2 & 3 Wheeler Lab Manual

7/23/2019 2 & 3 Wheeler Lab Manual

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Road performance test of a two wheeler using chassisdynamometer.

Ex.No. Date :

AIM:To study the performance of two wheeler using two wheeler chassis dynamometer.

APPARATUS REQUIRED:Two-wheeler chassis dynamometer, Two wheeler.

DESCRIPTION:

Chassis Dynamometers: This is a model concept for total electronic testing of two-wheeler chassis dynometer for motorcycles, scooter, mopeds etc. The chassis dynometersimulates the driing conditions on road in a control enironment. This has many distinctadantages of testing arious parameters of two-wheelers, the most important one is thepossi!ility of testing complete ehicle performance or engine performance as installed.There is no necessity to ta"e engine out from the ehicle.

#se of chassis dynamometer allows the test engineer to simulate road loadconditions in la!oratory and it can !e termed as $all weather road% for the test ehicle. Theroad load on the ehicle can !e put on the engine on a chassis and &uic" results can !eo!tained.

'R(CED#RE :

)R)* ref manual Chapter + oRT / C0R / T)'-++1/++2 3*ssue 45 6 )ttached as)nnexure - *

RESULT:Thus performance stud of a t!o !hee"er us#n$ a t!o !hee"er chass#s

dnamometer #s comp"eted%


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PER&ORMANCE TEST O& A S'OC( A)SOR)ER

Ex.No. Date :

AIM:

To study the characteristics of a shoc" a!sor!er.

APPARATUS REQUIRED:

7hoc" a!sor!er test rig

O)*ECTS O& T'E SUSPENSION ARE:

+. To preent road shoc"s from !eing transmitted to the ehicle components.

8. To safeguard the occupants from road shoc"s.

9. To presere the sta!ility of the ehicle in pitching or rolling in motion.

MAIN &UNCTIONS O& S'OC( A)SOR)ERS:

+. To control &uic" !ouncing of wheels on road surface.

8. To control slow !ouncing of the !ody on the suspension springs.

DESI+N CALCULATION :

+. Diameter of the piston 3dp5

'iston of diameter, dp mm.

8. Diameter of the rod 3dr5

The diameter of the rod, dr .4 ; dp

dr

9. (uter diameter of shoc" a!sor!er 3D5 3Dust coer5Diameter 3D5 mm.

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4. Determination of design compression force 3


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PER&ORMANCE TEST ON COIL SPRIN+

Ex.No. Date :

AIM :

To determine the following properties of a coil spring.

+. 7tiffness of the gien coil spring.

8. odulus of rigidity.

APPARATUS REQUIRED : 7pring testing machine, coil spring, ernier caliper.

PROCEDURE :

+. The spring is placed centrally oer the lower plate and the plate handle is slowly rotated.8.

Thic"ness of spring is measured and the num!er of turns is calculated.9. (uter diameter and inner diameter of spring is measured using a 0ernier Caliper.4. The pointer on the dial is adBusted to read ero when the top and !ottom plate Bust touches

the spring.2. Deflections on the gauge is noted while applying the load on the spring.. Deflection while unloading is noted and also aerage deflection is calculated.A. ) graph is plotted !etween load and deflection.

. The deflection of a spring is o!tained from the graph.

CALCULATION :

N/mm8

where, G - Ioad applied in N H 6 Deflection in mm R 6 ean coil radius of gien spring in mm d 6 Diameter of the spring wire in mm n 6 Num!er of turns in the gien spring

7tiffness of the spring " 3G/H5 N/mm ean radius R =3do-t5/8> mm do6 outer diameter

t 6 Thic"ness

RESULT :

odulus of rigidity of spring N/mm8

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7tiffness of spring N/mm

TA)ULATION :

7l.No

Ioad Deflection 3mm5 ean deflection3mm5@g N Ioading #nloadin

g

Mean rad#us of spr#n$:

7R 3mm5 07C 3mm5 TR 7RJ 07C;IC

(uter diameter3do5

Thic"ness 3t5

D*)FR):

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T,O ,'EELER C'AIN TENSION TEST AND AD*USTMENT%

Ex.No. Date :

AIM :To adBust the drie chain of the gien two wheeler.

APPARATUS REQUIRED : Tool set, Two wheeler

PROCEDURE :

Dr#-e cha#n ad.ustment: The serice life of the drie chain is dependent upon properlu!rication and adBustment. 'oor maintenance can cause premature wear or damage to thedrie chain and sproc"ets. #nder seere usuage, or when the motorcycle is runned in dustyareas, more fre&uent maintenance will !e necessary.

Inspect#on:

i5 Turn the engine off, place the motorcycle on its main stand and shift the transmission intoneutral remoe hole cap.ii5 Drie chain slac" should !e adBusted to allow approximately 8-9 mm ertical moement!y hand. Roll the motor cycle and chec" drie chain slac" as the wheel rotates. Drie chainslac" should remain constant as the wheel rotates. *f the chain slac" in one section and inanother, some lin"s are "ic"ed and !inding. Kuilding can !e eliminated !y fre&uentlu!rication.iii5 *nspect the sproc"et teeth for wear or damage.i5 *f the drie chain and sproc"ets are excessiely worn or damaged, they should !ereplaced. Neer use a chain with worn out sproc"ets since this will result in rapid chainwear.

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Ad.ustmenti5 Remoe the split pin and loosen the rear axle nut.

ii5 Ioosen the sleee nut, turn the adBusting nut on !oth the right and left chain adBusters toincrease or decrease chain slac". )lign the chain adBuster index mar"s with correspondingscale graduations on !oth sides of the swing arm.Note: *f drie chain slac" is excessie when the rear axle is moed to the farthest limit ofadBustment, the drie chain is worn out and must !e replaced.iii5 Tighten the rear axle and sleee nut.i5 Rechec" drie chain slac".5 *f rear !ra"e pedal free play is affected when repositioning the rear wheel to adBust driechain slac". Chec" rear !ra"e pedal free play and adBust as re&uired.

IN&ERENCE :

RESULT :

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SER/ICIN+ O& CLUTC' ASSEM)L0 &OR T,O AND T'REE,'EELER%

AIM :

To serice and adBust the clutch play for two and three wheeler as per specification.

TOOLS REQUIRED :

Tool set.

DESCRIPTION :Clutch assem!ly is fitted !etween engine and gear!ox. The purpose of the clutch

assem!ly to transmit power of the engine to the rest of the transmission system, !y

disconnecting L connecting the power is re&uired.

CLUTC' AD*USTMENT :

The only adBustment re&uired in a clutch is of the free leer play, which isnecessitated on account of wear of the friction lining due to continuous use or with the wearof the throw out !earing car!on ring due to the ha!it of the drier to press his hand alwayson the clutch leer. The wear of the friction lining decreases the free leer play. )nadBustment nut is proided at the lower end of the clutch leer. To slac"en the loc" nut first,ma"e the desired adBustment with the adBusting nut and retighten the loc" nut.Clutch adBustment may !e re&uired if the motorcycle stalls when shifting into gear or tendsto creep or if the clutch slips, causing acceleration to lag !ehind engine speed. Normal

clutch leer free play is + 6 8 mm at the leer.i5 To adBust the free play,loosen the loc" out. Rotate the adBusting nut to o!tain the specifiedfree play.Tighten the loc" nut and chec" the adBustment.ii5 7tart engine, pull the clutch leer and shift into gear. a"e sure the engine does not stall,and the motorcycle does not creep. Fradually release the clutch leer and open the throttle.The motorcycle should start smoothly while accelerate.

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RESULT :

Thus the sericing and free play adBustment of clutch for the gien two wheeler andthree wheeler as per specification are performed.

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SER/ICIN+ O& )RA(E ASSEM)L0 &OR T,O AND T'REE,'EELER

Ex.No. Date :

AIM:

To serice and adBust the of !ra"e system for two and three wheeler as perspecification.

TOOLS REQUIRED:

Tool set.

T,O ,'EELER

DESCRIPTION:

Due to the continuous use of the !ra"es, wear ta"e place of the !ra"e lining, lin"age

etc., which necessitates periodic inspection of the !ra"ing system and to ma"e suita!le

adBustment. The !ra"e adBustments can !e !roadly diided in to two types, i, the minor

and maBor adBustments.

inor adBustment mainly includes the adBustment of !ra"e shoes to compensate

lining wear and is done without remoing the wheels. ) maBor adBustment on the other hand,has to !e done after installation of new shoes or relining the old shoes. *f the following

conditions are not found, the minor adBustment is usually sufficientM

+. Gorn out or out of the round !ra"e drum

8. Kra"e lining soa"ed in oil

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9. Kra"e lining worn up to the riet heads

PROCEDURE :

To perform minor adBustment, on turning the adBustment nut the cam is also turned.

This cam is fitted on the !ra"e shoe and the adBusting nut is proided on the !ac" plate.

Turning this nut with spanner in the cloc"wise direction causes the shoes moe closer to the

!ra"e drum.

To perform maBor adBustment, remoe all !ra"e drums and inspect linings and drums.

*f the drums are worn out, turn them in case the damage is within limits or else replace

them. *n case of linings haing reached upto within +mm of riet heads, remoe the same

and reinstall the new ones.


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ii5 easure the !ra"e pedal free play !efore the !ra"e starts to ta"e hold.


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T'REE ,'EELER

DESCRIPTION :

Three wheelers use hydraulic operated foot !ra"e on the two rear wheels with anadditional hand !ra"e mechanically operated on the front wheel.

*n hydraulic !ra"es, care must !e ta"en that not een small &uantities of air enter into the !ra"ing system. The air !eing compressi!le, it gets compressed when the !ra"epedal is pressed. The result is that fluid pressure is not transmitted to the !ra"es. Ghich, as

a conse&uence, are not actuated.Due to the continuous use of the !ra"es, wear ta"e place of the !ra"e lining, lin"ageetc., which necessitate periodic inspection of the !ra"ing system and to ma"e suita!leadBustment. The !ra"e adBustments can !e !roadly diided in to two types, i, the minorand maBor adBustments.

inor adBustment mainly includes the adBustment of !ra"e shoes to compensatelining wear and is done without remoing the wheels. ) maBor adBustment on the other hand,has to !e done after installation of new shoes or relining the old shoes.

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PROCEDURE:

The procedure of driing air out of the !ra"ing system is called !leeding. ) special!leeding ale is proided for this purpose on the !ac" plate.


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DISMANTLIN+ AND ASSEM)LIN+ O& T,O ,'EELER +EAR)O1 AND &INDIN+ +EAR RATIO

Ex.No. Date :

AIM :

To Dismantle and assem!le of two wheeler gear!ox and find gear ratio.

TOOLS REQUIRED :

Tool set.

O)SER/ATION :

Fear !ox is the integral part of drie line whose function as follows as,

+. To proide different leerage at different driing speed.

8. To proide necessary Tor&ue, which starting the ehicle from rest

+EAR)O1 :

+. 'ower comes from engine to clutch shaft and clutch gear, which is always in mesh

with a gear on the lay shaft.

8. elical gears are in mesh always. elical gears are setting the power with the help offor", dogteeth and collar. Dogteeth clutch are splined to gear shaft.

9. Fears are proided with integral dogteeth.

4. Collar haing internal teeth loc"s the dogteeth on gear and dogteeth is fixed to theinput shaft.

1. Collar is operated !y means of for" leer.

2. Iay shaft is a forged component integral with !uilt in gears.

. Iay shaft is supported in the gear!ox housing with the help of !earings.

PROCEDURE :+.


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9. Then the lay out assem!ly is remoed.4.


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DISMANTLIN+ AND ASSEM)LIN+ O& T'REE ,'EELER+EAR )O1 AND &INDIN+ +EAR RATIOS

Ex.No. Date :

AIM :

To Dismantle and assem!le of three wheeler gear!ox and find gear ratio.

TOOLS REQUIRED :

Tool set.

O)SER/ATION :

Fear !ox is the integral part of drie line whose function as follows as,

+. To proide different leerage at different driing speed.

8. To proide necessary Tor&ue, which starting the ehicle from rest.

+EAR)O1 :

+. 'ower comes from engine to clutch shaft and clutch gear that is always in mesh witha gear on the lay shaft.

8. elical gears are in mesh always. elical gears are setting the power with the help offor", dogteeth and collar. Dogteeth clutch are splined to gear shaft.

9. Fears are proided with integral dogteeth.

4. Collar haing internal teeth loc"s the dogteeth on gear and dogteeth is fixed to theinput shaft.

1. Collar is operated !y means of for" leer.

2. Iay shaft is a forged component integral with !uilt in gears.

. Iay shaft is supported in the gear!ox housing with the help of !earings.

PROCEDURE :

+.


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8. Then the counter gear assem!ly is remoed.

9. Then the lay out assem!ly is remoed.

4.


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DETERMINATION O& TURNIN+ CIRCLE RADIUS O& T'REE,'EELERS

Ex.No. Date :

)im:

To determine the turning circle radius of the gien three wheeler.

Tools Re&uired:

eter scale, Thread, Chal"

'R(CED#RE:

'ar" the ehicle on a flat surface

'osition the ehicle in such a way that it will !e easy to mar" the turning circles L

angles

Note the wheel !ase 3!5 and wheel trac" 3c5 from ehicle specification or else

measure it Draw a straight line parallel to the rear axle wheel.

Turn the steering wheel fully to the left or right.

Draw the perpendicular line from !oth the front wheels.

The two perpendicular lines from the front wheel will meet at the line parallel to rear

axle. easure the turning centre point length from the rear inner wheel.

0erify true steering condition and calculate the turning circle radius using the

formulae.

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Tan b

a+x

Ghere,

x- distance !etween the rear wheel to the * centre

R- Turning circle radius

R b

tan Jac

2

Result:

Thus the turning circle radius of three wheeler is calculated.

E"ectr#ca" sstem d#a$nost#csEx.No. Date :

)im : To serice and diagnose the electrical systems of two wheeler.

Tools Re&uired: 7panner, 7crew drier, multimetre

Introduct#on:

)utomo!ile electrical system includes a starting system, charging system, ignitionsystem and lighting system and some accessories. The accessories include horn, o!ile

charging soc"ets, safety alarms, etc.

aBor components of a typical electrical systems are gien !elow:

2%2%I$n#t#on Sstem

3a5 7par" plugs

3!5 Relay

3c5 *gnition switch,

2%3%Char$#n$ Sstem

3a5 Fenerator or alternator

3!5 Regulator

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3c5 Rectifier

2%4%Start#n$ Sstem

3a5 Kattery

3!5 7tarting motor

3c5 Giring,

3d5 7witches

2%5% L#$ht#n$ sstem

3a5 eadlamps

3!5 Tail lamp

3c5 *ndicators

3d5 Garning lamps

3%6%Theor:

The electrical systems in automo!ile consists of four main circuits.

i5 Charging systemii5 *gnition systemiii5 7tarting systemi5 Iighting system

3%2%Char$#n$ sstem:

The charging system is re&uired to recharge the !attery which is an important

component of the electrical system of an automo!ile. This is done !y conerting mechanical

energy into electrical energy and then into chemical energy that is stored in !atteries. Kattery

supplies the current to run the starting motor, arious lights and horn, etc. The charging system

generates electricity to recharge the !attery and run other electrical components.

3%2%2%Components of a Char$#n$ Sstem

Charging system consists of :

#7 +enerator or A"ternator

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*t conerts mechanical energy into electrical energy.

##7 Re$u"ator

*t controls the generator output according to the need. *t controls the current or

oltage.

###7 Rect#f#er

*t conerts the alternating current produced in the alternator or generatorinto

direct current and sends it to !attery.

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3%3%I$n#t#on sstem:

*n spar" ignition engines, a deice is re&uired to ignite the compressed air-fuel mixture at

the end of compression stro"e. *gnition system fulfills this re&uirement. *t is a part of electrical

system which carries the electric current at re&uired oltage to the spar" plug which generates

spar" at correct time. *t consists of a !attery, switch, distri!utor ignition coil, spar" plugs and

necessary wiring.

3%3%2%Re8u#rements of #$n#t#on sstem:

3a5 The ignition system should !e capa!le of producing high oltage current, as high as

81 olts, so that spar" plug can produce spar" across its electrode gap.

3!5 *t should produce spar" for sufficient duration so that mixture can !e ignited at all

operating speeds of automo!ile.

3c5 *gnition system should function satisfactory at all engine speeds.

3d5 Ionger life of contact points and spar" plug.

3e5 7par" must generate at correct time at the end of compression stro"e in eery cycle

of engine operation.

3f5 The system must !e easy to maintain, light in weight and compact in sie.

3g5 There should !e proision of spar" adance with speed and load.

3h5 *t should !e a!le to function smoothly een when the spar" plug electrodes are

deposited with car!on lead or oil.

3%3%3%Tpes of #$n#t#on sstems

There are three types of ignition systems which are used in petrol engines.

3a5 Kattery ignition system or coil ignition system.

3!5 agneto ignition system.

3c5 Electronic ignition system.

Gith the !attery ignition system, the current in the primary winding is supplied !y a

!attery whereas it is supplied !y a magneto with magneto ignition system. The !attery ignitionsystem is used in cars and light truc". agneto ignition system is used in some scooters. Koth

the systems wor" on the principle of mutual electromagnetic induction. Electronic ignition

systems use solid state deices such as transistors and capacitors. *n most of the two wheelers,

magneto ignition system is used.

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3%3%4% Ma$neto9#$n#t#on Sstem

This system consists of a magneto in place of a !attery. 7o, the magneto produces and

supplies current in primary winding. The rest of the system is same as that in the !attery ignition

system.

The magneto consists of a fixed armature haing primary and secondary windings and a

rotating magnetic assem!ly. This rotating assem!ly is drien !y the engine.

Rotation of magneto generates current in primary winding haing small num!er of turns.

7econdary winding haing large num!er of turns generates a high oltage current which is

supplied to relay. The relay sends this current to spar" plugs. The magneto may !e of rotating

armature type or rotating magnet type. *n rotating armature type magneto, the armature haing

primary and secondary windings and the condenser rotates !etween the poles of a stationary

horseshoe magnet. *n magneto, the magnetic field is produced !y permanent magnets.

3%3%4%2% Ad-anta$es

3a5 Ketter relia!ility due to a!sence of !attery and low maintenance.

3!5 Ketter suited for medium and high speed engines.

3c5 odern magneto systems are more compact, therefore re&uire less space.

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3%3%4%3% D#sad-anta$es

3a5 )dBustment of spar" timings adersely affects the oltage.

3!5 Kurning of electrodes is possi!le at high engine speeds due to high oltage.

3c5 Cost is more than that of magneto ignition systems.

3%3%5 E"ectron#c #$n#t#on sstem

The modern day two wheelers use electronic ignition system. The type of electronic

ignition system used in two wheelers is "nown as Capacitor Discharge *gnition system 3CD*5.

The CD* system consists of a !attery, magnetic pic"up, diode, capacitor, thyristor,

ignition coil and spar" plugs. The diode, capacitor,thyristor, ignition coil are located in the CD*

module. The current flows from the !attery and charges the capacitor, the thyristor is placed in

!etween the !attery and capacitor to preent the !ac"flow of current from the capacitor. Thediode is used to purify the DC oltage. Now the magnetic pic"up coil sends signal to the CD*

module and the current flowing from the !attery stops.

Now the capacitor discharges the oltage stored in it and sent to the ignition coil. #nli"e

the conentional ignition coil, this one acts as a pulse coil, thus !uilding up heay current much

&uic"er than conentional ignition coils. Now this high oltage is sent to the spar" plugs.

3%3%5%2 Ad-anta$es

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The oltage !uilt up is ery high around 8-9"/ms, while the conentional coils do a!out

9-1/ms.

The intensity of the spar" produced is ery high.

Timing is highly precise

3%3%5%3 D#sad-anta$es

7par" produced doesn%t last for a longer time.

3%4% Start#n$ sstem

The starting system of an automo!ile is used to start the internal com!ustion engine.

Koth 7* and C* engines cannot start !y itself. These engines need to !e cran"ed !y a starting

motor. This motor is also called a starter or cran"ing motor. Cran"ing of any engine means

rotating its cran" shaft. Rotation of cran" shaft causes the piston to reciprocate. Ghen piston

reciprocates, suction, compression, expansion and exhaust stro"es of engine are completed.

Thus, engine completes its wor"ing cycle and it starts running.

7tarting motor produces necessary tor&ue to rotate the engine wheel 3cran" shaft5

through a suita!le gear 3one pinion on motor and other ring gear around engine wheel5.

3%4%2%Components of Start#n$ Sstem

7tarting system consists of the following :

3a5 7tarting otor :7tarting motor to produce rotation of cran" shaft.

3!5 Drie echanism: Drie mechanism to transfer rotary motion of starter to the cran"

shaft of the engine.

3c5 The ignition switch to start motor.

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3%5%L#$ht#n$ sstem

*t is a simple system using a single po! system. The current supplied to the system from

a !attery at 2-+8 olt. Circuit !egins at !attery passes through the armature and a fuse !efore it

reaches any switch.

The lighting system of a motor ehicle consists oflightingand signalling deices

mounted or integrated to arious parts of a motor ehicle. These may include the front, sides,

rear and, in some cases, the top of the ehicle. The purpose of this system is to

proide illuminationfor the drier. This ena!les safe ehicle operation after dar" and increases

the conspicuityof the ehicle. *t also informs of the ehicleOs presence, position, sie, direction

of trael, and the drierOs intentions regarding direction and speed of trael.

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http://en.wikipedia.org/wiki/Lighthttp://en.wikipedia.org/wiki/Motor_vehiclehttp://en.wikipedia.org/wiki/Lightinghttp://en.wiktionary.org/wiki/conspicuityhttp://en.wikipedia.org/wiki/Motor_vehiclehttp://en.wikipedia.org/wiki/Lightinghttp://en.wiktionary.org/wiki/conspicuityhttp://en.wikipedia.org/wiki/Light


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4%6%Eper#ment:

4%2%Procedure

i5 The electrical components to the diagnosed are indicator light, head light, tail lamp,

horn, starter motor, par"ing lamp, etc.

ii5 The engine is started and !attery coer is remoed .

iii5 #sing a multimeter, the head is tested for the load.

i5 Ii"e wise, indicator lamp, par"ing lamp, horn, tail lamp are tested.

5 Then engine is (


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2% Trou;"e shoot#n$ ta;"e:

SI no Defects Causes Remed#es

+. 7tarter motor

i5 No cran"inga5 Dead !attery

Recharge 3or5 replace the

!attery.

!5 (pen circuitTighten connections,

Replace wiring

ii5 Engine cran"s

slowly !ut does not run

a5 Run down !attery Chec" replace the !attery!5 0ery low

temperature

Kattery ma"e to full

charge

c5 7tarter motor

defectChec" the stater motor

8. orn

i5orn does not !low

a5 Defectie switch)dBust 3or5 replace switch

3or5 relay!5 *ncorrect

adBustment

defectie relay

contact points in

horn are !urned.

Replace the relay

ii5 orn gies incorrect

sound

a5 Too high 3or5 too

low generator

oltage.

Chec" and rectify the

generator oltage

!5 *ncorrectly adBust

horn.

)dBust the gap as

re&uiredc5 Excess drop in

oltage of the

circuit.

Rectify the fault

9. Iight

i5Iight does not glow

a5 Chec" fuse. Replace them if re&uired.!5 Chec" !ul!. Replace it if re&uiredc5 Chec" light

switch.Replace them if re&uired.

ii5 Iight glow and goes a5 Chec" wiring and Repair them if re&uired

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off switching4. Kattery

i5 (er charging

a5 igh charging

oltageChec" generator

!5 igh temperature

Reduce oltage regulator

setting

ii5 run down !attery

a5 Defectie

generator

Chec" the defect and

rectify

!5


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2 & 3 Wheeler Lab Manual

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