win#ow g%asses are cur$e# at passenger shou%#er %e$e%* The) are /a#e o( one3piece
sa(et) g%ass o( &out > ? // thicness* Lie win#shie%# g%ass the) are a%so /a#e o( toughene#
,te/pere#- or %a/inate# g%ass* The win#ow can &e raise# or %owere# &) /eans o( a win#ow %e$er through
/echanis/* A rac an# pinion /echanis/ is e/p%o)e# (or this purpose*
Door %ocing /echanis/ 2
To open (or/ outsi#e
As soon as the push &utton is presse#! the catch is raise# upwar#s an# the s%otte# #isc rotates an#
(ree (ro/ the U3(itting* 9hen the catch is raise# up! %ocing &ar is a%so raise# up with the catch* 9hen the
U3(itting is (ree (ro/ s%otte# #isc! the #oor is opene#*
To open (ro/ insi#e
To un%oc the #oor (ro/ insi#e! the %ocing &ar is raise# initia%%) an# then insi#e opening %e$er is
pu%%e# up* I( this insi#e opening %e$er is pu%%e# up the catch is raise# an# the s%otte# #isc rotate# an# (ee
(ro/ the U3(itting*
Door in c%ose# position
9hen the #oor is c%ose# the s%otte# #isc rotates an# (astens into the 73(itting* During this operation
the catch with %ocing &ar is a%so se%ecte# into the s%ot* Once the s%otte# si#e (astens the 73(itting! the #oor
is %oce#*
A#.ust/ent o( hea# %ight &ea/ 2
The hea#%ights o( a $ehic%e ha$e to &e (ocuse# to ensure that %ight (a%%s at proper ang%e on the roa#* To
a#.ust these procee# as (o%%ows
+ar the $ehic%e on %e$e% groun# ;> (eet awa) (ro/ a white wa%%* Draw three %ines A! 4 an# C* Distance
A4 shou%# &e center #istance o( hea#%ights an# #istance C shou%# &e hea#%ight center height (ro/ the
groun#* Now switch on the %ight* The /a.orit) o( %ight ra)s shou%# (a%% on circu%ar area as shown* I( one
%ight ra) goes up! #own or si#ewise! it shou%# &e a#.uste# through a#.usting screws (i1e# in the hea#%a/p
&o#) as shown
REMO7AL AND 6ITTIN8 O6 T5RE AND TU4E 2
The proce#ure (or the re/o$a% an# (itting o( t)re an# tu&e is as &e%ow2
1- Loosen the whee% nuts o( t)re to &e re/o$e#*
;- +%ace the we#ge &e(ore an# a(ter resting the three whee%s to pre$ent $ehic%e (ro/ ro%%ing*
<- 6i1 up .ac an# %i(t the $ehic%e to the e1tent that whee% is (ree (ro/ groun#*
=- Re/o$e the whee% a(ter re/o$ing the whee% nuts*
>- :eep the whee% (%at on groun# an# #e(%ate it a(ter re/o$ing $a%$e with $a%$e #ie*
?- Ha//er the t)re at shou%#er so that its &ea# is (ree (ro/ ri/ on &oth si#es*
@- +ress t)re %e$er &etween &ea# o( t)re an# ri/ (%ange*
A- Tae another t)re %e$erF press it in the sa/e wa) a %itt%e apart (ro/ the (irst %e$er*
B- Now press &oth %e$ers #own* 4) #oing so so/e portion o( t)re &ea# wi%% co/e out o( ri/*
1C- +u%% out (irst %e$er an# insert it again at so/e #istance awa) (ro/ the secon# %e$er* +ress it
#own*
11- Now go on changing the %e$er ti%% t)re is out o( the ri/ co/p%ete%)*
1;- 9hen one &ea# o( t)re is out tae out the tu&e a(ter unscrewing $a%$e &o#) securing nut*
1<- I( t)re is to &e co/p%ete%) rep%ace#! procee# in the sa/e wa) to re/o$e the secon# &ea#*
1=- In case! on%) tu&e is to &e rep%ace#! (i1 up the new tu&e*
1>- 6ina%%) rep%ace the t)re with caution using the %e$ers an# in(%ate it to correct pressure*
UNIT 3-MAINTENANCE, REPAIR AND OVERHAULING OF CHASSIS DRIVELINE COMPONENTS
CLUTCH TROU4LE SHOOTIN8 CHARTS2
COM+LAINT +OSSI4LE CAUSES CHEC:,OR-CORRECTION
1. Clutch slips
while engaged
Broken or weak pressure springs
Broken engine mount
Warped clutch disc
Grease or oil on disk facing
Replace
Replace
Replace
Replace facing or disk
2. Clutch chatters
when engaged
Warped clutch disc
Broken engine mount
Binding in clutch release linkage
Replace
Replace
Adjust and lubricate
. Clutch noises !isalignment of engine and transmission
"riction disc hub loose on the clutch shaft
Release le#er not properl$ adjusted
Realign
Replace worn parts
Readjust%or& Replace the
assembl$
'. Clutch pedal
pulsations
(ngine and transmission not aligned
"l$wheel not seated on the crankshaft
flange
Realign
)eat properl$
*. "riction disc
facing wear
+ri#er rides clutch
(,cessi#e and incorrect use of clutch
Crack in fl$wheel
-eep foot off clutch e,cept
when necessar$
Reduce use
Replace
.. Clutch pedal stiff Clutch linkage lacks lubricant
!isaligned linkage plate
Bent clutch pedal
/ubricate
Realign
Replace
MANUAL TRRANSMISSION TROU4LESHOOTIN82
COM+LAINT
+OSSI4LE CAUSES CHEC:,OR-CORRECTION
1. 0ard shifting into gear Gear shift linkage out of
adjustment
Gear shift lacks lubricants
(,cessi#e clutch free1pedal
pla$
Adjust
/ubricate
Adjust
2. 2ransmission sticks in gear Gear shift linkage out of
adjustment
Gear shift lacks lubrication
)$nchroni3ing unit stuck
Adjust
/ubricate
Replace damaged parts

. 4o power through
transmission
Clutch slipping
Gear broken
!isalignment of transmission
with engine
Adjust
Replace
Realign
'. 2ransmission nois$ in neutral Gears worn or teeth broken
Bearings worn awa$
2ransmission misalignment
with engine
Replace gears
Replace and lubricate
Realign
*. 2ransmission nois$ in gear 5nsufficient lubrication
Gears loose on mainshaft
)$nchronisers worn
6roperl$ lubricate with
correct lube.
Replace worn parts
Replace worn parts
.. Gears clash while shifting )$nchronisers defecti#e
5ncorrect lubricant
5dle speed e,cessi#e
5ncorrect free1pedal pla$
Repair or replace
Replace with correct lubricant
Readjust
Adjust
7. 2ransmission nois$ in
re#erse
Re#erse idler gear damaged
)hift mechanism damaged
Replace
Repair8 replace8 readjust
defecti#e parts
9. :il leaks "oaming due to incorrect
lubrication
:il le#el too high
:il seals damaged
+rain plug loose
Replace with correct lubricant
;se proper amount8 not
more
Replace
2ighten the plug
REMO7AL O6 MANUAL TRANSMISSION2
:n floor1shift space cars remo#ing the shift le#er.
Raise the #ehicle on a lift.
!ark rear a,le flange and dri#e shaft so that the dri#e shaft is reinstalled in the same manner.
+rain the lubricants present in transmission unit.
+isconnect the speedometer cable.
+isconnect the wiring to the backup light.
+isconnect the dri#e shaft.
)upport the engine with jack or engine support.
Remo#e the bolts attaching the transmission support to the cross member. 2hen remo#e bolts attaching cross
member to the bod$ frame and remo#e the cross member.
Remo#e the upper bolts attaching the transmission to the clutch housing and install guide pin in the hole.
Remo#e the other transmission attaching bolts. 2hen slide the transmission until the clutch shaft comes clear of
the clutch.
INSTALLATION O6 8EAR 4OO2
5nstallation is the re#erse of remo#al. <ust before installation8 shift the transmission in to each gear and turn the
input shaft to check whether the transmission works or not.
6lace a small amount of lubricant on the spline of input shaft.
6re1align the spline on the input shaft and the friction disc hub b$ turning the input shafts so that the splines line
up.
5nstall guide pins and slide the transmission in to position.
2urn the shaft if necessar$ to secure alignment of the shaft and hub splines.
2hen fi, the bolts and tighten them along the guide pins.
STEERIN8 S5STEM TROU4LE SHOOTIN82
COM+LAINTS
+OSSI4LE CAUSES CHEC:,OR- CORRECTION
1. (,cessi#e pla$ in steering
s$stem
/ooseness in steering gear
/ooseness in linkage
/oose wheel bearing
Readjust8 replace worn parts
Readjust8 replace worn parts
Readjust
2. 0ard steering /ow t$re pressure
"riction in steering gear
"riction in linkage
5nflate to correct t$re
pressure
/ubricate8 readjust8 replace
worn parts
/ubricate8 readjust8 replace
worn parts
. Car wander /ow or une#en t$re pressure
)teering gear binding
/inkage binding
5ncorrect wheel alignment
5nflate to correct t$re
pressure
Readjust8 lubricate8 replace
worn parts
Readjust8 lubricate8 replace
worn parts
Check alignment and
readjust
'. Car pulls to one side during
normal dri#ing
;ne#en t$re pressure
;ne#en castor or camber
Wheel not tracking
5nflate to correct t$re
pressure
Check alignment8 adjust
Check tracking8 replace
defecti#e parts
*. Car pulls to one side while
braking
Brakes grab
;ne#en t$re pressure
;ne#en castor or camber
Readjust8 replace brake
lining
5nflate to correct t$re
pressure
Check alignment8 adjust
.. "ront wheel shimm$ at low
pressure
;ne#en t$re pressure
/oose linkage
/oose ball joints
+$namic imbalance
5nflate to correct t$re
pressure
Readjust8 replace worn parts
Replace worn parts
Balance the wheels
7. )teering shakes ;ne#en t$re pressure
/ooseness in linkage
/ooseness in steering gear
)hock absorber defecti#e
5nflate to correct t$re
pressure
Readjust8 replace worn parts
Readjust8 replace worn parts
Repair or replace
9. 2$res s=ueal on turns%skids& (,cessi#e speed on cur#es
;ne#en t$re pressure
"ront alignment incorrect
Worn t$res
2ake cur#es at slow speed
5nflate to correct t$re
pressure
Check and adjust
Replace t$res
(,cessi#e looseness in the steering s$stem means that there will be e,cessi#e free pla$ of the
steering wheel without corresponding mo#ement of the wheels. A small amount of free pla$ makes steering easier.
But when the pla$ becomes e,cessi#e8 it ma$ make steering harder. !an$ dri#ers complain about it. (,cessi#e free
pla$ in the steering s$stem reduces the abilit$ of dri#er to accuratel$ steer and control the #ehicle.
);)6(4)5:4 )>)2(! 2R:;B/( )0::254G?
C:!6/A542 6:))5B/( CA;)() C0(C-%:R& C:RR(C25:4
1. 0ard or rough ride (,cessi#e t$re pressure
+efecti#e shock absorber
(,cessi#e friction in
suspension spring
Readjust to correct pressure
Repair %or& replace
/ubricate8 realign parts
2. )wa$ on turns /oose stabili3er bar
)agging springs
Castor incorrect
2ighten it
Repair or replace
Adjust
. )pring breakage :#erloading
+efecti#e shock absorber
/oose ;1bolts
A#oid o#erloading
Repair or replace
-eep bolts tight
'. )agging springs Broken leaf
)pring weak
+efecti#e shock absorber
Replace
Replace
Repair or replace
*. noises Cou%# co/e (ro/ an) %oose!
worn,or- un%u&ricate# part in the
suspension,or- steering s)ste/
9HEEL ALI8NMENT2
SER7ICIN8 STEERIN8 LIN:A8ES AND SUS+ENSION2
5f an$ defects are found8 the causes must be determined and corresponding corrections must be made before
aligning the wheels.
)er#icing steering and suspension includes remo#al8 replacement8 adjustment of tie rods8 rem8o#al and
replacement of other linkage parts.
All of these ser#ices8 if needed must be performed before aligning the wheels.
9HEEL ALI8NMENT2
2here are man$ t$pes of wheel aligners. )ome are mechanical t$pes that attach to the wheel spindles. )ome
ha#e light beams that displa$ the measurements on a screen in front of the car.
When doing front wheel alignment8 $ou should first check castor8 camber8 toe8 turning radius8 etc. 2hese are
not adjustable. 5f the$ are out of specification it means parts are damaged and must be replaced.
Before $ou make alignment checks8 the following pre1alignment inspections must be first made.
Check and correct t$re pressure.
Check and adjust wheel bearings.
Check and adjust wheel run out.
Check ball joints8 if the$ are too loose8 replace them.
Check wheel balance8 correct if necessar$.
Check front suspension height.
Check shock absorbers and replace them if the$ are defecti#e.
Check wheel tracking. 2his means whether rear wheels follow the front wheels. 5f the wheels are off the
track8 it usuall$ means frame is bent and it should be straightened.
W0((/ BA/A4C(?
2he wheel ma$ be checked for balance on or off the car. 2his is done in either of two wa$s? static or d$namic.
5n static balancing8 the wheel is taken off the car and put on a @bubbleA balancer to detect an$ imbalance. A
wheel that is out of balance is hea#ier in one section. 2his will cause the bubble in the centre of the balancer to
mo#e off the centre. 2o balance the wheel8 weights are added to the wheel rim until the bubble returns to
centre.
5n d$namic balancing8 the wheel is spun either on %or& off the car. An electronic wheel balancer is used to
balance a wheel on a car. /ack of balance shows up as a tendenc$ for the wheel to mo#e off the centre %or& out
of line as it spins. 5f the wheel is out of balance8 one or more weights are installed on the wheel rim.
A+<;)254G CA!B(R A4+ CA)2:R?
B$ installing %or& remo#ing shims.
B$ turning a cam.
B$ shifting inner shaft.
B$ changing length of strut rod.
A+<;)254G 2:(?
After correcting camber and castor8 toe is adjusted. 6lace the front wheels in straight1ahead position. 2hen
check the positions of the spokes in the steering wheel. 5f the$ are not centered8 the$ can be properl$ positioned
when toe is set.
2>R( !A542(4A4C(?
2he main purpose of t$res is that the$ ha#e air1filled cushions that absorb most of the
shocks caused b$ road irregularities and secondl$ the$ grip the road to pro#ide good traction. Good traction
enables the car to accelerate8 brake8 make turns without skidding. 2he main steps in#ol#ed in t$re maintenance
are?
Alwa$s maintain the recommended t$re inflation pressure.
+o not o#erload the #ehicle be$ond the capacit$ prescribed b$ manufacturer.
A#oid fre=uent sudden acceleration followed b$ sudden braking.
+o regular checks like wheel alignment8 condition of brakes8 springs8 wheels8 etc.
Regularl$ inspect the tread condition #er$ closel$ since it is e=uall$ important like other components.
Retread the t$res promptl$ before the$ are completel$ defected.
Replace the t$re before the t$re surface becomes smooth.
CA;)() :" 2>R( W(AR?
1. 54"/A25:4 6R());R(?
:#er inflation or under inflation will cause rapid t$re wear. :#er inflation results in wear of the centre portion
and under inflation results in wear of the shoulder.
2. 2:(154 :R 2:(1:;2?
2he e,cessi#e toe1in shows feathered edges on inside edges.
2he e,cessi#e toe1out results in feathered edge wear on outside edges.
. CA!B(R?
2oo much positi#e camber results in e,cessi#e wear on the outer shoulders of the t$res.
2oo much negati#e camber results in t$re wear of the inner shoulders.
'. CA)2:R?
(,cessi#e castor causes the spotting wear of t$res. ;ne=ual castor causes the wheel to pull to one side
resulting in e,cessi#e and une#en wear.
2>R( "A5/;R(?
2he amount of wear a t$re gets depends upon its location of the car. "or e,ample on a car with rear wheel
dri#e8 the right t$re wears twice as much as the left t$re. 2his is because man$ roads are slightl$ crowned
%higher in the centre& and also the right t$re is dri#ing. 2he crown causes the car to lean out a little so that the
right t$re carries more weight.
2o e=uali3e the wear as much as possible t$res should be rotated an$ time8 une#en wear is noticed as the
distance specified b$ the manufacturer.
:ne manufacturer recommends rotating radial t$res after 12BBBkms and then after e#er$ 2'BBBkms. Bias t$res
should be rotated e#er$ 12BBBkms.
2he amount of wear the t$re e,periences depends upon its rotation on the car.
:n a car with rear wheel dri#e8 the rear right t$re wears about twice as that of the rear left wheel.
2o e=uali3e wear as much as possible8 t$res should be rotated an$ time whene#er ene#en wear is noticed and
at the distance specified b$ the manufacturer.
2>6() :" 2>R( W(AR?
1. 2:(154 :R 2:(1:;2 W(AR?
(,cessi#e toe1in or toe1out on turns causes the t$re to be dragged sidewa$s as it mo#es forward and this
scraps off rubber.
5f both t$res show this t$pe of wear8 then toe is correct. But if onl$ one t$re shows this t$pe of wear8 steering
arm should ha#e been bent.
2. CA!B(R W(AR?
5f the wheel has e,cessi#e camber8 the tire runs more on one shoulder than the other.
. C:R4(R54G W(AR?
2his is caused b$ taking cur#es at high speeds producing diagonal t$pe of wear.
'. ;4(C(4 25R( W(AR?
5t occurs due to #arious mechanical problems. 2hese include misaligned wheels8 o#er inflation of t$res8
unbalanced wheels8 etc.
*. 05G01)6((+ W(AR?
2$res wear more rapidl$ at high speed than at low speed. 2$res dri#en at 11B11BkmDhr will
e,perience onl$ half the life of t$res dri#en at *B1.BkmDhr.
2>R( 54)6(C25:4?
2he purpose of inspecting the t$res is to determine whether the$ are safe for further use. When an improper
wear pattern is found8 technician must know the cause for abnormal wear and should correct the problem.
5f the t$res are in good condition the$ can be rotated.
While inspecting a t$re8 check for bulges in the side walls. A bulge is a danger signal. 5t can mean that plies are
separated or broken and the t$re is likel$ to go flat. A t$re with bulge should be remo#ed.
2o make complete t$re inspection8 remo#e all the stones from the tread. 2his is to ensure that no tire damage is
hidden b$ the stones.
A =uick wa$ to check tread wear is with a /incoln penn$ inserted in the tread groo#es. 2read of atleast B.7Emm
is needed.
A t$re can look oka$ from outside but it ma$ ha#e internal damage. 2o completel$ inspect a tire it should be
remo#ed from the rim and then e,amine it closel$8 inside and out.
UNI7ERSAL DOINT AND +RO+ELLER SHA6T MAINTENANCE2
;ni#ersal joints and propeller shaft do not re=uire maintenance in normal use.
)ome uni#ersal joints and pre1lubricated for life during original assembl$. When wear %or& noise occurs8 the
uni#ersal joints ha#e to be replaced. 0owe#er8 some manufacturers recommend lubricating the uni#ersal joints
e#er$ time a chassis lubrication is performed.
2he dri#e shaft and uni#ersal joints are carefull$ balanced during original assembl$. Alwa$s mark the position
and alignment of the parts before dismantling. 2hen after reassembl$ and installation8 the$ should be still in
balance. A dri#e shaft can often be balanced b$ installation of two worm1t$pe hose clamps.
DI66ERENTIAL TROU4LE DIA8NOSIS2
The (irst sign o( #i((erentia% trou&%e is usua%%) noise*
1. 0;!!54G?
A humming noise is often due to incorrect internal adjustment of dri#e pinion or the ring gear.
5ncorrect adjustment causes rapid tooth wear or e#en failure of differential.
2his humming noise will take on a growling noise as wear progresses.
2. 4:5)( :R ACC(/(RA25:4?
4oise from differential is louder when the car is accelerating since there is hea#$ contact on the ends of the
gear teeth.
4oise is louder when the car is coasting since there is hea#$ toe contact and both these conditions must be
corrected.
. 4:5)( :4 C;RC()?
5f the noise is heard onl$ when the car is going around a cur#e 8 the trouble is inside the differential case.
6inion gears tight on the pinion shaft8 damaged gears or pinions8 too much backlash between gears could
be cause for this problem.
When the car turns along a cur#e8 the parts inside the differential case more relati#e to each other.
'. /5!52(+1)/56 +5""(R(425A/?
2he limited slip differential re=uires a special t$pe of lubricant. 2he wrong lubricant can cause clutch
surfaces to grab. 2his ma$ produce chattering noise during a turn.
2he remed$ is to drain the old lubricant and fill specified lubricant designed for limited1slip differential. 5n
such cases wheel spin can also occur8 e#en though differential is in good condition.
BRA-( )(RC5C(?
+R;!1BRA-( 2R:;B/( )0::254G?
C:!6/A542 6:))5B/( CA;)( C0(C-%:R&C:RR(C25:4
1. Brake pedal goes to floor
board
/inkage or shoe out of
adjustment
Worn brake lining
/ack of brake fluid
Air in s$stem
Adjust
Replace
Add fluid
Add fluid
2. :ne brake drags )hoes out of adjustment
+efecti#e wheel c$linder
Weak return spring
Adjust
Repair or replace
Replace
. All brakes drag 5ncorrect linkage adjustment
2rouble in master c$linder
!ineral oil in the s$stem
Adjust
Repair or replace
Replace damaged rubber
partsF Refill brake fluid
'. Car pulls to one side while
braking
Brake shoes out of
adjustment
2$res not installed properl$
Brake lining clogged
Adjust
5nflate correctl$
Clean or replace line
*. )oft or spong$ pedal Air in s$stem
Brake shoes out of
adjustment
Add brake fluid
Adjust
.. Brakes too sensiti#e
%Grabbing&
)hoes out of adjustment
Brake lining greas$
+rums scored
Adjust
ReplaceF a#oid o#er
lubrication
2urn or grind drums
7. 4ois$ brakes /ining worn
/oose parts
)hoes warped
Replace
2ighten
Replace

H5DRAULIC 4RA:E2
6R(CA;25:4)?
Alwa$s keep the brakes properl$ adjusted.
4e#er allow the brake linings to wear down.
Regularl$ inspect the fluid le#el in the reser#oir and top up with brake fluid if necessar$.
Alwa$s e,ercise cleanliness when dealing with an$ part of h$draulic s$stem.
4e#er handle the internal h$draulic brake parts with greas$ hands.
Alwa$s use fresh brake fluid or alcohol for cleaning internal parts of the h$draulic s$stem.
:ne form of brake trouble that occurs fre=uentl$ due to mineral oil contamination and it is usuall$ caused b$
topping up the h$draulic s$stem with superior fluids %or& cleaning c$linders with petrol during ser#icing.
5f the brake s$stem has been contaminated8 it is a dangerous condition and immediate attempt has to be made
to flush off all the brake fluid from the s$stem and then refill with appropriate fluid.
B/((+54G :" 0>+RA;/5C )>)2(!?
2he process of remo#ing the brake fluid from the h$draulic pipe line and c$linder is known as bleeding.
5t is necessar$ whene#er an$ part of the s$stem is disconnected %or& fluid in the suppl$ tank e,ceeds the limit.
Whene#er seats are worn out it is possible for air to enter into the wheel c$linder without an$ sign of leakage
causing spong$ pedal and it is the usual indication of air in the s$stem.
4e#er8 under an$ circumstances use the fluid which has been bled from the s$stem to top up the suppl$ tank
because it ma$ be aerated8 ha#e too much moisture content %or& be contaminated.
B/((+54G 6R:C(+;R(?
Before starting to bleed8 follow the essential steps?
Before commencing bleeding at each bleed screw8 remo#e the dust co#er and clean thoroughl$. 5f the master
c$linder is fitted with bleeding screw8 bleed the master c$linder first.
Attach the bleed tube to wheel c$linder and then from the master c$linder to the glass jar containing brake fluid.
:pen the bleed screw to D'
th
of a turn sufficient to the brake fluid to flow freel$. +epress the foot pedal slowl$
throughout full stroke of the pedal and allow it to return to its position slowl$.
2here would be an inter#al of to ' seconds before making the ne,t stroke.
Repeat this action until the air bubbles sei3es and then close the bleed screw immediatel$.
While the pedal is thus held8 securel$ tighten the bleed screw and remo#e the tube. Replace the dust co#er on
the bleed screw. Repeat the same procedure on all the wheel c$linders.
After the bleeding operation8 top up the master c$linder reser#oir with appropriate brake fluid to a le#el of of D'
th
the reser#oir and replace the filler cap.
BRA-( 2()2(R)?
2here are two t$pes of brake testers8 namel$ static and d$namic.
)tatic tester has four tread plates and registering columns. 2o remo#e the tests8 the car is dri#en on to the tread
plates at specified speed and the brakes are applied hard. 2he stopping force at each wheel is registered on
four columns. 5f the readings are too low8 brake ser#ice is needed.
2he d$namic brake tester has rollers in the floor. 2he two wheels for which brakes are to be tested are placed
on the rollers. 5f these are the dri#e wheels8 the wheels are spun at specified speed b$ #ehicle engine. "or non1
dri#ing wheels8 the rollers and wheels are spun b$ electric motor. 2hen the electric motor is switched off and the
brakes are applied. 2he braking force at each wheel registers on meters and based on the readings8 ser#ice is
performed.
BRA-( )(RC5C(?
An$ complaint of fault$ braking action8 immediate measures ha#e to be taken.
Brake ser#ice includes?
Addition of brake fluid
Bleeding the h$draulic s$stem to remo#e air
Repair or replacement of master c$linder8 wheel c$linders8 etc.
Replacement of brake linings
Refinishing of brake drums
:#erhauling of power1brake units.
UNIT 3= MAINTENANE'RE#AIR AN( "ERVIING !+ ELETRIAL "*"TEM"
BATTERIES:
TESTS CONDUCTED ON 4ATTERIES2
ROUTINE OR LA4ORATOR5 TEST2
0$draulic test G 2o measure specific gra#it$ of electrol$te.
0igh discharge test G 2o measure discharging current.
5ndi#idual cell tests G Cell #oltage can be measured.
Cadmium test G Cell #oltage can be measured.
1. )6(C5"5C GRAC52> 2()2 %0>+:R!(2(R 2()2&
)pecific gra#it$ is the rate of densit$ of gi#en fluid to densit$ of water.
)pecific gra#it$ test is performed to know the condition of the batter$.
2here are two t$pes of h$drometers.
Ball t$pe 0$drometer?
2o use this h$drometer stick the rubber tube to the cell electrol$te8 then s=uee3e and release
the bulb. 2his draws electrol$te in to the glass tube8 the no. :f balls that float indicates the
batteries state of change. 5f all the balls float8 then the batter$ is full$ charged. 5f no balls float8
then the batter$ is full$ discharged.
"loat t$pe h$drometer?
2his has float with stem that sticks up abo#e the electrol$te le#el in the tube. 2he float stem s
marked to indicate the specific gra#it$ of the electrol$te. 2he height of the stem abo#e the
electrol$te indicates batteries state of change.
2. CA+!5;! 2()2?
2his test is performed to know the chemical condition of plates and it is performed when
the batter$ is either on1charge or discharge.
A cadmium rod is enclosed in a perforated ebonite tube and is immersed in electrol$te.
2hen the rod is connected to the negati#e terminal of #oltmeter and the positi#e terminal of
#oltmeter is connected alternati#el$ to positi#e and negati#e terminals of the batter$ cell.
2he #oltmeter shows reading for both positi#e and negati#e terminals .2he 2 readings are
then added to obtain potential difference between the plates. 2he plate in good condition
will show potential difference of abo#e B for positi#e plate and below B for negati#e plates.
. 05G0 RA2( +5)C0ARG( 2()2?
2his test determines actual capacit$ of the batter$ that con#erts chemical energ$ into
electrical energ$.
2his test should be conducted onl$ if specific gra#it$ of the electrol$te is more than 1.21*.
2he prods of the tester are placed on the cell terminals and the #oltmeter indicates the cell
#oltage.
2he duration the test is #er$ small since high current of 1BBA G 2BBA flows across
resistance.
"or a 12C batter$8 if the cell is full$ charged8 the test should show a batter$ #oltage not
less than 1BC and other cells should show the same reading.
/ower #oltage readings indicate fault$ cells or cell is not in proper position to hold full
charge.
'. :6(4 C:/2 2()2?
2o conduct this test8 #er$ accurate and sensiti#e #oltmeter is re=uired.
"or a 2C cell8 if a batter$ cell is in good condition and full$ charged8 it must ha#e a open
circuit #oltage of 2.1*C.
2he batteries which ha#e been just charged should not be tested since gases on the
plates would cause high reading. 2hese gases should be eliminated b$ subjecting the
batter$ to high discharge for few moments and we ha#e to measure the open circuit
#oltage.
5f the #oltage is 2.1*C for 2C batter$ cell8 then it indicates it is full$ charged. 0ere B.B1 #olt
of open circuit #oltage H B.B1 specific gra#it$ of electrol$te.
2herefore8 #oltage of the cell H specific gra#it$ I B.9'B.
INSTALLIN8 THE 4ATTER52
Batteries should be fitted in eas$ accessible position.
Batter$ connecting cables should be fle,ible ad sufficientl$ long to pre#ent strain on batter$.
ELECTTROL5TE LE7EL2
Check the le#el of the electrol$te periodicall$ once in forth night or e#er$ 9BB km.
Add pure distilled water as necessar$.
(lectrol$te le#el should be 1D'
th
abo#e the top of separator.
TERMINAL CONNECTION2
Clamp connections to the terminal post must fit well to a#oid contact resistance.
All the corrosion products should be remo#ed.
2erminals should be washed8 dried and co#ered with #asoline.
7ENT +LU82
-eep #ent holes free from dust disposition.
4ATTER5 CHAR8IN82
Batteries must be full$ charged to ha#e uniformit$ of the specific gra#it$ readings and #oltage of
the cells.
TEM+ERATURE O6 THE ELECTROL5TE2
2he temperature of the electrol$te must not e,ceed *BJC during charging.
:#er charging8 undercharging and o#er1discharging must be a#oided.
5f the specific gra#it$ of the electrol$te is 1.298 it indicates the batter$ is full$ charged. 5f the
specific gra#it$ of the electrol$te is 1.12*8 it indicates that batter$ is full$ discharged and it is
corrected to 27JC.
MAINTENANCE O6 STARTER MOTOR2
)tarter motor needs lubrication onl$ during o#erhaul or it re=uires lubrication e#er$ *BBB miles or
BB hours of operation.
Trou&%e Shooting2
Cisual and electrical checks should be made.
Check the batter$ #oltage and specific gra#it$.
5nspect the wiring for proper insulation.
!ake sure all ground connections are clear and tight.
There are = co//on s)/pto/s that in#icates #e(ect in the starter s)ste/s*
)tarter springs freel$.
(ngine cranks noisil$.
(ngine cranks slowl$.
(ngine does not crank.
Inspection an# Repair2
2he #arious parts line brushes 8 brush holder8 armature and the field coils should be inspected
and repaired.
MAINTENANCE O6 8ENERATORS2
2he maintenance of generator infact includes mainl$ its lubrication8 brush wear inspection and
adjustment of belt.
Certain generators do not need lubrication as their bearings are pre1packed with grease whereas
other models should be lubricated at the appropriate holes pro#ided for this purpose after
inter#als of 1B8BBB -m.
2he brushes should be inspected after e#er$ B8BBBkm and should be replaced if their wear is
found to be more than specified #alue.
2his inspection should be done on and off to see that there is enough tension.
2he sagging when present at the middle of the belt should be about 12mm.
5f the belt is too tight8 it is liable to damage the water pump gland and generator bearings.
:n the other hand a #er$ loose belt will not dri#e the generator efficientl$ and also ensure that
generator pulle$ does not become oil$ as this will cause the belt to slip.
TESTIN8 O6 8ENERATOR RE8ULATOR S5STEM2
An accurate ammeter is connected in series in the batter$ circuit. 2he reading on the ammeter
gi#es the charging rate.
2he state of the batter$ is tested with the h$drometer.
"rom the abo#e two obser#ations an$ of the four conditions is found to e,ist.
a& +ischarged batter$ and a high charging rate.
b& Charged batter$ and low charging rate.
c& Charged batter$ and high charging rate.
d& +ischarged batter$ and a low charging rate.
Out o( these ,a- an# ,&- are the nor/a% con#itions an# the re/aining ; con#itions /a) &e in$estigate# to
%ocate the source o( the trou&%e*
c- In$estigation o( charge# &atter) an# high charging rate2
Run the generator at medium speed.
+isconnect the " load at the regular terminals8 thereb$ opening the generator field circuit.
5f this causes the generator output to drop8 it indicates that generator is alright and so took for
the trouble in the regulator.
#- In$estigation o( #ischarge# &atter) an# %ow charging rate2
2he possible for this ma$ be
1 +efecti#e wiring or loose connection.
1 5f on inspection8 the connections are found to be correct and this leads to good condition
short cut the generator field circuit in the regulator.
1 With the generator running at medium speed and the generator field circuit shorted. 5f the
output increases8 the fault lies in the regulator.
1 5f the output doesKnt increase8 it indicates a fault$ generator.
8ENERATOR 6AULTS AND THEIR DIA8NOSISF
1. 4o ouput?
a& Cisual inspection?
5f the generator is not gi#ing an$ output8 the first step is to remo#e the co#er band and
ha#e #isual inspection.
Check for sticking brushes 8 burnt commutator and loose connections.
5f e#er$thing looks alright8 disconnect the generator leads and proceed with further
tests with the help of test1lamp.
b& Ground test?
5nsert some paper or some other insulation between commutator and the grounded
brush. Check for the ground with test lamp between generator brush and the frame.
c& :pen field test?
6lace the test lamp between the armature and generator field terminal. 5f the lamp
doesKnt light8 the field circuit is open.
d& )hort field test?
Connect a batter$ of the specified #oltage and ammeter in series with the field circuit.
5f the current flow is higher than the specified #alue b$ the manufacturer8 the field coils
are shorted and replaced.
2. /ow or unstead$ output?
2he following are the causes for it.
Generator dri#e belt ma$ be loose and be slipping.
Worn out brushes.
+efecti#e brush spring.
+irt$ or worn out commutators.
. (,cessi#e output?
5n the e,ternall$ grounded field t$pe of generator8 e,cessi#e output is caused because of
internal grounding of the field circuit8 which pre#ents e,cessi#e regulation.
2his ma$ be tested b$ connecting the test lamp between L"K terminal and the generator
frame8 with the L"K leads disconnected and some insulation is placed between the
commutator and field brush. 5f the test lamp lights the field is internall$ grounded.
'. (,cessi#e noise?
(,cessi#e generator noise ma$ be due to?
1 /oose dri#e pulle$.
1 Worn out bearings.
1 Worn out commutator.
1 5mproperl$ seated brushes.
ALTERNATOR MAINTENANCE2
An alternator in an AC generator producing alternating current instead of direct current.
1 At regular inter#als 8 inspect the terminals for corrosion and loose connection.
1 Check for mounting bolts8 nuts and belts.
1 Adjust the belt tension according to the recommendation of manufacturer of engine.
1 Check for nois$ operation that ma$ be due to worn out bearings.
On car test2
So/e tests can &e /a#e on charging s)ste/ without #isconnecting or re/o$ing an) part (ro/ the car*
Tests are (or $o%tage an# are /a#e with a $o%t/eter*
Begin with a charged batter$ and ignition off8 clip meter probe to the positi#e terminal of the car
batter$8 other to negati#e terminal. Read the #oltage which will be about 12C. 2his is batter$
reference #oltage.
4ow run the engine at fairl$ high speed with lights and all accessories off. Read the #oltage on
meter again and compare it to reference #oltage.
5f the #oltage has not changed8 the alternator is probabl$ defecti#e. 2o test the alternator8 if
#oltage is 2 or more #olts higher the reference #oltage8 regulator is defecti#e and should be
replaced. 5f the #oltage increase fall between B and 2C8 then make the ne,t test.
4ow run the engine at high speed with all the lights and accessories switched on. 5f the #oltage
increases b$ M #olt or abo#e reference #oltage8 then alternator and #oltage regulator are ok. 5f the
#oltage s increased b$ less than M #olt8 then proceed with the test.
4ow run the engine off8 then disconnect probe s of the #oltmeter. Reclip one of the probes to the
alternator terminal %BA2& and other probe to the ground. Restart the engine with lights and
accessories on at high speed again. 5f the #oltage does not increase more than M reference
#oltage8 turn off the engine and check alternator for the defects. 5f the #oltage increases b$ more
than MC then the regulator is defecti#e.
ALTERNATOR TESTS2
1& Rotor test?
Connection? Reading? Result?
:hm meter from slip ring to shaft. Cer$ low. Grounded.
11BC test lamp from slip ring to shaft. /amp glows. Grounded.
:hm meter across slip rings. Cer$ high. :pen.
11BC lamp across slip rings. 4o light. :pen.
2& )tator test?
Connection? Reading? Result?
:hm meter from load to frame. Cer$ low. Grounded.
11BC test lamp from load to frame. /amp glows. Grounded.
:hm meter across each pair of leads. Cer$ high. :pen.
11BC lamp across each pair of leads. 4o light. :pen.
& +iode test?
Connection? Reading? Result?
:hm meter across diode
then re#erse connections.
a& Both readings #er$
low.
b& Both readings #er$
high.
)horted.
:pen.
12C test lamp across diode
and then re#erse
connections.
a& 4o light in both
checks.
b& /amp lights in both
checks.
:pen.
)horted.
RE8ULATOR MAINTENANCE2
5nspect for burning of #arious regulator contacts. 2he contacts are burnt due to e,cessi#e current
caused b$ fault$ connections.
(#en during normal operation8 a small arc occurs during each time the regular contacts open and
o,ide formation takes place in the contacts and hence cleaning or replacement is re=uired. 5f
o,ide formation is small8 contacts must be cleaned and if there are large o,ide deposits then the
points ma$ be.
I8NITION SER7ICE2
CAUSES 6OR I8NITION 6AILURE2
1. /oss of energ$ in primar$ circuit?
2his ma$ be due to?
1 5mproper point setting
1 +ischarged batter$.
1 +efecti#e generator.
1 +efecti#e condenser.
1 Grounded primar$ circuit.
2. /oss of energ$ in secondar$ circuit?
2his ma$ be due to?
1 "ouled plugs.
1 +efecti#e high tension winding.
1 +efecti#e connection in the high tension circuit.
1 0igh tension leakage across coil head 8 rotor.
. out of time?
2his ma$ be due to?
1 5mproper ignition timing.
1 +efecti#e #accum ad#ance mechanism.
1 +efecti#e centrifugal ad#ance mechanism.
1 Worn distributor shaft.
1 6re1ignition due to fouled plugs.
I8NITION TIME3U+2
2est the batter$ and cables.
2est the ignition coils and condenser.
2est the distributor.
)elect the high tension wiring.
Check the contact points.
Check the spark plugs.
MAINTENANCE O6 LI8HTIN8 S5STEM2
A#.usting Hea# %ight2
5t is necessar$ to focus the bulb before aiming.
Adjustment of the bulb can be made b$ mo#ing the bulb back and forth with respect to reflector.
Aim the head lights such that it points correctl$ both hori3ontall$ as well as #erticall$.
Hea# %ight Ai/ing2
There are two ai/ing #e$ices in use2
1. )creen.
2. 6rism and reflector.
1* Screen test2
A screen on which the head light pattern can be studied with the #ehicle located 2* feet infront of
the screen.
+raw lines A8B8C. +istance AB should be centre distance of headlights and distance C should
be headlight centre height from the ground. 4ow switch on the light. 2he majorit$ of light should
fall on the lower portion of screen and if the light ra$s are not focussed properl$8 then it has to be
adjusted.
;*+ris/ an# re(%ectors2
2his does not re=uire so much room. 2his method consists of series of prisms and reflectors that
show an accurate miniature pattern of the head light beam and miniature screen.
Adjusting screw and mounting bracket nuts must be turned or loosened to permit swinging of light
up or down or from one side to others.
(/(C2R5C 0:R4 C5RC;52?
0:R4 6:))5B/( CA;)() A4+ R(!(+5()?
6roducing weak signal?
1 Check whether the #oltage is less than *.2*C %11 #olts mormall$& and test fro batter$.
1 ;se jumper lead to check rela$ as the cause for drop.
4o sound?
1 Check for open circuit.
1 Remo#e shell and inspect contact points.
1 Worn out parts.
1 :therwise winding ma$ be open8 so replace it.
8AU8ES2
EN8INE TEM+ERATURE 8AU8E2
2he engine temperature gauge is mounted on the intake manifold or at c$linder head.
2his t$pe of fuel gauge checks the temperature of engine cooling s$stem. 5t cautions the
dri#er b$ indicating engine is o#er heated and this ma$ lead to damage of engine parts8
especiall$ piston.
5n this figure8 the operating current is supplied from batter$ through the ignition switch to
both dash unit as well as engine unit.
2hroughout the operation of the gauge8 the current flowing through the left coil is constant
whereas the current flowing through the right coil changes depending on the water
temperature.
When the water is cold8 the batter$ current flows to the earth through the left coil. 2his
causes armature with pointer to mo#e to left and indicating that it is cold.
When is gets heated up8 the resistance decreases and more amount of current flows to
the right coil. 2his results in stronger magnetic field in the right coil. 0ence the armature
with the pointer indicates that it is hotter.
Testing2
Chec the wire connection (ro/ ignition switch to the gauge (or (au%ts* During starting &%ue 3
%ight g%ows in#icating co%# con#ition*
At 1;>P6 Again &%ue %ight g%ows in#icating co%# con#ition*
At ;=>P6 Re# %ight g%ows in#icating hot con#ition*
I( the &u%& #oes not %ight2
1 +isconnect and check for bulb.
1 Grounding of switching is checked.
1 5f necessar$ replace temperature switch.
6UEL 8AU8E2
2his mainl$ consists of 2 units8 dash unit and tank unit. 2hese both are connected in series with
suitable wire.
When the ignition switch is switched on8 the current flows from batter$ to both units.
2he tank consists of a float connected to the one end of hinged arm and other end is connected to
sliding content.
2he sliding contact mo#es along resistance. 2he float mo#es up or down according to the fuel
le#el in the tank.
When the fuel le#el in the tank is empt$ then8 the sliding contact mo#es to the left and thus more
current flows to the left coil in the dash unit and onl$ little pass through the right hand coil. 2he
armature along with pointer mo#es to the left indicating the fuel le#el in the tank.
)imilarl$ when the fuel le#el in the tank is high8 then the float mo#es up and the sliding contact
mo#es to the right and thus more current flows to the right coil in the dash unit than the left coil.
4ow the right coil is magneticall$ stronger than the left coil. 2he armature with the pointer mo#es
to the right indicating fuel le#el is high.
Testing 2
1 5f the gauges are inaccurate8 then calibrate it.
1 5f the #oltage reading is stead$8 then change the regulator.
1 5f the resistance is around 9 to 12 ohms8 float will be in upward position.
1 5f the resistance is around .B to 9B ohms8 float will be in downward position.
ELECTRIC 6UEL +UM+2
TROU4LE SHOOTIN82
1. 54);""5C5(42 ";(/ +(/5C(R>?
Causes2
Clogged filter screen in the pump.
Restriction in fuel line.
5ncorrect float le#er8 malfunctioning of inlet needle in carburetter.
Capour trapped in fuel.
Air leak on inlet side of fuel pump.
Re/e#ies2
Clean or replace filter.
Repair fuel line or remo#e restriction.
Check the #apour lock.
2ighten and clean all connection of the pump.
Clean gas cap or tank #ent.
;* +UM+ NOT O+ERATIN82
Causes2
+amaged wiring.
/oss of ground.
Re/e#ies2
5nspect mountings and all the wirings.
Clean frame on which pump is mounted.
Replace fuse.
<*CAR4URETTOR 6LOODIN82
Causes2
Worn needle and seat assembl$ in carburettor.
2oo much pressure due to wrong model fuel pump.
Air leak on inlet side of fuel pump.
5ncreased pressure due to fuel pump.
Re/e#ies2
Replace the worn needle.
Reduce the pressure.