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HEADLIGHT

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  Headlights Most cars have two head-lights with both upper and lower beams. They are mounted at the same level and at an equal distance from the centre of the vehicle. A headlight consists of a housing, the reflector, the light diffusing glass and the bulbs along with their sockets. The reflector concentrates the light, which is emitted by the bulb in all directions and then directs it ahead of the vehicle. The reflector is paraboloid in shape and its reflecting surface is "silvered", usually a thin coating of aluminium and protected by a thin film of quartz. The bulb consists of a coil or "coiled-coil" filament. The fixing tabs on the base of the bulb are located in such a way that the filament is accurately located at the focus of the reflector. Actually the bulbs are of the filament type with a built-in screen. The first filament i.e. for high beam or "far beam" is placed at the focus of the reflector. The other filament i.e., for low beam or "dim...
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ELECTROMECHANICAL RELAY

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Electromechanical Relay An electromechanical relay is a type of relay which function using a magnetic field produced by an electromagnetic coil when a control signal is applied to it. It is called as electromechanical since it has moving contacts in the output circuit which are operated by applying an electrical signal. Working Principle An electromechanical relay transfers signals between its contacts through a mechanical movement. It has three sections viz. input section, control section and output section. The input section consists of input terminals where a small control signal is to be applied. The control section has an electromagnetic coil which gets energised when control input signal is applied to the input terminals and the output section consists of an movable armature and mechanical contacts – movable and stationary, the movement of the armature makes or breaks the electrical circuit. When an input control voltage is applied to the electromagnetic coil, it gets magnetised ...
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STARTER MOTOR - COMPONENTS

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  Starter Motor components & their functions: Animation Armature The armature is an electromagnet, mounted on the drive shaft and bearings for support. It is a laminated soft iron core which is wrapped with numerous conductors loops or windings. Commutator The commutator is a section of the shaft at the rear of the housing on which the brushes run to conduct electricity. The commutator is made up of two plates attached to the axle of the armature. These plates provide the two connections for the coil of the electromagnet. Brushes The brushes run on a section of the commutator at the rear of the housing, making contact with the contacts of the commutator and conducting electricity. Solenoid The solenoid contains of two coils of wire that are wrapped around a moveable core. The solenoid acts as a switch to close the electrical connection and connects the starter motor to the vehicle's battery. Plunger The plunger works by using the connected vehicle battery and the solenoid to pu...
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DIRECTION INDICATOR CIRCUIT

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  AIM: DIRECTION INDICATOR CIRCUIT TOOLS & MATERIALS REQUIRED 1. Wire striper 2. Cutting plier 3. Combination plier 4. Fuse 5. Flasher unit 6. Buzzer 7. Hazzard switch 8. Toggle switch 9. Insulation tape 10. Wire - Required 11. Battery -12v 12. Battery clips Diagram PROCEDURE: 1. Right, left വശങ്ങളിലെ രണ്ട് ലൈറ്റുകൾ തമ്മിൽ പരസ്പരം connect ചെയ്യുക. 2. ബാറ്ററിയുടെ +ve ടെർമിനൽ ഫ്യൂസ് വഴി flasher unit ലേക്ക് connect ചെയ്യുക. 3. Flasher unit ന് parallel ആയി buzzer സ്ഥാപിക്കുക. 4. ഇവയുടെ out നേരിട്ട് hazzard switch ലേക്കും, toggle switch ലേക്കും connect ചെയ്യുക. 5. Hazzard switch ന്റെ രണ്ട് out point കളും left, right ഇൻഡിക്കേറ്ററിലേക്ക് loop ചെയ്ത് കൊടുക്കുക. 6. Toggle switch ന്റെ വലത് point left indicator ലേക്കും, ഇടത് point right indicator ലേക്കും connect ചെയ്യുക. 7. നാല് indicator ന്റെയും -ve വയറുകൾ loop ചെയ്ത് ബാറ്ററിയുടെ -ve terminal ലേക്ക് connect ചെയ്യുക. 8. ഇൻഡിക്കേറ്റർ ശരിയായി പ്രവർത്തിക്കുന്നു എന്ന് ഉറപ്പാക്കിയ ശേഷം inspection ന് വേണ്ടി submit ചെയ്യുക. RESULT : ഇൻഡിക്കേറ്റർ...
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HORN CIRCUIT

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  AIM : HORN CIRCUIT TOOLS & MATERIALS REQIRED: 1. Wire striper 2. Combination plier 3. Screw driver 4. Fuse 5. Insulation tape 6. Push button switch 7. Battery 12v 8. Battery clips 9. Relay - 4 leg Diagram PROCEDURE: 1. Connect the +ve terminal of battery to 30th pin of relay and the push button switch through a 15ohm fuse. 2. Then connect the out terminal of push button to the 85th point of relay by using a thin wire. 3. The 87th point of relay is connected to the horn directly by using a thick wire. 4. The - ve points from the horn and relay is connected to the -ve terminal of battery. 5. After completing the horn circuit, submit for the inspection. RESULT : The HORN CIRCUIT was completed successfully.
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BATTERY TESTING

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  AIM: CHECK THE CONDITION OF GIVEN BATTERY TOOLS & MATERIALS REQUIRED 1. Multimeter 2. Hydrometer 3. Screw driver (-) 4. Emery paper 5. Vaseline 6. Cotton waste 7. Beaker with water PROCEDURE : 1. ബാറ്ററിയുടെ 2 ടെർമിനലും clean ചെയ്യുക. 2. Multimeter ഉപയോഗിച്ച് ബാറ്ററി ടെസ്റ്റ്‌ ചെയ്യുക. 3. - scerw driver ഉപയോഗിച്ച് ബാറ്ററി ക്യാപ് remove ചെയ്യുക. 4. Hydrometer ഉപയോഗിച്ച് ഓരോ cell ന്റെയും reading എടുക്കുക. CALCULATION RESULT : തന്നിരിക്കുന്ന 12V ബാറ്ററിയിൽ _____ cell damage ഉം, ______% ചാർജും ഉണ്ട്.
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OVERHAULING OF STARTER MOTOR

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  AIM: OVERHAULING OF STARTER MOTOR TOOLS & MATERIALS REQUIRED: 1.10-11, 12-13 spanners 2. Screw driver (-) 3. Cir clip plier 4. Bench vice 5. Cleaning brush 6. Emery paper 7. Kerosene oil 8. Grease Diagram PROCEDURE : 1. 10mm സ്പാനർ ഉപയോഗിച്ച് എല്ലാ ഇലക്ട്രിക്കൽ കണക്ഷനുകളും വേർപെടുത്തുക. 2. 10/12mm സ്പാനർ ഉപയോഗിച്ച് solinoid സ്വിച്ച് remove ചെയ്യുക. 3. മോട്ടോറിന്റെ ലോങ്ങ്‌ ബോൾട്ട് അഴിച്ചുമാറ്റുക. 4. ആർമേച്ചർ, കാർബൺ ബ്രഷ് എന്നിവ പുറത്തെടുക്കുക. 5. Kerosene oil, cleaning brush & emery paper എന്നിവ ഉപയോഗിച്ച് എല്ലാ ഭാഗങ്ങളും clean ചെയ്യുക. 6. Damage ആയ ഭാഗങ്ങൾ മാറ്റി പുതിയത് സ്ഥാപിക്കുക. 7. Armature, bendex, carbon brush & shift lever എന്നിവ yoke ന് ഉള്ളിലേക്ക് ഘടിപ്പിക്കുക. 8. Back cover fit ചെയ്തതിനുശേഷം, solinoid switch fit ചെയ്യുക. 9. Starter motor പ്രവർത്തിക്കുന്നു എന്ന് ഉറപ്പാക്കിയ ശേഷം inspection ന് വേണ്ടി submit ചെയ്യുക. RESULT : തന്നിരിക്കുന്ന STARTER MOTOR വിജയകരമായി OVERHAUL ചെയ്തു.
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