AUTOMOTIVE

LEVEL-1
Students Handbook

CLASS IX

CENTRAL BOARD OF SECONDARY EDUCATION

Shiksha Kendra, 2, Community Centre, Preet Vihar, Delhi-110301
AUTOMOTIVE
LEVEL-1
Students Handbook

CLASS IX

CENTRAL BOARD OF SECONDARY EDUCATION

Shiksha Kendra, 2, Community Centre, Preet Vihar, Delhi-110301
Automotive Level-1

Students Handbook, Class IX

Price: `

First Edition 2014, CBSE, India

Copies:

Paper Used: 80 gsm CBSE Water Mark White Maplitho

"This book or part thereof may not be reproduced by

any person or agency in any manner."

Published By : The Secretary, Central Board of Secondary Education,

Shiksha Kendra, 2, Community Centre, Preet Vihar, Delhi-110301

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 THE CONSTITUTION OF INDIA
PREAMBLE
WE, THE PEOPLE OF INDIA, having solemnly resolved to constitute India into a 1SOVEREIGN
SOCIALIST SECULAR DEMOCRATIC REPUBLIC and to secure to all its citizens :
JUSTICE, social, economic and political;
LIBERTY of thought, expression, belief, faith and worship;
EQUALITY of status and of opportunity; and to promote among them all
FRATERNITY assuring the dignity of the individual and the2 unity and integrity of the Nation;
IN OUR CONSTITUENT ASSEMBLY this twenty-sixth day of November, 1949, do HEREBY ADOPT,
ENACT AND GIVE TO OURSELVES THIS CONSTITUTION.

1. Subs, by the Constitution (Forty-Second Amendment) Act. 1976, sec. 2, for "Sovereign Democratic Republic” (w.e.f. 3.1.1977)
2. Subs, by the Constitution (Forty-Second Amendment) Act. 1976, sec. 2, for "unity of the Nation” (w.e.f. 3.1.1977)

THE CONSTITUTION OF INDIA

Chapter IV A
FUNDAMENTAL DUTIES
ARTICLE 51A
Fundamental Duties - It shall be the duty of every citizen of India-
(a) to abide by the Constitution and respect its ideals and institutions, the National Flag and the National
Anthem;
(b) to cherish and follow the noble ideals which inspired our national struggle for freedom;
(c) to uphold and protect the sovereignty, unity and integrity of India;
(d) to defend the country and render national service when called upon to do so;
(e) to promote harmony and the spirit of common brotherhood amongst all the people of India transcending
religious, linguistic and regional or sectional diversities; to renounce practices derogatory to the dignity of
women;
(f) to value and preserve the rich heritage of our composite culture;
(g) to protect and improve the natural environment including forests, lakes, rivers, wild life and to have
compassion for living creatures;
(h) to develop the scientific temper, humanism and the spirit of inquiry and reform;
(i) to safeguard public property and to abjure violence;
(j) to strive towards excellence in all spheres of individual and collective activity so that the nation constantly
rises to higher levels of endeavour and achievement;
1
(k) to provide opportunities for education to his/her child or, as the case may be, ward between age of 6 and 14
years.

1. Subs. by the Constitution (Eighty - Sixth Amendment) Act, 2002

Preface
 Acknowledgements
Advisors
1. Dr. Satbir Bedi, IAS, Chairperson, CBSE
2. Prof. R.B. Shivgunde, Joint Director, PSSCIVE, Bhopal
3. Sh. M.V.V. Prasada Rao, Director (Voc & Edusat), CBSE

Content Developed By
1. PSSCIVE, Bhopal

Editing & Coordination

1. Dr. Biswajit Saha, Additional Director (Voc), CBSE
 Contents
Unit-1: History and Evolution of Automobiles 1
2
Session - 1 : Invention of Wheel 1
2
Session - 2 : Wheel Cart 6
2
Session - 3 : Invention of Automobiles 8
2
Session - 4 : Invention of Automobiles (Post World War II) 13
2
Suggested Reading 17

Unit 2: Various Types of Automobiles 19

2
Session - 1 : Two Wheelers and Three Wheelers 19
2
Session - 2 : Passenger Vehicles and Commercial Vehicles 24
2
Session - 3 : Agricultural Vehicles 28
2
Session - 4 : Construction Equipment Vehicles 32
2
Session - 5 : Special Vehicles 35
2
Suggested Reading 39

Unit 3: Major Systems & Components of an Automobile 40

2
Session - 1 : Chassis Frame and Auto Body 40
2
Session - 2 : Engine and its Components 46
2
Session - 3 : Lubrication System 58
2
Session - 4 : Cooling System 61
2
Session - 5 : Fuel Supply System 63
2
Session - 6 : Transmission System 65
2
Session - 7 : Front and Rear Axle 69
2
Session - 8 : Steering System 72
2
Session - 9 : Suspension System 74
2
Session - 10 : Wheel and Tyre 76
2
Session - 11 : Brake 78
2
Session - 12 : Electrical and Electronic System 81
2
Session - 13 : Air Conditioning System 83
2
Session - 14 : Active & Passive Safety 84
2
Suggested Reading 86
Unit 4: Road Safety 86
2
Session - 1 : Importance of Road Safety 87
2
Session - 2 : Safe and Responsible Driving 90
2
Session - 3 : Road Signs 94
2
Session - 4 : Driving Rules and Registration 108
2
Session - 5 : Driving License 111
2
Suggested Reading 113

Unit 5: Automobile and Environment 115

2
Session - 1 : Air Pollution 115
2
Session - 2 : Auto Emissions and EU/ BS Standards 118
2
Session - 3 : PUC Certification 122
2
Suggested Reading 125

126
 History and Evolution
Unit-1 of Automobiles
Introduction
You must have heard the word Automobile. Meaning of an automobile can be auto car, motor car or
car. It is a wheeled motor vehicle used for transporting goods or passengers, which also carries its
own engine or motor. The word automobile comes from the Ancient Greek word (autos, "self") and
the Latin mobilis ("movable"); therefore
automobile means a vehicle that moves
itself. The alternative name car is believed
to originate from the Latin word carrus or
carrum ("wheeled vehicle"), or the Middle
English word carre ("cart") (from Old North
French). These words in turn are said to
have originated from the Gaulish word
karros (a Gallic Chariot).
Most definitions of the term specify that
Automobiles are designed to run primarily
on roads, to have seating for one to eight
people, to typically have four wheels, and to
be constructed principally for the transport Fig.: NANO from India
of people and goods.
In this Unit, you will develop an understanding of the concept of wheel and role of wheel cart. You will
also learn various stages of development over several hundred years that made possible the
invention of an Automobile as we know it today. You will understand how various automobiles were
developed in past.

SESSION-1: INVENTION OF WHEEL

Relevant Knowledge
The Wheel is considered as one of the most important mechanical inventions of all time. The wheel
has been used by man since the beginning of civilization. Most primitive technologies since the
invention of the wheel have been based on its principles.
The invention of the Wheel was perhaps in the late Neolithic age. It is likely that it happened along
with other technological advances that gave rise to the early Bronze Age.
4500 BC : Invention of the potter's wheel, Chalcolithic (Ubaid period)
4500–3300 BC : Chalcolithic, earliest wheeled vehicles, domestication of the horse
3300–2200 BC : Early Bronze Age
2200–1550 BC : Middle Bronze Age, invention of the spoked wheel and the Chariot.

1
Invention of Wheel
Since the industrial revolution, the Wheel has been a basic element of nearly every machine
constructed by mankind. While the exact time and place of the invention of the wheel has been
disputed but its beginnings can be seen across ancient
civilizations.
History tells us that wheel was most likely invented in
Mesopotamia (modern day Iraq) around 3500 BC. This means
that the Wheel is about 5,500 years old !
The first use of the wheel for transportation was in
Mesopotamian chariots in 3200 BC. There are many references
to wheeled chariots in Indian mythology also dating to around
3,000 BC. It is interesting to note that wheels may have been
used in industrial or manufacturing applications before they
were used on vehicles.
Fig : Wheel
Egyptians started using wheel with spokes, first in chariots
around 2000 BC and use of wheels seems to have started in Europe by 1400 BC.

Wheel and Its Structure

It’s hard to imagine any
roller sledge sledge on roller
mechanized system that
would be possible
without the wheel or the
idea of a symmetrical
component moving in a sledge on roller which wheel and axle in one wheel joined to axle;
circular motion on an has become grooved piece; the axle fixed by fixed into crude
with use pegs bearing
axis. From tiny watch
gears to automobiles, jet
engines and computer
disk drives, the principle
is the same.
Early wheels were simple Fig : Use of Wheel
wooden disks with a hole
for the axle. Because of the structure of wood, a horizontal slice of a tree trunk is not suitable, as it
does not have the structural strength to support weight without collapsing, rounded pieces of
longitudinal boards are required.
The oldest known example of a wooden wheel and its axle were found in 2003 in the Ljubljana
Marshes some 20 km south of Ljubljana, the capital of Slovenia. According to the radiocarbon
dating, it is between 5,100 and 5,350 years old. It has a diameter of 72 centimetres (28”) and has
been made of ash wood, whereas its axle has been made of oak.
The spoked wheel was invented more recently, and allowed the construction of lighter and swifter

2
vehicles. In the Harappan civilization of the Indus Valley and North Western India, we find toy-cart
wheels made of clay with spokes painted or in relief, and the symbol of the spoked wheel in the
script of the seals, already in the second half of the 3rd millennium BC.
The earliest known examples of wooden spoked wheels are in the context of the Andronovo culture,
dating to ca 2000 BC. Soon after this, horse cultures of the Caucasus region used horse-drawn
spoked -wheel war chariots for the greater part of three centuries. They moved deep into the Greek
Peninsula where they joined with the existing Mediterranean peoples to give rise, eventually, to
classical Greece after the breaking of Minoan dominance and consolidations led by pre-classical
Sparta and Athens. Celtic Chariots introduced an iron rim around the wheel in the 1st millennium
BC. The spoked wheel was in continued use without major modification until the 1870s, when wire
wheels and pneumatic tires were invented.
The invention of the wheel has also been important for technology in general, important
applications including the water wheel, the cogwheel (see also antikythera mechanism), the
spinning wheel and the astrolabe or torquetum. More modern descendants of the wheel include the
propeller, the jet engine, the flywheel (gyroscope) and the turbine.
Therefore we see that a wheel is a circular component that can
rotate on its centre. Wheels, in conjunction with axles, allow
heavy objects to be moved easily while supporting a load. The
wheel is the main component of the wheel and axle assembly.
Wheel and axle were used in the first carriages. We shall learn
about these later.
A wheel greatly reduces friction by facilitating motion by rolling
together with the use of axles. In order for wheels to rotate, a
moment needs to be applied to the wheel about its axis, either by
way of gravity, or by application of another external force.
The wheel is a device that enables efficient movement of an Fig : Wheel
object across a surface where there is a force pressing the object
to the surface. Common examples are a cart pulled by a horse
and the rollers on an aircraft flap mechanism.
The low resistance to motion (compared to dragging) is
explained as follows:
2 the normal force at the sliding interface is the same.
2 the sliding distance is reduced for a given distance of travel.
2 the coefficient of friction at the interface is usually lower.
The classic spoked wheel with hub and iron rim was in use from
about 500 BC (Iron Age Europe) until the 20th century AD. We
can see the importance of wheel in various places and its role. Our national flag also contain a circle
like wheel. Wheel is very important in our daily life. Some of important drawings of wheel are given
herewith.

3
 Fig : Photograph of Wheel and its type

Exercise: Assignment
1. List the items where wheel has been used in machinery:

S.No. Items No. of Wheels

1
2
3
4
5
6
7
8
9
10

4
2. Observe and identify two types of wheels in your school and draw their diagrams:

3. Fill in the blanks:

1. _________________, is considered as one of the most important mechanical inventions
of all time.
2. Wheel was invented in __________________ around 3500 BC which is __________
years back.
3. A wheel is a _________ component that can rotate on its centre.
4. Wheel is a ____________ that enables efficient movement of an___________ across a
surface where there is a force pressing the object to the surface.
5. The coefficient of friction at the interface of wheel is usually ________.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Differentiate between different types of wheel.
Part B
Discuss in class the following:
2
What is wheel?
2
Components of a wheel.
2
Materials of wheel.
2
Design of the wheel.
Performance standards/criteria covered by this assessment
Performance Standards Yes No
Able to draw a wheel and label its parts
Able to identify wheel

5
 SESSION-2: WHEEL CART
Relevant Knowledge
Wheel cart is a vehicle designed for transport, using two wheels.
A handcart is pulled or pushed by one or more people. However,
from history we learn that animals instead of men were used for
pulling the cart. Animals can provide more power. Normally a cart
was pulled by a pair of draught animals. The draught animals
used for carts may be horses or ponies, mules, oxen, water
buffalo or donkeys, or even smaller animals such as goats or
large dogs.
Fig.: Use of Wheel Cart
Carts have been mentioned in literature as far back as the second
millennium B.C. All of you have heard about the Indian sacred book Mahabharat which depicts Lord
Krishna as the sarathi the Charioteer of the Rath, the Chariot carrying Pandav prince Arjuna, in the
battle field of Kurukshetra. In the Mahabharata war all the leaders used a ‘rath’ for fighting in the war.

Types of Carts
Larger carts may be drawn by animals, such as horses, mules, or oxen. They have been in
continuous use since the invention of the wheel, in the 5th millennium BC. Carts may be named for
the animal that pulls them, such as horse cart or oxcart. In modern times, horse carts are used in
competitions. A dogcart, however, is usually a cart designed to carry hunting dogs: an open cart with
two cross-seats back to back, the dogs could be penned between the rear-facing seat and the back
end.

Fig.: Different types of cart

A bullock cart or ox cart is a two-wheeled vehicle pulled by oxen (draught cattle). It is a means of
transportation used since ancient times in many parts of the world. They are still used today where
modern vehicles are too expensive or the infrastructure does not favour them.
Carts are used especially for carrying goods. Bullock cart is pulled by one or two bullocks. The cart
is attached to a bullock team by a special chain attached to yokes, but a rope may also be used for
one or two animals. The driver and any other passengers sit on the front of the cart, while the load is
placed at the back.

Horse Power
How many men would be needed to equal the power of a Horse?

6
Experiments were conducted to get answer to this interesting question. It was found that, on an
average 10 -12 men were needed to equal the power of one Horse. This is the reason why mankind
thought of using Horses for pulling the cart. This led to the development of a Horse Carriage.

Exercise: Assignment
1. List the different types of carts you have seen in your area:
S.No. Items No. of Wheels
1
2
3
4
5
6
7
8
9
10

2. Fill in the blanks:

a) Cart are driven by_____________.
b) In Mahabharata, chariot was pulled by________________.
c) A bullock cart or ox cart is a __________ pulled by oxen (draught cattle).
d) An average ________ men were needed to equal the power of one horse.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Differentiate between different types of Carts.
Part B
Discuss in class the following:
2
What is a Cart?
2
Different types of Carts.
2
Materials of Cart.
2
Importance of Horsepower.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to draw figure of a wheel cart and label its parts

7
 SESSION-3: INVENTION OF AUTOMOBILES
Relevant Knowledge
Till now we have learnt how wheel was used in carts and
horse powered carriages for transportation of goods and
people. Engineers kept on improving the Horse Carriage
design bit by bit. Parallely, man was working on a system that
could be self propelled, meaning that the system could be run
without any man or animal force required for moving it.
In the year 1672 the very first such model was developed in
the form of a toy. This was actually a steam engine. In this the Fig.: Cugnot Steam trolley
power of steam was used to provide momentum to the toy. (Jonathan Holguinisburg)

Further improvements continued in various parts of the world. Then in the year 1806, the first cars
powered by an internal combustion engine appeared. The fuel used for running this was ‘fuel gas’
instead of ‘steam’. Of course, the process of using Fuel Gas is different than the process required
for using Steam. Steam engine requires ‘External combustion’, whereas, fuel gas uses the principle
of ‘Internal Combustion’. We shall study this in detail later.
Meanwhile, engineers continued to improve designs till the
year 1885 when the first modern gasoline- or petrol-fueled
engine was developed in Europe. It is important to note that
inventions in science and technology can not often be used
immediately by general public. One reason is that the cost of
developing new technology is very high. Also, the first
models usually do not have any comfort features. However,
when more people demand the new models, the cost starts
to come down. More features can also be added for making it
attractive for general consumers.
Karl Benz a brilliant German engineer designed and Fig.: First practical car model
patented the first practical model in 1885. This model used
internal combustion Engine and was called Motorwagen.
Although, several other German engineers (including
Gottlieb Daimler, Wilhelm Maybach and Siegfried Marcus)
were working on the problem at about the same time, Karl
Benz generally is acknowledged as the inventor of the
modern automobile.
An automobile powered by his own four stroke cycle gasoline
engine was built in Mannheim, Germany by Karl Benz in
1885 and granted a patent in January of the following year, Fig: Photograph of the original Benz Patent
under the auspices of his major company, Benz & Cie., which Motorwagen, first built in 1885 and awarded
was founded in 1883. the patent for the concept given here)

8
It was an integral design, without the adaptation of other existing components and included several
new technological elements to create a new concept. He began to sell his production vehicles in
1888.
In 1879, Benz was granted a patent for his first engine, which had
been designed in 1878. Many of his other inventions made the use of
the internal combustion engine feasible for powering a vehicle. His
first Motorwagen was built in 1885, and he was awarded the patent
for its invention, basis his application on January 29, 1886. Benz
began promotion of the vehicle on July 3, 1886, and about 25 Benz
vehicles were sold between 1888 and 1893, when his first four-
wheeler was introduced along with a model intended for affordability.
They also were powered with four-stroke engines of his own design.
Emile Roger of France, already producing Benz engines under
license, now added the Benz automobile to his line of products.
Because France was more open to the early automobiles, initially
more were built and sold in France through Roger, than Benz sold in
Fig: Bertha Benz, the first
Germany. (Bertha Benz, the first long distance automobile driver in long distance automobile
the world in the photograph given here). driver in the world

In August 1888 Bertha Benz, wife of Karl Benz, undertook the first road trip by car, to prove the road-
worthiness of her husband's invention. During the last years of the nineteenth century, Benz was the
largest automobile company in the world with 572 units produced in 1899.
Towards the end of 19th century, many automobile companies came up in Europe and America.
They started producing different models. But
these automobiles were very expensive and very
few rich people could afford them like Kings,
Queens and Rajas in India.
An average person could only dream but could not
afford to own a car. Many attempts were being
made in Europe and America for reducing costs.
The large-scale, production-line manufacturing of
affordable automobiles was started by Ransom
Olds at his Oldsmobile factory in 1902 based on
the assembly line techniques pioneered by Marc
Isambard Brunel at the Portsmouth Block Mills,
Fig.: Car Ford Model T
England in 1802. The assembly line style of mass
production and interchangeable parts had been pioneered in the U.S. by Thomas Blanchard in
1821, at the Springfield Armory in Springfield, Massachusetts. This concept was greatly expanded
by Henry Ford, beginning in 1914. With the introduction of this new manufacturing process, FORD
Motor company launched the first large scale production of their Model T. In 1914, an assembly line
worker could buy a Model T with four months' pay of some two hundred American car makers in
existence in 1920.

9
In Europe much the same happened. Morris set up its
production line at Cowley in 1924 and soon outsold Ford,
while beginning in 1923 to follow Ford's practice of vertical
integration. They bought Hotchkiss (engines), Wrigley
(gearboxes), and Osberton (radiators), for instance, as well
as competitors, such as Wolseley: in 1925, Morris had 41%
of the total British car production. Most British small-car
assemblers, from Abbey to Xtra had failed. Citroen did the
same in France, coming to cars in 1919. Between them
Fig: 1926 Austin 7 Box
Renault's 10CV and Peugeot's 5CV, they produced
550,000 cars in 1925 and Mors, Hurtu, and others could not compete. Germany's first mass-
manufactured car, the Opel 4PS Laubfrosch (Tree Frog), came off the line at Russelsheim in 1924,
soon making Opel the top car builder in Germany, with 37.5% of the market.
Between the 1st and the 2nd World Wars a lot of attention of the Automobile industry went towards
development of defence vehicles. As a result several new vehicles like battle Tanks and Jeeps were
developed. The tank became very popular in the war field. It is a very versatile vehicle, which can
run in any road conditions i.e., in cross country terrain, hills, deserts and tranches etc.

Fig: Mark V Tank

However, during this period, there were some very

interesting designs in the passenger segment also.
Volkswagen in Germany developed a car in the 30s, which
looked like a crawling creature and was therefore called
“Beetle” This model has the engine at the back and front
bonnet was used as luggage compartment. The car was
very convenient to drive and also good looking and stylish.
It became very popular in Europe.
By 2002, over 21 million Type 1s had been produced, but by Fig: Jeweled one-millionth VW Beetle

10
2003, annual production had dropped to 30,000 from a peak of 1.3 million in 1971. Volkswagen
announced the end of production in June 2003. However, the opinion in the United States was not
very good. Perhaps because of the characteristic differences between the American and European
car markets. Henry Ford II the grandson of original Henry Ford, once described the car as “a little
box.”

Fig:1946 GAZ-M20 Pobeda one of the first mass produced car with ponton

Exercise: Assignment
1. Make a list of automobile vehicles developed in history:

S.No. Type of Vehicle Model

11
2. Collect the photograph of any vintage car seen in any magazine:

3. Fill in the blanks:

1. In the year __________ the very first such model was developed in the form of a toy.
2. In year 1806, the first cars powered by ___________________ appeared.
3. Karl Benz a brilliant ______________ designed and patented the first practical model in
1885.
4. Volkswagen in __________developed a car in the 30s which looked like a crawling
creature and was therefore called _________.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for the Assessment Activity.
Part A
2
Differentiate between various types of wheel invention.
Part B
Discuss in class the following:
2
When was the first vehicle invented?
2
Who was inventor of the first patented car?
2
Why development was made in vehicles?
2
Who was first rider of the car?
2
Name the important manufacturers of the car.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to list important invention of automobile

12
SESSION-4: INVENTION OF AUTOMOBILES (POST WORLD WAR II)
Relevant Knowledge
Till now you have gone through the development in the Automobile sector before World War II, now
we will concentrate on post World War II. Automobile Industry started on rapid modernization in the
50s and 60s. Many new models of cars were introduced like Edsel, Chevrolet etc.
In USA, road network was built after the second War. This road network was very modern with long
highways stretching across the length and breadth of the country. It is good to note that USA has a
very big land mass and vast geography. This allows open and wide roads to be built. On these roads
models like the Beetle do appear very tiny!
The Big Three of the car industry namely General Motors, Ford & Chrysler set about to design big
fast moving cars for the American roads. Edsel, Buick, Pontiac Firebird, Chevrolet Impala etc were
some of the big cars that came on American highways in the 50s and 60s.It may also be noted that
these models used large amounts of petrol or gasoline as it is called in US. But, petrol consumption
was not the main issue in those happy days. So, each car maker was competing with the other in
making bigger & bigger designs with more luxuries added for comfort. All this made owning and
maintaining a car quite costly. Still, more and more Americans were buying these models. One very
popular model from FORD was named ‘MUSTANG’.
However, things changed after 1973. This was the year of the first “Oil Crisis”. Petrol started
becoming costlier as all the Arab nations got together in an alliance. Now, suddenly even Americans
started looking for more economical designs.
Meanwhile, quietly but with determination, Japan was developing cars for marketing worldwide,
mainly in the USA. Actually, after the devastation of their country during the WW II, several
Japanese companies came into existence like Toyota, Mazda, Mitsubishi, Suzuki etc. Some of
these like Mazda, were using American Technology. But, these companies were also developing
their own Research capabilities. As a result when the 1973 oil crisis occurred, these companies
were very well positioned to roll out smaller, compact, economical models in USA.
Since then, companies like Toyota, Honda have been steadily increasing their market presence
worldwide. The modern era is normally defined as the 25 years before the current year. However,
there are some technical and design aspects that differentiate modern cars from antiques. Without
considering the future of the car, the modern era has been one of increasing standardisation,
platform sharing, and computer-aided design.
2
1966 – present Toyota Corolla – a simple small Japanese saloon/sedan that has come to be
the best-selling car of all time.
2
1970 – present Range Rover – the first take on the combination of luxury and four-wheel drive
utility, the original 'SUV'. Such was the popularity of the original Range Rover Classic, that a
new model was not brought out until 1994.
2
1973 – present Mercedes-Benz S-Class – electronic Anti-lock Braking System, supplemental
restraint airbags, seat belt pretensioners, and electronic traction control systems all made their

13
 debut on the S Class. These features would later become standard throughout the car industry.
2
1975 – present BMW 3 Series – the 3 Series has been on the Car and Driver magazine's
annual Ten Best list 17 times, making it the longest running entry in the list.
2
1977– present Honda Accord saloon/sedan – this Japanese sedan became the most popular
car in the United States in the 1990s, pushing the Ford Taurus aside, and setting the stage for
today's upscale Asian sedans.
2
1981–1989 Dodge Aries and Plymouth Reliant – the "K-cars" that saved Chrysler as a major
manufacturer. These models were some of the first successful American front-wheel drive,
fuel-efficient compact cars.
2
1983 – present Chrysler minivans – the two-box minivan design nearly pushed the station
wagon out of the market, and presaged today's crossover SUVs.
2
1984 – present Renault Espace – first mass one-volume car of noncommercial MPV class.
2
1986 – present Ford Taurus – this mid-sized front-wheel drive sedan with modern computer-
assisted design dominated the American market in the late 1980s, and created a design
revolution in North America.
2
1989 –1999 Pontiac Trans Sport – was one the first of the one box cars.
2
1997 – present Toyota Prius – launched in the Japanese market, in September 2010 reached
worldwide cumulative sales of 2.0 million units, becoming the most iconic hybrid electric
vehicle in the world.
2
1998 – present Ford Focus – one of the most popular hatchbacks across the globe, that is also
one of Ford's best selling world cars.
2
2008 – present – Tata Nano – The Tata Nano is an inexpensive( 100,000), rear-engine, four-
passenger city car built by the Indian company Tata Motors and is aimed primarily at the Indian
domestic market.
2
2010 – present, Nissan Leaf and Chevrolet Volt – an all-electric car and a plug-in hybrid
correspondingly, were launched in the U.S. and Japanese markets in December 2010,
becoming the first mass production vehicles of their kind.

Indian Automobile Scenario

We should now look at the Automobile industry in India. It started with import of cars for Royal
families. Perhaps the first cars imported in India were in 1920s.
For many years India did not
have any manufacturing
capability of its own. Hindustan
Motors is one of the original car
manufacturers in India, founded
in 1942 by Mr. B. M. Birla, it was
a leader in car sales until the
1980s, when the industry was
opened up from protection. It is Fig : Ambassador Car

14
the producer of the Ambassador car, widely used as a taxicab and as a government limousine. This
car is based on the Morris Oxford, a British car that dates back to 1954.
Another India company Premier Automobiles was founded in
1944. The company first launched production by building
vehicles under license from Dodge and Plymouth. In 1951,
they began producing versions of the Fiat 500 for the Indian
market. This was followed by the Fiat 1100 in 1954. In 1973,
the ‘Premier’ was used on their vehicles for the first time the
Premier President, based on the Fiat 1100 as Premier
Padmini. Ambassador and Fiat/Padmini were the two
dominant models of cars on the Indian roads till 1983.
In 1983, Government of India started Maruti Udyog in Fig : Fiat Car
collaboration with Suzuki of Japan. Maruti’s first model called
Maruti 800 became a big success. Within 5-6 years the
company reached an annual production level of nearly
1,00,000 cars per year. They launched various models like
800, Gypsy, Omni van, Esteem, Zen, Boleno etc.
By the end of 90s several other global multinational car
makers also started manufacturing their models in India.
Among them were, General Motors, Ford, Hyundai etc. Fig : Maruti Car

In just a few years the Indian market for cars has become a hot spot of global automotive activity.
As we see, Indian Auto industry started with import of cars in the 20s. Then the first manufacturing
started in the 40s. With continued progress many Indian companies like Maruti, Tata, Mahindra
have become very big global names. Now, they are not merely manufacturing to
European/American or Japanese designs. But, they are doing so with their own research &
development capabilities. As a result, Nano model was developed by TATA Motors. This is the
cheapest car in the world with all convenient and quality features. India is now also exporting nearly
12% of manufactured cars to Europe, USA and elsewhere in the world.
The automotive industry in India is one of the largest in the world and one of the fastest growing
globally. India's passenger car and commercial vehicle manufacturing industry is the sixth largest in
the world, with an annual production of more than 3.7 million units in 2010. According to recent
reports, India is set to overtake Brazil to become the sixth largest passenger vehicle producer in the
world, growing 16-18 per cent to sell around three million units in the course of 2011-12. In 2009,
India emerged as Asia's fourth largest exporter of passenger cars, after Japan, South Korea, and
Thailand. In 2010, India became Asia's third largest exporter of passenger cars, after Japan and
South Korea beating Thailand.
As on 2010, India is home to 40 million passenger vehicles. More than 3.7 million automotive
vehicles were produced in India in 2010 (an increase of 33.9%), making the country the second
fastest growing automobile market in the world. According to the Society of Indian Automobile
Manufacturers, annual vehicle sales are projected to increase to 5 million by 2015 and more than 9

15
million by 2020. By 2050, the country is expected to top the world in car volumes with approximately
611 million vehicles on the nation's roads.
The majority of India's car manufacturing industry is based around three clusters in the south, west
and north. The southern cluster near Chennai is the biggest with 40% of the revenue share. The
western hub near Maharashtra is 33% of the market. The northern cluster is primarily Haryana with
32%. Chennai, is also referred to as the "Detroit of India" with the India operations of Ford, Hyundai,
Renault and Nissan headquartered in the city and BMW having an assembly plant on the outskirts.
Chennai accounts for 60% of the country's automotive exports. Gurgaon and Manesar in Haryana
form the northern cluster where the country's largest car manufacturer, Maruti Suzuki, is based. The
Chakan corridor near Pune, Maharashtra is the western cluster with companies like General
Motors, Volkswagen, Skoda, Mahindra and Mahindra, Tata Motors, Mercedes Benz, Land Rover,
Fiat and Force Motors having assembly plants in the area. Aurangabad with Audi, Skoda and
Volkswagen also forms part of the western cluster. Another emerging cluster is in the state of
Gujarat with manufacturing facility of General Motors in Halol and further planned for Tata Nano at
Sanand. Ford, Maruti Suzuki and Peugeot-Citroen plants are also set to come up in Gujarat.
Kolkatta with Hindustan Motors, Noida with Honda and Bangalore with Toyota are some of the other
automotive manufacturing regions around the country.
Exercise: Assignment
1. List the models of car running in your area:
S.No. Name of Model
1
2
3
4
5
6
7
8
9
10

2. Observe a car and draw its diagram:

16
3. Fill in the blanks:
a) One very popular model from FORD was named ___________.
b) Big Three of car industry namely General Motors, Ford & Chrysler set about to design big
fast moving cars for the __________ roads.
c) First cars imported in India were in ___________.
d) Ambassador and Fiat/ Padmini were the two dominant models of ________ on the Indian
roads till 1983.
e) In 1983, Government of India started Maruti Udyog in collaboration with ____________ of
Japan.
f) First Cheapest Indian car name is __________.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Discuss the automotive industry of India.
Part B
Discuss in class the following:
2
When were cars imported in India?
2
Manufacturers of Indian Car.
2
Development of Automobiles in India.
2
Cluster of auto in India.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to make a list of Indian automobile manufactures.

Suggested Reading
Books
Title Author Publisher
Automobile Engineering Vol I Kirpal Singh Standard Publishers
Automobile Engineering, Vol II Kirpal Singh Standard Publishers
Text Book of Automobile Engineering R. K. Rajput Laxmi Publications
Automobile Engineering R. K. Singal S. K. Kataria and Sons
Automobile Engineering Theory Kapil Dev Computech Publications
Automobile Engineering K. M. Moeed S. K. Kataria and Sons

17
Websites
2
auto.indiamart.com/auto-technology
2
www.automobileindia.com/consumer-guide/automobile-technology
2
auto.indiamart.com/auto-technology
2
books.google.com/books/about/Automobile_Engineering.html
2
www.bikeadvice.org
2
www.wikipedia.com
2
www.tatamotor.com

List of Contributors
1. Mr. Sunil K. Chaturvedi, CEO, Automotive Skills Development Council, Core 4-B 5th Floor India Habitat
Centre, Lodhi Road, New Delhi – 110 003.
2. Mr. A.C. Deb, Sr. Lecturer, (Auto) – HOD, Pusa Polytechnic Pusa, New Delhi -110012.
3. Mr. Vikas Gautam, S.B.V. NO.1, Morigate, Delhi – 110006.
4. Prof. A.P. Verma, Ex. HOD, PSSCIVE, Bhopal.
5. Sh. Deepak Shudhalwar, Assistant Professor, E & T Division, PSSCIVE, Bhopal.
6. Dr. Saurabh Prakash, Associate Professor, E & T Division, PSSCIVE, Bhopal – Programme
Coordinator.

18
 Various Types of
Unit-2 Automobiles

Introduction
The Automotive industry in India is one of the largest in the world and one of the fastest growing
globally. India's Passenger Car and Commercial Vehicle manufacturing industry is the seventh
largest in the world, with an annual production of more than million units in 2011.
The Automobile segment comprises of the following four broad categories of vehicles:
2
Two-Wheelers and Three-Wheelers
2
Passenger Vehicles
2
Commercial Vehicles
2
Special Application Vehicles
Two-Wheelers, being the most popular means of personal transport, account for about 75% of the
total automobile production in India, while Passenger Vehicles account for nearly 16% of the
production. However, owing to their lower price. Two wheelers account for only around 32% of the
sales in terms of value, while Passenger Vehicles account for around 62% of sales.
As of 2010, India is home to 40 million Passenger Vehicles. More than 3.7 million Automotive
Vehicles were produced in India in 2010 (an increase of 33.9%), making the country the second
fastest growing automobile market in the world. According to the Society of Indian Automobile
Manufacturers, annual vehicle sales are projected to increase to 5 million by 2015 and to more than
9 million by 2020. By 2050, the country is expected to be at the top the world in car volumes with
more than 600 million vehicles on the nation's roads.
In this Unit, you will develop an understanding of the different types of vehicles used in our country
viz., Two Wheeler, Three Wheeler, Passenger Vehicles, Commercial Vehicles, Agricultural
Vehicles, Construction Equipment Vehicles and Special Application Vehicles.

SESSION-1: TWO WHEELERS AND THREE WHEELERS

Relevant Knowledge
Two Wheelers
As the name suggests, a two wheeler refers to vehicles, that run on two wheels. Two wheelers are
used all over the world. In developed, rich countries, two wheelers are used more for recreational
purpose. Whereas in our country it is an important means of transportation of passengers, both in
urban as well as rural areas. India has the largest population of two wheelers. More than 5.4 million
two wheelers are produced in our country every year. Motorcycles, Scooters and Mopeds are the
categories of two wheelers in our country. Motorcycle segment is about 78% in two wheeler
segment. Balance 22%, comprise of the scooters and mopeds.

19
India is the second largest producer of two-wheelers in the world. In the last few years, the Indian
two-wheeler industry has seen spectacular growth. The country stands next to China and Japan in
terms of production and sales respectively.
Majority of Indians, especially the youngsters, prefer motorbikes rather than cars. Capturing a large
share in the two-wheeler industry, bikes and scooters cover a major segment. Bikes are considered
to be the favourite among the youth as they help in easy commutation and also look stylish. Large
variety of two wheelers are available in the market, known for their latest technology and enhanced
mileage. Indian bikes, scooters and mopeds represent style and class for both men and women in
India.

Benefits of Two Wheelers

Two-wheelers are the most popular and highly sought out medium of transport in India. The trend of
owning Two-Wheelers is due to their:
2
Economical price
2
Safety
2
Fuel-efficiency
2
Comfort level
However, some Indian bike enthusiasts prefer high performance imported bikes. Some of the most
popular high-speed bikes are Suzuki Hayabusa, Kawasaki Ninja, Suzuki Zeus and Honda Unicorn.
These super bikes are specially designed for those who have a zeal for power and speed.
We can conclude that a motorcycle is a motor-powered two wheeler, similar in construction with
bicycles.

Identification of Two Wheeler:

You must have seen various types of two wheelers in your area or on the roads. Every Two Wheeler
has a sticker of its model type and name of the manufacturer. You can identify the make of the Two
Wheeler by the sticker/logo fixed on body. Popular brands of Two Wheeler manufacturers are Hero,
Honda, Bajaj, TVS, Suzuki. Two Wheeler manufacturers produces different models as per given
specification. Some of famous models are given below:
Hero make - Impulse, Splendor, CDdawn, Pleasure, Passion Plus
Bajaj make - Pulsar , Discover, Platina
TVS make - Apache, Star, Scooty streak, Scooty Pep, Star City
Honda make - Activa, Dio, aviator
Suzuki make - Access, Intruder M800, Zeus
These models vary by size, weight, dimension type size, engine capacity.

20
 Access 125 Sling Shot

Fig : Photograph of popular two

Three Wheelers
A Three-Wheeler is a vehicle with three wheels, either "human or people powered vehicles" (HPV or
PPV) or motorized vehicles in the form of a trimotorcycle, all-terrain vehicle (ATV) or automobile.
Auto rickshaws (often called just auto) are common all over India, and provide cheap and efficient
transportation. New auto rickshaws run on CNG and are environmentally friendly. Typical mileage
for an Indian-made auto rickshaw is around 35 kilometers per liter of petrol (about 2.9 L per 100 km,
or 82 miles per gallon [United States (wet measure), 100 miles per gallon Imperial (United Kingdom,
Canada)]. Many major nationalized banks in India offer loans to self-employed individuals seeking
to buy auto rickshaws. Auto rickshaw manufacturers in India include Bajaj Auto, Kumar Motors,
Kerala Auto Limited, Force Motors (previously Bajaj Tempo), Mahindra & Mahindra, Piaggio Ape
and TVS Motors. Auto rickshaws are found in cities, villages and in the countryside.
There are two types of auto rickshaws in India. In older versions the engines were situated below
driver's seat. In newer versions engines are in rear portion. They normally run on petrol, CNG and
diesel. The seating capacity of a normal rickshaw is 4, including the driver. There are also six seated
rickshaws in parts of Maharashtra. In cities and towns across India it is the backbone of city
transport. Normally their fare rates are controlled by govt. They have traffic meters.

21
Many three-wheelers which exist in the form of motorcycle-based machines are called trikes and
often have the front single wheel and mechanics similar to that of a motorcycle and the rear axle
similar to that of a car. Sometimes such vehicles are owner-constructed using a portion of a rear
engine, rear-drive Volkswagen Beetle in combination with a motorcycle front end.
Other trikes include ATVs that are specially constructed for off road use. Three-wheeled
automobiles can have either one wheel at the back and two at the front, (for example: Morgan Motor
Company) or one wheel at the front and two at the back (such as the Reliant Robin).

Fig.: Photograph of popular three wheelers

Fig.: Photograph of popular three auto wheelers

These are some of the popular three wheeler which are used for transporting of people and goods.

22
Exercise: Assignment
1. List the models of two wheelers and three wheelers used in your area:
S.No. Name of Model
1
2
3
4
5
6
7
8
9
10

2. Observe and identify two types of two wheelers in your school and draw their diagrams:

3. Fill in the blanks:

a) A two wheeler refers to ___________ that run on two wheels. Two wheelers are used all
over the ________.
b) More than 5.4 million _________________ are produced in our country every year.
c) A Majority of Indians, especially the youngsters prefer __________ rather than cars.
d) Motorcycle is a motor-powered ____________, similar in construction to bicycles.

23
 e) A three-wheeler is a vehicle with ________________ either "human or people-powered
vehicles" (HPV or PPV) or motorized vehicles in the form of a _________ or automobile.
f) Auto rickshaws are ___________ all over India, and provide cheap and efficient
__________.
g) New auto rickshaws run on ______ and are environmentally friendly.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Differentiate between two wheelers and three wheelers.
Part B
Discuss in class the following:
2
What is meaning of a two wheeler and three wheelers?
2
What are the different types of make of two wheelers?
2
Why we use two wheelers mostly?
2
Why three wheelers are used popularly.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to draw two wheelers and three wheelers
Able to distinguish between scooters, mopeds and motorcycles
Able to identify two wheelers and three wheelers

SESSION-2: PASSENGER VEHICLES AND COMMERCIAL VEHICLES

Relevant Knowledge
Passenger Vehicles
Passenger vehicle refers to a machine that can carry a person or a group of persons. There are
several types of passenger vehicles like cars/jeeps/tempos etc. you must have seen various
models of passenger vehicles in your village, town or city. You must have also travelled in these
passenger vehicles.
Some of the popular model of cars, buses, jeep, and tempo are illustrated below:
Car: A motor car or car is a wheeled motor vehicle used for transporting passengers, which also
carries its own engine or motor. Various popular cars in India are Maruti Suzuki, Tata motor, Hyundai
etc. Now a days various car manufacturers of International level have established in our country
and started production of cars etc.

24
 Fig: Photograph of popular four wheelers

Fig : Important passenger vehicle used in our country

Jeep: Jeep was first produced by Willys Overland. Jeep celebrated its 70th anniversary in 2011 and
it is the oldest off road vehicle and SUV in the world. Jeep is marque of Chrysler brand. Jeep is
mainly used for its excellent off road capabilities. Jeep was primarily designed and constructed to
aide military requirements. Slowly changes were made and the company started producing civilian
models. It has gone through various changes under different leaderships. It is part of Chrysler

25
Group LLC which is now part of FIAT Italy. Jeep is found in many countries around the world. The
models in Jeep range are Jeep Grand Cherokee, Jeep Patriot, Jeep Compass, Jeep Liberty, Jeep
Commander and Jeep Wrangler.
Commercial Vehicles
A Commercial Vehicle is a type of motor vehicle that may be used for transporting of goods as well
passengers. Commercial vehicles influence the trade, commerce and industry of a country in a
major way. Vehicles falling under this category are mainly buses & trucks.
It comes in various uses such as transportation of goods, shipping and handling of various
commodities and so on. The future of companies manufacturing these vehicles is very bright due to
India's growing commercial sector. The export of commercial vehicles has gone up considerably
breaking all previous records.
Trucks are basically used for carrying goods and materials in bulk. These trucks are classified into
sub-categories depending on their size and functional use: haulage, rigid trucks, tippers, cabs,
delivery vans and trailers. The fuel efficiency of these vehicles have also improved to a great extent
in the past few years. The major players of truck manufacturers in India are Ashok Leyland, Eicher,
Tata Motors and Swaraj Mazda.
A Bus is a huge commercial vehicle, said to have
originated in France in the year 1826 designed by
Stanislas Baudry under the name of 'Omnibus'. The
basic purpose of this vehicle is to carry the passengers
as it is an easy and cost-effective medium of transport.
The major producers of buses in India are Ashok
Leyland and Tata Motors, Swaraj Mazda, Volvo and
Hindustan Motors have made a big name in
manufacturing mini-buses. However, there are huge
subcategories of buses like Commuter Bus, School
Fig : Photograph of popular bus
buses, Electric buses and so on. In India, CNG buses
have occupied a huge market thus making it fuel efficient and environmental friendly vehicle.

Fig : Photograph of CNG Buses

26
 Fig : Photograph of popular tempo

Exercise: Assignment
1. List the models of passenger vehicle and commercial vehicle used in your area:

S.No. Name of Model

1
2
3
4
5
6
7
8
9
10

2. Observe and identify two types of passenger and commercial vehicles in your area and
draw their diagrams:

27
3. Fill in the blanks:
a) A passenger vehicle refers to that run on _____________ wheels.
b) Model of cars, buses, jeep, and tempo are _______________ in our country every year.
c) Jeep is a ____________ vehicle.
d) A Passenger vehicles are used for transporting_________ .
e) Commercial vehicle is used for____________.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Differentiate between passenger vehicle and commercial vehicle.
Part B
Discuss in class the following:
2
Who invented Jeep?
2
What are the different makes of a bus?
2
Why do we use car mostly?
2
Why cars and jeeps are used popularly.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to draw Passenger vehicles and Commercial Vehicles
Able to distinguish between Passenger vehicles and Commercial
Vehicles
Able to identify two Passenger vehicles and Commercial Vehicles

SESSION-3: AGRICULTURAL VEHICLES

Relevant Knowledge
You must have seen tractors in your area. Do you know
the meaning of tractor? It can be said that a tractor is an
engineering vehicle specifically designed to deliver a
high attractive effort (or torque) at slow speeds, for the
purposes of hauling a trailer or machinery used in
agriculture or construction. Most commonly, the term is
used to describe a farm vehicle that provides the power
and traction to mechanize agricultural tasks, especially
(and originally) till age, but nowadays a great variety of
tasks. Agricultural implements may be towed behind or Fig : Photograph of Tractor

28
mounted on the tractor, and the tractor, may also provide a source of power if the implement is
mechanised.
The word tractor was taken from Latin, being the agent noun of trahere "to pull". The first recorded
use of the word meaning "an engine or vehicle for pulling wagons or ploughs" occurred in 1901,
displacing the earlier term "traction engine" (1859). Tractors are heavy vehicles serving the purpose
of hauling at an extremely low speed. India being one of the major agricultural country, makes the
use of tractors on a large scale. It is one of the heaviest vehicle, basically used for carrying out the
agricultural tasks in an effective way.
Modern tractors usually employ diesel engines which
deliver 18 to 575 horsepower. The major producers of
tractors in India are Ashok Leyland, Escorts, Force
Motors and Swaraj Enterprise. The most common use
of the term "tractor" is for the vehicles used on farms.
The farm tractor is used for pulling or pushing
agricultural machinery or trailers, for plowing, tilling,
disking, harrowing, planting and similar tasks. A variety
of specialty farm tractors have been developed for
particular uses. These include row crop tractors with
Fig : Photograph of Tractor
adjustable tread width to allow the tractor to pass down
rows of corn, tomatoes or other crops. Many utility tractors are used for non-farm grading,
landscape maintenance and excavation purposes, particularly with loaders, backhoes, pallet forks
and similar devices. Small garden or lawn tractors designed for suburban and semirural gardening
and landscape maintenance also exist in a variety of configurations.
The durability and engine power of tractors make them very suitable for engineering tasks. Tractors
can be fitted with engineering tools such as dozer blades, buckets, hoes, rippers, etc. The most
common attachments for the front of a tractor are dozer blades or buckets. When attached to
engineering tools, the tractor is called an engineering vehicle.
Combine Harvester: The combine harvester, or
simply combine, is a machine that harvests grain crops.
The name derives from the fact that it combines three
separate operations, reaping, threshing, and
winnowing, into a single process. Among the crops
harvested with a combine are wheat, oats, rye, barley,
corn (maize), soybeans and flax (linseed). The waste
straw left behind on the field is the remaining dried
stems and leaves of the crop with limited nutrients
which is either chopped and spread on the field or baled Fig : Photograph of Combine Harvester
for feed and bedding for livestock.
Combine harvesters are one of the most economically important labor saving inventions, enabling a
small fraction of the population to be engaged in agriculture.

29
 Fig : Photograph of Combine Harvester

Exercise: Assignment
1. List the models of agricultural vehicles used in your area:

S.No. Name of Model

1
2
3
4
5
6
7
8
9
10

30
2. Observe and identify two types of agricultural vehicles in your area and draw their
diagrams:

3. Fill in the blanks:

a) Agricultural ____________ may be towed behind or mounted on the tractor.
b) An agricultural vehicle refers to that run on _______ wheels.
c) Combines are used for _______________and _________.
d) Advantages of using combine are_____________________.
e) Combine harvesters are one of the most economically important __________ inventions.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Differentiate between tractors and combines.
Part B
Discuss in class the following:
2
Why a tractor is used?
2
What are the different types of tractors?
2
What are advantages of using combines ?
2
In India, tractors are used popularly.
Performance standards/criteria covered by this assessment
Performance Standards Yes No
Able to draw tractor
Able to distinguish between tractor and combine

31
 SESSION-4: CONSTRUCTION EQUIPMENT VEHICLES
Relevant Knowledge
Lot of new roads, houses and plants are being built these days. You must have seen big machines
that reach the construction site to dig earth. These are Special Purpose Automobiles and are
sometime called Earth Moving Equipments.
There are several types of earthmoving or construction equipments such as:
2
Dumpers
2
Dozers
2
Road rollers
2
Tillers
2
Excavators
As their various names suggest they are used for various types of work like digging or excavating
earth and dumping it at a designated place. Road rollers are used for leveling roads.
Bulldozer : A bulldozer is a crawler (continuous tracked tractor) equipped with a substantial metal
plate (known as a blade) used to push large quantities of soil, sand, rubble, or other such material
during construction or conversion work and typically equipped at the rear with a claw-like device
(known as a ripper) to loosen densely-compacted materials.
Bulldozers can be found on a wide range of sites, mines and quarries, military bases, heavy industry
factories, engineering projects and farms.
The term "bulldozer" is often used erroneously to mean
any heavy equipment (sometimes a loader and
sometimes an excavator), but precisely, the term refers
only to a tractor (usually tracked) fitted with a dozer
blade. Most often, bulldozers are large and powerful
tracked heavy equipment. The tracks give them
excellent ground hold and mobility through very rough
terrain. Wide tracks help distribute the bulldozer's
weight over a large area (decreasing pressure), thus
preventing it from sinking in sandy or muddy ground.
Extra wide tracks are known as 'swamp tracks'. Fig : Photograph of bulldozer
Bulldozers have excellent ground hold and a torque
divider designed to convert the engine's power into improved dragging ability. The Caterpillar D9,
for example, can easily tow tanks that weigh more than 70 tons. Because of these attributes,
bulldozers are used to clear areas of obstacles, shrubbery, burnt vehicles, and remains of
structures. The bulldozer's primary tools are the blade and the ripper.
Road Roller: A road roller (sometimes called a roller-compactor, or just roller) is a compactor type
engineering vehicle used to compact soil, gravel, concrete, or asphalt in the construction of roads

32
and foundations. Similar rollers are used also at landfills or in agriculture. In some parts of the world,
road rollers are still known colloquially as steam rollers, regardless of their method of propulsion.
This typically only applies to the largest examples
(used for road-making Road rollers use the weight of
the vehicle to compress the surface being rolled (static)
or use mechanical advantage (vibrating). Initial
compaction of the substrate on a road project is done
using a pad foot drum roller, which achieves higher
compaction density due to the pads having less surface
area. On large freeways a four wheel compactor with
padfoot drum and a blade, such as a Caterpillar
815/825 series machine, would be used due to its high
weight, speed and the powerful pushing force to spread
bulk material.
Dumper: Dumper is a vehicle designed for carrying
bulk material, often on building sites. Dumpers are
distinguished from dump trucks by configuration. A
Dumper is usually an open 4-wheeled vehicle with the
load skip in front of the driver, while a Dump Truck has
its cab in front of the load. The skip can tip to dump the
load, this is where the name "dumper” comes from.
They are normally diesel powered. A towing eye is fitted Fig : Photograph of Road Roller
for secondary use as a site tractor. Dumpers with
rubber tracks are used in special circumstances and are popular in some countries.
Modern dumpers have payloads of up to 10 tonnes (11 short tons, 9.8 long tons) and usually steer
by articulating at the middle of the chassis (pivot steering). They have multi-cylinder diesel engines,
some turbocharged, electric start and hydraulics for tipping and steering and are more expensive to
make and operate.

33
 Fig : Photograph of Dumper

Exercise: Assignment
1. List the models of Construction Equipment vehicles used in your area:
S.No. Name of Model
1
2
3
4
5
6
7
8
9
10

2. Observe and identify two types of Construction Equipment vehicles in your area and
draw their diagrams:

34
3. Fill in the blanks:
a) A road roller is a _________ type engineering vehicle used to compact soil, gravel,
__________ or asphalt in the ____________of roads and foundations.
b) Dumper is a vehicle designed for carrying ________________.
c) Dumper is a ____________ vehicle.
d) A Construction equipment vehicles are used for _________ .
e) Modern dumpers have payloads of up to ____________.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Differentiate between Road Roller and Dumper.
Part B
Discuss in class the following:
1. Role of Dumper.
2. What are the different types of construction equipment vehicle?
3. Why we use Road Roller?
4. Why Bulldozer are used popularly.
Performance standards/criteria covered by this assessment
Performance Standards Yes No
Able to draw Construction Equipment Vehicles
Able to distinguish between different Construction Equipment
Vehicles
Able to identify Construction Equipment Vehicles

SESSION-5: SPECIAL VEHICLES

Relevant Knowledge
Automobile technology has several other applications
also. We shall now get acquainted with some of these
special applications. You would have all travelled by a
Train. Railway locomotive is basically an automobile,
but, much bigger than a car, bus or a truck. In the
beginning trains were pulled by locomotives which
were powered by steam. Now a days, most rail engines
run on diesel fuel or electricity. In India, rail is a very

35
important means of transportation of goods and
passengers. As you know that, a train cannot run
on roads but runs on a railway track.
Many of you must have also seen big machines
which have long extended arms for reaching
high rise buildings or top of electric poles. These
are mounted on an automobile and the complete
machine is called a Crane. Some time you may
have seen traffic police using a crane to lift cars
which are wrongly parked.
Fig.: Railway Track

Fig.: Figure of Fork Lift

Another interesting application of an automobile is the Fork Lift. A fork lift is used mostly in industry
and in large warehouses for carrying components and goods within the premises of the factory or
the godown/ warehouse. So a fork lift is normally used for carrying goods for very short distances
within the four walls of a building but never on the outside road.
When liquids like water, milk, oil, petrol, diesel etc are required to be transported to long distances, it
is done in Tankers. These tankers have very big
cylinders mounted horizontally on the chassis of
a specially built automobile. Capacity of these
tankers can vary.
Sometime, you may have seen the sign
“inflammable material”. This is a warning sign
written on the tankers that carry volatile fluids like
petrol & diesel. This warning is to caution people
on the road that they should not bring any ignited
object like match stick or fire crackers near the
tanker. This is because petrol & diesel can catch

36
fire very easily since their flash point is very low
and if there is any source of intense heat or
ignited objects the tanker can catch fire and
cause lot of damage.
It may be noted that sometimes these tankers
are also mounted on railway trains. Also you may
have seen pictures of tankers on a ship. Pictures
of some of important special equipment such as
fire brigade, trawler etc have been shown for
your reference.
Fig : Photograph of Tanker

Fig : Photographs of Trawler

Exercise: Assignment
1. List the models of special vehicles used in your area:
S.No. Name of Model
1
2
3
4
5
6

37
 7
8
9
10

2. Observe and identify two types of Special Vehicle in your area and draw their diagrams:

3. Fill in the blanks:

a) A train is pulled by ________.
b) Train can not run on __________but on a railway track.
c) Crane is a ____________ vehicle.
d) When liquids like water, milk , oil , petrol, diesel etc are required to be transported to
______distances, it is done in ___________ .
e) Fire brigade vehicle is used for____________.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Differentiate between special vehicles.
Part B
Discuss in class the following:
2
Role of special vehicles.
2
What are the different types of cranes?
2
Why we use tankers mostly?
2
Why cranes are used popularly?
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to draw Special Vehicles
Able to distinguish between different Special Vehicles
Able to identify two Special Vehicles

38
 Suggested Reading
Books
Title Author Publisher
Automobile Engineering Vol I Kirpal Singh Standard Publishers
Automobile Engineering, Vol II Kirpal Singh Standard Publishers
Text Book of Automobile Engineering R. K. Rajput Laxmi Publications
Automobile Engineering R. K. Singal S. K. Kataria and Sons
Automobile Engineering Theory Kapil Dev Computech Publications
Automobile Engineering K. M. Moeed S. K. Kataria and Sons

Websites
2
auto.indiamart.com/auto-technology
2
www.automobileindia.com/consumer-guide/automobile-technology
2
auto.indiamart.com/auto-technology
2
books.google.com/books/about/Automobile_Engineering.html
2
www.bikeadvice.org
2
www.wikipedia.com

List of Contributors
1. Mr. Sunil K. Chaturvedi, CEO, Automotive Skills Development Council, Core 4-B 5th Floor India Habitat
Centre, Lodhi Road, New Delhi – 110 003.
2. Mr. A.C. Deb, Sr. Lecturer, (Auto) – HOD, PUSA Polytechnic PUSA,New Delhi -110012.
3. Mr. Vikas Gautam, S.B.V. NO.1, Morigate, Delhi – 110006.
4. Prof. A.P. Verma, Ex-Prof. & HOD, PSSCIVE, Bhopal.
5. Sh. Deepak Shudhalwar, Assistant Professor, E & T Division, PSSCIVE, Bhopal.
6. Dr. Saurabh Prakash, Associate Professor, E & T Division, PSSCIVE, Bhopal – Programme
Coordinator.

39
 Major Systems & Components
Unit-3 of an Automobile

Introduction
By now you are already familiar with an Automobile. Automobiles are made up of several
components, assemblies and systems. The growing auto industry has given rise to a growing auto
component industry also. India has emerged as global outsourcing hub for manufacturing of
various automobile components. All major Companies like Toyota, Hyundai, Ford, Volvo, Renault
and Daimler Chrysler and others are now sourcing their automotive components from Indian
manufacturers.
The auto components industry is predominantly divided into five segments:
2
Engine parts
2
Drive Transmission & Steering Parts
2
Suspension & Brake Parts
2
Electrical Parts
2
Body and chassis
Global automobile manufacturers see India as a manufacturing hub for auto components
due to:
2
Low cost labour force and availability of raw material which makes India cost competitive.
2
India has an established manufacturing base.
2
Major international auto-components including Delphi, Visteon, Bosch and Meritor have set up
operations in India.
2
Automobile manufacturers and auto component manufacturers have set up International
Purchasing Offices (IPOs) in India.
2
Fine-quality components are manufactured in India.
2
India is a global hub for R&D: GM, Daimler Chrysler, Bosch, Suzuki, Johnson Controls etc. All
have their research centre in India.
In this Unit, you will learn about various components and systems that makeup a complete
automobile. Therefore you will be introduced to engine and its part, Body and chassis, Drive
Transmission & Steering Parts, Suspension & Brake Parts, Electrical Parts and other systems that
make it possible for running of an automobile.

SESSION-1: CHASSIS FRAME AND AUTO BODY

Relevant Knowledge
The Chassis
Chassis is a French term and was initially used to denote the frame or main structure of a vehicle.

40
The chassis contains all the major units necessary to propel the vehicle, guide its motion, stop it,
and allow it to run smoothly over uneven surfaces. It is the main mounting for all the components
including the body. It is also known as carrying unit.
The chassis includes the following major components:
1. Major part of a chassis is a steel frame.
2. In case of a passenger car the whole body is also an integral part of the chassis. However,
in commercial vehicles like trucks & buses the body is not a part of the chassis. Therefore a
chassis is almost a complete vehicle except body, other accessories which are not involved
in the movement of the vehicle.
3. Other major components like Engine, Transmission System, Front & Rear Axle, Steering
System, Suspension System, Wheels Tires & Brakes.
Functions of the chassis frame
1. To carry the weight of the vehicle and its passengers.
2. To withstand the engine and transmission torque and thrust stresses, as well as accelerating
and braking torque.
3. To withstand the centrifugal force while cornering.
4. To withstand the bending loads and twisting due to the rise and fall of the front and rear axles.

Fig: Diagram of different types of chassis frame

41
Fig. Different type of automobile body

Fig. Parts of the Automobile vehicle

42
 Fig : Frame of the body

Oil Dipstick
Air Cleaner
Battery
Fuel Injection
Radiator
Sealed
Beam
Headlight

Rear
Suspension
Alternator
Rear Axle
Mutfser
Power Front (on undercarriage)
Suspension
Steering
Reservoir Brake Fluid
Reservoir Disc Brake

Fig. Components of a Vehicle

43
 Fig : Photograph of a Complete Car

Auto body or superstructure

In case of integral or frameless construction the body is the integral part of chassis frame. But in
case of the conventional chassis frame the body or superstructure is made after receiving the
chassis from the manufacturer. The shape of the body depends upon the ultimate use for which the
vehicle is meant.
Body is made of sheet metal or fiber glass, so that the passengers can sit in it. To make journey
comfortable cushioned seats are provided. Body is provided on all sides with glass-panes fixed to
protect the passengers from dust and rain. Bus bodies are mostly all metal bodies and can be either
of (a) steel section pillars with steel sheet paneling, (b) steel section pillars with aluminum paneling,
(c) all aluminum bodies, i.e., pillars, frame work and paneling are all made up of aluminum sections
and sheets. This is because aluminum is very light in weight compare to steel. In the truck bodies
only the driver’s compartment is covered whereas the rest is kept open. Such bodies are usually
called load bodies. In most of the cases, it is an open body, whereas for liquid material like water,
milk and fuel products a tank is mounted on the chassis. The body is fixed to the chassis with the
help of I or U-bolts with rubber packing placed between the chassis and body cross members as
shown below:

Fig. U bolt

Requirements of Automobile Body

The body of a motor vehicle should fulfill the following requirements:
1. The body should be light.

44
2. It should have minimum number of components.
3. It should have long fatigue life.
4. It should have uniformly distributed load.
5. It should provide sufficient space for passengers and luggage.
6. It should have good access to the engine and suspension system.
7. It should create minimum vibrations when the vehicle is running.
8. It should have minimum resistance to air.
9. It should be cheap and easy in manufacturing.
10. It should provide clear all-round vision through glass areas.
11. It should be attractive in shape and colour.

Exercise: Assignment
1. Name the component of chassis of a vehicle:

S.No. Name of Model

1
2
3
4
5
6
7
8
9
10

2. Observe and identify components of a car in your area and draw their diagrams:

3. Fill in the blanks:

a) A chassis is almost a complete vehicle _________ body.
b) The shape of the body _________upon the ultimate use for which the vehicle is meant.

45
 c) Major part of a chassis is a __________frame.
d) In commercial vehicles like trucks & buses the body is not a _________ of the chassis.
e) In most of the cases, it is an open body, whereas for liquid material like water, milk and
fuel products a __________ is mounted on the chassis.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Differentiate between chassis frame and auto body.
Part B
Discuss in class the following:
2
Functions of the chassis frame.
2
Requirements of Automobile Body.
Performance standards/criteria covered by this assessment
Performance Standards Yes No
Able to draw a chassis and auto boy and its parts

SESSION-2: ENGINE AND ITS COMPONENTS

Relevant Knowledge
Engine
Engine is heart of an automobile. Its role is very important. It converts the Chemical Energy (heat
energy) to Mechanical Energy. This energy is utilized for vehicular movement. There are different
ways of igniting fuel in an auto engine. Accordingly engines are called Internal Combustion (IC) OR
external combustion Engines. Even within the IC engine category ignition can be by a spark or by
high compression.
Camshaft
Distributor
Valves

Piston
Spark Plug

Crankshaft

Timing Belt
Alternator

Fig : Engine assembly Fig. Some Engine components

46
Automotive engines are called internal-combustion (IC) engines because the fuel that runs them
engine burned internally, or inside the engines. There are two types engines – reciprocating engine
and rotary engine.
Reciprocating means moving up and down, or back and forth. Almost all automotive engines are of
the reciprocating type. This type of engine is called a piston engine.
Rotary engines have rotors that spin, or rotate. Wankel has invented the Rotary engine, hence it is
named as Wankel engine and these are slowly coming up in use today.
There are two kinds of piston engines (IC Engines).
1. Spark-ignition (Petrol or gas) engine.
2. Compression ignition (diesel) engine.
The differences between these two engines are:
2
The type of fuel used.
2
The way the fuel gets into the engine cylinders.
2
The way the fuel is ignited.
The spark-ignition engine (petrol or gas engine)
Spark plug
The spark-ignition engine uses a highly volatile fuel
Valve spring
which turns to vapor easily, such as gasoline or Camshaft
Cylinder head
gasohol. The fuel is mixed with air before it enters the Inlet valve Exhaust valve
Head gasket
engine cylinders. The fuel turns into a vapor and Piston
Piston rings
mixes with the air to form a combustible air-fuel Engine block Piston pin

mixture. This mixture is then enters the cylinders and Cooling water
Connecting rod
is compressed. Next, an electric spark produced by Con rod bearing
Oil pan gasket
the ignition system to ignite the combustible mixture, Crankshaft
Oil sump (pan)
which is already being compressed into the Oil
combustion chamber of engine.
Fig. Ignition System
The compression-ignition (diesel engine)
In the compression-ignition engine or GASOLINE DIESEL
ENGINE ENGINE
diesel engine, only fresh air enters the
Intake Valve
cylinder, which is then compressed to a
Fuel
very high temperature and pressure. The Exhaust Valve

air is compressed so much that its Air Exhaust Gas

temperature goes up to 10000F (5380C) Piston

or higher. Then the diesel is injected Cylinder
(sprayed) into the engine cylinder. This
Crank Disk
spray contains very very fine and tiny
COMPRESSION

COMPRESSION
INCREASED

cloud of diesel known as atomized form in

REGULAR

automobile jargon. The hot air, or heat of

compression, ignites the fuel. This is why
the diesel engine is called a compression- Fig: Ignition System

ignition engine.

47
Components of I.C. engine
1. Cylinder: The cylinder of an I.C. engine is considered as the main body of the engine in which
piston reciprocates to develop power. It has to withstand very high pressures (about 70 bar)
and temperatures (about 22000C) because there is Exhaust Valve Intake Valve
direct combustion inside the cylinder. Therefore, its Exhaust Port Spark Plug
Intake Port
material should be such that it can retain strength at
high temperatures, should be good conductor of heat
and should resist to rapid wear and tear due to
Combustion
reciprocating parts. Generally, ordinary cast iron is Chamber
used, but in case of heavy duty engines, alloy steels or
aluminum alloy are used.
Piston
2. Cylinder Head: The cylinder head closes one end of
the cylinder. It houses the inlet and exhaust valves.
The charge (fuel and air mixture for SI engine and only
Fig.: Cylinder
air for CI engine) enters through inlet valves and after
producing power the exhaust gases escapes through
the exhaust valves to the atmosphere.
Rocker arm Stud hole
pivots to open valve

Valve clearance adjuster

Rocker shaft
Valve retainer
Springs close valve Threaded hole for
bolting rocker cover
to cylinder head
Intake ports

Housing for thermostat

Pushrod moves up and
down to pivot rocker arm

Fig : Cylinder Head Block

Cylinder head is usually cast as one piece and bolted to the top of the cylinder (engine block).
A copper and asbestos gaskets are provided between the cylinder and cylinder-head to obtain
a gas-tight joint. The material used for the cylinder-head is also cast iron or aluminum alloy.
3. Piston and Piston Rings: Piston is the heart of the engine. The functions of the piston are to
compress the charge during compression stroke and to transmit the gas force to the
connecting rod and then to the crank during power stroke. The pistons of I.C. engines are
usually made of cast iron, cast steel and aluminum alloy. The aluminum alloy has the
advantage of higher thermal conductivity and lower specific gravity.
The piston rings are housed in the circumferential grooves provided on the outer surface of
the piston. It gives gastight fitting between the piston and the cylinder and prevents the
leakage of high pressure gases. These are made of special grade cast iron. This material
retains its elastic property at very high temperature. The upper piston rings are called the
compression rings and the lower piston rings are called the oiling or oil control rings.

48
 Piston

Compression
Rings
Piston Pin
Oil Rings

Connecting
Rod

Two Stroke
Piston Ring Styles
PG (side pin) gap

GI (center pin) gap

GI gap

GI gap

Fig: Piston Ring

4. Connecting Rod: It is usually a steel forging of circular, rectangular, I,T, or H section and is
highly polished for increased strength. Its small end forms a hinge and pin joint with the piston
and its big end is connected to the crank by crank pin. It has a passage for the transfer of
lubricating oil from the big end bearing to small end bearing (gudgeon pin).

Circlip

Gudgeon pin (wrist pin)

Needle sleeve bearing

Short arm of
connecting rod

Circlip

Fig : Connecting Rod

49
 Top End Bushing Serrated Section
Top End Upper Shell Bearing

Bolts

Bottom End Lower Shell Bearing

Bearing Cap

Fig : Connecting Rod

5. Crank and Crankshaft: Both crank and crankshaft are steel forged and machined to a
smooth finish. The two are held together by means of a key. Crankshaft is supported in main
bearings and has a heavy wheel, called flywheel, to even out the fluctuations of torque. The
power required for any useful purpose is taken from crankshaft only. The crankshaft is the
backbone of the engine.

Internal Combustion Engine

Camshaft Cylinder
Intake Compression Combustion Exhaust bearing/bush
Piston

Valves
Up
Camshaft Piston Pin
Bolt
Down

Small end
bush Connecting
Rod
Connecting
rod
Flywheel
Around in
Cylinder a Circle
block Crank Pin

Crankshaft

Crank Shaft Lower Rod

Bearing Cap
Washer
Nut
Main Bearings Connecting Rod Bearings Main Bearings

Fig: Crankshaft of multi cylinder engine Fig: Crankshaft of single cylinder engine

6. Piston Pin or Wrist Pin: The piston pin provides the bearing for the oscillating small end of
the connecting rod.

50
 Pin Con Rod

Snap ring

Snap ring

Fig : Piston Pin or Wrist Pin

7. Inlet Valve: This valve controls the admission of the charge into the petrol engine or air into
diesel engine during suction stroke of the engine.

Spark plug
Exaust Valve
Inlet Valve

Piston

Connecting Rod
Crank

Fig : Inlet Valve

8. Exhaust Valve: The removal of exhaust gases after doing work on the piston, is controlled by
this valve.
9. Valve Spring: The valves are kept closed by the valve springs.

Variable Cam Timing Acuator

Oil Pressure Ports

Cam Follower/Lifter

Cam Return Spring

Valve

Fig: Valve Spring

10. Inlet Manifold: It is the passage which carries the charge from carburetor to the petrol engine
or only air to the diesel engine.

51
 ‘Gas Flow’
Inlet manifold

Exhaust manifold
Gass Flow Cylinder Head

Fig : Inlet Manifold

11. Exhaust Manifold: It is the passage which carries the exhaust gases from the exhaust valve
to the atmosphere.

Air Cleaner

Carburetor
Intake
Manifold

Exhaust
Manifold
Heat control
valve spring

Fig : Exhaust Manifold

12. Camshaft: The function of the cam shaft is to operate the intake and exhaust valves through
the cams, cam followers, push rods and rocker arms. The cam shaft is driven positively from
the crankshaft at half the speed of the crankshaft.

Fig : Camshaft

13. Cam and Cam Follower: It is made of a required profile to give desired motion to the valve
through the follower.

52
 Follower

Teace point

Pitch curve
Cam profile
Base
circle

Normal Prime circle

Pressure
angle
Direction
of motion

Fig : Cam and Cam follower

14. Push Rod and Rocker Arm: The motion of the cam is transmitted to the valve through the
push rod and rocker arm. These links together are also known as valve gear.
Rocker Arm
Valve Spring Retainer

Spring Collet
Push Rod
Valve Spring

Cam Follower
Cam
Valve Guide
Camshaft

Valve Stem
Valve Head

Valve Seat Insert

Fig : Push Rod and Rocker Arm

15. Crank Case: It is the base which holds the cylinder and crankshaft. It also serves as the sump
for the lubricating oil.

Fig : Crank Case

53
16. Water Pump and Water Jacket: The function of water pump is to draw water from the
radiator and supply it to water jacket at certain pressure for the purpose of proper circulation of
coolant between engine water jacket and radiator. The jackets are provided in the crankcase
(cylinder block) for the circulation of coolant to carry away the excessive heat of the engine.
Pressure
Cap Inlet
Hose
Radiator Thermostat Aftercooler
Housing To Thermostat

Thermostat Cylinder
Bypass Head

Oil
Cooler

Coolant
Pump

Drain

Coolant Manifold
Integral of
Cylinder Block

Fig : Water pump and Water Jacket

17. Radiator: It has two tanks located at top and bottom. It is the storage of coolant for cooling the
engine. It has a pressure cap to increase the boiling point of coolant.

Fig : Radiator

18. Bed Plate: The lower portion of the crank case is known as bedplate. The bed plates are held
by the bed bolts to concrete foundations.

54
19. Flywheel: It is a wheel mounted on the crankshaft which stores the energy during the power
stroke and transmits the energy through transmission to the wheels when the clutch is
engaged.

Fig: Fly Wheel

20. Governor: It is run by drive from the crankshaft. The function of the governor is to regulate the
charge in case of petrol engine and amount of fuel in case of Diesel engine to maintain the
speed of the engine constant, when the load requirement varies.

Fig: Governor

The components described above are commonly used for all types of IC engine. Here we are
describing only few components which are used in a particular types of engines.
21. Carburetor: The function of the carburetor is to supply the uniform air-fuel to the cylinder of a
petrol engine through the intake manifold. The mass of the mixture entering the cylinder in
controlled by a special valve called as throttle valve will be described in later sessions.
B

A C
N Idel speed screw Idel mixture screw
D
D G Chake plate
Throttle plate

Clean air
enters throat
M
Fuel/air mixture
flows to engine
E
F H
A: Airhorn
B: Choke plate L K Float
C: External bowlvent Fuel line
D: Choke pull-off J
E: Throttle body & mounting base Float bowl
F: Float bowl Fuel filter
G: Fuel inlet Jet
H: Idle mixture adjusting screw
J: Vacuum nipples Pedestal Fuel enters fuel
K: Fast-idle cam line from fuel
L: Throttle lever
M: Idle speed adjusting crack screw Carburetor and Fuel System tanks and pump
N: Internal bowlvent

Fig : Carburetor

55
22. Spark Plug: The function of the spark plug is to ignite the mixture after completing the
compression in the petrol engine. It is generally mounted in the cylinder head. This is only
used in petrol engine.
Metal Shell Terminal Nut
Ground Electrode
Hexagon
Gasket
Thread Corrugations

Electrode
Gap

Centre Electrode
(with copper core) Insulator Top Insulator

Insulator Nose

Fig : Spark Plug

23. Fuel Injection Pump: It forces the fuel oil at high pressure in automized condition through fuel
nozzle into the cylinder at the end of compression stroke in diesel engine.
nipple
Spring oil outlet valve
spring
valve oil outlet valve seat
pump body
Cylinder
tooth ring
To Camshaft barrel
Drive Distributor rack
plunger
Quantity rotating sleeve
(load) retainer
4 to 1 Gear Ratio Metering and
or Equivalent Control
Pressure Pump spring
retainer
Filter roller body adjusting screw
Storage Filters 280 KPa
Tank roller
Low Pressure Pump (transfer pump)
camshaft body

Fig : Fuel Injection Pump

24. Fuel Injector: The function of fuel injector is to break up the oil into fine spray (atomized
condition) as it enters the cylinder of diesel engine.
FUEL RAIL

O-Ring
Filter

Electrical Connector

Electric Coil

Magnet
Spring
O-Ring

Intake Manifold

Valve Pintle Cap

Copyright 2004-Fordtuetinjection.com

Fig : Fuel Injector

56
 NOTE: Now a days fuel injectors are also used in spark ignition engine (in the inlet manifold) to
spray petrol or gasoline in case of MPFI engines (all modern petrol engines).

Exercise: Assignment
1. Name the auto component system used in a vehicle:
S.No. Name of Model
1
2
3
4
5
6
7
8
9
10

2. Observe and identify engine in a workshop and draw their diagrams:

3. Fill in the blanks:

a) Engine is __________ of an automobile. Its role is very important.
b) Engine ___________the Chemical Energy (heat energy) to Mechanical Energy.
c) Major parts of engine are________,_________,____________, _____________.
d) The function of the carburetor is to supply the uniform _________ to the cylinder of a
__________ through the intake manifold.
e) Sparkplug is ________ used for ____________.
f) __________ It is a wheel mounted on the crankshaft which stores the energy.

57
Checklist for Assessment Activity
Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Different components of an engine.
Part B
Discuss in class the following:
2
Role of different components of an engine.
2
Water pump and Water Jacket.
2
Role of governor and carburetor.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to draw engine and label its parts

SESSION-3: LUBRICATION SYSTEM

Relevant Knowledge
As you know that our body requires fluids like water and also oil in the form of fats like ghee, butter,
cooking oil for maintenance of our system. Similarly lubrication is required for maintenance of
engine. Lubrication circuit is one of the most important ones in the engine. The engine cannot run
smoothly for more than a few minutes without the lubricating oil.

Fig: Lubrication system of the engine.

58
Whenever two metallic surfaces move over each other under direct contact, dry or solid friction is
produced. This is due to the irregularities on the two surfaces interlocking each other. The dry
friction thus created produces a lot of heat and results in wear of the metal surface.
Objective of Lubrication
The primary objective of lubrication are:
1. To reduce friction between moving parts to its minimum value so that power loss is minimized.
2. To reduce wear of the moving parts as far as possible.
Apart from these primary objectives, lubrication also serves other important purposes, which may
be called secondary. These are as follows:
1. To provide cooling effect – The lubricating oil takes heat from the hot moving parts during its
circulation and delivers it to the surrounding air through the crank case.
2. To provide cushioning effect – The lubricating oil serves also as a good cushion against the
shocks experienced by the engine. For example, instant combustion of the fuel in the
combustion chamber produces a sudden pressure rise in the cylinder and the shock goes to
the bearings through the piston, gudgeon pin and the connecting rod. This shock is then
absorbed by the layer of oil present in the main bearings.
3. To provide cleaning action – The lubricating oil serves another useful purpose in providing a
cleaning action. During its circulation it carries away many impurities, e.g. carbon particles.
4. To provide a sealing action – The lubricating oil also helps the piston rings to maintain an
effective seal against the high pressure gases in the cylinder from leaking out toward the crank
case side.
Other than engine, lubricants are used for protecting following components also:
2
Gear box
2
Differential
2
Steering gear box
2
In different joints grease is used as lubricant.

Exercise: Assignment
1. List the important function of lubrication:
S.No. Functions of lubrication
1
2
3
4
5
7
6

59
 8
9
10

2. Observe and draw their diagram of lubrication system:

3. Fill in the blanks:

a) Dry or solid fictions is produced in _____________.
b) Dry fiction creates lot of ________________.
c) Objective of lubrication is to reduce __________.
d) Lubrication provides ________ effect and ______ effect.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Importance of lubrication.
Part B
Discuss in class the following:
2
Importance of lubrication in engine.
2
Lubrications are used for various purpose.
2
Lubrication is an essential component.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to draw figure of lubrication system of engine
Able to identify components of lubrication system of engine

60
 SESSION-4: COOLING SYSTEM
Relevant Knowledge
Cooling System: As our body requires air and water for cooling our system similarly engine also
requires cooling. The cooling system has three primary functions. These functions are as follows:
1. Remove excess heat from the engine.
2. Maintain a constant engine operating temperature.
3. Increase the temperature of a cold engine as quickly as possible by maintaining the thermostat
valve in closed position which is fitted in the path of coolant circulation.
pressure-release cap
thermostat (regulates
flow of water)
pump (circulates water
through jacket to cool cylinders)
tan (draws in air
through radiator to
cool water)

air flow

drain cock

overflow pipe cylinders

Pressure cap Cooling fins between walls

Radiator apply line
Vent line

Engine

Bypass
line
Cooling
Radiator
fins

Makeup
Water
pump line

Radiator return line

Fig: Cooling of Engine

Necessity of Cooling
The cylinders of internal-combustion engines require cooling because of the inability of the engine
to convert all of the heat energy released by combustion into useful work. Liquid cooling is employed
in most IC engines, whether the engines are for use in automobiles or elsewhere. The water
(coolant) is circulated around the cylinders to pick up heat and then through a radiator to dissipate
the heat. Usually a thermostat is located in the circulating system to maintain the design jacket

61
temperature – 710C to 820C. The cooling system is usually pressurized to raise the boiling point of
the coolant with the help of a pressure radiator cap which increase the heat transfer capacity of the
radiator.

Exercise: Assignment
1. List the important function of cooling system:
S.No. Functions of Cooling
1
2
3
4
5

2. Observe and draw the diagram of cooling system:

3. Fill in the blanks:

a) Cooling system remove excess __________ from the engine.
b) Cooling ________ a constant engine operating temperature.
c) Objective of cooling is to reduce __________.
d) Liquid cooling is employed in most _____ engines.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Importance of cooling system.
Part B
Discuss in class the following:
2
Importance of Cooling in engine.

62
2
Coolants are used for a purpose.
2
Cooling system is an essential component.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to draw figure on cooling system of engine
Able to identify the components of cooling system of engine

SESSION-5: FUEL SUPPLY SYSTEM

Relevant Knowledge
Fuel Supply System
In petrol engines, the air and fuel is mixed outside the engine and partly evaporated mixture is
supplied to the engine. The fuels such as petrol, benzol and alcohol used in S.I. engine, vaporizes
easily if injected in the flow of air, therefore, the engine suction is sufficient to draw the mixture easily
in to the cylinder.
The oil fuels which are used in C.I. engines do not vaporize easily. Therefore, a separate injection
system is used consists of fuel injection pump (FIP) and injectors.

Fuel Composition Function

Manifold
Valve Injection pump

Engine-Driven Fuel filter

Fuel Fuel Pump
Discharge Fuel injection pump
Nozzle
Oil outlet valve
Fuel injector
Fuel Tank
Fuel/Air Combustion chamber
Auxiliary Fuel
Control
Pump

Fig: Fuel supply system for electronic injection Fig: Conventional Fuel supply system for diesel engine

Fuel Pump

Pressure Regulator
Filter
Ignition Coil
Injector

Air Induction
Fast Idle Mechanism System
Intake Temperature Sensor
Engine
Intake Manifold Sensor
Temperature
Sensor

ECU Crank Angle

Sensor

Fig: Fuel System

63
 Fuel Supply Components Fuel Supply Components
For S.I. Engine For C.I. Engine
l Fuel tank Fuel tank
l

l Fuel lines Fuel lines

l

l Fuel pump (A.C. mechanical type or Fuel feed pump (Mechanical type or
l

electrical type) electrical type)

l Fuel filter Fuel filters
l

l Carburettor Fuel injection pump (FIP)

l

l Inlate manifold Fuel injectors

l

l Air cleaner
Note: In case of modern MPFI engines
carburetor is replaced by injectors and sensor.

Exercise: Assignment
1. List the important function of fuel supply system:
S.No. Functions of fuel supply
1
2
3
4
5

2. Observe and draw the diagram of fuel supply system:

3. Fill in the blanks:

a) Air and fuel is _______ outside the engine and partly evaporated __________ is supplied
to the engine.
b) The fuels such as petrol, benzol and alcohol used in _____ engine.

64
 c) Suction is sufficient to draw the _______ in to the cylinder.
d) Oil fuels which are used in C.I. engines do not _________vaporize easily.
e) Injection system used consists of fuel injection pump (FIP) and _________.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Importance of fuel supply system.
Part B
Discuss in class the following:
2
Importance of fuel supply in engine.
2
Fuels are used for a purpose.
2
Fuel supply system is an essential component.
Performance standards/criteria covered by this assessment
Performance Standards Yes No
Able to draw figure on fuel supply system of engine
Able to list the components of fuel supply system of engine

SESSION-6: TRANSMISSION SYSTEM

Relevant Knowledge
Transmission system is used in motor vehicles, where the transmission systems supply the output
of the internal combustion engine to the drive wheels. The transmission reduces the higher engine
speed to the slower wheel speed, increasing torque in the process. Transmissions are also used on
pedal bicycles, fixed machines, and anywhere else rotational speed and torque needs to be
adapted.
Transmission System
The transmission system consists of following components.
1. Clutch assembly
2. Gear box assembly (transmission case assembly)
3. Propeller shaft
Clutch Assembly
Clutch is a mechanism which enables the rotary motion of one shaft to be transmitted, when
desired. The axis of driving shaft and driven shaft are coincident.

65
 Pilot bushing

Threw out bearing

Clutch components

Throw-out
bearing

Pressure plate
Flywheel
Clutch disk
Throw-out Clutch pressure Clutch disc
fork plate assembly

Fig : Different parts of Clutch Assembly

Function of a clutch
1. To disconnect the engine power from the gear box as required under following circumstances.
(a) To start the engine and warm it up.
(b) To facilitate to engage 1st and 2nd gear to start the vehicle from rest.
(c) To facilitate to change the gear as required.
(d) Disconnecting drive from the engine to stop the vehicle after application of brakes.
2. Allow the engine to take up load gradually without shock or jerk.
Requirements of a Clutch
1. Torque transmission: The clutch should be able to transmit maximum torque of the engine.
2. Gradual engagement: The clutch should engage gradually to avoid sudden jerks.
3. Heat dissipation: The clutch should be able to dissipate large amount of heat which is
generated during the clutch operation due to friction.
4. Dynamic balancing: The clutch should be dynamically balanced. This particularly required in
the case of high speed engine clutches.
5. Vibration damping: The clutch should have suitable mechanism to damp vibrations to
eliminate noise produced during the power transmission.
6. Size: The clutch size should be as small as possible so that it will occupy minimum space.
7. Free pedal play: The clutch should have free pedal play in order to reduce effective load on the
carbon thrust bearing and its wear.
8. Easy in operation: The clutch should be easy to operate requiring as little exertion as possible
on the part of the driver.
9. Lightness: The driven member of the clutch should be made as light as possible so that it will
not continue to rotate for any length of time after the clutch has been disengaged.

66
Main Parts of a Clutch
The main parts of clutch are divided into three groups:
1. Driving members: The driving members consist of a flywheel mounted on the engine
crankshaft. The flywheel is bolted to a cover which carries a pressure plate or driving disc,
pressure springs and releasing levers. Thus the entire assembly of the flywheel and the cover
rotate all the times. The clutch housing and the cover provided with openings, dissipate the
heat generated by the friction during the clutch operation.
2. Driven members: The driven member consists of a disc or plate, called the clutch plate. It is
free to slide lengthwise on the splines of the clutch shaft (primary shaft). It carries friction
materials on both of its surfaces. When it is gripped between the flywheel and the pressure
plate, it rotates the clutch shaft through the splines.
3. Operating members: The operating members consist of a foot pedal, linkage, release
bearing, release levers and the springs.
Gear Box (Transmission Case) Assembly

Input
Output shaft
shaft No. 1

Fork

Defferential

Fig : Gear Box and Gear

We need different gear ratios in the gear box or transmission system to enable the vehicle move in
different speed. At the time of starting the vehicle, maximum amount of torque available on the fly
wheel, for which low gear ratio has to be selected for the movement of the vehicle. As the engine
speed increases the amount of torque is reduced in the fly wheel and it is required to select higher
gear ratio.
Function:
1. The main purpose of the gear box is to provide a means to vary the leverage or torque ratio
between the engine and the road wheels as required.
2. The transmission also provides a neutral position so that the engine and the road wheels are
disconnected even with the clutch in the engaged position.
3. A means to reverse the car by selecting the reverse gear.

67
Exercise: Assignment
1. Make a list of parts of clutch assembly used in the vehicle:
S.No. List of parts of clutch
1
2
3
4
5

2. Draw the photograph of clutch of a vehicle:

3. Fill in the blanks:

a) Transmission system is used for __________.
b) Main parts of clutch are __________,__________and_________.
c) Different gear ratios in the _________ to enable the vehicle move in different speed.
d) Clutch main parts are_________, ____________ and Operating members.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Discuss the role of transmission system.
Part B
Discuss in class the following:
2
Why transmission is necessary?
2
Role of clutch in transmission system.
2
Function of gear box.
2
Transmission system and its component.

68
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to explain transmission system
Able to identify the components of transmission system

SESSION-7: FRONT AND REAR AXLE

Relevant Knowledge
For movement of a body of a car we need axle and steering system which transmit power to the
wheel.
Propeller Shaft
This is the hollow tubular shaft which transmits the drive from the gear box to the bevel pinion of final
drive. It consists mainly of three parts:
1. Shaft: As this has to withstand mainly torsional loads, it is usually made of tubular cross
section. It also has to be dynamically balanced.
2. One or two universal joints: Depending upon the type of rear axle drive used. The universal
joints account for the up and down movements of the rear axle when the vehicle is running.
3. Slip joint: Depending upon the type of drive, one slip joint may be there in shaft. This serves to
adjust the length of the propeller shaft when demanded by the rear axle movements.

C D

A
Snap Ring Type
E

M
Rear Propeller Shaft
N

Front Propeller Shaft

G F
L K

U-Bolt Type
J H

Fig : Propeller Shaft and Universal Joint

69
Front and Rear Axle
Front Axle
Front axle is usually a drop forging of steel. The axle has to take bending loads due to load of the
vehicle and also torque loads due to braking of the wheels. For this reason, front axle is made of
I-section in the central portion, while the ends are made either circular or elliptical.

A downward sweep is given to the centre portion to keep a low chassis height. Both the end of front
axle are mounted with stub axles with the help of king pin. The front road wheels are mounted on
stub axles.

1 2 3 4

10 7

Fig: Front Axle

Rear Axle

Ring gear
Axle shaft
Axle shaft
side gear
Axle shaft

Pinion gear
Axle hoarding

Pinion shaft
Universal joint

Differential
side gear

Fig: Rear Axle

The functions of rear axle are as follows:

1. It bears the weight of vehicle body and load due to occupants through springs.
2. It enables to transmit driving and breaking torque to the chassis frame and body of the vehicle.

70
3. It also experience the side thrust or pull due to any side load on the wheel.
4. It supports the bevel pinion (drive from propeller shaft transmit to the pinion), bevel gear, cage of
sun gear and star pinions, axle shafts and different support bearings.
5. Rear road wheels are mounted on the axle shaft.
6. The differential mechanism enables to move outer wheel faster than the inner wheel while
taking a turn.

Exercise: Assignment
1. Make a list of parts of front and rear axle used in the vehicle:
S.No. List of parts of front and rear axle
1
2
3
4
5

2. Draw the photograph of front and rear axle of a vehicle:

3. Fill in the blanks

a) Front and rear axle system is used for __________.
b) Main parts of front and rear axle are __________,__________and_________.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Discuss the role of front and rear axle.
Part B
Discuss in class the following:
2
Why front and rear axle is necessary?

71
2
Role of front and rear axle in transmission system.
2
Function of front and rear axle.
2
Front and rear axle and its component.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to explain front and rear axle
Able to identify the components of front and rear axle

SESSION-8: STEERING SYSTEM

Relevant Knowledge
Role of Steering is to turn the front wheels using a hand–operated steering wheel which is
positioned in front of the driver.
It consists of steering column, universal joints to allow it to deviate somewhat from a straight line.
Functions of Steering System: 1
1. It helps in swinging the wheels to the left or right.
2. It helps in turning the vehicle according to the 2
will of the driver.
3. It provides directional stability.
3
4. It helps in controlling wear and tear of tyres.
5. It helps in achieving the self-straightening effect. 4

6. It converts the rotary movement of the steering

5
wheel into an angular turn of the front wheels.
Rack and pinion steering mechanism:
7. It multiplies the effort of the driver by leverage in 1) Steering wheel 2) Steering column
order to make it fairly easy to turn the wheels. 3) Rack and pinion 4) Tie rod 5) Kingpin

8. It absorbs a major part of the road shocks thereby preventing them to get transmitted to the
hands of the driver.
Various components of steering system:
2
Steering wheel 2
Steering column
2
Steering linkage with universal joint 2
Steering gear box
2
Drop arm 2
Tie rod
2
Steering arm 2
Track rod with adjuster
2
Ball joints 2
Stub axle arm
Note: The steering system is fitted with the stub axle arm of front wheel with the help of ball joints.

72
Exercise: Assignment
1. Make a list of various components of steering system:

S.No. List of components

1
2
3
4
5

2. Draw the photograph of steering system of a vehicle:

3. Fill in the blanks:

a) Steering system is used for __________.
b) Main parts of steering system are __________,__________and_________.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Discuss the role of steering system.
Part B
Discuss in class the following:
2
Why steering system is necessary?
2
Role of power steering system.
2
Function of steering system.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to explain steering system
Able to identify the components of steering system

73
 SESSION-9: SUSPENSION SYSTEM
Relevant Knowledge
Suspension is the term given to the system of springs, shock absorbers and linkages that connects
a vehicle to its wheels. Suspension systems serve a dual purpose, contributing to the vehicle's road
holding/handling and braking for good active safety and driving pleasure, and keeping vehicle
occupants comfortable and reasonably well isolated from road noise, bumps, and vibrations, etc.
Importance of Suspension System
The main purposes of suspension system are as under:
1. To safeguard the occupants against road shocks and provide, riding comfort.
2. To minimize the effects of stresses due to road shocks on the mechanism of the motor vehicle
and provide a cushioning effect.
3. To keep the body perfectly in level while travelling over rough uneven ground, i.e. the up and
down movement of the wheels should be, relative to the body.
4. To isolate the structure of the vehicle from shock loading and vibration due to irregularities of the
road surface without impairing its stability.
5. To provide the requisite height to body structure as well as to bearthe torque and braking
reactions.
Functions of a Suspension System
1. It provides comfort.
2. It gives cushioning effect.
3. It relieves strain on the frame and other components due to the road shocks.
4. It maintains body level and prevents it from rolling.
5. It provides a good contact for road holding, i.e. the system must always keep the tyres in contact
with the road.
6. It transfers driving torque to the wheels as well as breaking force to the chassis.
Various Components of Suspension System
Mechanical Suspension
2
Leaf Springs
2
Coil Springs
2
Rubber Springs
2
Torsion bars
Hydraulic Suspension
2
Hydraulic Shock Absorber
2
Telescopic fork

74
Air Suspension
Compressed air is used for air suspension system.

Exercise: Assignment
1. List the component of Suspension system:
S.No. Name of component
1
2
3
4
5

2. Draw the photograph of parts of suspension system of a vehicle:

3. Fill in the blanks:

a) Propeller shaft is used for ___________.
b) Universal joint account for up and down movement of __________.
c) Slip joints is used for ___________.
d) Front axle is used for ________.
e) Rear axle helps in ____________.
f) Steering system help in swinging the wheels to the __________ or_______.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Discuss the suspension system.
Part B
Discuss in class the following:
2
Role of suspension system?

75
2
Function of suspension system.
2
Component of suspension system.
Performance standards/criteria covered by this assessment
Performance Standards Yes No
Able to draw propeller shaft
Able to identify the components of propeller shaft

SESSION-10: WHEEL AND TYRE

Relevant Knowledge
Wheels and Tyre
The wheel is an important component of a vehicle. Wheel is assembly hub, disc or spokes, rim, tyre
and tube. The wheels not only support the weight of the vehicle, but also protect it from the road
shocks. All the four wheels must resist the braking stresses and withstand side thrust.
Functions the wheel
1. Strong enough to withstand the weight of the vehicle.
2. Flexible to absorb the road shocks.
3. Able to grip the road surface.
4. Perfectly balanced dynamically and statically.
5. Light and easily remarkable.
Rim: The rim is the "outer edge of a wheel, holding the tire." It makes up
the outer circular design of the wheel on which the inside edge of the tire
is mounted on vehicles such as automobiles. For example, on a bicycle
wheel the rim is a large hoop attached to the outer ends of the spokes of
the wheel that holds the tire and tube.
Different types of Wheel Rims
2
Disc wheel rim.
2
Wire spoke wheel rim ( used in motor cycle, bicycle). Fig : Photograph of Rim

2
Split wheel rim (used in scooter).
2
Heavy vehicle wheel rim (available in three piece and four piece
including locking ring).
Tyre
The tyre is mounted on the wheel rim. It has to carry the vehicle load and
provide a cushioning effect. It must produce a minimum noise, while the
wheel is turning on the road. It resists the tendency for the vehicle to over
steer. It should have good grip while accelerating and braking the
vehicle on both the dry and wet roads. Fig : Photograph of Tyre

76
Desirable Tyre Properties
A tyre must have the following desired properties:
1. Non-skidding: The tyre should not skid or slip on the road surface. It should have good grip.
2. Uniform wear: The tyre must get wear uniformly over its outer circumference.
3. Load carrying: The tyre should be able to carry the vehicle load.
4. Cushioning: The tyre should be able to absorb vibrations set-up by the road surfaces, thus
providing cushioning effect.
5. Power consumption: While rooling on the road, the tyre should consume least power
developed by the engine.
6. Noise: The tyre should create minimum noise while running on the road.
7. Balancing: The tyre should be balanced dynamically as well statically.
Function of Tyre
1. Carry the load of the vehicle.
2. Absorb the small road shocks.
3. Reduce the vibration to some extent.
4. Transmit the power from the engine through gearbox propeller shaft and rear axle to the
ground with which the vehicle moves.
5. The treads made on the tyres grip the road for better traction.
Types of Tyre
1. Solid Tyre (used in baby cycle).
2. Tube Tyre (used in almost all types of vehicles).
3. Tubeless tyre ( used in modern cars).

Exercise: Assignment
1. List the different type of rim:

S.No. Name of Rim

1
2
3
4
5
6
7
8
9
10

77
2. Draw the photograph of wheel and rim of a vehicle:

3. Fill in the blanks:

a) Wheel is used for ___________.
b) Properties of tires are__________, ____________and _____________________.
c) Rim is used for ___________.
d) Tube is used for ________.
e) Rim is outer edge of ____________.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Discuss the wheel and tyre
Part B
Discuss in class the following:
1. Role of wheel and tyre.
2. Function of wheel.
3. Component of wheel.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to draw wheel and tyre
Able to identify the components of wheel and tyre

SESSION-11: BRAKE
Related Knowledge
Brake: Brakes are one of the most important control components of a vehicle. They are required to
stop the vehicle within the smallest possible distance and this is done by converting the kinetic
energy of the wheels into the heat energy which is dissipated into the atmosphere.

78
Functions of Brakes
There are two distinct functions of the brakes:
1. To stop or slow down the vehicle in the shortest possible distance in
emergencies.
2. To control the vehicle speed while moving on plain roads and hills.
Requirements of a good breaking system
1. The brakes should stop the vehicle in shortest possible distance and Fig : Brake
time.
2. The brakes should work equally well on fair or bad roads.
3. Pedal effort applied by the driver should not be more so as not to strain the driver.
4. Brakes should work equally well in all weathers.
5. It should have very few wearing parts.
6. It should require little maintenance.
7. Brakes, when applied should not disturb steering geometry.
8. There should be minimum sound when brakes are applied.
Types of Brakes
1. With respect of application:
(a) Foot brake
(b) Hand brake
2. With respect to the method of braking contact:
(a) Internal Expanding brakes
(b) External contracting brakes (e.g. disc brakes of automobile and railway brakes)
3. With respect to the brake gear:
(a) Mechanical brakes
(b) Power brakes
4. With respect to the nature of power employed:
(a) Vacuum brakes
(b) Air brakes
(c) Hydraulic brakes
(d) Hydraulic brake assisted with air
(e) Hydrostatic brakes
(f) Electric brakes

79
Exercise: Assignment
1. List the different types of brakes used in automobile:
S.No. Types
1
2
3
4
5

2. Draw the photograph of brake of a vehicle:

3. Fill in the blanks:

a) Brakes are used for __________ component of a vehicle.
b) Tubes are used for __________.
c) Functions of a brake is ________ or ________ vehicle.
d) Brake should work in ____________or _______ roads.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Role of brake
Part B
Discuss in class the following:
2
Importance of brake in the automobile.
2
Brake for the automobile.
2
Properties of good brake system.
Performance standards/criteria covered by this assessment
Performance Standards Yes No
Able to draw the brake
Able to identify different type of brake.

80
 SESSION-12: ELECTRICAL AND ELECTRONIC SYSTEM
Relevant Knowledge
It is a very important system of a car as now days all the automobile vehicles are running with the
help of electrical and electronic system.
Electrical and Electronics System
The electrical and electronic system consists of following:
2
Starting System: The starting motor is driven by means of the current taken from the battery.
2
Ignition System: The function of the ignition system is to produce a spark in the engine
combustion chamber at the end of the compression stroke.
2
Generating or Charging System: The function of the charging system in an automobile is to
generate, regulate and supply the electrical energy for charging the battery.
2
Lighting System: It consists of various types of lighting used during the vehicle running, such
as head light, tail light, fog light, brake light, reversing light, left and right indicators, parking
light, cabin light, panel board lights, etc.
2
Connections for other accessories:

Main Component of the Electrical System

Generating or
Starting System Ignition System Lighting System Accessories
Charging System

Battery
l Generator/
l Battery
l Head
l light Horns
l

Starting
l Motor Alternator Ignition
l switch Side
l light Wind
l screen
Motor
l Control Ammeter
l
Ignition
l coil Rear
l light wiper
The
l cut-out Distributor
l Fog Lamps
l
Electric
l fuel
Switch
l
pump
Spark
l plugs Number
l plate
The
l battery illumination lamp Fuel
l gauges
Contact
l breaker
Voltage
l and Interior
l lights Temperature
l
Automatic
l
current regulator gauge
advance and Indicator
l flashers
retard unit Radio
l sets

Vacuum
l control Cigar
l

unit lighter/mobile
phone charger
Heater
l

Wind
l screen
defroster
Signaling
l devices

NOTE: In modern vehicles various types of electronic sensors and actuators are fitted in different
system of the engines, which are also operated electrically.

81
Exercise: Assignment
1. List the different component using electrical and electronic system:
S.No. List of component
1
2
3
4
5

2. Draw the photograph of electrical items of a vehicle:

3. Fill in the blanks:

a) Electrical system are used for ___________.
b) Electronic system help __________ a vehicle.
c) Charging system is used for _______________ vehicle.
d) Important accessories used in vehicle having electrical system are _________.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Role of Electrical and Electronic System.
Part B
Discuss in class the following:
2
Importance of electrical and electronic system in the automobile.
2
Components using electrical and electronic system.
2
Advantages of electronic system.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to explain the advantages of electrical & electronic system

82
 SESSION-13: AIR CONDITIONING SYSTEM
Relevant Knowledge
Automobile Air Conditioner
During summer, an automobile requires considerable amount of
refrigerating capacity to maintain cool comfort conditions in the
sitting space. Similarly when moving in a cold day in winter, the
same vehicle would require considerable heating capacity to keep it
comfortably warm for passengers.
Modern day automobiles have an air conditioning unit to maintain
suitably controlled temperature and humidity conditions inside the Fig : Air Conditioner in Car
vehicle. An air conditioner is a refrigeration machine requiring
electrical energy. In automobiles its air conditioner draws energy from the battery system. The
battery of course is charged by energy of the engine.
For heating purposes, the warm water from the engine cooling system is used. The heat required to
warm the automobile is generally provided by circulating warm water through a heating coil.
The air conditioner also serves to clean the air along with the control of temperature level. During
summer days humidity of the air inside the vehicle is reduced with air-conditioner in operation. This
results in creating comfortable conditions inside the automobile.
Car air conditioner comes inbuilt in the car and same can be fitted in car also.
Different components of Automobile Air-conditioning system
2
Compressor
2
Magnetic Clutch
2
Condenser
2
Receiver-driver (or dehydrator)
2
Expansion valve
2
Evaporator
2
Suction throttling valve

Exercise: Assignment
1. List the different component of air conditioning system:

S.No. List of component

1
2
3
4
5

83
2. Draw the photograph of air conditioner of a vehicle:

3. Fill in the blanks:

a) Air conditioning system are used for ___________.
b). Air conditioning system help __________ in a vehicle.
c) Passive safety helps in __________.
d) Active system is used for _______________ vehicle.
e) Important accessories used in vehicle having air conditioning system are _________.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Role of Air Conditioning System.
Part B
Discuss in class the following:
2
Comfort used by active and passive safety.
2
Components of air conditioning system.
2
Advantages of air conditioning system.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to explain the advantages of Air Conditioning system

SESSION-14: ACTIVE & PASSIVE SAFETY

Relevant Knowledge
Active and Passive Safety and Security Systems
There are different safety and security systems are available in the market and some of which are
fitted by the manufacturer. Following are the few active and passive security systems.

84
Safety Glass
Safety glass is used in all auto windows and doors. The safety glass employed in today’s vehicles is
of two types: laminated or tempered. These types are considered to be safety glass because of their
construction.
Laminated plate glass is used to make all wind shields. This type of glass consists of two thin sheets
of glass with a thin layer of clear plastic between them. Some glass manufacturers have increased
the thickness of the plastic material for greater strength. When this type of glass is broken, the
plastic material will tend to hold the shattered glass in place and prevent it from causing injury.
Tempered glass is used for side and rear window glass but rarely for windshields. This type of glass
is a single piece of heat-treated glass and has more resistance to impact than regular glass of the
same thickness.
Seat Belts
A seat belt, sometimes called a safety belt, is a safety harness designed to
secure the occupant of a vehicle against harmful movement that may
result during a collision or a sudden stop.
A seat belt reduces the likelihood and severity of injury in a traffic collision
by stopping the vehicle occupant from hitting hard against interior
elements of the vehicle or other passengers, by keeping occupants
positioned correctly for maximum benefit from the airbag.
In most vehicles the passenger must fasten the seat belt for crash
protection. The passive safety system operates automatically whenever
there is an accident. No action is required of the occupant to make it
Fig : Seat Belt
functional.
In modern cars seat belts are also provided for rear seat occupants also.
Air Bags
An airbag is a vehicle safety device. This is one of the passive
safety systems for the occupants of car. The electrical system of
air bags includes the impact sensors and the electronic control
module.
When there is an accident the sensor detects the impact and the
air bag operates to save the driver and other occupants. Fig : Air Bags

Energy-Absorber Safety Bumpers

Modern bumpers are designed to absorb the energy of a low-speed impact, minimizing the shock
directed to the frame and to the occupants of the vehicle. Most energy absorbers are mounted
between the bumper face bar or bumper reinforcement bar and the frame.
Security and Antitheft Devices
There are three basic types of antitheft devices available: locking devices, disabling devices, and
alarm systems.

85
Exercise: Assignment
1. List the different Active & Passive safety device:
S.No. List of Devices
1
2
3
4
5

2. Fill in the blanks:

a) Air bags are used for ___________.
b) Seat belt __________ in a vehicle.
c) Passive safety helps in __________.
d) Active system is used for _______________ vehicle.
e) Important accessories used in vehicle having are _________.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Role of Active & Passive safety
Part B
Discuss in class the following:
2
Comfort used by active and passive safety
2
Components of active and passive safety
2
Advantages of active and passive safety.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to explain about active and passive safety
Able to identify the components of active and passive safety

Suggested Reading
Books
Title Author Publisher
Automobile Engineering Vol I Kirpal Singh Standard Publishers

86
 Automobile Engineering, Vol II Kirpal Singh Standard Publishers
Text Book of Automobile Engineering R. K. Rajput Laxmi Publications
Automobile Engineering R. K. Singal S. K. Kataria and Sons
Automobile Engineering Theory Kapil Dev Computech Publications
Automobile Engineering K. M. Moeed S. K. Kataria and Sons

Websites
2
auto.indiamart.com/auto-technology
2
www.automobileindia.com/consumer-guide/automobile-technology
2
auto.indiamart.com/auto-technology
2
books.google.com/books/about/Automobile_Engineering.html
2
www.bikeadvice.org
2
www.wikipedia.com
2
auto.indiamart.com/auto-technology
2
http://en.wikipedia.org/wiki/Airbag

List of Contributors
1. Mr. Sunil K. Chaturvedi, CEO, Automotive Skills Development Council, Core 4-B 5th Floor India Habitat
Centre, Lodhi Road, New Delhi – 110 003.
2. Mr. A.C. Deb, Sr. Lecturer, (Auto) – HOD, PUSA Polytechnic PUSA,New Delhi -110012.
3. Mr. Vikas Gautam, S.B.V. NO.1, Morigate, Delhi – 110006.
4. Prof. A.P. Verma, Ex-Prof. & HOD, PSSCIVE, Bhopal.
5. Sh. Deepak Shudhalwar, Assistant Professor, E & T Division, PSSCIVE, Bhopal.
6. Dr. Saurabh Prakash, Associate Professor, E & T Division, PSSCIVE, Bhopal – Programme Coordinato.

85
Unit-4 Road Safety

Introduction
All of you must have seen some road accident
in which people lose their life. India has a very
high number of accidents on the road. In
recent years there is some improvement in
this area. However, with rapid increase of
vehicles on the road the traffic conditions are
under a lot of pressure.
Therefore, road safety is one of the nation's
most serious public health issues. It has an
impact on everyone, whether you drive, walk
or cycle. We should take care of ourselves
and respect others on the road.
Fig : Road Accident
What is Road Safety
Road safety refers to methods be adopted by everyone while using roads. These safety methods
are meant for reducing the risk of accidents and injuries or causalities on the road. These rules must
be followed by all users of roads including pedestrians, cyclists, and motorists, bus & truck drivers.
Safety methods also relate to the construction, layout of roads as well as traffic regulation systems.
So we can summarise that road safety involves various aspects including:
The design of roads and highways
Laws pertaining to traffic and vehicles
Systems of traffic safety and control
Driver education
School student’s education about road safety
Mass education about road safety
Traffic and road safety signs
Vehicle design
Motor vehicle safety inspection and maintenance.
Actually it is not difficult to keep our roads safe. Imagine that everyone follows simple safety
measures and traffic rules. In that situation there will not be any accidents.
In this Unit, you will develop an understanding of the various types of road safety measures to be
adopted. You may understand Importance of safety rules, road signs, traffic signals and rules,
driving rules, registration and licensing adopted in our country.

86
 SESSION-1: IMPORTANCE OF ROAD SAFETY
Relevant Knowledge
Road Safety
Many studies have shown following major causes of road accidents are as follows:
2
Highway safety.
2
Driving in drunk condition.
2
Driving in sleepy condition.
2
Using cell phone while driving.
2
Over speeding / rash driving.
2
Driving in wrong lanes.
2
Turning without giving signal.
2
Overtaking from wrong side.
It can be seen that Road Safety is a collective responsibility. Therefore each one of us has to take
steps required of us:
Government and Public Sector
To develop stricter road safety polices.
Generate/ Create funds for road safety awareness.
Stricter enforcement by government.
Building of better roads and highways.
Role of General Community
Acceptance of Road Safety Rules, Regulations and Policies.
Participation in Road Safety Awareness Drives to enhance their knowledge on Road Safety.
Education Sector
Inclusion of Road Safety modules in school curriculum.
Impart Road Safety education with the help of experts in this area.
Impart effective Driver Training for learners as well as existing drivers.
Role of Media
Communicate road safety messages through print and electronic media Support Road Safety
initiatives through responsible and objective reporting.
Role of Health Professionals
Strengthen Trauma facilities in our country.
Organize workshops for saving the lives of people in road accidents.
Improvement in Infrastructure
Adopt effective and safe traffic management measures while planning designing of infrastructure.

87
For e.g. Proper road design, design of overbridges, road signages etc.
Hurdles in Road Safety
Negligence of Civilians.
Pathetic Condition of roads.
Unsafe Vehicle Design.
Under implementation of Road Safety Standards.
Lack of Emergency Services.
Important Schemes administered by Road Safety cell are:
2
Publicity Programs.
2
Grants-in-aid to Voluntary Organizations for organizing road safety programs.
2
National Highway Accident Relief Service Scheme.
2
Refresher Training to Heavy Vehicle Drivers in Unorganized Sector.
2
Setting up of Model Driving Training school.
2
Within the M.O.R.T.H.s massive road sector development program, the govt. is working
closely with agencies: World Bank, Asian Development Bank to improve road safety.
Road Safety Tips
Road safety is a result of contributing efforts from all the sectors of the society including both
civilians and Govt. officials. In addition to the human sufferings, the estimated costs of the road
injuries are a noticeable amount in GNP per annum. So, some tips can be fruitful in this direction.
Few important Road Safety Tips are mentioned below:
2
Don't use your mobile phone whilst driving.
2
Use belt in the back seat also.
2
Don't drink and drive.
2
Always adhere to speed limits.
2
Take special care about children, senior citizens and pedestrians.
2
Don't drive if tired.
2
Pedestrians should walk cautiously and always cross the road through Zebra crossing.
2
Always observe and anticipate actions by other road users.
2
Keep your distances and always wear helmets and seat belts.

Safety Devices

Fig : Bicycle Helmet Fig : Air Bags

88
 Fig : Two wheeler helmet Fig : Two wheeler helmet

Two Wheeler Helmet: A two wheeler helmet is a type of protective headgear used by motorcycle
and scooter riders. The primary goal of a two wheeler helmet is riders safety - to protect the rider's
head during impact, thus preventing or reducing head injury or saving the rider's life. Some helmets
provide additional conveniences, such as ventilation, face shields, ear protection etc.
Out of all the organs in our body, the heart and the brain are the most vital ones. When a two wheeler
is involved in an accident, it is the brain that might be at a greater risk of injury. And only the brain is
the one that might be affected the most. A brain injury can result due to skull fracture, a concussion,
brain hemorrhage, which can result in death.
Even if a part of the brain has been damaged, it might result in the loss of speech or motor skills. In
order to protect the brain one must wear a helmet. A motorcycle helmet protects the skull and the
brain from extensive damage.

Exercise: Assignment
1. List the Road safety rules followed in road:
S.No. Name of Rule
1
2
3
4
5
6
7
8
9
10

2. Observe and identify road safety poster in your school and draw their diagrams:

89
3. Fill in the blanks:
a) Accident take places in our daily life due to lack of _____ measure.
b) Road safety is emerging as a major __________ in the country.
c) Road safety is a ________ of contributing efforts from all the sectors of the society
including both _______ and _________.
d) Hurdles inroad safety are_________.___________and_________
e) Important rules of road safety cannot be___________.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Share hurdles of road safety in our country.
Part B
Discuss in class the following:
2
What is importance of road safety?
2
What are the road safety tips?
2
Why we should take care in road safety?
2
Road safety importance can not be ignored.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to list hurdle of road safety
Able to list road safety tips

SESSION-2: SAFE AND RESPONSIBLE DRIVING

Relevant Knowledge
Safe and Responsible Driving Getting ready to drive Before driving
2
Ensure that you are comfortable with your mental and physical condition.
2
Inspect your vehicle and observe the driving conditions.
While driving you should carry your driving licence, registration certificate, insurance certificate and
pollution control certificate. Transport and commercial vehicle drivers should carry the permits and
vehicle fitness certificates also. A combination of knowledge, skill and attitude is required to be a
safe driver.
Knowledge of traffic rules and driving practices that help traffic move safely. Skill to care about the
safety of others on the road. We all are responsible for avoiding accidents.

90
Attitude to co-operate with other drivers to keep
traffic moving safely. We must be courteous, giving
other drivers space to change lanes, not cutting
them off and signaling before turning.
Physical and mental alertness
Be in good physical and mental condition
before driving.
DON'T DRIVE IF YOU
2
have been drinking alcohol.
2
taking any medicine or drug that affects your responses.
2
are tired as tiredness affects your driving skills and reaction time.
2
are sick or injured.
2
are angry or upset.
You could be risking your life or lives of others on the road.
Know your vehicle
Go through the vehicle owner's manual.
You should know the features of the vehicle you are going to drive.
Example - Anti-lock brakes, 4-wheel drive.
Ensure you know where the controls and instruments are and what
they do. Check that all emergency signals and instruments work.
You should be able to turn on wipers, washers, headlights, indicators
etc. without having to look at them and without taking your eyes off Fig : Seat Belt
the road. Seating position Proper, upright position gives more
stability while driving. Make sure you can see over the steering wheel and hood. You should be able
to see the ground 4-5 feet in front of the vehicle for proper judgment.
Sit straight upright in the seat with your elbows slightly bent. Adjust the seat so your feet reach the
pedals easily. Place your feet flat on the floor under the brake pedal. You are seated properly if you
can do this. Adjust the head-rest to proper height. It protects in case of a collision.
Cars with air bags: Air bag can cause injuries if the seating position is incorrect.
Know your blind spots
Blind spot is an area on each side of the vehicle that you cannot see
through the mirrors. Mostly blind spots are to the back left and back
right of the vehicle. In the above graphic, the red car is in the blind
spot area of the silver car.
The green areas in the above graphic show the blind spots of the
silver car.Adjust the mirrors to get the maximum view and identify
your blind spots. You may not see vehicles when they are in these spots.

91
Position the interior mirror so that the centre of the mirror
shows the centre of the rear window. When the interior
mirror is properly adjusted you would be able to see
directly behind your vehicle.
The exterior (wing) mirror adjustment should be made
while seated normally for driving. Do not set the right-
hand exterior mirror by placing your head against the
glass of the driver's door window. Do not adjust the left-
hand exterior mirror by leaning to the centre of the Fig : Adjustment of Interior Mirror
vehicle.
Side mirrors show only narrow angles of view, so you have to turn your head to make sure there is
nothing in your blind spots.
Fasten your seat belt
Fasten your seat belt before you start. Seat belts are for
your safety not just for avoiding challans.
Seat belts should be worn comfortable enough to keep
you in your seat if there is a collision. Put the shoulder
strap over your shoulder, never under your arm. The lap
belt should be put low over the hips, not over the stomach.
Seat belt saves life
2
Seat belt keeps you behind the wheel and in control
of the vehicle in case of a collision.
2
Seat belt keeps your head and body from hitting the
inside of the vehicle.
2
Seat belt keeps you inside the vehicle in a collision. A
person who is thrown out of the vehicle during the
collision has a higher chance of getting serious
injury. Fig : Fasten your seat belt

Turn on headlights at night and in poor light

conditions
Turn on headlights around 30 minutes before sunset and
keep them on until 30 minutes after sunrise. Turn on your
lights when fog or rain reduces your visibility to less than
100 meters.
Keep your headlights clean and get them adjusted
regularly so that they aim properly. In dim light, use your headlights, not parking lights. Parking lights
are only for parking.
High beams are banned in cities like Delhi, Chandigarh and other cities. You should not use high
beams on roads. If you are travelling on a highway and using high beam headlights, switch to low

92
beams within 150 metres of an oncoming vehicle. Switch to your low beams when you are less than
60 meters behind another vehicle.

Exercise: Assignment
1. List the know your vehicle rule followed in driving:

S.No. Name of Rule

1
2
3
4
5
6
7
8
9
10

2. Draw the blind spot diagrams:

3. Fill in the blanks:

a) Safety belt is used in ____________.
b) Before driving you should have important__________ with you.
c) Mental status before driving should be _________.
d) Mirror is adjusted to see_________view.
e) Avoid _________ and__________while driving.

93
Checklist for Assessment Activity
Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Safety precautions have been taken while driving two or four wheeler.
Part B
Discuss in class the following:
2
Safe practices followed in car
2
Different signs for different purpose.
2
Blind spot while driving car.
2
Use of high beam in vehicle.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to state safety procedure while driving
Able to distinguish between various safety measures

SESSION-3: ROAD SIGNS

Relevant Knowledge
Arm Signals
Signal plays important role during smooth movement of traffic. Road signals are to be followed
systematically, otherwise it may lead to an accident. For use when direction indicator signals are not
used, or when necessary to reinforce direction indicator signals and stop lights.

I intend to move in to the I intend to move out to the I intend to stop.

left or turn left right or turn right

Indicating the car following

I intend to slow down. you to overtake.

94
 TRAFFIC SIGNS
Traffic signs are divided into 3 main categories
Mandatory/Regulatory signs
Cautionary signs
Information signs

Red circle instructs what Blue circle instructs Triangle cautions Blue rectangle informs
should not be done. what should be done.

TYPICAL CAUTIONARY SIGN

Right/Left Hand Curve: This sign is used where the direction of ali changes. The sign forewarns
the driver to reduce the speed and proceed cau along the road.

Right/Left Hair Pin Bend: This sign is used where the change in direction is so considerable that it
amounts to reversal of direction. The symbol bends to right or left depending upon the road
alignment.

Right/Left Reverse Bend: This sign is used where the nature of the reverse bend is not obvious to
approaching traffic and constitutes a hazard. If the first curve is to the right, a right reverse bend
shall be used. If the first curve is to the left, a left reverse bend is used.

95
Narrow Bridge: This sign is erected on roads Gap In Median: This gap is installed ahead of
in advance of bridges where the clear width a gap in the median of a divided carriageway,
between the kerbs or wheel guards is less other than an intersection.
than normal width of carriageway.

Narrow Road: This sign is normally found in Road Widens: This sign is normally found in
rural areas where a sudden reduction in width rural areas where a sudden widening of road
of pavement causes a danger to traffic. causes a danger to traffic, such as, a two-lane
road suddenly widening to a dual
carriageway.

Cycle Crossing: This sign is erected in Pedestrian Crossing: This sign is erected in
advance of all uncontrolled cycle crossings. advance of both approaches to uncontrolled
pedestrian crossings.

School: This sign is erected where school Men at Work: This sign is displayed only
buildings or grounds are adjacent to the road when men and machines are working on the
where the traffic creates a hazard to children. road or adjacent to it or on overhead lines or
poles. This sign is removed when the work is
completed.

96
Side Road Left/Right: This sign is displayed in advance of the side road intersections where a
large volume of entering traffic together with restricted sight distance is likely to constitute a hazard.
The driver is warned of the existence of a junction.

Y-Intersection: These signs are displayed on the approach to a bifurcation o any road. This sign
warns of the existence of a junction and no other indication given.

Major Road: These signs are displayed in advance of crossing with the major road, where a
sufficiently large volume of traffic together with a sufficiently large volume of traffic together with
restricted sight is likely to cause a hazard.

Staggered Intersection: This sign is used to indicate junctions where the distance between two
junctions is not more than 60 meters.

97
T-Intersection: This sign is displayed in Roundabout: This sign is used where it is
advance of T-junctions where the nature of necessary to indicate the approach to a
inter-section is not obvious to approaching roundabout.
traffic. This sign is used to warn the driver of
the existence of a junction.

Start of Dual Carriageway: This sign is End of Dual Carriageway: This sign is
displayed when a single carriageway ends displayed when a dual carriageway is ending
into a dual carriageway. and a single carriageway is starting.

Reduced Carriageway: These signs caution the driver of the reduction in the width of the
carriageway ahead. This is displayed on undivided carriageways when some portion of the
carriageway is closed or reduced for repairs.

Two Way Operation: This sign is used to Cross Road: This sign is displayed in
caution the driver of a changed pattern of advance of the cross road where a sufficiently
traffic operation of the carriageway expected large volume of crossing or entering traffic
to carry traffic in one direction only. with restricted sight distance is likely to
constitute a hazard.

TYPICAL CAUTIONARY SIGN

98
Cattle: This sign is used where there is Traffic Diversion on Dual Carriageway:
danger due to farm animals or cattle crossing This sign warns the driver of the diversion of
on the road. traffic from one carriageway to the other. It is
used on dual carriageway when one
carriageway is closed.

Falling Rocks: This sign is used wherever Ferry: This sign is used to warn the drivers
rocks are liable to fall on the road seasonally about the existance of a ferry crossing across
or throughout the year. The symbol may be a river.
reversed to show the side from which rockfall
is expected.

Lane Closure: This sign cautions the driver of the closure of a portion of the carriageway on multi-
lane highways.

Barrier: This sign is erected in advance of a Loose Gravel: This sign is used on section
gate controlling entry into a road. A definition of a road on which gravel may be thrown up
plate with words "SLOW BARRIER AHEAD" by fast moving vehicles.
or "TOLL BARRIER AHEAD" is also
displayed on the sign.

99
Overhead Cable: This sign cautions Quary Side or River Bank: This sign is used
driver of the presence of overhead power to caution the driver of the presence of water
transmission lines. by the side of the road and theimpending
danger.

Rough Road: This sign is posted where the Runway: This sign is used to warn the drivers
road is rough and the drivers are required to of the presence of runway ahead and
slow down their vehicles for safe travel. possible movement of the aircrafts.

Series of Bends: This sign is used to Slippery Road: This sign is used to warn that
installed to caution the driver of the presence the section of the road ahead may be
of zig-zag for a long distance over the section particularly slippery.
of road ahead.

Sudden Side Wind: This sign is used to Traffic Signals: This sign is used to caution
caution the driver of the danger of side winds the drivers of the presence of traffic signals.
which endangers the lives of travellers. This
sign is posted at places where such weather
conditions exist.

100
Unguarded Railway Crossing: This sign is used on the approaches of level crossings where there
are no gates or other barriers. An advance warning sign (with two bars) is installed at a distance of
200 meters and second sign (with one bar) is installed near the crossing.

Guarded Railway Crossing: This sign is used to warn traffic on the approaches to guarded railway
crossing. An advance warning sign (with two bars) is installed at a distance of 200 meters and
second sign (with one bar) is installed near the crossing.

Steep Ascent/Steep Descent: This sign is displayed before a steep upgrade/downgrade that may
constitute a hazard to traffic. A gradient of 10 per cent and above is considered steep gradient.

Sudden Side Wind: This sign is used to Traffic Signals: This sign is used to caution
caution the driver of the danger of side winds the drivers of the presence of traffic signals.
which endangers the lives of travellers. This
sign is posted at places where such weather
conditions exist.

Speed Breaker: This sign warns the drivers of the presence of a speed breaker.

101
 PARKING SIGNS

P P P P P P P
Parking Parking Scooter & Cycle Taxi Auto-rickshaw Cycle-rickshaw
This Both Motor Cycle Stand Stand Stand Stand
Side Sides Stand

SPEED LIMIT AND VEHICLE CONTROL SIGNS

Speed Limit: This sign is erected at the beginning of the section of the road or area covered by a
speed restriction, with numerals indicating the speed limit in kilometers per hour.

Width Limit: This sign is used where entry of Height Limit: This sign is erected in advance
vehicles exceeding a particular width is of an overhead structure where entry is
prohibited. prohibited for vehicles whose height exceeds
a certain limit.

Length Limit: This sign is used where entry Load Limit: This sign is used where entry of
of vehicles exceeding a particular length is vehicles is prohibited for vehic.
prohibited.

102
Axle Load Limit: This sign is used where entry of vehicles is prohibited for vehicles whose gross
load exceeds a certain limits.

PROHIBITORY SIGNS

Straight Prohibited or No Entry: These signs are located at places where the vehicles are not
allowed to enter. It is generally erected at the end of one-way-road to prohibit traffic entering the
roadway in the wrong direction and also at each intersection along the one-way road.

One Way Sign: These signs are located at the entry to the one-way street and repeated at
intermediate intersections on that street.

Vehicles Rrohibited in Both Directions: Horn Prohibited: This sign is used on

This sign is used at the approact end of the stretches of the road where sounding of horn
roads where entry to all types of vehicular is not allowed, near hospitals and in silence
traffic is prohibited, especially in areas which zones.
have been designed as pedestrian malls.

Cycle Prohibited: This sign is erected on Pedestrian Prohibited: This sign is erected
each entry to the road where cycles are to be on each entry to the road where pedestrians
prohibited. are to be prohibited.

103
Right/left Turn Prohibited: These signs are used at places where vehicles are not allowed to make
a turn to the right or left. The signs are also used at the inter-sections of one-way street to
supplement the one-way sign.

U-Turn Prohibited: This sign is used at Overtaking Prohibited: This sign is erected
places where vehicles are forbidden to make at the beginning of such sections of highways
a turn to the reverse direction of travel where sight distance is restricted and
between the sign and the next inter-section overtaking will be dangerous.
beyond it.

All Motor Vehicles Prohibited: This sign is Trucks Prohibited: This sign is used at the
used at places where entry to all types of entrance to the road where movement of
motor vehicles is prohibited. trucks is prohibited.

Hand Cart Prohibited: This sign is erected Bullock Cart Prohibited: This sign is
on each entry to the road where hand carts erected on each entry to the road where
are to be prohibited. bullock carts are to be prohibited.

Tonga Prohibited: This sign is erected on Bullock Carts & Hand Carts Prohibited:
each entry to the road where tongas are to be This sign is erected on each entry to the road
prohibited. where all types of slow moving vehicles
except cycles are to be prohibited.

104
 STOP AND GIVE WAY SIGNS

Stop Sign: This sign is used on roadways Give Way Sign: This sign is used to assign
where traffic is required to stop before right-of-way to traffic on certain roadways and
entering a major road. The vehicle shall intersections, the intention being that the
proceed past the stop line only after vehicles controlled by the sign must give way
ascertaining that ths will not cause any to the other traffic having the right-of-way.
damage to traffic on the main road.

RESTRICTION ENDS SIGN

This sign indicates the point at which all prohibitions notified by prohibitory signs for moving of
vehicles cease to apply.

COMPULSORY DIRECTION CONTROL AND OTHER SIGNS

Compulsory Turn Left/Right: These signs indicate the appropriate direction in which the vehicles
are permitted to proceed.

105
Compulsory Ahead or Turn Left/Right: These signs indicate the appropriate directions in which
the vehicles are permitted to proceed. Vehicles are supposed to move either of the given two
directions.

Compulsory Ahead: This sign indicates that Compulsory Keep Left: This sign is most
the vehicle is only permitted to proceed frequently used on bollards or islands and
ahead. refuges in the middle of the carriageway and
at the beginning of central reserves of dual
carriageway. The vehicles are obliged to keep
left only.

Compulsory Cycle Rickshaw Track: This Compulsory Sound Horn: This sign means
sign means only cycles and rickshaws are the motor vehicles shall compulsorily sound
allowed on this road/carriageway. horn at the location where the sign is placed.
This sign is mostly put at sharp curves on hill
roads.

Slip Road Ahead: This sign means the Main Road Ahead: This sign means the
vehicles can either go straight or turn left. vehicles can either go straight or turn right.

Pedestrians Only: This sign means only Buses Only: This sign means that only buses
pedestrians are allowed and the traffic is not are allowed and other traffic is not allowed on
allowed on this road / carriageway. this road/carriageway.

106
Exercise: Assignment
1. Draw various signs of traffic:

2. Fill in the blanks:

a) A traffic sign help in ____________movement of traffic.
b) Hand can also be used as ___________ in emergency.
c) Signal traffic light have__________, __________and ________colour.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
All traffic signal are drawn and displayed.
Part B
Discuss in class the following:
2
No entry sign.
2
Different signs for different purpose.
2
Signal role in road safety.
2
Safety signs for different purpose help whom.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to draw road safety sign
Able to distinguish between various safety road sign

107
 SESSION-4: DRIVING RULES AND REGISTRATION
Relevant Knowledge
The basic idea to devise driving rules is to make the traffic more organized and safe. Driving rules
are very important; Government has made driving rules for the citizen. These rules are to be
followed by every citizen. If you violate then you have to pay the fine or you have to appear in front of
court. Rule and their rule number with penalty is explained here.
Driving rules
S.No. Rules Description Rule No. Fine
1. Violation of mandatory signs 199/177/MVA Rs.100
2. Improper Parking 122/177/MVA Rs.100
3. Without Helmet 129/177/MVA Rs.100
4. Not using seat belt 138.3/CMVR/177 Rs.100
5. Dangerous Driving 184/MVA Rs.1000
6. Moving against one way 17RRR/177/MVA Rs.100
7. Using an registered 39/192/MVA Rs.2000
vehicle/Violation of R. C. Condition
8. Number plate note as per guidelines 50/177/CMVR Rs.100
9. Without Light/Head/Tail light 105 Rs.100
CMVR/177/MVA
10. Without Helmet pillion rider 129/!77/MVA Rs.100
11. Tripple riding 128/177/MVA Rs.100
12. Carrying passenger in goods Vehicles 84.2/OMVR Rs.100
177/MVA
13. Conductor without uniform 23 DMVR Rs.100
177 MVA
14. Driver without uniform 7DMVR Rs.100
177/MVA
15. Driver without permit/Violation of permit 66.1/192A/MVA To court
conditions
16. Without Registration Certificate 32/RRR/177/MVA Rs.100
17. Wrong overtaking 184/MVA Rs.1000
18. Violation of speed limit 112.1/183/MVA Rs.400
19. Use of Tinted Glass 100.2CMVR/177MVA Rs.100
20. Violation of stop line 177/MVA Rs.100
185/MVA
21. Drinking Driving 177/MVA To court

108
 22. Violation of no entry restrictions 115/194/MVA Rs.2000
23. Other/Unspecified violations u/s Rs.100

Registration
Whenever a vehicle is purchased then it is registered with State Transport office. All the district have
Road Transport Office (RTO). RTO gives a registration number to all road vehicles. Every vehicle is
fixed with a registration plate which is commonly known as number plates. These number plates are
placed in the front and back of the vehicle.

Registration Rules and Process

Necessity for Registration
No person shall drive any Motor Vehicle and no owner of Motor Vehicle shall cause or permit the
vehicle to be driven in any public place or any other place, unless the vehicle is registered in
accordance with Chapter 4 of IMV Act 1988.
Registration where to be made?
Every owner of Motor Vehicle shall cause the Vehicle to be Registered by a Registration Authority in
whose Jurisdiction he has residence or place of business where the vehicle is normally kept.
Temporary Registration
An application for Temporary Registration shall be made in Form 20 of the Central Motor Vehicle
Rules, 1989 prescribed for Registration, under the Act marked "Temporary" to the Registering
Authority or to the dealer dealing in the sale of New Motor Vehicles Recognised by the Transport
Commissioner. It shall not be necessary to fill in the items 23 to 32 of the Form notwithstanding that
be may be a Transport Vehicle.
Permanent Registration
An application for registration of a Motor Vehicle shall be made in Form 20 to the Registering
Authority within a period of 7 days from the date of delivery of such vehicle excluding the period of
journey and shall be accompanied by Sales certificate in Form 21.
2
Road worthiness certificate in Form 22 from the manufacturers (Form 22A from the Body
builder).
2
Valid Insurance Certificate.
2
Proof of Address (Ration Card, Electricity Bill, .....).
2
Design approval copy of STA in case Trailer or Semi Trailer.
2
Original Sales Certificate from the concerned Authorities in Form 21 in the case of Ex_Army
Vehicle.
2
Pollution Under control Certificate.
2
Customs Clearence Certificate in the case of Imported Vehicles.
2
Appropriate Fee as specified in Rule 81 of CMV Rules

109
Exercise: Assignment
1. List the types of forms used in RTO office while registering a vehicle:

S.No. Name of Forms

1
2
3
4
5
6
7
8
9
10

2. Fill in the blanks:

a) RTO is office used for _________ of vehicle.
b) Vehicle registration is made at _________ office.
c) Vehicle registration is compulsory for driving______________.
d) Minimum age of driving of a vehicle is _______year.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Differentiate between registration and license.
Part B
Discuss in class the following:
2
Why registration is required?
2
What are the different types documents used in registration?
2
What are advantages of using driving license?
2
Important rules of registration should be known to all.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to fill registration form
Able to distinguish different registration form

110
 SESSION-5: DRIVING LICENSE
Relevant Knowledge
Driving License
As you must know that while driving a vehicle a person or driver must have a valid document of
driving a vehicle. This document is called Driving License. We can say it driver's license/license or
driving license, It is an official document which states that a person may operate a motorized
vehicle, such as a motorcycle, car, truck or a bus, on a public roadway. Minimum age is 18 years for
all vehicles, however motor cycle having engine capacity below 50 cc may be driven at age of 16.
According to the Motor Vehicle Act 1988, a valid Driving License is necessary to drive any motor
vehicle on public roads.
2
Driving License is issued by the Regional Transport Office (RTO) of Motor Vehicles Inspector's
Office after the recipient has passed a driving test and has proved the required age.
2
The Driving License in India is segregated as Motorcycle License, Light Motor Vehicle (LMV)
license, and Heavy Motor Vehicle (HMV) License.
2
Learner's License is issued after passing a theory test.
2
The legislation of Driving License is done through the 'Rules of the Road Regulation' and the
Motor Vehicle Act 1988.
2
The driver of the vehicle is required to keep the original copy of the license while driving.
Types of Driving Licenses in India
To drive a motor vehicle in any public place an effective Driving License is necessary. By effective
Driving License it means license issued to a person authorizing him/her to drive vehicle of that
particular category. There are different types of licenses issued by the RTO offices. Here we will
discuss each of them separately.
1. Learner Driving License: This is a temporary license that is valid up to 6 months from the date
of issue. It is basically issued to learn driving of Motor Vehicles.
2. Permanent Driving License: Permanent driving license is issued to those who become
eligible for it after thirty days (to apply within 180 days) from the date of issue of the learner
license. Person suppose to get permanent driving license should be conversant about the
vehicle systems, driving, traffic rules & regulations.
3. Duplicate Driving License: In case of loss, theft, or on mutilation, Duplicate License is issued.
The documents to be produced are FIR of the lost license, challan clearance report from RTA
Office (in case of Commercial licence renewal) and an application in Form LLD. The particulars
are verified by the authority from the records. The duplicate license will have the valid period
same as the previous license. If the license is lost and expired by more than 6 months it
requires permission from Head Quarter of Transport Department.
It is recommended to keep a photocopy of the original license or particulars of license noted in
order to make it easier for the issuing authority to locate the particulars from their record.

111
4. International Driving License: The motor licensing authority also issues International Driving
License. The validity of this license is for one year. Person visiting the country is required to
collect the license from there within one year period. Apart from address proof and birth
certificate, one has to produce a valid passport and valid visa while applying.
5. Motorcyle License or Two-wheeler License: Two-wheeler license is issued by the Regional
Transport Authority (RTO) to permit driving of only two-wheeler vehicles like bike, scooter and
moped.
6. Light Motor Vehicle License (LMV): Light Motor Vehicle License is issued to drive light
vehicles like auto rickshaws, motor car, jeep, taxi, three-wheeler delivery vans, etc.
7. Heavy Motor Vehicle License (HMV): Heavy Motor Vehicle License is issued to drive heavy
vehicles like trucks, buses, tourist coaches, cranes, goods carriages, etc. A person with HMV
license can drive light vehicles but Light Motor Vehicle License do not permit to drive heavy
vehicles.

Exercise: Assignment
1. List the types of forms used in RTO office while making a licence:

S.No. Name of Forms

1
2
3
4
5
6
7
8
9
10

2. Fill in the blanks:

a) RTO is office used for _________ of vehicle2. Driving licence is made at _________ office.
b) License is compulsory for driving______________.
c) Minimum age of driving licence of a vehicle is _______year.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Differentiate between temporary and permanent license.

112
Part B
Discuss in class the following:
2
Why license is required?
2
What are the different types documents used in license?
2
What are advantages of using driving license?
2
Important rules of license should be known to all.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to fill license form
Able to distinguish different license form

Suggested Reading
Books
Title Author Publisher
Automobile Engineering Vol I Kirpal Singh Standard Publishers
Automobile Engineering, Vol II Kirpal Singh Standard Publishers
Text Book of Automobile Engineering R. K. Rajput Laxmi Publications
Automobile Engineering R. K. Singal S. K. Kataria and Sons
Automobile Engineering Theory Kapil Dev Computech Publications
Automobile Engineering K. M. Moeed S. K. Kataria and Sons

Websites
2
auto.indiamart.com/auto-technology
2
www.automobileindia.com/consumer-guide/automobile-technology
2
auto.indiamart.com/auto-technology
2
books.google.com/books/about/Automobile_Engineering.html
2
www.bikeadvice.org
2
www.wikipedia.com
2
auto.indiamart.com/auto-technology
2
http://drivingtest.in/forms-fees-procedure.php
2
http://en.wikipedia.org/wiki/Driving_licence_in_India
2
http://india.gov.in/howdo/howdoi.php?service
2
www.chandigarhtrafficpolice.org

113
List of Contributors
1. Mr. Sunil K. Chaturvedi, CEO, Automotive Skills Development Council, Core 4-B 5th Floor India Habitat
Centre, Lodhi Road, New Delhi – 110 003.
2. Mr. A.C. Deb, Sr. Lecturer, (Auto) – HOD, PUSA Polytechnic PUSA, New Delhi -110012.
3. Mr. Vikas Gautam, S.B.V. NO.1, Morigate, Delhi – 110006.
4. Prof. A.P. Verma, Ex-Prof. & HOD, PSSCIVE, Bhopal.
5. Sh. Deepak Shudhalwar, Assistant Professor, E & T Division, PSSCIVE, Bhopal.
6. Dr. Saurabh Prakash, Associate Professor, E & T Division, PSSCIVE, Bhopal – Programme
Coordinator.

114
 Automobiles and Our
Unit-5 Environment
Introduction
Pollution is of great concern to the human race. As we know that we are not able to conserve our
environment properly. If we don’t start conserving our environment then our natural resources will
be depleted / finished soon. Pollution in any form is dangerous. Pollution of air, water, noise has to
be controlled to save our environment. It is necessary for us to adopt national and international
emission standards which ensure better utilization of resources. These standards help in controlling
the pollution. Governments all over the world are now serious about environment. Therefore, we get
emission standards to follow in design & maintenance of automobiles. All the product and services
have to follow national standards. Now day’s strict measures are being taken by car designers to
adopt Bharat Standard (BS). You must have noticed BSIV written on vehicles. This is the latest
version of emission standards to be followed in India. Similarly all the vehicles are supposed to carry
PUC certificate so that pollution is controlled. You should visit a nearby petrol pump and observe
how they check pollution coming out of an automobile.
In this Unit, you will develop an understanding of the air pollution, auto emissions, Standards like
EU/BS, PUC Certification and ways to control pollution.

SESSION-1: AIR POLLUTION

Relevant Knowledge
Air Pollution
Human population size has grown enormously over the last hundred years. This means increase in
demand for food, water, home, electricity, roads, automobiles and numerous other commodities.
These demands are exerting tremendous pressure on our natural resources, and are also
contributing to pollution of air, water and soil. The need of the hour is to check the degradation and
depletion of our precious natural resources and pollution without halting the process of
development.
Pollution is an undesirable change in physical, chemical or biological characteristics of air, land,
water or soil. Agents that bring about such an undesirable change are called pollutants. In order to
control environmental pollution, the Government of India has passed the Environment
(Protection) Act, 1986 to protect and improve the quality of our environment (air, water and soil).
Air Pollution and Its Control
We are dependent on air for our respiratory needs. Air pollutants cause injury to all living organisms.
They reduce growth and yield of crops and cause premature death of plants. Air pollutants also
deleteriously affect the respiratory system of humans and of animals. Harmful effects depend on the
concentration of pollutants, duration of exposure and the organism. Smokestacks of thermal power
plants, smelters and other industries release particulate and gaseous air pollutants together with

115
harmless gases, such as nitrogen,
oxygen, etc. These pollutants must be
separated/ filtered out before releasing
the harmless gases into the atmosphere.
Automobiles are also a major cause for
atmospheric pollution at least in the metro
cities. Actually it is the badly designed and
badly maintained automobiles that are a
major cause of air pollution. You must
have seen on roads a bus or truck or car
or tempo releasing black smoke. This is
because of poor maintenance of the Fig : Photograph of Air Pollution
vehicle. This happens when engine is not
burning the fuel completely or properly. It can also happen because of improper mixture of air and
fuel or perhaps the poor quality of fuel could be the reason. As the number of vehicles increase on
the streets, this problem is now shifting to the other cities also. Proper maintenance of automobiles
along with use of lead-free petrol or diesel can reduce the pollutants they emit. Catalytic converters,
having expensive metals namely platinum-palladium and rhodium as the catalysts, are fitted into
automobiles for reducing emission of poisonous gases. As the exhaust passes through the catalytic
converter, unburnt hydrocarbons are converted into carbon dioxide and water. Also, carbon
monoxide and nitric oxide are changed to carbon dioxide and nitrogen gas, respectively. Motor
vehicles equipped with catalytic converter should use unleaded petrol because lead in the petrol
reduces effectiveness of the catalyst.
Controlling Vehicular Air Pollution: A Case Study of Delhi
With its very large population of vehicular traffic, Delhi leads the country in its levels of air-pollution –
it has more cars than the states of Gujarat and West Bengal put together. In the 1990s, Delhi ranked
fourth among the 41 most polluted cities of the world. Air pollution problems in Delhi became so
serious that a public interest litigation (PIL) was filed in the Supreme Court of India. After being
censured very strongly by the Supreme Court, under its directives, the government was asked to
take, within a specified time period, appropriate measures, including switching over the entire fleet
of public transport, i.e., buses, from diesel to compressed natural gas (CNG).
It was nice that the government of Delhi decided to convert all the buses of to run on CNG by the end
of 2002. This resulted in dramatic improvement in the pollution levels.
You may ask the question as to why CNG is better than diesel. The answer is that CNG burns most
efficiently and completely. On the other hand petrol or diesel are partly left un burnt. Moreover, CNG
is cheaper than petrol or diesel, cannot be siphoned off by thieves and cannot be adulterated like
petrol or diesel. The main problem with switching over to CNG is the difficulty of laying down
pipelines to deliver CNG through distribution points/pumps and ensuring uninterrupted supply.
Therefore you may have noticed long ques at the CNG stations.
Simultaneously parallel steps are also being taken for reducing vehicular pollution include phasing
out of old vehicles, use of unleaded petrol, use of low-sulphur petrol and diesel, use of catalytic
converters in vehicles, application of stringent pollution level norms for vehicles, etc.

116
The Government of India through a new auto fuel policy has made a plan to cut down vehicular
pollution in Indian cities. More stringent norms for fuels means steadily reducing the sulphur and
aromatics content in petrol and diesel fuels. Euro II norms, for example, stipulates that sulphur be
controlled at 350 parts-per-million (ppm) in diesel and 150 ppm in petrol. Aromatic hydrocarbons
are to be contained at 42 per cent of the concerned fuel. The goal, according to the roadmap, is to
reduce sulphur to 50 ppm in petrol and diesel and bring down the level to 35 per cent.
Corresponding to the fuel, vehicle engines will also need to be upgraded.
All automobiles and fuel-petrol and diesel – were to have met the Euro III emission specifications in
these 11 cities from April 1, 2005 and have to meet the Euro-IV norms by April 1, 2010. The rest of
the country will have Euro-III emission norm compliant automobiles and fuels by 2010. Thanks to
the efforts made, the air quality has significantly improved in some cities like Delhi. According to an
estimate, a substantial fall in CO2 and SO2 level has been found in Delhi between 1997 and
2005.This has been possible by introducing CNG buses on the roads.

Exercise: Assignment
1. List the reasons for Air Pollution:
S.No. Reasons for Air Pollution
1
2
3
4
5
6
7
8
9
10

2. Observe and identify Air Pollution poster in your school and draw their diagrams:

117
3. Fill in the blanks:
a) Need of the hour is to check the ________ and __________ of our precious natural
resources and pollution.
b) In order to control environmental pollution, the Government of India has passed the
________________) Act, 1986 to protect and improve the quality of our
____________(air, water and soil).
c) Air pollutants deleteriously affect the _______ system of humans and of animals.
d) Full form of CNG is __________________.
e) Automobiles are a major _____________for atmospheric pollution.
f) Euro II norms, for example, stipulate that sulphur be controlled at _________ parts-per-
million (ppm) in diesel and ________ ppm in petrol.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Share importance of air pollution.
Part B
Discuss in class the following:
2
Why control of air pollution is necessary?
2
What is the role of convertor in automobile?
2
Case study of pollution control in Delhi.
2
Importance of using CNG.
2
Which first city has followed strictly air pollution norms?
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to explain reason of air pollution
Able to explain measure to control air pollution

SESSION-2: AUTO EMISSIONS AND EU/ BS STANDARDS

Relevant Knowledge
Sometimes you must have seen black or white smoke
coming from car, scooter, tempo or truck. This smoke is a
byproduct of combustion process and from evaporation of
fuel itself. This smoke is called pollution. It is also known as
auto emission.

118
Auto Emissions
When emission from automobiles carry unburnt hydrocarbons it causes air pollution. Pollution from
cars comes from by-products of this combustion process (exhaust) and from evaporation of the fuel
itself.

Fig : Photograph of Automobile Emission

The Combustion Process

Petrol and diesel fuels are mixtures of hydrocarbons, compounds which contain hydrogen and
carbon atoms. In a “perfect” engine, oxygen in the air would convert all the hydrogen in the fuel to
water and all the carbon in the fuel to carbon dioxide. Nitrogen in the air would remain unaffected. In
reality, the combustion process cannot be “perfect,” and automotive engines emit several types of
pollutants.

Emission Standards
Governments and regulatory bodies all over the world sit down with Automobile companies and list
down requirements that set specific limits to the amount of pollutants that can be released into the
environment. Many emissions standards focus on regulating pollutants released by automobiles
(motor cars) and other powered vehicles but they can also regulate emissions from industry, power
plants, small equipment such as lawn mowers and diesel generators. Frequent policy alternatives
to emissions standards are technology standards (which mandate Standards generally regulate
the emissions of nitrogen oxides (NOx), sulfur oxides, particulate matter (PM) or soot, carbon
monoxide (CO), or volatile hydrocarbons (see carbon dioxide equivalent.

119
Emission Norms in India
With more and more vehicles coming on the roads there is possibility of large scale pollution caused
bt these vehicles. However, if vehicles are designed and maintained as per regulations then this
danger will be reduced considerably.
It was only in 1991 that the first stage emission norms came into force for petrol vehicles and in 1992
for diesel vehicles. From April 1995 mandatory fitment of catalytic converters in new petrol
passenger cars sold in the four metros of Delhi, Calcutta, Mumbai and Chennai along with supply of
Unleaded Petrol (ULP) was affected. Availability of ULP was further extended to 42 major cities and
now it is available throughout the country.
The emission reduction achieved from pre-1989 levels is over 85% for petrol driven and 61% for
diesel vehicles from 1991 levels.
In the year 2000 passenger cars and commercial vehicles started meeting Euro I equivalent India
2000 norms, Euro II equivalent Bharat Stage II norms are in force from 2001 in 4 metros of Delhi,
Mumbai, Chennai and Kolkata.
India is still behind Euro norms by few years. These are standards followed by European countries.
However, with many vehicles manufactured in India now being exported a beginning has been
made, and emission norms are being aligned with Euro standards and vehicular technology is
being accordingly upgraded. Indian Vehicle manufactures are also working towards bridging the
gap between Euro standards and Indian emission norms.
Bharat stage emission standards are emission standards instituted by Government of India to
regulate the output of air pollutants from internal combustion engine equipments, including motor
vehicles. The standards and the timeline for implementation are set by the Central Pollution Control
Board under the Ministry of Environment & Forests.
Now a days India has adopted Bharat stage –IV norms in automobile sector. For metro cities it has
become compulsory to use standard product.
The implementation schedule of EU emission standards in India is presented here in Table 1.

Table 1
Indian Emission Standards (4-Wheel Vehicles)
Standard Reference Date Region
Nationwide
2000
India 2000 Euro 1 NCR*, Mumbai,
2001
Kolkata, Chennai
2003.04 NCR*, 11 Cities†
Bharat Stage II Euro 2
2005.06 Nationwide
2005.06 NCR*, 11 Cities†
NCR*, 11 Cities†
Bharat Stage III Euro 3 2010.14
Nationwide
Bharat Stage IV Euro 4 2010.14 NCR*, 11 Cities†

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 * National Capital Region (Delhi)
† Mumbai, Kolkata, Chennai, Bangalore, Hyderabad, Secunderabad, Ahmedabad,
Pune, Surat, Kanpur and Agra
The above standards apply to all new 4-wheel vehicles sold and registered in the respective
regions. In addition, the National Auto Fuel Policy introduces certain emission requirements for
interstate buses with routes originating or terminating in Delhi or the other 10 cities.
For 2-and 3-wheelers, Bharat Stage II has been applicable since April 1, 2005 and Stage III
standards came in force from April 1, 2010.

Exercise: Assignment
1. List the reasons for auto emission pollution:

S.No. Reasons for Emission

1
2
3
4

2. Observe and identify auto emission of vehicle in your area and make sketches of your
observations:

3. Fill in the blanks:

a) Burning of fuel takes place in the ________ of automobile to give power to vehicle.
b) Smokes are byproduct of ___________ process (exhaust) and from ____________ of
fuel itself.
c) First stage emission norms came into force for petrol vehicles in the year___________.
d) Emission reduction achieved from pre-89 levels is ______ for petrol driven and
__________ for diesel vehicles from 1991 levels.
e) Euro II equivalent Bharat Stage II norms are in force from 2001 in 4 metros of _______,
___________, _________ and_________.

121
Checklist for Assessment Activity
Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Share role of emission in air pollution.
Part B
Discuss in class the following:
2
Why emission control of air pollution is important?
2
What is Bharat standards/Euro standard in automobile?
2
How control of emission helps.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to explain importance of emission norms
Able to discuss about bharat standards

SESSION-3: PUC CERTIFICATION

Relevant Knowledge
In this chapter you have learnt about various aspects of automobile pollution and measures taken to
control pollution.
Adulteration of fuel leads to the weak combustion process and ultimately leads to pollution. You
must have read in newspaper that some petrol pump owner’s adulterate petrol with kerosene to get
higher margin of profit. They should not do this because it causes incomplete combustion which
leads to air pollution from vehicles using adulterated petrol. Steps have also been taken to improve
the quality of fuel. Proper maintenance of vehicle keeps pollution check by reducing the emission.
Gradually, new measures like lead free fuel, CNG fuel, biofuel etc are also being adopted in
automobile sector.
Hence quality of fuel is very important. The Fuel Quality plays a very important role in meeting the
stringent emission regulation. The fuel specifications of petrol and diesel have been aligned with the
Corresponding European Fuel Specifications for meeting the Euro II, Euro III and Euro IV emission
norms.
As you have learnt that the use of alternative fuels has been promoted in India both for energy
security and emission reduction. Delhi and Mumbai have more than 100,000 commercial vehicles
running on CNG fuel. Delhi has the largest number of CNG commercial vehicles running any where
in the World. India is planning to introduce Biodiesel, Ethanol Gasoline blends in a phased manner
and has drawn up a road map for the same.
The Indian auto Industry is working with the authorities to facilitate introduction of alternative fuels.
India has also setup a task force for preparing the Hydrogen road map. The use of LPG has also

122
been introduced as an auto fuel and the oil industry has drawn up plans for setting up of Auto LPG
dispensing station in major cities.
Pollution Under Control (PUC) Certificate
Presently, all vehicles need to undergo a periodic emission check (3 months/6 months) at PUC
Centers at Fuel Stations and Private Garages which are authorised to check the vehicles. It is
mandatory for every vehicle owner to carry a valid Pollution Under Control (PUC) Certificate and
maintain the vehicle with in prescribed emission norms.
You must have seen at a nearby petrol pump the Computerised facilities for checking of pollution
levels and issue of PUC Certificates (to vehicles meeting emission standards).These authorised
Pollution Checking Centres are spread in all cities. At present, number of Centres for petrol driven
vehicles and the diesel driven vehicles are functioning. These centres issue Pollution Under Control
Certificates (PUC) if the vehicle is found meeting prescribed emission norms. In case the vehicle is
found polluting beyond prescribed norms, necessary repairs/ tuning in the vehicle would be
required.
If a vehicle is not having the valid PUC pollution certificate, then is liable to be prosecuted under
Section 190(2) of the Motor Vehicles Act. A penalty of Rs.1000/- for first offence and Rs. 2000/- for
every subsequent offence of violation has been provided.
Fees for pollution checking are fixed by state transport department and it is very nominal like:-
Petrol / CNG / LPG vehicle Rs.25
Diesel vehicle Rs.50
Minor adjustment (Carbureted petrol vehicles only) Rs.5
If any vehicle is found polluting although it is carrying a valid PUC certificate then The PUC
Certificate of vehicle shall be cancelled and you will be directed (under Rule 116 of CMV Rules) to
produce a fresh PUC Certificate within seven days. The failure to comply with this direction would
result in prosecution under section 190(2) of the Motor Vehicles Act.. if vehicle is not polluting and
PUC Certificate has expired or I do not have a PUC Certificate then also offence of not having a PUC
Certificate also attracts prosecution under section 190(2) of the Motor Vehicles Act.
There are regulations also that require, transport vehicles to undergo an annual fitness check
carried out by RTOs for emissions, safety and road worthiness. Now the government is also
preparing plans for compulsory inspection of vehicles after a certain number of years.
Some other way to control pollution is to
Keep car one day off in a weak
Pool the car for going to office
Use bicycle for short distances
Keep your vehicle properly maintained
Delhi metro is best example of controlling pollution
and providing comfort to the public.

123
Exercise: Assignment
1. List the reasons for controlling pollution:
S.No. Reasons for Air Pollution
1
2
3
4
5
6

2. Prepare a poster depicting controlling of air pollution by better Designed and better
maintained automobiles:

3. Fill in the blanks:

a) New alternate fuel used in Delhi is_____________.
b) Meaning of PUC is ____________________________________.
c) PUC is checked at___________________.
d) Full form of CNG is __________________.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for pollution control.
Part A
2
Share importance of air pollution.
Part B
Discuss in class the following:
2
Why control of pollution is necessary ?
2
What is the purpose of PUC?
2
Important tips about controlling pollution.
2
Delhi metro is successful model of controlling pollution.
Performance standards/criteria covered by this assessment
Performance Standards Yes No
Able to explain importance of pollution control
Able to discuss about role of PUC

124
 Suggested Reading
Books
Title Author Publisher
Automobile Engineering Vol I Kirpal Singh Standard Publishers
Automobile Engineering, Vol II Kirpal Singh Standard Publishers
Text Book of Automobile Engineering R. K. Rajput Laxmi Publications
Automobile Engineering R. K. Singal S. K. Kataria and Sons
Automobile Engineering Theory Kapil Dev Computech Publications
Automobile Engineering K. M. Moeed S. K. Kataria and Sons

Websites
2
auto.indiamart.com/auto-technology
2
www.automobileindia.com/consumer-guide/automobile-technology
2
auto.indiamart.com/auto-technology
2
books.google.com/books/about/Automobile_Engineering.html
2
www.bikeadvice.org
2
www.wikipedia.com

List of Contributors
1. Mr. Sunil K. Chaturvedi, CEO, Automotive Skills Development Council, Core 4-B 5th Floor India Habitat
Centre, Lodhi Road, New Delhi – 110003.
2. Mr. A.C. Deb, Sr. Lecturer, (Auto) – HOD, PUSA Polytechnic PUSA, New Delhi -110012.
3. Mr. Vikas Gautam, S.B.V. NO.1, Morigate, Delhi – 110006.
4. Prof. A.P. Verma, Ex. HOD, PSSCIVE, Bhopal.
5. Sh. Deepak Shudhalwar, Assistant Professor, E & T Division, PSSCIVE, Bhopal.
6. Dr. Saurabh Prakash, Associate Professor, E & T Division, PSSCIVE, Bhopal – Programme
Coordinator.

125
 Introduction to Vehicle
Unit-6 Maintenance and Servicing

Introduction
Automobiles need Maintenance from time to time. Like we need to wash, bathe similarly our
automobiles also need to be kept clean. Automobiles have to run on dirty roads and in polluted
environment. Automobiles also run on uneven roads with pot holes and other obstructions.
Automobiles and its parts are subjected to loads as described above. This makes them either
damaged or in poor working condition. Therefore there is need for regular maintenance and
servicing of automobiles. Maintenance of an Automobile is usually done in a place called Auto
Workshop or Auto Service Station.
In this Unit, you will develop an understanding of the concept of vehicle maintenance and servicing.

SESSION-1: IMPORTANCE TO VEHICLE

MAINTENANCE AND SERVICING
Relevant Knowledge
As you know that there is increase in the number of vehicle in our city. Vehicles such as motorcycle,
scooter, bus, car, jeep, tempo, truck and tanker etc are running in the our cities.
Every new vehicle comes with a vehicle maintenance manual. Vehicle owner should read and use
this manual. This manual helps user for vehicle maintenance tips during driving. People after
getting a car or vehicle often care little about regular car maintenance.
Although you may be doing regular servicing of your vehicle, but with the help of vehicle
maintenance tips given in your vehicle maintenance manual, lasting of your vehicle can be
increased to a much greater extent.
The Vehicle Maintenance and Servicing is carried out when the vehicle completes certain kilometer
on its normal running and when the vehicle does not give proper performance. It is suggested that
vehicle owner should do regular and periodical checkup of their vehicle. Some of checks are given
her for users.
Daily Inspection (DI)
It is the responsibility of a driver or owner of a vehicle to carry out the following inspection/checks
daily before the starting of engine to avoid any type of breakdown on the road.
2
Check all the tyre pressure visually or hitting the tyre wall with the help of a stone piece and
judging the sound.
2
Check radiator coolant level.
2
Check the fan belts for looseness.

126
2
Check the level of engine oil.
2
Check the wind screen, rear view mirror and rear window glass for their cleanliness.
Maintenance Checkup
When you plan to go outside from your home for long distance travel, It is necessary to do some
routine checkup. We should read vehicle maintenance manual for more clarification. Some of
important checkups is to be done for better maintenance.
1. Topping of oil level
2. Proper tension of Belt
3. Battery for cleanliness and level of electrolyte (Add only distilled water for topping of electrolyte
water)
4. Brakes
5. Toping up of Coolant if required in the coolant reservoir
6. Check the Serviceability of cooling system Hoses
7. Proper Tyre inflation pressure
8. Air-conditioning.
Vehicle maintenance/checkup is generally done at vehicle service centre.
You must visit to nearby vehicle service centre and see how a vehicle is
being properly maintained.
We will be visiting a nearby vehicle service centre and see the how the Fig : Service Centre

common checkups are being made by service mechanic. Some of

important checkup are discussed here:
Check/Top up all vehicles’ oil levels: Service mechanic with the help of
measuring stick check the engine oil, coolant, brake oil, and water. During
routine checkup, oil, water, coolants are topped up otherwise it is changed.
Belt Checkup: Checking of belt is very important. If it is loose or broken Fig : Checking of Oil Levels
then it will be replaced immediately.
Battery: Battery is very important component of a vehicle. It should be
checked up regularly. Battery electrolyte (distilled water) is checked by
removing the battery caps and looking inside. If level is low, it will be topped
up by distilled water. Now day’s battery are maintenance free batteries.
Maintenance free batteries have sealed caps and require no checking. But
some batteries say maintenance free but do have removable caps. These Fig : Battery
should be checked in the usual manner.

Brakes: Service mechanic chekup the break also by pushing the pedal. If
he feels that there is need of servicing, he will inform to the customer.

Fig : Wheel Brakes

127
Cooling System: Technician checks the cooling system by topping up the
coolant. The cooling system should be refilled with the correct coolant.
Don't refill with just straight water.

Fig : Cooling System

Air-conditioning: Service mechanic will check the cooling and heating by
checking the airflow is coming from all appropriate vents.

Fig : Air-conditioning
Tyres: Mechanic will check the tyre by checking correct tyre pressures. He
will also see also external damage also if any.

Fig : Tyres

The Safety Rules during servicing of

vehicle to be followed: You have
visited the service station and seen that
service technician is doing their work
properly. During servicing of vehicle in a
garage or service station the technician
must follow some precaution and safety
rules to prevent the accidents to occur,
please observe that whether safety
rules are being followed or not. These
safety rules are:
2
Always select right tools for specific
job. The wrong tool could damage
the part being worked on and could
cause you to get heart.
Fig : Service Station
2
Keep your tools and equipments under control.
2
Wipe excess oil and grease off your hands and tools so that you can get a good grip on tools or
parts.
2
Work quietly and give full attention on your job.
2
Keep jack handles out of the way. Stand the creeper against the wall when it is not in use.

128
2
Do not put sharp objects, such as screw drivers, in your pocket. You could cut yourself or get
stabbed, you could damage the seat.
2
Make sure that technician cloths are right for the job and he should wear full leather safety
shoes.
2
If oil, grease, or any liquid spill on the floor, clean it up so that no one will slip and fall.
2
Always wear eye protection when using a grinding wheel or welding equipment or working with
chemicals such as solvents.
2
While using jack, place it properly to avoid slip.
2
Never run an engine in a closed garage that does not have proper ventilation system. The
exhaust gases contain carbon monoxide. Carbon monoxide is a colourless, odorless,
tasteless poisonous gas that can kill you.

Exercise: Assignment
1. List the pre checkup activity of a vehicle to be taken:

S.No. Pre Checkup Activity

1
2
3
4
5
6
7
8
9
10
2. Observe and identify vehicles in your area/ premises and suggest preventative
maintenance to be taken:

Type of Vehicle Preventive Maintenance

3. Fill in the blanks:

a) The Vehicle Maintenance and Servicing is carried out when the vehicle completes
_________ kilometer.
b) After overhauling the vehicle regains its almost __________________.
c) When you plan to go ________ from your home for long distance travel, take some time to
make sure that your________ is ready to take you to outside.

129
 d) During pre checkup following items like vital fluids, battery,_________, air conditioning,
____________, belt & hoses, cooling system should be touched.
e) Always select right _______ for specific job. The wrong tool could damage the part being
worked on and could cause you to get __________.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Pre check points of an vehicle.
Part B
Discuss in class the following:
2
What Safety Rules during servicing of vehicle to be followed?
2
Why right tools are selected for right jobs. List the reasons?
2
Important safety gadget should be used by service technician.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to list pre service checkup which should be done by
vehicle owner
Able to list safety precautions during vehicle checkup and servicing

SESSION-2: TIPS TO EXTEND THE LIFE OF VEHICLE

Related Knowledge
Care and Maintenance tips keep your car running in good condition. These tips will help in better
maintaining of a vehicle. You must observe these points in your daily life.
1. Drive the vehicle with care everyday
2. Be patient during the accident or breakdown of a vehicle, call helpline number of vehicle or
police or hospital
3. Buy petrol at reputable service stations
4. Don’t fill up if you see the tanker
5. Go easy when you’re stuck
6. Car key chain should be lighten
7. Preserve your car during long-term storage
8. Park in the shade
9. Clean the inside, too
10. Clean dash gauges carefully

130
11. Preserve door and window seals
12. Don’t try to carry too much
13. Use upholstery cleaners on soiled seats
14. Place a towel under baby seats
15. Protect car paint from the sun
16. Wash in winter
17. Wax to protect your car’s paint job
18. Maintain proper inflation
19. Check for uneven wear
20. Rotate your tires
21. Have wheel alignment checked
22. Top off your brake fluid
23. Care for anti-lock brakes
24. Check engine oil at every other fill-up
25. Change oil frequently
26. Don’t mix coolants
27. Avoid hose hassles
28. Test drive-belt tension
29. Clean your engine
30. Run your AC in winter
31. Maintain your car’s battery
32. Seal a leaky radiator
33. Dilute your coolant.

Exercise: Assignment
1 List some important safety tips of a vehicle:

S.No. Tips
1
2
3
4
5
6
7
8

131
2. Observe and draw maintenance practices done of a vehicle in your area:

3. Fill in the blanks:

a) Clean dash gauges ___________.
b) Let floor mats ________ winter’s beating.
c) Maintain proper inflation in ___________.
d) Protect ______paint from the sun .
e) Preserve door and _____________ seals.
f) Fix bad __________ stripping immediately.
g) Keep leather from ___________ and cracking.
h) Maintain your ____________car’s battery.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Importance of safety tips of a vehicle.
Part B
Discuss in class the following:
2
What is the use of servicing a vehicle?
2
Important service tips.
Performance standards/criteria covered by this assessment

Performance Standards Yes No

Able to list the tips of servicing of a vehicle
Able to list the servicing point of a vehicle

132
 SESSION-3: INTRODUCTION TO VEHICLE SERVICE PROCEDURE
Related Knowledge
During the visit of vehicle service centre, you must have seen that authorized automobile service
centre adopt certain procedure during service of a vehicle. We shall list the common activity done in
the centre. One of the most important part is Job Card and its filling procedure. At this level you must
know some of these servicing activities in your training programme.
Common activity in the workshop:
2
Job card and its filling procedure
2
Washing of vehicle and Washing Procedure
2
Engine Minor tune up
2
Oil Replacement
2
Checking of battery electrolyte level and top up
2
Clutch and brake free play and their adjustment
2
Lighting System, its various part and their checking
2
Identification of greasing points of wheelers and procedure of greasing
2
Checking of tyre inflation and procedure of inflation.
Job card and its filling procedure
When a vehicle owner enters in service centre. He is attended by supervising engineer. Customer
informs about vehicle defect After getting the feed back from the vehicle owner/driver regarding
defects of the vehicle, the supervising engineer in a service station or workshop carry out an
inspection on it. The defects pointed out or listed are noted down in a standard format, which is
called the Job card or Work Order.
In order to indicate his satisfaction with the diagnosis made by the supervising engineer, the
customer of the vehicle puts his signature on the Job card before the repairs on the vehicle are
started. The work assigned to the appropriate person to carry out the repairs. And the supervisor
puts his signature on the job card. The work order/Job card is prepared in duplicate.
Contents of a standard job card
2
Job card Number
2
Name address & phone no. of the Service Centre
2
Name address & phone no. of customer
2
Details of vehicle such as – Make; Model, Registration No., Chassis No, Engine No., Date of
Sale, Kms. Reading, Receiving date & time and delivery date & time by the service centre
2
Check list before trial
2
Customer’s observation
2
Job to be done
2
Estimated cost in Rs. for customer and Insurance company

133
2
Labour required
2
Name of Mechanic
2
Name & Signature of Supervisor
2
Customer’s authorization for repair and his signature
2
Acknowledgment.
Filling the Job Card: Almost all the information’s must be properly filled in the job card by the
supervisor and has to be signed by him and the customer also has to sign on the authorization for
work column. Then the repairing or servicing job on the vehicle is taken over. A standard job card is
shown below. The student must practice to fill the same.

134
Exercise: Assignment
1. List some important vehicle service procedure of a vehicle:
S.No. Vehicle Service Procedure
1
2
3
4
5
6
7
8
9
10

2. Fill in the blanks:

a) Job card is used for filling _________of a vehicle.
b) Customer of the vehicle puts his _________ on the Job card before the repairs on the
vehicle are started.
c) The work order/Job card is prepared in ____________.
d) Engine tune up means different things to different ________.
e) The work order/Job card is prepared in _____________.

Checklist for Assessment Activity

Use the following checklist to see if you’ve met all the requirements for Assessment Activity.
Part A
2
Importance of safety service procedure of a vehicle.
Part B
Discuss in class the following:
2
What is the use of servicing a vehicle?
2
Job card and its importance.
2
Activities during service of a vehicle.
Performance standards/criteria covered by this assessment
Performance Standards Yes No
Able to discuss safety service procedure

135
 Suggested Reading
Books
Title Author Publisher
Automobile Engineering Vol I Kirpal Singh Standard Publishers
Automobile Engineering, Vol II Kirpal Singh Standard Publishers
Text Book of Automobile Engineering R. K. Rajput Laxmi Publications
Automobile Engineering R. K. Singal S. K. Kataria and Sons
Automobile Engineering Theory Kapil Dev Computech Publications
Automobile Engineering K. M. Moeed S. K. Kataria and Sons

Websites
2
auto.indiamart.com/auto-technology
2
www.automobileindia.com/consumer-guide/automobile-technology
2
auto.indiamart.com/auto-technology
2
books.google.com/books/about/Automobile_Engineering.html
2
www.bikeadvice.org
2
www.wikipedia.com

List of Contributors
1. Mr. Sunil K. Chaturvedi, CEO, Automotive Skills Development Council, Core 4-B 5th Floor India Habitat
Centre, Lodhi Road, New Delhi – 110003.
2. Mr. A.C. Deb, Sr. Lecturer, (Auto) – HOD, PUSA Polytechnic PUSA, New Delhi -110012.
3. Mr. Vikas Gautam, S.B.V. NO.1, Morigate, Delhi – 110006.
4. Prof. A.P. Verma, Ex. HOD, PSSCIVE, Bhopal.
5. Sh. Deepak Shudhalwar, Assistant Professor, E & T Division, PSSCIVE, Bhopal.
6. Dr. Saurabh Prakash, Associate Professor, E & T Division, PSSCIVE, Bhopal – Programme
Coordinator.

136