AUTOTECH Kerala

Aim: OVERHAULING OFHORN & TUNING TOOLS REQUIRED : 1. SCREW DRIVER (-,x) 2. FEELER GAUGE 3. MULTY METER 4. 10mm D/E OPEN SPANNER MATERIALS REQUIRED 1. EMERY PAPER 2. COTTON WASTE 3. GREASE PROCEDURE Dismantling   Disconnect the wires from the horn assembly and remove the mounting nuts and take out the horn unit Remove the horn from the vehicle. Loosen the cover fixing screws. Remove the cover, packing washer, diaphragm assembly  and shim. Remove the terminal's nuts and washer. Remove the contact breaker assembly from the housing. Inspection Clean the contact breaker points with fine emery paper. If necessary, replace the points. Check the coil for continuity and resistance by an ohmmeter for 12 volt - 0.75 -0.85 ohm and for 24 volt - 3.25 -3.5 ohms. Replace the coil if found burnt or defective. Check the diaphragm visually, replace if it is found damaged. Check all the screw threads visually, and if necessary, replace the screws. Clean all the parts. Assembling ...

Aim : TRACING THE LIGHTING CIRCUIT IN A VEHICLE TOOLS REQUIRED     MULTY METER  12-13 OPEN END SPANNER  10-11 OPEN END SPANNER  SCREW DRIVER(-) MATERIALS REQUIRED . COTTON WASTE PROCEDURE Trace the battery cable from the battery (1) to the ammeter (2) and check for proper connections. Trace the wire from the ammeter (2) to the fuse unit (3) (or circuit breaker) and check for proper connections. Trace the wire from the fuse unit (3) to the junction box (4) and check for proper connections. Trace the wire from the junction box (4) to the headlamp switch (5) and check for proper connections. Trace the wire from the headlamp switch (5) to the dipper switch (6) and check for proper connections. Trace the wire from the dipper switch (6) to the connection of the headlamp's high beams (7a) and low beams (76) and check for proper connections. 7b Trace the wire from the high beam (7a) circuit to the beam indicator lamp (8) in the instrument panel. Trac...

AIM: DRILLING, REAMING & TAPPING TOOLS REQUIRED 1. TRY SQUARE & TAP WRENCH 2. 12" BASTARD FLAT & 6" SMOOTH FLAT FILES 3. COUNTER SUNK 4. CENTER PUNCH & HAMMER 5. TAP SET :- M6 AND M10 6. DRILL BITS :- 9.4mm, 4.2mm & 6mm. 7. REAMER :- 9.6mm, 4.7mm &10mm. MATERIALS REQUIRED 1. 100 x 50 x 12 M.S FLAT 2. MARKING BLUE 3. OIL 4. CLEANING BRUSH 5. COTTON WASTE PROCEDURE 1. FILE THE WORK PIECE INTO THE RECTANGULAR SHAPE OF 100mm LENGTH AND 45mm HEIGHT. ENSURE THAT ALL ADJACENT SIDES ARE MUTUALLY PERPENDICULAR TO EACH OTHER. 2. THEN MARK THE WORK PIECE AS PER THE GIVEN DRAWING BY USING A VERNIER HEIGHT GAUGE. 3. AFTER MARKING PUNCH ALL CENTER POINTS FOR DRILLING BY USING A CENTER PUNCH AND HAMMER. 4. DRILL THE WORK PIECE AS PER THE DRAWING BY USING 9.4mm, 4.2mm & 6mm. DRILL BITS. APPLY THE COOLANT WHILE DRILLING.  5. THEN REAM THE DRILLED HOLES FOR BETTER FINISHING BY USING 9.6mm, 4.7mm &10mm REAMERS. APPLY OIL WHILE REAMING. AFTER REAMING C...

TOOLS REQUIRED 1. VERNIER HEIGHT GAUGE 2. DIVIDER & STEEL RULE 3. SCRIBER & DOT PUNCH 4. BALL PEEN HAMMER 5. 12" BASTARD FLAT FILE 6. 6" FLAT SMOOTH FILE 7. VERNIER CALIPER MATERIAL REQUIRED 1. Dia. 45 x 5 M.S ROD 2. MARKING BLUE 3. CLEANING BRUSH 4. COTTON WASTE PROCEDURE 1. MARK THE VERTICAL AND HORIZONTAL CENTER LINES OF GIVEN WORK PIECE BY USING VERNIER HEIGHT GAUGE. 2.  THEN DRAW A HEXAGON IN THE SURFACE OF WORK PIECE BY USING A DIVIDER, SCRIBER AND STEEL RULE. ALSO APPLY THE MARKING BLUE IN TO THE SURFACE. 3. PUNCH THE HEXAGON WITH THE HELP OF A PUNCH AND HAMMER. 4. AFTER PUNCHING HOLD THE JOB ON THE BENCH VICE TIGHTLY. THEN REMOVE THE UNWANTED AREA BY FILING. 5. AT FIRST 12" BASTARD FLAT FILE IS USED TO REMOVE LARGE AMOUNT OF MATERIAL. 6. THE EXCESS MATERIAL (LESS AMOUNT) WAS REMOVED BY FILING USING A 6" FLAT SMOOTH FILE. 7. MAINTAIN FACE TO FACE DISTANCE OF HEXAGON AT 39mm. IT IS CHECKED BY USING A VERNIER CALIPER. 8. AFTER COMPLETION, DE...

AIM TO MAKE A ROUND FROM A SQUARE TOOLS REQUIRED 1. STEEL RULE & SCRIBER 2. CENTER PUNCH 3. BALL PEEN HAMMER 4. DIVIDER, SCRIBER 5. 10" SECOND CUT FLAT FILE 6. HACK SAW BLADE & FRAME 7. 6" SMOOTH FLAT FILE MATERIALS REQUIRED 1. 45 x 45 x 5mm. M.S. Flat 2. MARKING BLUE 3. COTTON WASTE PROCEDURE 1. INITIALLY CHECK THE DIMENSION OF GIVEN WORK PIECE WITH IN THE RANGE OF 45mm SQUARE AND 5mm THICK. 2. IF THE WORK PIECE HAVE LARGER IN SIZE, FILE THE JOB INTO THE RECOMMENDED DIMENSION. (SQUARE OF 45mm.) 3. THEN FIND OUT THE CENTER OF WORK PIECE BY MARKING THE DIAGONALS USING SCRIBER AND STEEL RULE. 4. PUNCH CENTER POINT OF WORK PIECE BY USING A CENTER PUNCH AND BALL PEEN HAMMER. 5. THEN APPLY THE MARKING BLUE INTO THE SURFACE OF WORK PIECE. 6. AFTER THAT MARK THE CIRCLE OF DIAMETER 45mm BY USING A DIVIDER POINTING THE CENTER OF JOB. THEN PUNCH THE MARKED LINES BY USING DOT PUNCH AND HAMMER. 7. THEN CUT OFF THE UNWANTED AREA OF WORK PIECE AS PER THE GIVEN DRAWING B...

AIM :  TO MAKE A 'T' - JOINT TOOLS REQUIRED 1. STEEL RULE & SCRIBER 2. TRY SQUARE & DOT PUNCH 3. 8" BASTARD FLAT FILE 4. 6" SMOOTH FLAT FILE 5. 6" SMOOTH TRIANGULAR FILE 6. SAFE EDGE FILE 7. HACK SAW BLADE & FRAME 8. BALL PEEN HAMMER MATERIALS REQUIRED 1. 62 x 50 x 5 mm M. S. FLAT (2Nos.) 2. MARKING BLUE 3. COTTON WASTE PROCEDURE 1. CUT OFF THE WORK PIECES FROM THE GIVEN RAW MATERIAL BY USING A HACK SAW BLADE AND FRAME. ALSO MARK THE RAW MATERIAL AS THE DIMENSION OF 62mm. LENGTH. 2. THEN FILE ANY TWO MUTUAL SIDES PERPENDICULAR TO EACH OTHER BY USING A 12" BASTARD FLAT FILE. 3. THE PERPENDICULARITY IS CHECKED BY USING A TRY SQUARE. 4. AFTER FILING THE DATUM SIDES MARK THE WORK PIECES AS PER THE GIVEN DRAWING BY USING A VERNIER HEIGHT GAUGE. ALSO APPLY THE MARKING BLUE IN TO THE SURFACE OF WORK PIECE FOR BETTER CLARITY. 5. THEN PUNCH THE MARKED LINES WITH THE HELP OF A PRICK PUNCH AND BALL PEEN HAMMER. 6. THEN REMOVE THE UNWANTED AREA O...

AIM :  TO MAKE A SQUARE TOOLS REQUIRED: 1. STEEL RULE 2. SCRIBER, DOT PUNCH 3. HACK SAW BLADE AND FRAME 4. BALL PEEN HAMMER 5. TRY SQUARE 6. 12" BASTARD FLAT FILE 7. 6" SMOOTH FLAT FILE MATERIALS REQUIRED 1. 50 x 50 x 6 M. S. FLAT 2. MARKING BLUE 3. CLEANING BRUSH PROCEDURE: 1. INITIALLY CUT OFF THE WORK PIECE FROM RAW MATERIAL BY USING A HACK SAW FRAME AND A BLADE. THE MARKING IS DONE BY A SCRIBER AND STEEL RULE. 2. THEN DEBURR ALL THE EDGES BY USING A FILE. 3. AFTER DEBURRING HOLD THE JOB ON THE BENCH VICE TIGHTLY. 4. THEN FILE ANY ONE EDGE TO BECOME FLAT. IT IS CHEECKED BY USING A TRY SQUARE. ALSO THE FILING IS DONE BY BOTH 6" AND 12" FLAT FILES. 5. THEN FILE THE ADJACENT SIDE MUTUALLY PERPENDICULAR TO EACH OTHER BY USING 12" BASTARD FLAT FILE. THE PERPENDICULARITY WAS CHECKED BY A TRY SQUARE. 6. AFTER COMPLETING THE DATUM SIDES, MARK THE LENGTH AND HEIGHT OF 45mm. BY USING A VERNIER HEIGHT GAUGE. ALSO APPLY THE MARKING BLUE INTO THE SURFACES OF ...

  AIM :  CUTTING PRACTICE. TOOLS REQUIRED :                                                                      1. STEEL RULE       2. SCRIBER       3. PRICK PUNCH       4. TRY SQUARE     5. HACK SAW BLADE AND FRAME     6. 12'' BASTARD FLAT FILE     7. 6'' SMOOTH FLAT FILE     8. BALL PEEN HAMMER MATERIALS REQUIRED  1. 52 X 48 X 6 M.S. FLAT  2. MARKING BLUE  3. CLEANING BRUSH PROCEDURE :     1. CUT THE WORK PIECE FROM GIVEN RAW MATERIAL AS PER THE SIZE OF 52 x 48 x 6mm.     2. FILE ANY TWO ADJACENT SIDES MUTUALLY PERPENDICULAR TO EACH OTHER, BY USING A 12'' BASTARD FLAT FILE. ALSO CHECK THE PERPENDICULARITY BY USING A TRY SQUARE.     3. THEN MARK...

AIM:    TO MAKE A 'V' - JOINT AT THE ANGLE OF 90° TOOLS REQUIRED 1. HACK SAW BLADE & FRAME 2. TRY SQUARE & STEEL RULE 3. DOT PUNCH & BALL PEEN HAMMER 4. SAFE EDGE FILE 5. 10" SECOND CUT FLAT FILE 6. 6" SMOOTH FLAT FILE 7. 6" SMOOTH TRIANGLE FILE MATERIALS REQUIRED 1. 50 x 50 x 5 M.S. FLAT - 02 Nos. 2. MARKING BLUE 3. CLEANING BRUSH PROCEDURE 1. CUT OFF THE JOB FROM THE GIVEN RAW MATERIAL AS THE SIZE OF 50mm SQUARE (2 Nos.) BY USING A HACK SAW BLADE AND FRAME. THE MARKING IS DONE BY A STEEL RULE AND SCRIBER. 2. HOLD THE WORK PIECE TIGHTLY INTO THE BENCH VICE 3. INITIALLY FILE THE DATUM SIDES OF BOTH WORK PIECES WITH THE HELP OF 10" SECOND CUT FLAT FILE. 4. THEN MARK THE HEIGHT AND LENGTH OF 45mm BY USING A VERNIER HEIGHT GAUGE. THEN PUNCH THE MARKED LINES WITH THE HELP OF A PRICK PUNCH AND HAMMER. 5. AFTER MARKING, FILE THE WORK PIECE TO A SQARE OF 45mm SIDE. MAKE SURE THAT ALL THE SIDES ARE MUTUALLY PERPENDICULAR TO EACH OTHER. 6. AFT...