LAB MANUAL TWO & THREE WHEELER SERVICE LAB SUBJECT

DEPARTMENT OF AUTOMOBILE ENGINEERING

LAB MANUAL

SUBJECT:

CODE:

SEMESTER:

REVISION:

TWO & THREE WHEELER SERVICE LAB

&MINI PROJECT

4059

4 TH

2015

Department Vision

To provide highly competent, efficient manpower to meet the ever-changing needs of the global automotive industry and the society.

Department Mission

To impart quality education and training to the students. To prepare students for creative thinking and innovativeness. To fulfill Industrial requirements globally by Imparting Innovative Knowledge, Ethical

values and Collaborative works.

Program Educational Objectives (PEO’s)

PEO 1:-Students will apply knowledge of automotive engineering & practices to pursue successful career in the field of automotive technology.

PEO 2:-Students will contribute to the academics and research for socio-technological development.

PEO 3:-Students will demonstrate lifelong learning skills by engaging in professional activities and up-gradation of knowledge quotient.

Program Specific Outcomes

PSO1:-Diagnose the automotive system failures and repair / replace the components / systems so as to bring the vehicle in original condition.

PSO2:-Perform the role of motor claim approver and loss assessor with confidence and competence.

PSO3:-Use relevant machinery, materials, equipment and processes to manufacture automobile components.

REVISION-2015 TWO & TREE WHEELER SERVICE AND MINI PROJECT (4059)

1 MA’DIN POLYTECHNIC COLLEGE, MALAPPURAM

SL NO LIST OF EXPERIMENT

1 ADJUSTING OF BRAKE PEDAL FREE PLAY IN TWO WHEELER

2 ADJUSTING OF CLUTCH PEDAL FREE PLAY IN TWO WHEELAR

3 ADJUSTMENT or CENTERING OF TWO WHEELER STEERING

4

STUDY OF THREE WHEELER CHASSIS FRAME AND POWER

TRANSMISSION SYSTEM.

5 DISMANTLING AND ASSEMBLING OF THREE WHEELER GEAR BOX

6 DISMANTLING AND ASSEMBLING OF THREE WHEELER ENGINE

7 DISMANTLING AND ASSEMBLING OF CHAIN

MA'DIN POLYTECHNIC COLLEGE



EXP NO:

DATE:

ADJUSTING OF BRAKE PEDAL FREE PLAY IN TWO WHEELER

AIM:To adjust the free play of brake pedal

OBJECTIVES:Checking and adjustment of brake

TOOLS AND MATERIAL REQUIRED:Double end spanner set,Cotton waste,Grease,Oil ….

PROCEDURE:

*Park the vehicle in centre stand

*Check the brake pedal play

*If it is exceed as per company recommended (25-30mm)

*Then tighten the adjusting nut present at the end of brake linkage

*Check the brake pedal play using steel rule

*Set it as per specified

*Lubricate the brake linkages with oil and grease

*Run the vehicle and check the performance

RESULT

Then checked and adjusted the brake pedal free play of two wheeler




EXP NO:

DATE:

ADJUSTING OF CLUTCH PEDAL FREE PLAY IN TWO WHEELAR

AIM:To adjust the free play of clutch pedal

OBJECTIVES:Checking and adjustment ofclutch

TOOLS AND MATERIAL REQUIRED:Double end spanner set,Cotton waste,Grease,Oil ….

PROCEDURE:

PARK THE VEHICLE IN CENTRE STAND

CHECK THE CLUTCH LIVER FREE PLAY

LOOSEN THE LOCK NUT IN CLUTCH LIVER END SIDE.

TURN THE ADJUSTING NUT TO OBTAIN THE SPECIFIED FREE PLAY(10-20MM).

TIGHTEN THE LOCK NUT AND CHECK THE ADJUSTMENT

START THE ENGINE, PRESS THE CLUTCH LEVER AND SHIFT INTO GEAR.

MAKE SURE THE ENGINE DOES NOT STALL AND THE MOTORCYCLE DOES NOT CREEP.

GRADUALLY RELEASE THE CLUTCH LEVER AND OPEN THE THROTTLE.

THE MOTORCYCLE SHOULD START SMOOTHLY AND ACCELERATE.

RESULT

Then checked and adjusted the clutch lever free play of two wheeler




EXP NO:

DATE:

ADJUSTMENT or CENTERING OF TWO WHEELER STEERING

AIM:To adjust and center the two wheeler steering

TOOLS AND MATERIAL REQUIRED:Spanner set , grease, oil….

PROCEDURE:

Check that the control cables do not interfere with the handlebar rotation.

Check for smooth action & maneuverability.

Park the motorcycle on its main stand and raise the front wheel off the ground.

check that the handlebar rotates freely from side to side.

If the handlebar moves unevenly, binds, or has play, inspect and adjust the steering head

bearings.

Check for worn steering stem bearings by grabbing the front fork leg and attempting to

move the front for side to side.

Adjust/replace the bearings if any play is observed.

RESULT

Studied and adjusted the steering of two wheeler.







STUDY NO:

DATE:

STUDY OF THREE WHEELER CHASSIS FRAME AND

POWER TRANSMISSION SYSTEM.

AIM :

To study the various features and measure the various dimension of the chassis frame of

three wheeler and power transmission system.

TOOLS REQUIRED :

Measuring tape.

PROCEDURE :

Using the measuring tape, note that

Wheelbase: It is the distance between the centre points of front wheel to the centre point of rear

wheel.

Wheel track: It is the distance between the centre points of two rear wheels.

Over all length: It is the through out distance between front side to the vehicle.

Over all width: It is the distance taken from top portion of the vehicle to the ground level.

Ground clearance: It is the distance taken between nearest part or portion towards ground level.

(ex: differential)

POWER TRANSMISSION SYSTEM :

The system by which the power from engine is transmitted to the wheels is called

transmission system. Transmission system carries engine power to the rear wheel. Power at the rear

wheels move the vehicle forward overcoming external forces. Clutch is located between the engine

and gearbox. Clutch transmits engine power to the gearbox. In Three-wheeler, multiple clutches is

used. When the clutch is in the disengaged position, the power transfer is interrupted. Such power

interruption will enable shifting of gears smoothly with out damaging gear teeth. Gearbox provides

different torque at the rear wheel according to the requirements by engaging different gear

combination.

PROPELLER SHAFT DRIVE :

This system is mostly used in three-wheeler. Like four wheelers, the propeller shaft in this

system also consists of a sliding joint at one end and universal joints at both the ends.




RESULT :

Thus the various features of the chassis are studied & its dimensions have been measured and

the power transmission system also studied.

THREE WHEELER CHASSIS FRAME

TRANSMISSION SYSTEM



8 THREE WHEELER CHASSIS FRAME MA’DIN POLYTECHNIC COLLEGE, MALAPPURAM

EXP:

DATE:

DISMANTLING AND ASSEMBLING OF THREE WHEELER GEAR BOX

AIM:

DISMANTLING AND ASSEMBLING OF THREE WHEELER GEAR BOX AND FIND THE

GEAR RATIO

TOOLS REQUIRED AND MATERIALS REQUIRED:

Tool set ,Spanner set,box spanner set, srew driver,cotton waste,kerosine….

OBSERVATION AND FUNCTIONS

Gear box is the integral part of drive line whose function as follows as,

1. To provide different torqueat different driving speed.

2. To provide necessary Torque, which starting the vehicle from rest.

3. TO PROVIDE REVERSE GEAR

4. TO PROVIDE A NUETRAL POSITION

PROCEDURE

DISMANTLING

1. PARK THE VEHICLE IN THE LEVEL GROUND

2. BATTERY CONNECTION FROM STARTING MOTOR

3. DRAIN THE GEAR OIL

4. DISMOUNTED REAR FOUNDATION BRACKET

5. DISMANTLE THE CABLE CONNECTION FROM RELEASE FORK

6. UNSCREWED ALL NUTS AND BOLTS FROM ENGINE

7. PLACE THE GEAR BOX ON THE WORK TABLE

8. DISMANTLE THE GEAR BOX AND SEPARATE ALL SHAFTS FROM HOUSING

INSPECTION

1. CLEAN AND CHECK ALL COMPONENTS

2. REFIT OR REPLACE WORNOUT PARTS FROM THE GEAR BOX

ASSEMBLING

1. REFIT ALL SHAFTS WITH GEAR INTO THE HOUSING

2. TIGHTEN THE ALL NUTS AND BOLTS




3. FITTED THRUST BEARING WITH CLUTCH FORK

4. FILLED GEAR OIL (SAE 90) UPTO MAXIMUM MARK AND CHECK THE LEVEL USING

DIP STICK

5. CONNECT THE GEAR BOX WITH ENGINE

6. MOUNTED STARTER MOTOR

7. PROPERLY TIGHT GEAR BOX FOUNTATION

8. RUN THE ENGINE AND CHECK THE PERFORMANCE

RESULT DISMANTLED AND ASSEMBLED THE THREE WHEELER GEAR BOX

GEAR RATIO:PRODUCT OF NUMBER OF DRIVEN GEAR TEETH

PRODUCT OF NUMBER OF DRIVING GEAR TEETH




EXP:

DATE:

DISMANTLING AND ASSEMBLING OF THREE WHEELER

ENGINE

AIM:DISMANTLING AND ASSEMBLING OF THREE WHEELER ENGINE

TOOLS REQUIRED AND MATERIALS REQUIRED:

Tool set ,Spanner set,box spanner set, srew driver,cotton waste,kerosine….

PROCEDURE

PROCEDURE

1. PARK THE VEHICLE LEVEL GROUND

2. BATTERY CONNECTION FROM BATTERY

3. DRAIN THE GEAR OIL AND ENGINE OIL

4. DISMANTLE THE CABLE CONNECTION FROM RELEASE FORK

5. DISMOUNTED FOUNDATION BRACKET FROM ENGINE

6. UNSCREWED ALL NUTS AND BOLTS FROM ENGINE AND GEAR BOX

7. PLACE THE ENGINE ON THE WORK TABLE

8. DISMANTLE THE ENGINE AND SEPARATE ALL PARTS

INSPECTION

1. CLEAN AND CHECK ALL COMPONENTS

2. REFIT OR REPLACE WORNOUT PARTS FROM THE ENGINE

ASSEMBLING

1. REFIT ALL PARTS PROPERLY INTO TNE ENGINE

2. TIGHTEN THE ALL NUTS AND BOLTS OF GEAR BOX AND ENGINE

3. FITTED THRUST BEARING WITH CLUTCH FORK

4. FILLED GEAR OIL (SAE 90),AND ENGINE OIL (SAE 20 ) UPTO MAXIMUM MARK AND

CHECK THE LEVEL USING DIP STICK

5. MOUNTED STARTER MOTOR ON THE ENGINE

6. PROPERLY TIGHT GEAR BOX AND ENGINE FOUNTATIONS

7. RUN THE ENGINE AND CHECK THE PERFORMANCE

RESULT DISMANTLED AND ASSEMBLED THE THREE WHEELER ENGINE







EXP NO:

DATE:

DISMANTLING AND ASSEMBLING OF CHAIN

AIM: DISMANTLING AND ASSEMBLING OF CHAIN

TOOLS REQUIRED AND MATERIAL REQUIRED:

SPANNER SET, SCREW DRIVER , COMBINATION PLIER, COTTON WASTE, KEROSENE, ….

PROCEDURE:

1. PARK THE VEHICLE ON A LEVEL GROUND

2. KEEP THE VEHICLE ON CENTRE STAND

3. REMOVE THE SOCKET SIDE COVER AND CHAIN COVER

4. ROTATE THE TYRE WITH NEUTRAL POSITION AND FIND THE LOCK PIN AND

UNLOCK IT

5. REMOVE CHAIN AND CLEAN WITH KEROSENE

6. REFIT THE CHAIN FROM SOCKET SIDE AND LOCK THE LOCK PIN IN TYRE SIDE

7. ADJUST THE CHAIN TENSION WITH ADJUSTING NUT

8. START THE ENGINE AND RUN TO CHECK THE PERFORMANCE

RESULT

DISMANTLED AND ASSEMBLED THE CHAIN FROM GIVEN VEHICLE




2.LOCK PIN


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LAB MANUAL TWO & THREE WHEELER SERVICE LAB SUBJECT