AUTOTECH Kerala

MAGNETO COIL IGNITION SYSTEM The above figure shows the diagram of a Magneto coil ignition system. It contains two circuits like primary and secondary circuits. The primary circuit have a rotating magnet, Ignition switch, primary coil, CB point, and condenser. The secondary circuit having secondary coil, HT cable, distributor, rotor and spark plug. The magneto is a self-contained generator of high voltage that provides ignition to an engine through spark plugs. The moment the contact points open, a rapid magnetic flow generates a high voltage in the secondary coil, which ignites the spark plug, thus firing the engine.

.  BATTERY COIL IGNITION SYSTEM The above figure shows the diagram of a battery coil ignition system. It contains two circuits like primary and secondary circuits. The primary circuit have a battery, Ignition switch, primary coil, CB point, and condenser. The secondary circuit having secondary coil, HT cable, distributor, rotor and spark plug. When the driver turn on the Ignition switch, a low voltage current from the battery is passes through the primary circuit. At the same time the cam starts to rotates it cut off the current flow through it. So the current transmits the primary winding to secondary winding. It also helps to increases current low voltage to high voltage. This high voltage current flows to the distributor and spark plug through High Tension cable.

IGNITION SYSTEM FUNCTION The function of the ignition system is to produce a spark in the engine cylinder towards the end of the compression stroke. In a four-stroke engine, a spark should occur in each cylinder after two revolutions of the crankshaft, whereas in a two-stroke engine a spark in each cylinder is required every revolution of the crankshaft. Thus, for instance, in a 6-cylinder 4 stroke engine running at 5000 r.p.m., the number of sparks required per minute will be 15000 and these have to be timed very accurately. REQUIREMENTS OF AN IGNITION SYSTEM 1. Spark at the plug electrodes must be regular and synchronously timed with respect to the cylinder-piston position at all speeds and loads on the engine. 2. The spark should be sufficiently strong so as to start ignition of the charge. Since lean air fuel mixtures are less conductive, they require higher ignition voltages. Thus on modem emission-controlled engines that use lean-mixtures, higher-voltage ignition system is requir...

AIM: OVERHAULING OF LEAF SPRING ASSEMBLY  TOOLS REQUIRED 1. BOX SPANNER SET 2. RING SPANNER SET 3. DOUBLE END OPEN SPANNER SET 4. HYDRAULIC JACK 5. LONG SCREW DRIVER (-) 6. TORQUE WRENCH 7. MALLET MATERIALS REQUIRED 1. KEROSENE OIL 2. COTTON WASTE 3. EMERY PAPER 4. GREASE 5. RUBBER BRUSHES 6. LUBRICANT 7. GRAPHITED OIL PROCEDURE 1. Chock the wheels. 2. Jack up the frame and lift the vehicle just enough for the wheels to clear the ground. 3. Place a horse to support the frame and take out the jack. 4. Disconnect the shock absorber, if provided. 5. Remove the clamp bolt from the shackle. 6. Remove the spring fixing bolts and nuts all pads. 7. Put the jack to support the axles. And Remove the grease nipples. 8. Remove the shackle pins with the help of special tools. 9. Remove the leaf spring assembly from the axle. 10. Put up the spring in a press, measure the pre - camber. 11. Apply full load and observe the camber. This will be the negative camber. 12. Set the spring eye...

AIM:      OVERHAULING OF SINGLE PLATE CLUTCH TOOLS REQUIRED 1. DOUBLE END OPEN SPANNER SET 2. DOUBLE END RING SPANNER SET 3. TRY SQUARE 4. SPRING COMPRESSOR 5. SCREW DRIVER (-) 6. CLUTCH JIG MATERIALS REQUIRED 1. KEROSENE OIL 2. COTTON WASTE 3. EMERY PAPER PROCEDURE Task 1: DISMANTLE THE CLUTCH 1. Mark with some paint the position of the clutch cover and flywheel. 2. While resetting, this mark will be aligned to ensure the original position of the clutch cover and the flywheel so that the balancing of the flywheel and clutch cover does not get disturbed. 3. Remove the locking wire of the clutch cover mounting set screws. 4. Unscrew the diagonally opposite mounting set screws  of the clutch cover. Each screw should be loosened by two turns at a time, If these screws are loosened and removed all at once, then the spring pressure will act on the remaining screws and the screw thread in the flywheel may shear. 5. Remove the clutch cover assembly a...

AIM:   OVERHAULING CYLINDER HEAD ASSEMBLY TOOLS REQUIRED: 1. 12-13mm RING SPANNER 2. BOX SPANNER SET 3. VALVE GRINDING STICK 4. FEELER GAUGE 5. SCREW DRIVER (-, +) 6. VALVE LIFTER, TORQUE WRENCH 7.CAM GEAR PULLER MATERIALS REQUIRED 1. KEROSENE OIL 2. COTTON WASTE 3. GRINDING PASTE 4. EMERY PAPER PROCEDURE DISMANTLING   1. Ensure that the cylinder head does not tilt while removing, so as to avoid damage to the cylinder head studs. 2. Place the cylinder head on a workbench over two wooden block stands. 3. Remove rocker arm assembly the cylinder head. 4. Remove the cylinder head gasket and keep it in a safe place. 5. Press the valve spring with the help of the special tool. 6. Take out the cotters locks/collets using the special tool. Release the valve spring and take out the special tool. Remove the spring, and the valve and retainer. 7. Keep the valves in order. Number the valves.   Cleaning and inspection 1. Clean exhaust manifold with solvent (cau...

AIM: OVERHAULING OF WORM & ROLLER TYPE STEERING GEAR BOX. TOOLS REQUIRED 1. BOX SPANNER SET 2. DOUBLE END OPEN SPANNER SET 3. DOUBLE END RING SPANNER SET 4. SCREWDRIVER (-) 5. PLASTIC HAMMER 6. TORQUE WRENCH MATERIALS REQUIRED 1. KEROSENE OIL 2. COTTON WASTE 3. EMERY PAPER 4. TRAY 5. LUBRICATING OIL PROCEDURE DISMANTLING   1. Disconnect the battery. 2. Chock the wheels. 3. Remove the bottom shield of the steering assembly. 4. Disconnect the horn button and horn wire at the bottom of steering assembly. 5. Remove the horn button. 6. Release the steering wheel nut lock. 7. Remove the steering nut. 8. Remove the steering wheel by using the puller 9. Remove the instrument panel bracket. 10. Remove the exhaust pipe from the manifold. 11. Remove the steering column cover plate on the floor board. 12. Note the position of the steering gearbox and make a mark on the frame and steering gearbox. 13. Remove the steering gearbox mounting bolts and bracket. 14. Remove...