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Department of Technical Education Diploma Course in Automobile Engineering Fourth Semester Subject: Automobile Electrical & Electronics Lab

Contact Hrs / Week : 6 Hrs Sl No 1 2 3 4 5 6 7 8 9 10 TOPIC ANALYSIS Contents Testing of electronics components Battery Testing: Servicing, Charging and troubleshooting. Dynamo: Testing, Servicing and troubleshooting Alternator: Testing, Servicing and troubleshooting Starter Motor: Testing, Servicing and troubleshooting Ignition System: Components Testing, Servicing and troubleshooting Accessories: Inspection and servicing. Preparation of individual wiring circuits of different systems. Local workshop visits Test and revision Total Hrs Contact Hrs / Semester : 96 Hrs No of Hrs 06 06 06 06 06 18 15 21 06 06 96

GENERAL EDUCATIONAL OBJECTIVES 1. Understand testing of electronic components. 2. Understand servicing, testing, charging & maintenance of battery. 3. Understand servicing& testing of Dynamo. 4. Understand servicing& testing of alternator. 5. Understand servicing& testing of starting motor. 6. Understand servicing, testing fault finding of ignition system. 7. Understand servicing, testing fault finding of ignition system. 8. Understand servicing, testing of accessories 9. Construct wiring circuits for different systems 10. Learn about different types of bulbs, switches and fuses.

LIST OF EXERCISES 1. a) Find the Voltage drop in series and parallel circuits b) Check the value of unknown resistance by using Wheatstone bridge 2. a) Check the Zener diode used to regulate the cut-off voltage b)Test Transistor for amplification and switch off 3. a) Test the battery charge condition using hydrometer, Voltmeter. b) Test the cell capacity using high rate discharge cell tester. 4. a) Practice on preparation of electrolyte and charging of lead acid battery by constant current method, constant voltage method, charging multiple batteries and trickle charging. b) Maintenance and servicing of batteries. 5. Servicing of the dynamo. 6. Test field windings, brush holders armature for continuity, short and open circuit using growler/ Multifunction Tester. 7. Servicing of the Alternator. 8. Test field windings, brush holders armature for continuity, short and open circuit using Multifunction Tester / Multimeter / Test lamp. 9. Servicing of the Starter motor. 10. Test field windings, brush holders armature for continuity, short and open circuit using growler/ Multifunction Tester. 11. Study ignition system circuits (Battery coil & Magneto). 12. Servicing of the distributor, setting CB points gap and checking dwell angle. 13. Servicing of the sparkplug cleaning, testing and adjusting gap. 14. Checking and setting ignition timing and starting the engine. 15. Servicing and tuning of horns and electrical fuel pump 16. Servicing of the Wiper motor. 17. Practice on aiming of head lights. 18. Practice on testing of fuel gauge, Temperature gauge and Oil pressure gauge. 19. Practice on replacement of bulbs, fuses and relays. 20. Construction of different circuits like: i) Ignition Circuit ii) Charging Circuit. iii) Starting circuit. iv) Wind screen wiper circuit v) Horn circuit vi) Fuel, Oil pressure, Temperature gauges circuits vii) Head lights, parking lights, direction indicators circuits.

IMPORTANT NOTE:
1. 2. 3. Servicing includes Dismantling, Cleaning, Inspection, Repair / Replacement of worn parts, reassembling with necessary adjustments. For every Exercise mention the detailed Trouble shooting chart in the Lab records. The lab-record must have the following contents for each exercise : 1. Aim. 2. Tools & Equipments required

3. Procedure 5. chart.

4. Precautions if any Results / Reports 6. Troubling shooting SCHEME OF EVALUATION

Serial no

Description Writing procedure a) One exercise from list of exercises 01-02 b) One exercise from list of exercises 03-20 Conducting & Performance a) One exercise from list of exercises 01-02 b) One exercise from list of exercises 03-20 Viva-voice Lab-record

Marks

(10+10) = 20

(20+35) = 55

3 4

20 05

Total

100

TOOLS & EQUIPMENT LIST 1. 2. 3. 4. 5. 6. 7. Mechanic tool kit Arbor press Volt meter, Ammeter, Multimeter, Tong tester, feeler gauges, Air compressor Tripod stands Three jaw bearing pullers Growler

8. Multifunction tester 9. Battery Charger 10. Spark plug cleaning & testing machine 11. Neon timing light 12. Tach-dwell tester 13. Hydrometer 14. Cell tester 15. Test lamps 16. Auto electrical test bench LIST OF COMPONENTS REQUIRED 1. 2. 3. 4. Lead Acid Batteries. Dynamos Alternators Starting motors of different starting drives (Bendix, Axially sliding armature, Over running clutch type). 5. Spark plugs 6. Distributor assemblies 7. Ignition coils 8. Magneto assembly 9. Fuel, Oil, Temperature gauges. 10. wiper motors 11. Horns different types 12. All types of bulbs, fuses, relays. 13. Diodes 15V-30A, 15V-5A 14. Zener diodes 15V 30A 15. Resistors of different values 16. Transistors PNP, NPN 17. Capacitors 1000 F -15V. 18. Recent Make 4 Wheeler.