MODULE DESCRIPTOR

MODULE CODE: AET 04101

Module Name: Basics of Automotive Technology
Number of Credits: 12
Sub Enabling Outcomes:
1. Describe safety workshop regulations as applied in automotive
maintenance and repairs industry
2. Describe common tools and equipment used in automotive maintenance
and repairs.
3. Identify vehicle layout as applied in automotive technology.
4. Describe different types of engines and functions of vehicle systems used
in automotive industry
5. Use common tools and equipment to maintain automotive systems.
6. Overhaul engine assembly as per standard/manufacturer’s specifications.
Prerequisite module:
Learning Context: The module will be conducted through lectures, workshop
practical and tutorials.
Learning materials: Manuals, books, hand out, journals, visual/audio aids,
interactive simulations.
References:
1. Hillier V. A. W. and Pittuck F. W., Fundamentals of Motor Vehicle
2. Technology, Hutchison Educational, Latest Edition, London.
3. Dolan J. A., Motor Vehicle Technology and Practical Work, Latest Edition,
London, Heinemann.
4. Crouse W. H., Automotive Mechanics, Latest Edition, London, McGraw-Hill
Publisher.
5. Bricker F. C., Automotive Guide, Latest Edition, Indianapolis, Theodore
Andel and Co.
6. Black P. O., Diesel Engine Manual, Latest Edition, Indianapolis ,Theodore
Andel and Co.
7. Kates et al, Diesel and high Compression Gas Engines, Latest Edition,
Chicago, American Technical Society,

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 8. Martin A. L., Science and Calculations for Motor Vehicle technician, Latest
Edition, London the English University Press.
16.3.9Integrated Methods of Assessment:
Continuous assessment.....................................50%
End of semester practical examination:............50%

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 ARUSHA TECHNICAL COLLEGE

AUTOMOTIVE ENGINEERING DEPARTMENT

MODULE TITLE: BASICS OF AUTOMOTIVE TECHNOLOGY –T

MODULE CODE: AET 04101
INTRODUCTION TO AUTOMOBILE
What is an automobile?
A car (or automobile) is a wheeled motor vehicle used for transportation. Most
definitions of car say they run primarily on roads, seat one to eight people, have
four tires, and mainly transport people rather than goods. Cars came into global use
during the 20th century, and developed economies depend on them.
The year 1886 is regarded as the birth year of the modern car, when German
inventor Karl Benz built his Benz Patent-Motorwagen. Cars did not become widely
available until the early 20th century. One of the first cars that was accessible to
the masses was the 1908 Model T, an American car manufactured by the Ford
Motor Company. Cars were rapidly adopted in the US, where they
replaced animal-drawn carriages and carts, but took much longer to be accepted in
Western Europe and other parts of the world.
Cars have controls for driving, parking, passenger comfort and safety, and
controlling a variety of lights. Over the decades, additional features and controls
have been added to vehicles, making them progressively more complex. Examples
include rear reversing cameras, air-conditioning, navigation systems, and in car
entertainment. Most cars in use in the 2010s are propelled by an internal
combustion engine, fueled by the combustion of fossil fuels. This causes air
pollution and is also blamed for contributing to climate change and global
warming. Vehicles using alternative fuels such as ethanol flexible-fuel
vehicles and natural gas vehicles are also gaining popularity in some
countries. Electric cars, which were invented early in the history of the car, began
to become commercially available in 2008.
Types of automobiles
The types of automobiles are classified as bellow
1. With respect to the use
a) Auto cycle
b) Motorcycle
c) Cars
d) Tractors

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 2. With respect to capacity
a) Heavy transport vehicle
b) Light transport vehicle
c) Medium transport vehicle
3. With respect to fuel used
a) Petrol vehicle
b) Diesel vehicle
c) Gas vehicle
d) Electric vehicle
e) Steam engine vehicle
4. With respect to maker
a) Toyota
b) Nissan
c) Land rover etc
5. With respect to wheel and axle
a) Two wheels
b) Four wheels
6. With respect to suspension
a) Conventional suspension
b) Independent suspension
7. With respect to body
a) Sedan
b) Station wagon
c) Hard top etc
8. With respect to transmission
a) Conventional
b) Automatic c) Semi automatic
WORKSHOP SAFETY RULES
Workshop safety rules include all effort done to limit accident or to minimize
accident which may occurs at the workplace
Such effort includes
1. Workshop layout

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 Is the proper arrangement of machine, tools, availability of firefighting
equipment proper workshop dimension and enough ventilation etc
Also proper warning signs and safety instruction posted around the machines
or workshops all these should be observed to minimize accidents.

CAUSES OF ACCIDENTS
Most of the accident caused by careless, inattention to the job, use damaged
tools, ignorance etc

Workshop safety rule can be stated as follows;

1. Keep your work area clean and orderly; neatly arrange equipment and
material. Do not allow parts, metal, wires, scrap or other material to
accumulate on the shop floors or in work areas. Place drink cups, cans,
bottles, paper, lunch scraps, etc., in the proper containers.

2. Report every injury to your supervisor immediately, no matter how slight

or insignificant the injury may seem.
3. If you are unsure about the safe operation or process of a job, request
assistance from your supervisor.

4. Report any unsafe conditions to your supervisor immediately. Rely on

your judgment and knowledge of safety to guide you.

5. Horseplay is forbidden. Do not disturb or interfere with other technicians

when they are performing their job.

6. Be certain all safety guards are in place before operating any machine or
equipment. Guards must be replaced as soon as repairs or servicing on a
machine has been completed and before the machine is put into operation.

7. Verify the safety of all personnel before energizing or operating any

equipment.

8. All equipment must be locked out prior to any repairs or maintenance.

Never attempt to open the switch or operate any equipment that is under
repair. Lockouts may only be removed by authorized personnel.
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 9. When a machine is de-energized for the purpose of changing setup or
making minor adjustments, the operator must pull the switch controlling
this machine. This will allow the equipment to come to a complete stop,
enabling the operator to lock and tag out this machine. He must then push
the start button to ensure the machine is definitely de-energized.

10.Never tie down, block out or otherwise make inoperative any type of
safety device, attachment, method or guard.

11.Observe all caution and danger signs. Be alert and pay attention to horns,
alarms or verbal commands. Be sure to follow the requirements on
Material Safety Data Sheets (MSDSs).

12.Never oil, remove guards or attempt to repair machinery while it is in

motion. Do not climb on machinery while oiling or greasing. Repairs of
machinery must only be made by authorized personnel or manufacturer’s
representatives.

13.Do not use electrical equipment while standing on damp or wet surfaces
or when your hands are wet.

ACCIDENTS

What are accidents?

Accidents are unplanned and sudden events that cause damage to person or
property.

Causes of accidents:

1) Individual carelessness.
2) Lack of implementation of safety instructions by the supervisor / manager.

Prevention of Accidents:

1) Developing safe working habits.

2) Development of safe working conditions.
3) Ensuring employees’ participation in safety programmes.

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 4) Corrective action when safety rules are ignored.
5) Observing safety in different industrial aspects.

HAZARDS

Hazard is a danger or risk.

TYPES OF HAZARDS

The most famous hazards in the workplace are chemical, physical, biological, and
ergonomic.

1. CHEMICAL AND BIOLOGICAL HAZARDS

 Chemical agents
 Work Hazardous Materials Information System (WHMIS)
 Biological Hazards
2. PHYSICAL HAZARDS
 Mechanical Hazards
 Electrical Hazards
 Fire Hazards
 Radiation Hazards
 Noise and vibration Hazards
 Pressure Hazards
 Hazard of Temperature extreme
 Ergonomic Hazards
 Falling, Impact, Acceleration, Lifting, and Vision Hazards

CHEMICAL AND BIOLOGICAL HAZARDS-

Workplace Hazardous Materials Information System (WHMIS) and

Transportation of Dangerous Goods (TDG)-These systems are provided with
effective means of dealing with hazardous materials in the workplace.
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WHMIS Hazard classes:

Class A - Compressed Gas.

Class B – Flammable and Combustible Material.

Class C – Oxidizing Material

Class D – Poisonous and Infectious Materials

Class E – Corrosive Material

Class F – Dangerously Reactive Material

Two types of labels are provided to control products under WHMIS (supplier
labels and workplace labels).

Dangerous Goods – are transported by land, air, and water. To minimize the
potential harm to humans and the environment, the government has enacted
legislation to regulate the transport of dangerous goods.

DANGEROUS GOODS

Dangerous goods are substances that are corrosive, flammable, explosive,

spontaneously combustible, toxic, oxidizing or water-reactive. Petrol, LPG,
paints, pesticides and acids are examples of commonly used dangerous goods.

Incidents involving dangerous goods typically result in explosions or fires and

have the potential to cause serious or fatal injuries as well as large-scale damage
to property and the surrounding environment.

Unsafe use of dangerous goods can also cause poisoning, chemical burns and
other serious health problems.

These types of goods are widely used in industry, so it's vital that they are stored,
handled and transported safely.

The Dangerous Goods Act

The Dangerous Goods Act 1985 sets out the general duties for the manufacture,
storage, transport, transfer, sale and use of dangerous goods and the import of

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explosives into Victoria. The Act also enables regulations to be made about
dangerous goods.

The Dangerous Goods Storage and Handling Regulations

They are defined in the Dangerous Goods Act 1985 and are classified in the
Australian Code for the Transport of Dangerous Goods by Road and Rail (ADG
code) according to their common hazardous properties.

Some dangerous goods, such as explosives, high consequence dangerous goods

and asbestos, have particular risks and are dealt with under specific legistilation.

The key dangerous goods storage and handling regulations detail the
requirements regarding:

 classification and labeling

 preparation of a Material Safety Data Sheet
 worker consultation and training
 risk assessment and review
 design of new premises, plant, processes and systems of work
 fire protection systems
 external placard (a sign for public)
 registers
 incidents, and
 Notification of quantities in excess of manifest quantities.

How Are Dangerous Goods Different To Hazardous Substances?

Dangerous goods and hazardous substances are classified according to different

criteria. Dangerous goods are classified on the basis of immediate physical or
chemical effects – such as fire, explosion, corrosion and poisoning – on property,
the environment or people. They are covered by the Dangerous Goods (Storage
and Handling) Regulations 2012.

Hazardous substances are classified only on the basis of health effects, both
immediate and long-term. They are covered by the Occupational Health and
Safety Regulations 2007.

Many substances are both hazardous substances and dangerous goods, and in
these cases, both sets of laws will apply.

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THE DANGEROUS GOODS STORAGE:

 Toxic Substances-A substance that has a negative effect on the health of a

person or animal or interferes with the normal biological function of the zz
 person. (E.g. Mercury, Lead, Chloroform, Carbon monoxide, Nickel,
Asbestos and Nitrogen dioxide)
 Chemical Agents-Single elements or compounds that may be toxic to
human.
 Biological Agents-Living things or substances produced by living things
that may cause harm to humans

BIOLOGICAL HAZARDS - harmful biological agents are living microorganism

or toxins produced by living plants or animals that have the ability to cause disease
or illness in humans.

Different forms of biological agents may include:

o Bacteria – Microscopic single cell organisms found in food, water and air
(e.g. Anthrax)

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 o Virus-Microscopic organisms that invades a host to reproduce.(e.g. HIV
Virus is the virus that causes AIDS.
o Parasites-Organisms that live on or in a host and lay eggs to reproduce (e.g.
malaria)
o Fungi-simple plants that feed on dead or living tissue of other organisms.

ERGONOMIC HAZARDS – Ergonomic is a science of conforming the

workplace and all its elements to use worker. The word ergonomics is derived
from the Greek language, Ergon means work and nomos means laws (work laws)

Ergonomics involving the following:

o Using special design and evaluation techniques to make task, objects,

and environments more compatible with human abilities and
limitations.
o Seeking to improve productivity and quality by reducing workplace
stressors, reducing the risk of injuries and illnesses, and increase
efficiency.

MANUAL MATERIAL HANDLING

Manual Lifting Procedures – moving goods or equipment without the aid of

machinery

LIFTING TECHNIQUES:

 Test weight
 Plan route
 Wide stance
 Bend knees
 Get close
 Best hold
 Stable position
 Tighten stomach
 Use legs
 Keep back straight
 Lift smoothly

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AVOID OR MINIMIZE

 Bending and Twisting

 Reaching out with weight

REACHING OVERHEAD

 Wide base of support.

 Safe platform or step stool.

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 CARRYING GOODS

SAFETY IN MANUAL MATERIAL HANDLING

1) Objects having wet, dry and slippery surfaces such as greasy or oily ones
should be completely wiped off dry before handling them.
2) Workers handling object should wear protective clothing, safety shoes,
leather hand gloves, long sleeves etc.
3) Items like barrels and drums should preferably be handled by some
mechanical lifting and carrying device.
4) While storing material, it should be ensured that the electrical panels and fire
extinguishers and hoses are kept clear and have free accessibility.
5) Too heavy loads can result in serious injury so for lifting heavy loads, knees
should be bent back kept straight and the chin ticked in. The load should be
firmly gripped and lifted by straightening the legs.

FALLING, IMPACT, ACCELERATION AND LIFTING HAZARDS

Some of the common accidents in the workplace happen as the result of slipping,
falling, and improper lifting. Impact from a falling object is also a common cause
of accidents.

IMPACT ACCIDENTS – Involve a worker being struck by or against an object.

SLIP AND FALL - Accidents that occur when the worker’s centre of gravity is
suddenly thrown out of balance.

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STEP AND FALL – An accident that occurs when a person’s foot encounters an
unexpected step down.

ACCELERATION – Increase in the speed of a falling object before impact,

LIFTING HAZARD – Any factor that if not properly dealt with many lead to an
injury from lifting

MECHANICAL HAZARDS – Accidents associated with power-driven

machines, whether automated or manually operated.

Common mechanical injury hazards are:

o Cutting and tearing – occurs when a body part comes in contact with a
sharp edge.
o Shearing – results from forces being applied to a body by two contacting
parts moving parallel to the plane of contact.
o Puncturing – results when object penetrates straight into the body and pulls
straight out, creating a wound in the shape of the penetrating object.
o Crushing – occurs when a part of the body is caught between two hard
surfaces that progressively move together, thereby crushing anything
between them.
o Breaking (Fracture) – because broken bones, A break in a bone is known
as a fracture.

HAZARDS OF TEMPERATURE EXTREMES

A work environment in which the temperature is not properly controlled can be

uncomfortable. Extremes of either heat or cold can also be more than
uncomfortable, they can be dangerous (e.g. heat stress, cold stress and burns)

PRESSURE HAZARDS - A hazard caused by a dangerous condition involving

pressure. There are many sources of pressure hazard e.g. most created by humans
and others are natural.

ELECTRICAL HAZARDS – occur when a person makes contact with a

conductor carrying a current and simultaneously contacts the ground or another
object that includes a conductive path to the ground. This person completes a

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circuit loop by providing a load for the circuit and thereby enables the current to
pass through his or her body. People can be protected from this danger by
insulating the conductors, insulating the people or isolating the danger from the
people.

The major causes of electrical shock or electrical hazards are:

o Contact with a bare wire carrying current.

o Electrical equipment that has not been properly grounded.
o Short circuits.
o Using metal ladders to work on electrical equipment.
o Working on electrical equipment without ensuring that the power has been
shut off.
o Working with electrical equipment on damp floors or water.

FIRE HAZARDS – are conditions that favour fire development or growth. Fire or
combustion is a chemical reaction between oxygen and combustible fuel.
Combustion is the process by which fire converts fuel and oxygen into heat energy.
By-products of combustion include light and smoke.

Three elements are required to start and sustain fire:

i. Oxygen
ii. Fuel
iii. Heat

RADIATION HAZARDS – includes ionizing radiation, radioactive materials,

restricted area, air dose, personal monitoring devices, radiation areas, and high
radiation areas.

o Radiation – consists of energetic nuclear particles and includes alpha rays,

beta rays, gamma rays, X-rays, neutrons, high-speed electrons, and high-
speed protons.
o Radioactive materials – is material that emits electromagnetic emanations
as the result of spontaneous nuclear disintegration.
o A dose - is the amount of ionizing radiation absorbed per unit of mass by
part of the body or the whole body.

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 o A restricted area – is any area to which access is restricted in an attempt to
protect employees from exposure to radiation or radioactive materials.
o An unrestricted area – is any area to which access is not controlled because
there is no radioactivity hazard present.

NOISE AND VIBRATION HAZARDS

 SOUND – any change in pressure that can be detected by the ear.

 NOISE – unwanted sound.
 VIBRATION – oscillations of solid or semi-solid objects that can be
perceived by the sense of touch.

Noise can be reduced by applying either engineering controls or administrative

controls which limit human exposure to noise.

NEED OF SAFETY PROGRAMMES

Safety awareness can be brought about by safety meetings, posters, booklets, and
safety class rooms’ sessions.

Safety training is the subject aims to increase the interest of employees in accident
prevention.

Workers in particular and employees in general should be trained in general

aspects such as:

1) Safe working
2) Handling of tools and equipments
3) General precautions and safety rules

SAFETY POSTERS & SIGNS– is a large printed picture or notes used for safety
awareness.

E.g. of safety Posters & Signs

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PERSONAL PROTECTIVE EQUIPMENT (PPE)

PPE is equipment that will protect the user against health or safety risks at work. It
can include items such as safety helmets, gloves, eye protection, high-visibility
clothing, safety footwear and safety harnesses. It also includes respiratory
protective equipment (RPE).

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The Personal Protective Equipment Regulations 2002 and the Personal Protective
Equipment at Work Regulations 1992 (as amended) give the main requirements.

Other special regulations cover hazardous substances (including lead and

asbestos), and also noise and radiation.

PPE should only be used as a last resort. When it is used, employers must
consider the following:

· PPE must be effective and protect the worker

· PPE must be provided and maintained free of charge

· Employees should be involved in the selection of PPE

· Employees must have adequate information, instruction and training to enable

them to use the PPE effectively

-Employers have duties concerning the provision and use of personal protective
equipment (PPE) at work.

· Employees must take reasonable steps to ensure that any PPE provided is used
properly

TYPES OF PPE YOU CAN USE:

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 1. Eyes Protection

Note
Make sure the eye protection chosen has the right combination of
impact/dust/splash/molten metal eye protection for the task and fits the user
properly

Hazards
Chemical or metal splash, dust, projectiles, gas and vapour, radiation

Options
Safety spectacles, goggles, face screens, face shields, visors

2. Head and neck Protection

Note

 Some safety helmets incorporate or can be fitted with specially-designed eye

or hearing protection
 Don't forget neck protection, eg scarves for use during welding
 Replace head protection if it is damaged

Hazards
Impact from falling or flying objects, risk of head bumping, hair getting tangled in
machinery, chemical drips or splash, climate or temperature

Options
Industrial safety helmets, bump caps, hairnets and firefighters' helmets

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 3. Ears Protection

Note

 Provide the right hearing protectors for the type of work, and make sure
workers know how to fit them
 Choose protectors that reduce noise to an acceptable level, while allowing
for safety and communication

Hazards
Noise – a combination of sound level and duration of exposure, very high-level
sounds are a hazard even with short duration

Options
Earplugs, earmuffs, semi-insert/canal caps

4. Hands and arms Protection

Note

 Avoid gloves when operating machines such as bench drills where the
gloves might get caught
 Some materials are quickly penetrated by chemicals – take care in selection,
see HSE’s skin at work website
 Barrier creams are unreliable and are no substitute for proper PPE
 Wearing gloves for long periods can make the skin hot and sweaty, leading
to skin problems. Using separate cotton inner gloves can help prevent this

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Hazards
Abrasion, temperature extremes, cuts and punctures, impact, chemicals, electric
shock, radiation, vibration, biological agents and prolonged immersion in water

Options
Gloves, gloves with a cuff, gauntlets and sleeving that covers part or the entire arm

5. Feet and legs Protection

Note

 Footwear can have a variety of sole patterns and materials to help prevent
slips in different conditions, including oil- or chemical-resistant soles. It can
also be anti-static, electrically conductive or thermally insulating
 Appropriate footwear should be selected for the risks identified

Hazards
Wet, hot and cold conditions, electrostatic build-up, slipping, cuts and punctures,
falling objects, heavy loads, metal and chemical splash, vehicles

Options
Safety boots and shoes with protective toecaps and penetration-resistant, mid-sole
wellington boots and specific footwear, eg foundry boots and chainsaw boots

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 6. Lungs Protection

Note

 The right type of respirator filter must be used as each is effective for only a
limited range of substances
 Filters have only a limited life. Where there is a shortage of oxygen or any
danger of losing consciousness due to exposure to high levels of harmful
fumes, only use breathing apparatus – never use a filtering cartridge
 You will need to use breathing apparatus in a confined space or if there is a
chance of an oxygen deficiency in the work area
 If you are using respiratory protective equipment, look at HSE’s publication
Respiratory protective equipment at work: A practical guide

Hazards

 Oxygen-deficient atmospheres, dusts, gases and vapours

Options – respiratory protective equipment (RPE)

 Some respirators rely on filtering contaminants from workplace air. These

include simple filtering face pieces and respirators and power-assisted
respirators
 Make sure it fits properly, eg for tight-fitting respirators (filtering face
pieces, half and full masks)
 There are also types of breathing apparatus which give an independent
supply of breathable air, eg fresh-air hose, compressed airline and self-
contained breathing apparatus

7. Whole body Protection

Note

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  The choice of materials includes flame-retardant, anti-static, chain mail,
chemically impermeable, and high-visibility
 Don't forget other protection, like safety harnesses or life jackets

Hazards
Heat, chemical or metal splash, spray from pressure leaks or spray guns,
contaminated dust, impact or penetration, excessive wear or entanglement of own
clothing

Options
Conventional or disposable overalls, overcoats, boiler suits, aprons, chemical suits,
reflector jackets

SAFETY AGAINST FIRE HAZARDS (FIRE FIGHTING)

Fire extinguishers are most of the one of the most important pieces of safety
equipment. All workshop personnel must know the location of the fire
extinguishers in the workshop. If you have to waste time looking for an
extinguishers after a fire starts, the fire could get out of control before you get fire
the extinguisher into operation. Fire extinguishers should be located where they are
easily accessible at all times. Everyone working in the workshop must know how
to operate the fire extinguishers. There are several different types of fire
extinguishers.

Precautions:

1) Proper means of escape in case of fire

2) Exit doors from any room shall not be locked or fastened.

Training for handling fire fighting equipments

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 1) Everyone should know the position of the fire fighting equipments(Fire
extinguisher)
2) Workers should be aware of the procedure of calling the fire brigade, raising
the alarm of fire and communicating to others.

HOW FIRE STARTS?

Fire is a chemical reaction involving rapid oxidation or burning of a fuel (or a

chemical reaction between oxygen and a combustible fuel). It needs three elements
to occur:-

1) FUEL – Fuel can be any combustible material (e.g. in form of solid, Liquid
or Gas).
2) OXYGEN – Fire needs Air.
3) HEAT – Caused ignition to occur.

FIRE HAZARD is conditions that favour the ignition and spread of fire.

There are three methods of extinction (extinguishing) fire, these are:-

1) STARVATION – This is a process of removing fuel material from fire.

2) SMOTHERING – This is a process of removing oxygen(e.g. covering the
burning material)
3) COOLING – This is a process of removing heat (e.g. spraying water into a
burning material)

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Methods of Heat Spread:-

1) CONDUCTION-the transfer of heat between two bodies that are touching

or from one location to another within a body.
2) CONVECTION-the transfer of heat from one location to another by way of
a moving medium.
3) RADIATION-consists of energetic nuclear particles and includes rays, high
speed electrons and high speed protons.

REDUCING FIRE HAZARDS

 Prohibit smoking near any possible fuels.

 Store fuels away from areas where electrical sparks from equipment, wiring,
or lighting may occur.
 Keep fuels separate from areas where there are open flames. These may
includes welding torches, heating elements or furnaces.
 Isolate fuels from tools or equipment that may produce mechanical or static
sparks.

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NB: When tackling fire press the fire alarm or shout FIRE!! FIRE!!!(Do not be
close to fore)

FIRE CLASSFICATION & FIRE EXTINGUISHERS

The table below identified which fire extinguishers are suitable for each class of
fire:

Fire Fire Risk Wate Foam CO2 Powder Wet

Classification r Chemical

Class A Wood, Paper, Textiles   

and Fabrics
Class B Flammable Liquids-   
Petrol, Oil, Paints
Class C Flammable Gases 
Class d Metal Fires Special
powder
only
Class E Electrical Fires  
Class F Cooking Oils and Fats 

FIRE EXTINGUISHERS CODES

The use of fire extinguishers should play a major role in any fire risk assessment
that is why a range of fire extinguishers are provided to assist in controlling the
risk of fire.. All fire extinguishers carry the kite mark, are approved with Fire
Brigade and come with five year guarantee.

FIRE EXTINGUISHER COLOUR CODE:

1. WATER = RED
2. DRY POWDER = BLUE
3. FOAM = CREAM
4. CARBON DIOXIDE (CO2) = BLACK
5. VAPOURIZATION LIQUIDS = GREEN
6. WET CHEMICAL = YELLOW

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FIRE EXTINGUISHERS INFORMATION

1. WATER FIRE EXTINGUISHERS-is suitable for extinguish Wood,

Cloth, Paper, some Plastics, Coal, People, and Fires involving solids.
Not to be used on burning fat, oil or electrical appliances.. Remember
that the water takes away the heat of the fire by cooling the burning
material.

METHOD OF USE: Point the jet at the base of the frames and keep it moving
across the area of the fire. Ensure that all areas of the fire are out.

2. DRY POWDER FIRE EXTINGUISHERS-is suitable for

extinguish Wood, Cloth, Paper, Plastics, Coal, Liquids such as grease,
fats, oil, paint and petrol. The powder is not good at getting into tiny
spaces in electrical equipment easily so the fire may re-ignite.(not to
be used on chip pan fires) as well as knocking down frames, on
burning solids it melts to form a layer of skin that smothers the fire.

METHODS OF USE: Point the nozzle at the base of the flames and with a quick
sweeping motion, drive the fire away from you until all the flames are out.

3. SPRAY FOAM FIRE EXTINGUISHERS-is used for limited

number of liquid fires. Forms a fire extinguishing film on the surface
of a burning liquid, Has a cooling action with a wider extinguishing
application than water on solid combustible materials..Do not use on
chip pan fires (check manufacturer’s instructions for suitability of use
on other fires involving liquids)
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METHODS OF USE: Do not aim jet straight into the liquid. Where the liquid on
fire is in a container, point the jet at a surface nearby the burning liquid. Allow the
foam to build up and run across the liquid

4. CARBON DIOXIDE (CO2) FIRE EXTINGUISHERS-is suitable

to extinguishing liquids such as grease, fats, oil paint, petrol etc. but
not on chip pan fires.. This type of extinguisher does not cool the fire
very well and you need to watch that the fire does not start up again.
Fumes from CO2 extinguishers can be harmful if used in confined
spaces so ventilate the area as soon as the fire has been controlled
(These extinguishers are generally not recommended for home use).
The vaporizing liquid gas smothers the flames by displacing oxygen
in the air.

METHODS OF USE: The discharge horn should be directed at the base of the
flames and the jet kept moving across the area of the fire.

5. FIRE BLANKETS-is suitable for fires involving solids and liquids.

Excellent for small fires on clothing and for chip and fat pan fires..
The blanket must completely cover the fire or it will not be
extinguished. The fire blanket smothers the fire.

METHODS OF USE: Place carefully over the fire. Keep your hands away from
the fire and place the blanket down away from you.

29
FIRST AID

Some persons should be properly trained for First Aid. First Aid box having
medication i.e. life saving, pain killer and alcoholic solution, dressing
materials, tools and instruments e.g. cotton, bandages, pair of scissors,
thermometer, plaster, mask, torch etc.

Definition:
FIRST AID - is a service provided at initial care for an illness or injury .It is
usually performed by non – expert person to a sick or injured person before
medical treatment can be accessed.
OR
FIRST AID – is the immediate care that is given to the victim of an illness
or injury before professional rescuers arrive.

Aims of First Aid:

 To preserve (save) life – aim of all medical care of first aid is to save
life e.g to stop bleeding, to open airway, and to treat any irregularities
condition.
 To prevent further harm, and to limit worsening of the condition.
 To promote recovery – starts the recovery process for illness or
injured person.
 To limit (prevent) worsening of the condition etc, etc.

FIRST AID KITS OR BOXES

30
First aid kit or box is a collection of supplies and equipment for use in
giving first aid. (The packages consists medicine, instruments and tools).
First aid kits should be clearly identified and conveniently. These kits
contain such items as bandages and ointment required for minor cuts. All
workshop personnel must be familiar with the location of first aid kits. At
least one of the workshop personnel should have basic first-aid training and
this person should be in charge of administering first aid and keeping first
aid filled.

FORMAT AND APPEARANCE OF FIRST AID KITS

First aid kit it is any type of container or standard kits or durable plastic
boxes, fabric pouches or wall mounted cabinets.. The international
organization for standardization (ISO) sets a standard for first aid kits of
being green, with a white cross, in order to make them easily recognizable to
anyone requiring first aid.
NOTE\; RED CROSS use white boxes with red cross.

FIRST AID SYMBOLS

31
FIRST –AIDER is someone in an organization who has been trained to give
immediate medical help in an emergency (or one trained in giving first aid)

CONTENTS OF FIRST AID KIT (first aid kit checklist)

7. Medication-
a) Life saving medication e.g. Aspirin.
b) Pain killers’ medication e.g. Paracetamol
8. Bandages(different sizes)
9. Pair of scissors
10.Safety pins
11.Plasters
12.Spirit(Alcoholic solution)
13.Snake bite lancet
14.Tweezers
15.Syringe(disposable)
16.Thermometer
17.Mask
18.Blood pressure machine and cuff
19.Stethoscope
20.Torch
21.Disposable gloves
22.Cotton swabs
23.Gauze(different sizes)
24.Hydrogen peroxide

32
 SOME CONDITIONS THAT OFTEN REQUIRE FIRST AID:
 Burns
 Electrical shock
 Wounds
 Poisoning
 Stroke
 Bone fracture
 Accident
 Dog bite
 Snake bite
 Toothache
 Heat attack
 Joint dislocation
 Chocking
 Headache etc.

WOUNDS-A wound is a break in the continuity of tissues, especially an injury

involving a cut or break in the skin or an injury to living tissue caused by a cut,
blow, or other impact.

Types of wounds

1. Incision-the action of cutting made in skin or flesh.

2. Laceration-tear or deeply cut which cause pain to the flesh or skin.
3. Abrasion- wound due to wearing of skin by rubbing.

33
 4. Puncture-deformation which reduce the size and cause a small hole by a
sharp object.
5. Contusion-an injury that does not break the skin but results in some
discolouration(unnatural)

CARDIOPULMONARY RESUSCITATION (CPR)

Cardiopulmonary resuscitation (CPR) is a lifesaving technique useful in many

emergencies, including heart attack or near drowning, in which someone's
breathing or heartbeat has stopped.

CPR can keep oxygenated blood flowing to the brain and other vital organs until
more definitive medical treatment can restore a normal heart rhythm.

When the heart stops, the lack of oxygenated blood can cause brain damage in only
a few minutes. A person may die within eight to 10 minutes.

Before starting CPR, check:

 Is the person conscious or unconscious?

 If the person appears unconscious, tap or shake his or her shoulder and ask
loudly, "Are you OK?"
 If the person doesn't respond and two people are available, one should call
the emergency number and one should begin CPR..

REMEMBER TO SPELL A-B-C

Remember to use the acronym of ABC —airway, breathing, compressions, to help

people remember the order to perform the steps of CPR. 

AIRWAY, BREATHING & CIRCULATION (A B C‘s)

First aid treats the ABC’s as the three elements of basic life supports and
foundation of good treatment.

A-Airway (establishment and clear of an airway)

B-Breathing (artificial ventilation of the lung, breathe for the person)

34
C-Circulation or Compressions (artificial circulation of blood through the
body which restores blood circulation)

6. A-AIRWAY MANAGEMENT:
 Tilt the victim’s head back and lift the chin to open the airway.
 Opening the airway with a head tilt-chin lift maneuver.
 Clear open and maintain head treat and chin lift to establish airway
 Apply a technique of jaw thrust maneuver if a person is broken backbone

AIRWAY: CLEAR THE AIRWAY

1. If you're trained in CPR and you've performed 30 chest compressions, open

the person's airway using the head-tilt, chin-lift maneuver. Put your palm on
the person's forehead and gently tilt the head back. Then with the other hand,
gently lift the chin forward to open the airway.
2. Check for normal breathing, taking no more than five or 10 seconds. Look
for chest motion, listen for normal breath sounds, and feel for the person's
breath on your cheek and ear. Gasping is not considered to be normal
breathing. If the person isn't breathing normally and you are trained in CPR,
begin mouth-to-mouth breathing. If you believe the person is unconscious
from a heart attack and you haven't been trained in emergency procedures,
skip mouth-to-mouth breathing and continue chest compressions.

35
 7. B-BREATHING MANAGEMENT
 Give mouth-to-mouth rescue breaths.
 Look for chest and abnormal movement
 Feeling for expired air (artificial ventilation of the lung)
 Listening for expired air through mouth and nose

BREATHING: BREATHE FOR THE PERSON

Rescue breathing can be mouth-to-mouth breathing or mouth-to-nose breathing if

the mouth is seriously injured or can't be opened.

1. With the airway open (using the head-tilt, chin-lift maneuver), pinch the
nostrils shut for mouth-to-mouth breathing and cover the person's mouth
with yours, making a seal.
2. Prepare to give two rescue breaths. Give the first rescue breath — lasting
one second — and watch to see if the chest rises. If it does rise, give the
second breath. If the chest doesn't rise, repeat the head-tilt, chin-lift
maneuver and then give the second breath. Thirty chest compressions
followed by two rescue breaths is considered one cycle.
3. Resume chest compressions to restore circulation.

36
 4. Continue CPR until there are signs of movement or emergency medical
personnel take over.

8. C-CIRCULATION(COMPRESSIONS) MANAGEMENT
 Push hard and fast on the centre of the victim’s chest.
 Position 90deg your two hands on chest then push hard at a rate of about 100
compressions a minute..
 Continue chest compressions until there are signs of movement or until
emergency medical personnel take over. If you have been trained in ABC’s,
go on to checking the airway and rescue breathing.

COMPRESSIONS: RESTORE BLOOD CIRCULATION

1. Put the person on his or her back on a firm surface.

2. Kneel next to the person's neck and shoulders.
3. Place the heel of one hand over the center of the person's chest, between
the nipples. Place your other hand on top of the first hand. Keep your
elbows straight and position your shoulders directly above your hands.
4. Use your upper body weight (not just your arms) as you push straight
down on (compress) the chest at least 2 inches (approximately 5
centimeters). Push hard at a rate of about 100 compressions a minute.
5. If you haven't been trained in CPR, continue chest compressions until there
are signs of movement or until emergency medical personnel take over. If
you have been trained in CPR, go on to checking the airway and rescue
breathing.

37
TO PERFORM CPR ON A CHILD

The procedure for giving CPR to a child age 1 through 8 is essentially the
same as that for an adult. The differences are as follows:

 If you're alone, perform five cycles of compressions and breaths on the child
— this should take about two minutes — before calling your local
emergency number.
 Use only one hand to perform chest compressions.
 Breathe more gently.
 Use the same compression-breath rate as is used for adults: 30 compressions
followed by two breaths. This is one cycle. Following the two breaths,
immediately begin the next cycle of compressions and breaths.
 Continue until the child moves or help arrives.

TO PERFORM CPR ON A BABY

Most cardiac arrests in babies occur from lack of oxygen, such as from drowning
or choking. If you know the baby has an airway obstruction, perform first aid for
choking. If you don't know why the baby isn't breathing, perform CPR .To begin,
examine the situation. Stroke the baby and watch for a response, such as
movement, but don't shake the baby.

If there's no response, call for help immediately while you attend to the baby.

38
 AUTOMOTIVE WORKSHOP TOOLS AND EQUIPMENT
Many of the tools and items of equipment are necessary to enable the Motor
vehicle workshop to cope with the wide variety of servicing and repair Work. The
following is a list of tools and equipment in the auto shop.

Hand tools: Many kind types and sizes of tools are used in automobile Work.
1. Double Ended Spanner set: These are the most commonly used type of
spanner in garage. The opening should be the right size to fit the nut or bolt.
If the spanner opening is too large, it could round off the corners of the hex.
These make the use of the proper spanner more difficult. These spanners are
available in different sizes ranging from 6 to 32mm.

2. Ring spanner : In ring spanners the end openings completely enclose the
nut or the bolt head, so that they do not slip and cause damage. Further, the
end holes in the ring spanners are twelve sided, because of which they can
be used in restricted spaces, since the nut or the bolt head can be worked
upon even when the swing of the spanner is restricted to 15.

3. Tubular spanner : These are also used for the same purpose as ring
spanner. It will be like a long tube having hexagonal ends at each end of
different size. They may vary in size from 8mm to 32mm. it can be used
where double end and ring spanner cannot be used.

4. Socket spanners: These types of spanners are useful in restricted spaces

where common types of spanners cannot be used. They consist of sockets of
different sizes which can be used with various types of handles. The handles
have projection at one end around which the sockets fit. One type of handle
has a universal joint at the projection end which makes it possible to work
with the handle at an inclination with the socket. A ratchet handle is also
available which obviates necessity of lifting of the socket from the nut or the
bolt head.

39
5. Adjustable wrenches: This wrench has jaws that can be adjusted to fit nuts
and bolt heads of various sizes. These types of wrenches have advantage that
these can be suitable for a large number of nut and bolt head sizes.

6. Torque wrenches : Important nuts and bolts in automobile work have to be

tightened with a specified amount of torque, because excessive torque may
result in their breakage while less torque they will remain loose. This is
made possible by a torque wrench. It is a specialized form of socket
spanners.

7. Screw driver: The screw driver is used to drive, or turn screws. The most
common type has a single flat blade for driving screws with slotted heads.
There are also the Phillips head and reed, and prince screw drivers.

40
8. Hammers: A medium weight ball pen hammer is the one commonly used in
automobile work. It should be gripped on the end of the handle. When you
swing the hammer, the face should strike the object squarely, and not an
angle.

9. Pliers: pliers are a special type of adjustable wrench. The two legs move on
a pivot so that items of various sizes can be gripped. There are two types
gripping pliers and cutting pliers.

41
10.Pullers: Pullers come in a variety of types and sizes and are used to remove
wheels, gears and bearing from shafts from housings. Each pulling operation
differs from the other, and care must be exercised to prevent damage to the
parts during pulling.

11.Spark plug spanner: For removing or tightening spark plugs.

12.Feeler gauge : For measurements such as valve clearance, spark plug gap,
contact breaker gap etc., we use feeler gauges which are simply blades of
different thickness.

42
13.Valve spring compressor: Valve spring compressors or lifters are used to
compress the valve spring to facilitate the removal of the valve retain lock or
keeper from the valve stem.

14.Piston ring compressor: Piston ring compressors are places around the
piston covering the rings. As the compressor is tightened, it compresses the
piston rings into their grooves on the piston. Then the piston and rod
assembly is installed into the cylinder.

15.Piston ring expander: It is generally use to expand and remove the piston
rings from their grooves without breaking.

43
SERVICE STATION EQUIPMENTS
A large number of different types of equipments are required in a Workshops or
service station for carrying out different types of repair works. Different types of
equipments are required to cope up with the wide variety of work to be done can
be classified as under.

1. SPECIAL EQUIPMENTS FOR SERVICE STATION

1. Compressed air plant

2. Car washing machine

3. Lifting tackles
(a) Hydraulic jack
(b) Car lift

(c) Axle stands

44
 (d) Jib crane
(e) A chain hoist
4. Chassis dynamometer
5. Wheel balancer

6. Tire remover

7. Brake drum lathe

8. Brake shoe lining riveting machine
9. Spark plug tester
10. High pressure grease gun
11. Wheel alignment gauges
12. Degreasing plant

SPECIAL EQUIPMENTS FOR ENGINE REPAIR:

1. Crankshaft grinding machine
2. Cylinder head surface grinding machine
3. Line boring machine
4. Connecting rod big end bearing boring machine
5. Cam shaft grinding machine

45
6. Valve reface machine
7. Hydraulic press
8. Cylinder boring machine
9. Cylinder honing machine
10. Connecting rod rebating jig

SPECIAL EQUIPMENTS FOR COMPRESSION ENGINES

1. Bench nozzle testing and cleaning equipment
2. Fuel injector tester
3. Fuel pump tester
4. Nozzle and needle grinding and lapping machines.

Power tools: Power tools are increasingly used in modern automated auto
workshops. They are operated by pneumatic, electric, hydraulic powers. Their use
envisage quicker, effortless and efficient service.

Pneumatic Nut and Bolt Tightened: It tightens and loosens the nuts and bolts in
no time. This is a portable machine whose working end can be changed to suit
different sizes of bolts and nuts.

Valve Reface: It is used to recondition the wear and worn valve faces. On
employing an attachment, it can be used to grind valve stem, tappet and the rocker
arm.

Portable Drilling Machine: This is an electrically powered machine which is used

to make holes whenever required. It can be taken conveniently to any area of repair
since it is handy, compact and portable.

Drill Stand: It is used to mount the drill machine. The job to be drilled can be
placed and clamped on its base. The height of the drill machine can be adjusted
suitably to accommodate jobs of different heights. For this purpose the grooves are
cut on its vertical stand. The height adjustment is done by means of a lever and
mechanical linkage.

Polisher and Sander: This is an electrically powered machine used to rub the
burrs from the surfaces of components, and then polish it to super finishing
accuracy. The standing is accomplished by means of emery paper or emery cloth
of coarse grade while the fine grade is used for polishing.

46
Portable Grinder: This is used to grind the rough surfaces, unwanted projections,
protruding corners etc. being sturdy and handy; it can be taken to any remote,
restricted and less accessible areas for repairing.

ASSIGNMENT 3

1. What is garage, service station and specialist repair shop.

2. What are the tools used in garage, service station and specialist repair shop.
3. Explain the tools and equipment used in garage, service station and specialist
repairs Shop.
4. Write about power tools.

MEASURING/CHECKING TOOLS & INSTRUMENTS are used for taking

and giving measurements, mechanics work need to follow measurements specified
by the manufacturers of the vehicle.(E.g. tape measures, Vermeer Caliper, Tire
pressure gauge, hydrometer, Feeler gauge, Torque wrench, Engine stethoscope,
Battery tester, Multi meter, Tester, Compression Tester, & Try Square etc, are
measuring tools / Instruments.(e.g)

(a) Tape Measure – is one of the most useful tools you can have. It can be used
for a great number of jobs such as; measuring pieces for length or diameter
and checking dimension measurement on a vehicle.
(b)Compression tester (compression gauge) is used to check cylinder
compression, because the operation of an engine depends on the
compression of the air-fuel mixture within its cylinders.
(c) Battery Hydrometer is used to measure the specific gravity of the batteries
electrolyte to give a fairly good indication of the battery’s state of charge.
(d) Torque Wrench is used to measure how tight a nut or bolt is. Many of the
car’s nuts and bolts should be tightened to a certain amount and have a
torque specified by manufacturer’s.

47
(e) Feeler Gauges – are available in blade sets of varying thickness and widths ,
ranges from 0.0015” to 0.040”(0.038 mm to 1.016 mm)
(f) A straight edge – is used to check flat surfaces for irregularities.
(g) Micrometer – micrometer is a precision instrument; it is based on a very
simple principle.
(h) Vernier Caliper – it refers to a short scale made to a slide along the
divisions of a graduated instrument to indicate parts of divisions between
Main scale and Vernier scale
(i) Dial Indicators – is an instrument used to measure alignment or movement
in a component.

48
49
TESTING DEVICES & DIAGNOSTIC EQUIPMENTS are those equipments
and devices used for testing purposes,(E.g. Nozzle(Injector) Tester, Injection Pump
Tester, Engine-Dynamometer, Scan Tool, (e.g)

(a) Scan Tool is a microprocessor designed to communicate with the vehicle’s

computer (ECU) , connected to the diagnostic connectors. A scan tool can
run tests to check system operations and monitor the activity of the system.
(b) Stethoscope is used to locate the source of engine and other noises. The
Stethoscope pickup is placed on the suspected component, and the
Stethoscope receptacles are placed in the Technician’s ears.
(c) Multimeter (Electrical Test Meter) is used for diagnosing the individual
components of an electrical system, it may be Analogue or Digital
Multimeter measures volts, ohms and low current.
(d)Test Lights (Tester) – can be used to test electrical circuits for the presence
of voltage.
(e) Battery test meter – designed primarily to test batteries.

50
Major Equipment For Service Station
Introduction
A good automobile shop must have an equipment such as car washing machine, air
compressor, vehicle hoist and grease gun to undertake servicing jobs of vehicles

Car Washing Machine

Regular chassis washing of both cars and commercial vehicles to remove grease,
oil, mud and other corrosive deposits is most essential. This type of cleaning is a
time representative of preventive maintenance. This is easily done by a spray of
water with a solvent, at high pressure (above 25 kg/cm2).
Car washer consists of a pump which is driven by a electric motor. The pump
sucks water from a well or from water tank filled beneath it and delivers to the
nozzle through a pipe of hoses with high pressure. There are two types of car
washers as follows.

51
 PUMP
GAUGE
MOTOR
hose
HOSES

That provided with single hose which can be used to wash only one vehicle at a
time
1. That provided with twin hoses which can be used to wash two
vehicles at a time. The nozzles are adjustable, so that the delivery of
water can be regulated at variable force from fine spray to solid jet.
2.
Automatic Washing-
The automatic car wash machine has a three horse power pumping station which
pumps up to 100ltrs of water per minute through 15 numbers of nozzles, 12 of
which spray as a pre-wash arch which washes tires, wheels and rocker panels and
rest three nozzles sprays on back top brush. The machine dispenses a specially
formulated foaming, high pressure chemical during a prewash pass which is
applied along with high pressure wash.
The high pressure spray automatically adjusts to the vehicle’s dimensions by the
use of P L C based control panel and lastly, high pressure air blowers maintain the
best air-steam helps to dry the complete vehicle surfaces.

The features and benefits of Automatic Washing

1. Washes all shapes, sizes and configurations of vehicles.
2. All brushes are made of extremely durable at soft bristles that are carefully
hand-woven.
3. There is an intensified rear wash programmed to effectively double wash the
backs of vehicles.

Vehicle hoist
In a big workshop, a hydraulic hoist becomes necessary to facilitate the service
work. Different types of hoists are used in automobile workshop. They are.
(i) Drive on lift or single post hoist

52
(ii) Two post hoist
(iii) Four post hoist
(iv) Six post hoist.
(v) Generally single post hoist as shown in fig 2.2 used in workshop.

PLATFORM
VALVE A
VALVE
B&C PLUNGER

HYDRA C
GROUND
CYLINDER

Fig 2.2 Vehical Hoist

The lift or hoist consists of a platform which is fixed on the top of the ram working
in a hydraulic cylinder. Normally the platform will be at ground level and will be
raised with the help hydraulic pressure applied on the ram.
When valve ‘A’ is actuated, high pressure air form the compressor acts an oil
surface in the reservoir. Oil rushes trough piping into hydraulic cylinder via
another pilot valve ‘B’.
Pressured oil entering the bottom cylinder, lifts the plunger up. An automobile
stationed on platform attached to the plunger is thus lifted up giving access for
washing and servicing.
To lower the vehicle, valve is brought to the original position. Due to self weight
of vehicle, platform etc., and plunger descends gradually pushing back oil into the
reservoir through the restriction valve ‘C’. The speed at which the vehicle or
platform is to lowered.

Air Compressor
Air compressors are used to compress the air which can be used for a number of
purpose like washing of vehicle, cleaning of engine, spraying of lubricating oil,
spraying of paint, tyre inflation, greasing a vehicle, for lifting hoist, for pneumatic
grinder, for spark plug cleaning etc.
53
 LOW PRESSURE CYLINDER
HIGH PRESSURE CYLINDER

MOTOR
OUTLET
AIR

FAN

Fig 2.3 Air Compressor

An air compressor is shown in fig2.3. It can be compared with the working of
petrol engine or any other engine. The air compressor is coupled to electric motor.
An automatic pressure controller is provided between motor and main current line,
to break the circuit when the pressure inside the air tank reduces a maximum valve.
Compressor piston draws air into the cylinder during suction stroke through the
inlet valve. As piston moves upward during its next stroke, the inlet valve closes
and the air gets compressed and delivered to the air tank through outlet valve. One
pressure gauge is fitted on air tank for observing the filling position.

2.4 Lubrication Equipments

Lubrication is the most important factors in the maintenance of the car.
If this is neglected in any way the mechanism wears more rapidly and troubles are
apt to occur. On the other hand liberal lubrication means long life and efficient
running, with general freedom from trouble.
To lubricate certain components beneath the chassis with the help of lubrication
equipments, grease guns and high pressure lubrication equipments are used.
Grease guns
Grease guns are used to lubricate the chassis components with grease.
Several types of hand operated grease guns are available. They are.

(a) Push Type (b) Grease gun

(c) Light type,

54
 Fig 2.4 Grease Gun
(a) Push type
(b) Grease gun
(c) Light type, and
(d) Bucket type
Hand and compressed air- operated
Depending upon the type of lubricant and pressure used the first three types of
hand operated grease guns.

Push type grease guns consist of a cylindrical barrel one end of which is fitted with
a nozzle cup, a piston moves inside the barrel. The piston rod assemble cap is
screwed tightly to barrel. To and fro movement of piston rod develops pressure
inside the barrel. When lever is depressed grease comes out of the nozzle under
high pressure.
Bucket type grease gun valve will be operated by a fever which sucks grease from
the central tube and delivers through outer tube and hand nozzle. It is shown in fig
above.

High Pressure Lubrication Equipment

High pressure lubrication equipment is shown in fig 2.4. it is similar to hand
operated grease gun but operated under air pressure.

55
 Air regulator valve

Air compressor

gauge

Compressed air
Grease gun

Fig 2.6 High Pressure Lubricator

Automobile Engine Reconditioning Equipment

Introduction
Engine reconditioning is a method of engine servicing. Some companies set up
special engine dissemble and rebuilding lines. They bring in old, worn engines,
dissemble them completely , repair or replace all worn parts and then completely,
recondition the engine using the old parts that are still in good condition. By
reconditioning the engine becomes as good as new. There are many machine
operations performed on engine parts. Good machining will give like new quality,
while poor machining can ruin salvageable parts. Hence care should be taken to get
the parts machined from well equipped machine shop which has a reputation of
quality work.
Different types of equipments are required for reconditioning of engine.
They are cylinder reboring and honing equipments, cylinder ridge reamer, line
boring machine, valve reconditioning equipment, crankshaft grinder etc.

Degreasing Plant
A layer of oil, grease and dirt gets coated to the engine parts with passage of time
and usage. Before performing servicing of the engine (i.e. disassembly, inspection
and measure), the unwanted layer should be removed. This can be done by hand
cleaning or by means of certain cleaning methods. For small parts, where only a
limited number is concerned, a paraffin bath can be used, the parts being brushed
or scrubbed with a stiff bristle brush to get rid of hard deposits.

56
 Tray
Container

Condenser

Reservoir

Fig 3.1 This type of degreasing plant is shown

For the larger components it is usual in small workshop to use a hot caustic soda
bath or stem bath. The caustic soda should not be used for aluminum alloys since it
has a masked chemical action-paraffin or steam bath is recommended instead. In a
larger workshop special chemical degreasing plant is employed to clean engine
parts. Usually, the dirty parts are placed in a large perforated tray or wire basket
and exposed within a tank like contains to the vapor of the heated
trichloroethylene. It is a cheap and powerful solvent and is non-inflammable. A
condenser is used to condense the vapors and return to the reservoir for the further
use. De-Carbonizing
Carbon is deposited in cylinder due to rich mixture supply, use of wrong
grade oil, unnecessary idling, too much oil. Poor fitted piston and piston rings.
Deposition of carbon causes engine knockings, missing of explosions
and burnt valve resulting in loss of power. The carbon collector at the valve
head make the head unable to dissipate heat resulting its burning or warping
sometimes. The carbon depositing in between valve and seat and impact of
valves causes pits in the seat. Therefore, a loss of compression, reduced power,
greater fuel consumption are caused. There, are in general three methods of
decarbonising or decoding-
1. Scraping method
2. Oxygen decarbonising method
3. Chemical method of decarbonising.
1. Scrapping method : The scraping of the carbon is done usually by
hand scraping with the help of tools. To remove carbon from the piston, remove
it from the cylinder. Now scrap the carbon removing brushes may be fixed in the
chuck of an electric portable drill. To clean valve grinder, valve stems etc., special
wire brushers may also be use.

57
2. Oxygen decarbonising method : It is the process of removing
carbon from the inside of the cylinder and head of the piston without removing
the cylinder head by means of an oxygen flame. The equipment consists of an
oxygen tank fitted at an initial pressure of 156kg/cm2. The oxygen is applied to
the combustion space by inserting a flexible delivery jet through a valve plug
orifice or spark plug hole by slightly bending or turning it. The oxygen flame will
burn away all the carbon deposits completely.
3. Chemical method of decarbonising : The chemical method consists
in injecting into each cylinder head trough the spark plug hole a special chemical
in liquid form. The engine should be in a warm condition so that the liquid can
act more efficiently, after standing for about12 hours the carbon is loosened, so
that upon starting up the engine it is blown out of the exhaust pipe.

Cylinder Ridge Removal

Cylinders should be inspected for the ridge at the top which shows the upper limit
of piston travel in cylinder, it is shown in Fig 3.2

Electric
ridge
motor

Ridge reamer

Cylinder head

(a) Ridge Formation (b) Removing

Ridge with Ridge Cutter

Fig 3.2 Cylinder Ridge Removal

(a) This ridge if found must be removed before proceeding further, because
otherwise the rings are liable to break once the attempt is made to take out the
piston rod assembly from the top. The ridge is removed by means of a special ridge
reamer is shown in Fig 3.2
(b) However, care should be taken not to remove any excess metal from the
cylinder. Further before starting ridge removal, rotate the crankshaft so that piston
58
of the cylinder being worked upon is at the bottom of the stroke. In this position
stiff clean in the cylinder.

Cylinder Reboring Method

In recent practice the method of truing worm cylinders with the baring bar has
become widely used on account of its rapidity and precision. Reboring is done on
special machines, it is shown in Fig 3.3.
In this machines uses a single point tool (or) cutter which is set to the exact
diameter required with special micrometer. The cutting edge is sharpened on a
revolving disk, using a mixture of diamond dirt and oil. The cutter blade shaft is
mounted inside a column which moves up and down its housing in the mixed part
of the machine, for tool feeding purpose. The cutter is driven at low speed by an
electric motor mounted on the machine.

Drive head
Boring bar shaft

Rack and pinion feed

column
motor

Handle for hand

cut
2 feed&2 speed handle

Boring bar
Cylinder block
Cutting tool

head
Fig 3.3 Cylinder Reboring machine

The top surface of the cylinder block is thoroughly cleaned and the boring bar set
at one of the cylinder bores. The bar is centered set to the desired depth of cut and
the machine started. The cutter will bore progressively to the other end, and the
machine stops when the boring complete. After the job is complete again the
cylinder must be washed thoroughly to remove all abrasive

59
particles.
Before starting reboring operation it is very important to prevent the entry of metal
or abrasive particles in the oil galleries. It is a good practice to warp insulation
tapes on crank pins and to cover other parts as is possible

Cylinder honing method

Honing the cylinder walls is necessary after reboring, or to remove minor
imperfections and glaze. A hone consists of four or six narrow, fine-graded
grinding stones mounted in cage around a spindle which is rotated by an electric
motor.
In the fixed, machine-shop type hone, the cylinder block is mounted on the
machine table, and the vertical or stroking movement of the hone up and down the
bore often effected automatically. Portable hones, designed to be driven by a heavy
duty electric drill mounted on a stroking stand are also widely used, especially in
conjuction with a portable boring bar; in these cases the stroking action is effected
manually.
Place the hone in the cylinder and expand the stones until the assembly can just be
turned by hand and machine started. Home drive at drill speed while
moving the hone up and down the entire length of the cylinder until the hone
begins to run free. During this operation a liberal amount of kerosene, or other
suitable cutting fluid, should be used to keep the stones clean.

Feed lever
stand
motor

adapter

block

stone

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 Fig 3.4 Cylinder Honing Machine
Valve seat cutting & valve grinding
The valve seats can be reconditioned with the help of valve seat grinders by 30 , 45
and 60 stone to get actual contact width. In absence of valve seat grinding machine
valve seat cutters can also be used. Although the seats cut by valve seat cutters are
not very good.

Valve seat grinding

The grinding stone of proper shape in rotated on the valve seat by means of
concentric grinding .in this system the stone is kept concentric with the valve seat
by a pilot installed in the valve guide. the pilots are usually adjustable enabling
them to fit tightly in guides over a range of different sizes. Therefore, the use of
pilot means that the valve guide must be serviced before the seat is ground. The
stone is automatically lifted about once a revolution. this permits the stone to clear
itself of dirt and dust by centrifugal force.

handle

motor
Cutter tool
adaptor
Valve seat spring
Valve seat stone

Centering pilot
Centering Valve guide
Valve guide pilot

Fig 3.5 Valve Seat Cutting and Griding

Valve Refacing
If the valve face is badly scored or pitted, it may be done on a special valve
refacing machine.
The machine consists of a grinding wheel operated by an electric motor.
The valve is held in chuck which is also rotated with electric motor. There is a
provision to set the valve chuck at any desired angle. This angle must just match
the valve seat angle. Then put the valve into the chuck and tighten the chuck.
The valve should be placed in the chuck so that the part of the stem that runs in the
valve guide is gripped by the chuck.
Crank shaft grinding

61
A special lathe or a crankshaft grinder is required to grind the journal and crank
pins of a crankshaft. Crankshaft machine consists of a bed on which guide ways
are provided, at one end head stock is mounted and another end tail stock is
mounted. Both head stock and tail stock combined move on the bed ways along
with crankshaft, a hand wheel is provided in front of machine for this purpose. The
spindle can be driven by a separate motor.
At the back of the machine big grinding wheel is installed an a suitable base. It can
be moved forward and backward by a hand wheel provided in front of the machine.

coolant
Grinding stone
motor

Counter Counter weight

weight

Tail stock

bed
Coolant pump

Fig 3.7 Crankshaft grinding machine

Diesel Fuel Injection System recondition
Introduction
While assembling a new injection pump or after long periods of service,
it is necessary to check, test and calibrate the pump. These lists are performed
by a skilled operator, with the help of a typical precision testing equipment.
Three important tests must be carried out before refitting a pump to an engine.
They are phase angle check test, calibration and governor test.

Fuel Injection Pump Test Bench (Phasing And

Calibration Tests)
This bench is of two types
(a) Hand operated and (b) The motor driven.

On hand operated machine the pump is calibrated at limited speeds, thus also do
not perform the governor test. Therefore the motor driven machine is very common
to test the injection pumps now-a-days.
The motor driven bench consists of an electric motor of 2 to 3 h. p.

62
Therefore the operating range of the pump can be obtained up to 4000rpm.
This covers the full range of engine speed. The machine is mounted on a table,
which has provisions to connect the pump at right alignments. A flexible coupling
is provided to connect the shafts thus small error in alignment is eliminated. A trip
plate is provided which trips-off at every 14seconds.
The delivery pipes from the pump are connected to the injection nozzles, the
valves of which are spring loaded. The fuel delivered from the nozzle is measured
by the glass vessels.
When the test to performed, the shaft is rotated at the testing speed, then the pump
elements also deliver their fuel into a tray provided above elements also deliver
their fuel into a tray provided above the measuring vessels. When complete air of
the system is removed then the tray is quickly swung and the fuel is allowed to be
delivered into the measuring vessels. This delivery of the fuel is allowed for 200
revolutions of the camshaft by the means of a counting device.
After completing the above revolutions, the tray is automatically and quickly
moved over to cover the tops of the measuring vessels.

gauge
column
Glass Fuel pipes

Measuring
cylinder Injector Coupling vice
Fuel
pump
pipe Speed adjustment

Wheel 4 valves
Base

Fig 5.1 Fuel Injection Pump Test Bench

In this way the fuel delivered from the individual pump element can be read and
compared from the measuring vessels. In this way the fuel delivered from the
individual pump element can be read and compared from the measuring vessels.
Finally pump is set and calibrated as specified by the manufactures.

Phase angle test

63
The object of this test to check interval between successive injections, so that for a
six-cylinder pump the intervals will be 60 and for a four-cylinder pump 90.

Calibration
Calibration of the pump should be carried after the phase angle test.
This consists of adjusting each element to deliver an equal quantity of fuel to the
cylinders. The quantity delivered per stroke depends upon the manufacturer’s
requirement. As the elements of the fuel pump deliver the fuel at various speeds
and for different control – rod position.

Fuel Injector Testing

With the help of injector tester, the injectors are tested for the following job
characteristics
1. Pressure test
2. Leak-off test
3. Spray test.

1. Pressure test :
To check the setting pressure, the pump is operated by the hand lever and the
pressure at which fuel leaves the nozzle noted. In case the pressure is less, it is
increased by loosening the check nut and tightening the adjusting screw and if it is
more than specified, the adjusting screw is loosened.
Typical values for setting pressures, which are slightly higher than working
pressures, are 175 atmospheres for direct injection and 120-150 atmospheres for
indirect injection.

3. Leak test :
Fix up injector on tester, build up pressure of 150 atmospheres and keep the
pressure for about 10 seconds (without spraying).
After 10 seconds check up there is no drop in pressure and wetness is not felt on
the tip of nozzle body. Incase there is a drop of pressure in wetness is felt or
droplet is seen of nozzle body, dismantle the injector, get the seat nozzle valve
grounded and nozzle body seat lapped. Incase nozzle valve seat is pitted is should
be replaced or grounded. Fix up injector again and test in the same order.

4. Spray test :
Inspect the spray pattern of the fuel; normally the spray should be uniform. If it is
in stream form, the nozzle seat and valve seat should be grounded and checked
once again. The spray sound is also checked good injector gives peculiar whistling
sound. The spray angle is also checked during this test.Pressure gauge

64
 Pressure adjusting Fuel tank
screw

Injector
Check valve

Air vent screw

Injection pipe Operating lever

Fig 5.2 Fuel Injection Testing

Using the right tools and equipments when working on your car will make the job
easier. However, every technician and auto owner should have some basic hand
tools and safety equipment to perform periodic maintenance and minor repairs.

Choose the right tool for the job. Otherwise you could damage the part you are
working on, the tool, or yourself.

Mechanical / Automotive tools can be summarized divided into five groups:

1) Hand Tools
2) Measuring/checking Tools and Instruments
3) Special Tools
4) Equipments and Power Tools
5) Test & Diagnostic equipments

Assignment 4

1. What is phasing?
2. What is calibration?
3. What is pressure test, leak-off test, spray test?

4. Explain the procedure of fuel injection pump test bench

5. Write about the procedure of fuel injector tester

65
OCCUPATIONAL HEALTH AND SAFETY (OSH)

NATIONAL OCCUPATIONAL SAFETY AND HEALTH (OSH) -

REGULATIONS IN TANZANIA

Health and Safety

What are the laws in Tanzania relating to the issues of Occupational Safety
and Health?
66
In Tanzania we have pieces of legislation covering the Occupational Health and
Safety of an employee and these include the Employment and Labour Relations
Act, 2004. However, a more specific, relevant and direct legislation is the
Occupational Health and Safety Act, 2003.The Act is aimed at protecting workers’
rights in health and safety in the workplace. It also provides for the protection of
persons other than persons at work against hazards to health and safety arising out
of or in connection with activities of persons at work, and to provide for connected
matters.

Who does the Occupational Health and Safety Act, 2003 cover?

The Act applies to factories and all other work places unless exempted by the
Minister in accordance with the provisions of the Act.

Does the Act impose any duty on behalf of workers?

Yes. The following are some of the duties of a worker imposed under the law:

 Workers must take reasonable care for the health and safety of themselves
and any other persons who may be affected by his/her actions or omissions
at work.
 They also have a duty to cooperate with the employer to enable the duty or
requirement imposed by the employer to be performed or complied with.
 They have a duty to carry out any lawful order given to him/her and to obey
the health and safety rules and procedures laid down by employer or an
authorized person in the interest of health and safety.
 To report to his/her employer or health and safety representative any unsafe
or unhealthy situation coming to their attention.
 To report to his/her employer or health and safety representative any
incident or accident which may cause injury to their health as soon as
practicable (not later than the end of a shift unless circumstances prevent so).

What is the general duty of an employer under this law?

The employer has the following duties under the Occupational Health and Safety
Act:

 To register his/her factory/workplace/business with the Occupational Health

and Safety Authority.
 To conduct regular medical examinations of his/her employees in
accordance with the Act.
67
  To choose health and safety representatives in a workplace with four or
more workers.
 Employers must make sure that the workplace is safe and healthy, and must
not allow any worker to do work that is potentially dangerous.
 They must inform workers of any possible dangers in the workplace.
 They must reduce any dangers to a minimum before issuing protective
clothing.
 They must issue protective clothing where necessary.
 They must give necessary training to workers who use dangerous machines
and materials, to make sure they know the safety precautions.
 They must prevent workers from using or working with dangerous materials
or machines, unless all safety rules have been followed.
 They must ensure that dangerous machines are in good working order and
are safe to work with.
 They must make sure that dangerous machinery carries warnings and
notices.
 They must make sure that somebody who knows the work is supervising the
operations to ensure the safety of workers.
 They must keep the workplace open so that workers can escape from danger
if necessary.

Is there any punishment for non-compliance Act by employer or employee?

Where such a contravention has been occasioned by an employer and as a result an

employee is killed or suffers serious body injury the employer may be liable to a
fine of not less than 10 million or to imprisonment for a term not exceeding two
years or both imprisonment and fine. The Court may in addition to a fine or instead
of imposing a fine may also order the cause of contravention to be remedied.

If an employee contravenes the provisions of this law relating to health and safety,
they will be liable for penalty or imprisonment or both penalty and imprisonment
depending on the offence.

Can an employer punish a worker for complaining about safety conditions?

No. The law prohibits an employer from dismissing an employee, reducing the rate
of his/her remuneration, altering the terms and conditions of his/her employment
for the following reasons:

 Giving evidence in court about their conditions at work.

 Responding to any requests by an inspector.
68
  Refusing to do anything that is against the law.
 Giving information about their conditions at work.
 Complying with a lawful prohibition, requirement, request or direction of an
inspector.
 Contracting an occupational or any other disease.

Is an employer required to report accidents occurring at the workplace?

The employer is required to report any incident or accident which has occurred at a
place of work and has resulted in either death, body injury, lost of conscious,
occupational illness or has permanently incapacitated a worker, within twenty four
hours from the time the incident has occurred.  Within seven days from the day the
incident was reported the employer is required to send a duly completed prescribed
form containing information on the incident.

How are the provisions of this Act enforced?

The Occupational Health and Safety Authority (OSHA) was established (under
Executive Agencies Act No. 30 of 1997) and is the custodian of Occupational
Health and Safety Act No.5 of 2003.

The primary objective of the Occupational Safety and Health Authority (OSHA) is
to ensure the creation and maintenance of ideal work environments which are free
from occupational hazards that may cause injuries or illness to all employees in
work environment. The authority has employed Labour Inspectors whose duty
includes the inspection of health and safety in workplaces. After they prepare a
report, the same is submitted to the Chief Inspector for relevant action which could
be:

 Advising the employer accordingly.

 Issuing an improvement notice.
 Issuing a prohibition notice.
 Referring the matter to court.

INTERNATIONAL OSH- REGULATIONS

Occupational safety and health (OSH) also commonly referred to as occupational

health and safety (OHS) or workplace health and safety (WHS) is an area
concerned with the safety, health and welfare of people engaged in work or
employment. The goals of occupational safety and health programs include
fostering a safe and healthy work environment. OSH may also protect co-workers,
69
family members, employers, customers, and many others who might be affected by
the workplace environment. In the United States the term occupational health and
safety is referred to as occupational health and occupational and non-occupational
safety and includes safety for activities outside work.

Occupational safety and health can be important for moral, legal, and financial
reasons. In common-law jurisdictions, employers have a common law duty
(reflecting an underlying moral obligation) to take reasonable care for the safety of
their employees, Statute law may build upon this to impose additional general
duties, introduce specific duties and create government bodies with powers to
regulate workplace safety issues: details of this will vary from jurisdiction to
jurisdiction. Good OSH practices can also reduce employee injury and illness
related costs, including medical care, sick leave and disability benefit costs.

70
Occupational Health and Safety Act (OSHA)

The Occupational Safety and Health Act (OSHA) was passed by the United
States government in 1970.(N:B The Occupational Safety and Health Act (OSHA)
regulates working conditions in the United States)

Definitions:

The Occupational Safety and Health Act (OSHA)-Legislation that sets out the
rights and duties of all parties in the workplace for the protection of workers
against hazards on the job.

Laws - Rules that limit behavior.

Legislation – Laws brought into force by a legislative body

Regulations – Specific rules that often support other legislation.

Act – Document containing laws made by provincial legislature or federal

parliament.

The purposes of this legislation are:

3. To assist and encourage the citizens of the United States in their

efforts to ensure safe and healthful working conditions by providing
research, information, education, and training in the field of
occupational safety and health.
4. To ensure safe and healthful working conditions for working men
and women by authorizing enforcement of the standards developed
under the act.

The Occupational Health and Safety Act aims to provide for the health and safety
of persons at work and for the health and safety of persons in connection with the
activities of persons at work and to establish an advisory council for occupational
71
health and safety.

Since approximately 25% of workers are exposed to health and safety hazards on
the job, the OSHA is necessary to monitor, control, and educate workers regarding
health and safety in the workplace. Employers and employees should be familiar
with workplace Hazardous Materials Information Systems (WHMIS).

REVIEW QUESTIONS

1. Explain the purposes of the Occupational Safety and Health Act (OSHA)
2. Describe any five safety precautions necessary for personal protection in the
workshop.
3. Explain why smoking is dengerousin the workshop.
4. List five rules related to general workshop safety.
5. Describe how to put out a fire with a fire extinguisher.
6. Fire is a chemical reaction. What is going on?
7. What are the three methods of heat transfer ? Describe each
8. What are the classes of fires?
9. Define the following terms: Occupational Safety and Health Act(OSHA),
Hazards, Fire, First-Aid, and Dangerous goods.
10.Define the term ergonomics. Explain its origins.
11.Explain briefly the most common kinds of falls.
12.List and briefly explain the common types of mechanical injury hazards
13.Differentiate between sound and vibration.
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73