SRM UNIVERSITY

DEPARTMENT OF AUTOMOBILE
ENGINEERING
LAB MANUAL
VEHICLE TESTING LABORATORY
AE1019/15AE405L
REGULATION 2013/2015

Faculty of Engineering and Technology

SRM Nagar, Kattankulathur
Kancheepuram, Tamil Nadu-603203
FOR PRIVATE CIRCULATION ONLY
ALL RIGHTS RESERVED

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INSTRUCTIONS

General:

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 1. Students must follow proper dress code (uniform) inside the laboratory with shoes
covering the whole foot as a measure of safety. Long hair should be tied back.

2. M a i n t a i n s i l e n c e , o r d e r a n d d i s c i p l i n e i n s i d e t h e l a b a n d a v o i d u s i n g
c e l l p h o n e s i n s i d e t h e laboratory.

3. Make sure you possess the lab manual prior to entering the lab.

4. Read carefully and understand the description of the experiment as

provided in the lab manual.

5. Refer the manual provided and other appropriate books, to be completely familiar with
the concepts and hardware and be prepared to answer the pre-lab questions.

6. Do not hesitate to report to the faculty or the lab instructor in case of any doubts/
grievances.

7. Bring necessary materials needed (writing materials, graphs, calculators,

etc.) to perform the required preliminary analysis.

8. Ensure that you get your experiments evaluated by the faculty in-charge
prior to coming for the next lab session.

Specific:

1. Students are strictly not allowed to operate any of the equipment without the presence of
the lab instructors.

2. Students are strictly not allowed to operate any of the test vehicles.

3. Students are strictly not allowed to sit inside the test vehicles except conducting
experiments.

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 15AE405L- VEHICLE TESTING
LABORATORY
CONTENTS

Page
S.No Name of the Experiment No

Studying the performance of a two wheeler using Eddy current

1. chassis dynamometer. 5

2. Testing of four wheeler using chassis dynamometer 9

Determination of slide slip, suspension efficiency, brake

3. efficiency and headlight alignment using car test lane. 12

Engine analysis using engine diagnostic system for gasoline and

4. diesel engine.

5. Wheel balancing, tire removal and fitment. 23

6. Wheel alignment 26

7. Study of chemiluminescent NOx analyzer 39

Measurement of HC, CO, CO2 and O2 using exhaust gas

8. analyzer. 41

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 9. Testing of diesel smoke intensity 44

10. Fuel injections pump timing adjustment and testing.

DATE:

1. STUDYING THE PERFORMANCE OF A TWO WHEELER USING

EDDY CURRENT CHASSIS DYNAMOMETER

Aim :
To test the performance of the given motorcycle using chassis dynamometer and to find,
i) Maximum HP at the rated maximum engine speed.
ii) Maximumtorque
iii) Exhaust temperature
Importance/Significance :
Chassis dynamometers are used to conduct performance test for vehicles. This
experiment is used to conduct performance test on two wheelers of different make and it
is used to find the power and torque produced in thhe drive wheels.
Apparatus required & Specifications :

S.No
Specifications
Apparatus Required

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 One Royal Enfield
Thunderbird 350cc
1. Motorcycle Twin spark.

2. 2-Wheeler chassis dynamometer Single roller type

3. Electrical power 220V, 50Hz/60Hz

4. Screw driver set 1
5. Spanner set 1

Experimental Setup :

Procedure :
1.High tension cable of the spark plug is connected to the tachometer of the dynamometer.
2.Regulated power supply is given from the CPU to the dynamometer setup.
3.Load sensor of the dynamometer is connected to the load input display box.

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 4.Fuel consumption sensor is connected to the fuel consumption display box.
5.The motor cycle is mounted on the dynamometer platform by placing the rear wheel over
the dynamometer roller and the front wheel of the motorcycle is held tight in the
platform wheel clamp.
6.Since the engine is tested in stationary conditions, the engine cooling is done by an
external ccoling fan which is placed in front of the engine.
7.After all the above setup has done, the testing program in the computer was initiated,
the motorcycle was started and the motorcycle is ridden on the dynamometer to
simulate the actual riding conditions.
8.The controls on the dynamometer can be set to simulate the effects of tyre rolling
resistance, aerodynamic drag and inertia of the vehicle moviing along a road under
various conditions.
9.The conditions are the same as if the vehicle actually were being driven except for the
wind loads.
10.The following parameters are obtained as realtime output from the dynamometer.
a) Continuous graph of torque
b) Continuous graph of HP
c) Time vs Kmph graph
d) Engine speed vs Kmph graph

Observation Tabulation :

S.No Engine speed Torque Power

. (Rpm) Vehicle speed ( Nm) (kW)

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Prelab Questions :
1. What is an Eddy current dynamometer?
2. What is the difference between engine dynamometer and chassis dynamometer?
3. What is the difference between IHP and BHP?
4. What is meant by load cell?
5. Brief the importance of torque vs HP graphs.

Inferences:

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Result :
a) Maximum HP at the designed maximum engine speed of_______ rpm = _____HP
b) Maximum torque at the engine speed of______rpm = ________ Nm
c) Exhaust temperature = _______ ℃
d) Continuous graph of HP is attached.
e) Continuous graph of torque is attached.
Model Graphs:

DATE:

2. TESTING OF FOUR WHEELER USING CHASSIS DYNAMOMETER

Aim :
To test the performance of the given four wheeler using chassis dynamometer and to find,
i) Maximum HP at the rated maximum engine speed.
ii) Maximum torque
iii) Exhaust temperature

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Importance/Significance :
Chassis dynamometers are used to conduct performance test for vehicles. This
experiment is used to conduct performance test on 2WD four wheelers of different make
and it is used to find the power and torque produced in the drive wheels.
Apparatus required & Specifications :

S.No
Specifications
Apparatus Required
1. Four wheeler Mahindra Scorpio

2. 4-Wheeler chassis dynamometer Single roller type

3. Electrical power 220V, 50Hz/60Hz

Procedure :
1.High tension cable of the spark plug is connected to the tachometer of the dynamometer.
2.Regulated power supply is given from the CPU to the dynamometer setup.
3.Load sensor of the dynamometer is connected to the load input display box.
4.Fuel consumption sensor is connected to the fuel consumption display box.
5.The motor cycle is mounted on the dynamometer platform by placing the rear wheel over
the dynamometer roller and the front wheel of the motorcycle is held tight in the
platform wheel clamp.
6.Since the engine is tested in stationary conditions, the engine cooling is done by an
external ccoling fan which is placed in front of the engine.
7.After all the above setup has done, the testing program in the computer was initiated,
the motorcycle was started and the motorcycle is ridden on the dynamometer to
simulate the actual riding conditions.
8.The controls on the dynamometer can be set to simulate the effects of tyre rolling
resistance, aerodynamic drag and inertia of the vehicle moviing along a road under
various conditions.
9.The conditions are the same as if the vehicle actually were being driven except for the

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 wind loads.
10.The following parameters are obtained as realtime output from the dynamometer.
e) Continuous graph of torque
f) Continuous graph of HP
g) Time vs Kmph graph
h) Engine speed vs Kmph graph

Prelab Questions :

1. What is an Eddy current dynamometer?

2. What is the difference between engine dynamometer and chassis dynamometer?
3. What is the difference between IHP and BHP?
4. What is meant by load cell?
5. Why a 4WD vehicle cannot be tested in this dynamometer?

Observation Tabulation :

S.No Engine speed Torque Power

. (Rpm) Vehicle speed ( Nm) (kW)

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Inferences:

Result :
f) Maximum HP at the designed maximum engine speed of_______ rpm = _____HP
g) Maximum torque at the engine speed of______rpm = ________ Nm
h) Exhaust temperature = _______ ℃
i) Continuous graph of HP is attached.
j) Continuous graph of torque is attached.
Model Graphs:

DATE:

3. DETERMINATION OF SLIDE SLIP, SUSPENSION EFFICIENCY,

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 BRAKE EFFICIENCY AND HEADLIGHT ALIGNMENT USING CAR
TEST LANE.

Aim :
To measure the side slip, suspension efficiency, brake efficiency using car test lane
and to carry out headlight alignment.
Importance/Significance :
The test lane is used to test the dynamics of an automobile like the condition of the
suspension, brakes and the steering system. It is used to find the side slip angle,
performing adherence test on suspension and braking efficiency at different operating
conditions.
Apparatus required & Specifications :

S.No Specifications
Apparatus Required
1 Roller brake tester 4kW, 5.3 km/h

2 Suspension tester 25Hz Max

~ 2 k m / h
3 Side slip tester transiting speed

4 Headlamp tester

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Schematic of the Experimental Setup :

Monitor

Keyboard

IR receiver

Stop button
Main switch

Printer bay

CONTROL CABINET

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 REMOTE CONTROL LAYOUT

ADHERENCE TESTER

ROLLER BRAKE TESTER

Procedure :
Side slip test:
1. The car is driven over the side-slip test plate very slowly (max 2 km/h), at right angles to
the plate without holding the driving wheel.
2. The slip plate, crossed over by the right wheel, moves in a direction opposite to the sum
of wheel slip (the left wheel touches the ground and is added to that of the right wheel).

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 3. Once the plate has been crossed over, the side-slip reading is automatically displayed
after the vehicle axle has reached the adherence tester.
4. The crossing of the plate can also be manually confirmed by means of the ENTER/F3
key.
5. The result of the side-slip test is displayed for a few seconds.

Adherence test: ( Suspension test)

The adherence test consists in measuring the weight bearing on each wheel during swinging of
the platforms on which these are resting. The results of the adherence test indicate the minimum
weight determined during such shaking in relation to the static weight of the wheel. The greater
the adherence, the better the road-holding of the vehicle.It should nevertheless be remembered
that wheel adherence does not only depend on suspensions, but also on a series of other factors
like: tyre pressure, load distribution, any play on the arms. Consequently, before performing the
test, check to make sure that the vehicle is roadworthy.
Reading are normally assessed as follows:
Adherence ≥ 60% good
Adherence 20~60% acceptable
Adherence < 20% below standard
Difference > 15% excessive
Difference ≤ 15% acceptable

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 If below standard adherence or excessive differences are shown, the shock absorber
should not be immediately replaced. It is first best to check whether the out-of-
tolerance result might be due to the other like tyre pressure, load distribution, etc.
Procedure:
1. Move the vehicle axle onto the adherence-test platforms, visibly at right angles to the
platform axis.
2. The test starts automatically once the system detects a weight of at least 60-80 daN on
both platforms.
3. The left platform is first started and then the right platform. At the end of the test, the
outer indicators on the screen display the percentage adherence readings of the left and
right wheels and the percentage difference between these.
4. The displayed readings are automatically stored after a few seconds. Within this time, the
operator can nevertheless press the F2 key to display the test graph.

Adherance test graph:

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 ➢The adherence graph shows: the evolution of the percentage measurements detected on
the left and right wheels depending on the frequency of platform movement.
➢The lowest point of the curve shows the frequency at which minimum weight on the
wheel is detected; this frequency, called resonance frequency, is normally 12 ÷ 18 Hz.
➢To exit from graph display, press the STOP/F1 key on the remote control. The monitor
will once again show the page with the numeric results of the suspension test.
➢At this point, the operator can store the test just performed by pressing ENTER/F3 or
repeat it by pressing START/F4.

Brake test:
1. drive the vehicle onto the rollers with the remote control inside the vehicle and the pedal
pressure measuring device fitted on the brake pedal. The display page in Figure below
will appear.
2. The brake test performs the following measurements: -
• Single wheel drag
• Brake ovality (out-of-roundness)
• Maximum brake force on wheels

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 • Braking unbalance between wheels of the same axle
• Braking efficiency of service, emergency and parking brakes
• Pressures applied to brake pedal and handbrake lever

#
3. The parking brake test is normally performed after testing the service brake of the rear
axle and is therefore automatically required by the system after this stage. The operator
can however manually select the parking brake test on the front axle as well before
starting the rollers, by means of the special key with the handbrake symbol.
4. After engaging the roller assembly, the system is enabled to start the rollers and begin the
braking procedure; press START/F4 to start the rollers.
5. When the rollers are stopped the wheel symbols are green; when the rollers are started
these switch to red.

Wheel drag, brake heating:

1. After starting the rollers, wait for the braking pressure readings to appear on the digital
indicators; at this stage, DO NOT BRAKE.
2. The readings that appear on the outer upper indicators, referring to the left and right
wheels indicate the pressure needed to drag the unbraked wheels by rolling resistance

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 only.
3. Slowly press the brake pedal until a pressure reading of at least 60-80 daN is displayed on
the indicators and maintain this pressure for a few seconds to heat the brake friction
elements.
4. Release the brake pedal and observe the pressure readings on the digital and analog
indicators, assessing whether there is an immediate return to minimum readings
corresponding to rolling force.

Brake ovality or out-of-roundness:

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 1. Operate the brake pedal until a pressure reading of 80-100 daN is shown on the
indicators; press the key with the ovality symbol; on the left side of the screen, the ovality
procedure symbol will appear (see Figure 19); maintain the same pressure on the brake
pedal throughout.
2. During this stage, the screen shows the absolute reading of the braking pressure swing
due to disc ovality or drum out-of-roundness. This swing will only return to the
percentage relating to maximum braking pressure at the end of the braking action on final
summary and printout.
3. Press the ovality key again and release the brake pedal, as suggested by the icon that
appears on the left. On the left side, the symbol of the axle being tested appears; the
system is now ready to analyse a braking progression.
Braking progression, unbalance calculation and braking efficiency:
1. Slowly and gradually operate the brake pedal, observe the braking pressure and pedal
pressure readings on the analog and digital indicators and assess their simultaneous
progression.

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 #
2. Continue to slowly and gradually operate the brake pedal until the wheels stop moving
(1), observe the max braking pressure readings and respective pedal pressure on the
analog and digital indicators.

#
3. The mid upper indicator also shows the braking dynamic unbalance reading; at this stage,
assess whether this is within tolerance; if it is outside tolerance, the reading is displayed
in RED.
4. At the end of the rear axle and handbrake braking procedure (if the latter operates on the
rear axle), the system is already able to assess the % braking efficiency of the service
brakes and parking brake.
5. The left indicator shows the above braking efficiency reading; at this stage, assess

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 whether this is within tolerance; if it is outside tolerance, the reading is displayed in RED.
After assessing the final result of braking, if the operator wishes, this can be stored by
means of the ENTER/F3 key; alternatively, to repeat the test, the rollers can be started
again by pressing the START/F4 key.

#
6. To pass onto the next stage, after completing axle test, the vehicle axle must be moved off
the rollers. If the axle on the rollers is the driving axle and the brake tester motors are not
self-braking, the rollers will have to be started by means of the START/F4 key to
facilitate exit.

Brake test graph:

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 At the end of the axle braking procedure, by pressing key F2 on the remote control, a
braking force pattern graph can be displayed. The axis of ordinates shows the left and right
braking forces, while the axis of the abscissa shows the time that has passed or the pressure
applied on the brake pedal if the system features a measuring unit. Press STOP/F1 to exit from
graph display and return to numerical test display. The graph shows up to 15 seconds of test from
when the minimum braking threshold is passed ,normally about 20 daN.

Prelab Questions :

1. Brief the importance of adherance test.

2. What is meant by side slip and mention its effects?
3. What is the neccessity for warming brakes befor test?
4. Mention the effects and causes of braking imbalance.

Inferences :

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Result :

Model Graphs :

DATE:

5. WHEEL BALANCING TIRE REMOVAL AND FITMENT

Aim :
To find out the quantum of imbalance in the wheels using the given wheel balancing
equipment and to perform tyre removal and fitment using the tyre changing equipment.

Importance/Significance :
Numerous reasons exist for wheel unbalance, but it is usually caused by a nonsymmetric
distribution of the rim fabrication materials, above all of the tyre with respect to the rotation axis
and equatorial plane of the wheel, to imperfect mutual rim-tyre positioning and to incorrect
wheel centring on the hub. The purpose of this experiment is to cancel out, or at least reduce to
within acceptable limits, the vibrations of the wheel that cause driving problems and damage
mechanical parts. This can be achieved by fitting counterweights of suitable size and in specific
positions to wheels that are not correctly balanced. A wheel can be considered completely

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balanced only once it is dynamically balanced, as this also ensures dynamic balancing.
Apparatus required & Specifications :

S.No
Specifications
Apparatus Required
Max wheel weight
65kg
230V/50-60 Hz/
single phase power
1. Wheel balancing equipment supply

2. Tyre changing equipment

3. LMV wheel assembly 185/65-R14

4. Balancing weights Asper requirements
5. Balancing weight fitment and removal tool 1 Nos

Schematic of the Experimental Setup :

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Dynamic balancing:
Dynamic balancing is a procedure that offsets the wheel vibrations using two weights on
different planes.
Static balancing:
Static balancing is a procedure that offsets the wheel vibrations using a single adhesive
weight on a single plane.
Procedure :
1. First it is ensured that the wheel is clean of any stones or mud it.
2. Previously installed counter weights are removed.
3. The wheel is fitted in the equipment and it is fastened properly.
4. The equipment is switched on and the program selection button (CENTR) is selected to
enter the wheel specifications and balancing modes.
5. Start button is pressed to start the wheel to spin.
6. The wheel is stopped automatically and the position where the weights to be added is

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 displayed with the direction in which to move the wheel.
7. The right position has to be set by rolling the wheel manually and the external weights
are fitted approximately in the 12’o clock position in the inner or outer side if the rim.
8. The above procedure is repeated again to find any other imbalance in the wheel.
Prelab Questions :
1. What is an imbalance in wheels?
2. What is the cause of wheel imbalance?
3. What is the meant by wheel hop, shimmy and wobble?
4. What is meant by tyre designation?
5. What are the effects of an unbalanced wheels?

Inferences:

Result :
The given wheel was checked for imbalance statically and dynamically and the counter
weights are fixeed whereever necessary.

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 DATE:
6. WHEEL ALIGNMENT
Aim:
To measure castor, camber and toe values of the given car and rectify if necessary.

Importance/Significance:
Specifications:

S.No Apparatus Required Specifications

1 vehicles with wheelbases 1800 mm (min.) and 4700 mm (max.)

Power supply: 220 / 240 V

AC single phase 50/60Hz
2 ARP3D system machine Max. absorbed power: 500w
Operational temperature range 0 to
40°C.

3 Rotating plates disc diameter of 360 mm

Schematic of the Experimental Setup:

! !
• Cabinet mounting
• Clamp/Target Mounting
• Mounting the measurement head unit supports
Vehicle diagnosis and adjustment:

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 1. Preliminary Operations
a) Vehicle Check Preliminary Operations
b) Measurement Preliminary Operations
2. Vehicle Make and Model Selection
3. Selected Vehicle Technical Specification Displaying
4. Thrust Out-of-centre with Automatic Acquisition
5. Measurement Preliminary Operations
6. Vehicle alignment / direct measurement operations
7. Steering Procedure
8. Vehicle Diagnosis
9. Adjustment Preliminary Operations
10. Rear Axle Adjustment
11. Front Axle Adjustment
a) Front toe-in adjustment with steered wheels
12. Summary of DIAGNOSIS and ADJUSTMENT data
13. Additional Functions Menu
14. Printout of Measurements taken
1) Preliminary Operations
a) Vehicle Check Preliminary Operations
Before starting the check of vehicle geometrical alignment, the following checks shall be carried
out:
• Check and, if necessary, eliminate any clearance on suspensions and on steering linkage
• Check and, if necessary, eliminate any hard spot or yielding of suspension spring parts.
• Adjust tyre pressure to the values specified by the manufacturer.
• Position and distribute any load envisaged by the manufacturer.

b) Measurement Preliminary Operations

Prepare the vehicle for measuring as described below:
• Properly place the vehicle with the front wheels on the rotating plates

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 • Fit clamps with the four targets onto wheels
• Connect and switch on (*) the 2 measuring heads on lift edges
• Lock rotating plates

2) Vehicle Make and Model Selection

Press F4 to select vehicle make and model. Programme shows the list of the makes of the
selected group

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 !
Or press F5 to start a search using keys (model/make/year) or the V.I.N number
(Vehicle Identification Number) which is a unique serial number used by the automobile industry
to identify motor vehicles. V.I.N. consists of a 17-alphanumeric digit plate usually positioned
inside engine compartment.
Note: by pressing F5 you select the search mode: Through search keys such as Make name,
model/year, or VIN (Figure 21) or through a manual selection.

• Press to move cursor from "model name" to "V.I.N." entering field.

• Press to continue, and display the list of all the vehicles complying with the just entered
search criteria; then select the correct vehicle and display the page of the selected vehicle
technical specifications.
• Make and model of the vehicle shall be compulsorily selected.
3) Selected Vehicle Technical Specification Displaying
When selecting a vehicle, a page showing the measurements and tolerances supplied by the
manufacturer is displayed.

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 !
4) Thrust Out-of-centre with Automatic Acquisition
The out-of-centre procedure proves useful to compensate for rims and clamps unbalance.
With ARP3D model this procedure is compulsory
• Simply press F4.
• This procedure can be enabled also after having diagnosed the vehicle, by selecting the
special option from menu
• To carry out the out-of-centre procedure, you should have performed the preliminary
operations, as explained.
• The clamps must be positioned with the targets at approximately “12 o’clock”, so that
during run-out they are always clearly visible to the cameras. If one or more positions are
not acceptable, the error message screen indicated below appears, which shows an
example of an improperly positioned rear right clamp. Simply position the clamp at “12
o’clock”: the program will proceed automatically.
• If instead you press F1, the error is not considered. You may not be able to complete the
procedure when performing the run-out.
To carry out the thrust out-of-centre operation, it is recommended to carefully follow the
displayed instructions.

# #

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# #

# #

5) Measurement Preliminary Operations

After having carried out the out-of-centre procedure as explained, it is necessary to prepare the
vehicle for measurement operations.
The following screen will be displayed:

#
• Release front plates, and any rear platform
• Brake wheels with hand brake, and lock brake pedal with the special tool (this operation
is necessary when carrying out a steering for kingpin correct calculation).
• Settle vehicle front and rear ends (necessary only if vehicle had been previously lifted
and the suspensions unloaded).
• Press to continue.

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 6) Vehicle alignment / direct measurement operations
To proceed to vehicle alignment and direct angle detection, you should have first carried out
measurement preliminary operations, as explained.

#
When the alignment has been achieved, the “STOP” symbol is displayed, signalling that the
programme is taking the vehicle measurements. The programme proceeds automatically only
after the wheels have been aligned.

7) Steering Procedure
After wheels have been aligned, the steering procedure can be carried out in order to define

• Caster • Included angle

• Kingpin • Steering at 20°

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 • ACK steering (at 20° with steering • Steering at 10°
geometry) • Max. steering

8) Vehicle Diagnosis
After carrying out the steering procedure, a diagnosis page showing a summary of the operations
carried out on vehicle rear axle will be displayed.

#
• Press F5 to change diagnosis data display preferences, i.e. on 1 or 2 pages (rear and
front). The selection will be stored for the next diagnosis.
• Press F4 to display the diagnosis page with a summary of front axle measurements.
• If you press F3 from here, programme will allow the printout of diagnosis measurements.
Press F4 to continue with data adjustment, programme will display, press F4 again to
confirm.

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 #
The vehicle can now be prepared for adjustment, by pressing F4 to confirm.

9) Adjustment Preliminary Operations

By selecting F4, it is necessary to carry out adjustment preliminary operations. Follow the
displayed instructions to carry out adjustment preliminary operations. Press F4 to continue.

#
10) Rear Axle Adjustment
Rear axle adjustment procedure can be made by pressing F4 from Figure 36 after carrying
out adjustment preliminary operations.

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 #
Proceed to adjustment, where allowed, as follows:
• Rear camber - Rear partial toe
11) Front Axle Adjustment
Front axle adjustment procedure is launched by selecting in the rear axle adjustment page after
carrying out adjustment preliminary operations.

#
To adjust angles, the correct sequence is the following: CASTER – CAMBER – TOE.

12) Front toe-in adjustment with steered wheels

• Front toe-in adjustment procedure with steered wheels is started by pressing F3 from
front adjustment page.
• The following picture, requesting to steer left or right, will be shown. Press F5 to
confirm.

#
Note: Steering level indicator is displayed only to give the operator a reference of the value,

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which should remain within the maximum alignment reading range (about 22÷24°).
• After pressing F5, the page shown in Figure 40 will be displayed. "De-freeze" to enable
carrying out of partial toe-ins. Use F2 (LH partial toe-in) or F3 (RH partial toe-in).
• When adjustment has been completed, press F1 to return to front adjustment phase. The
programme will request to steer back toward the centre before the front adjustment page
is displayed.

13) Summary of DIAGNOSIS and ADJUSTMENT data

This page is displayed when vehicle adjustment has been completed, after pressing F4 in the
front adjustment phase.

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 #

14) Printout of Measurements taken

By selecting the following key from the customer data entry page, the following page will be
displayed:
• A report on the performed test is printed with customer data, vehicle data before and after
adjustment, vehicle technical specifications supplied by manufacturer, and any other
remarks for the customer.
• To access the data contained inside customer database, press F3 from the start page.
• Legend of the printout example shown in the previous page.

1 - SPACE logo of the manufacturer 10 - Space devoted to manual remarks

2 - Space dedicated to workshop data
customisation
3 - Test date and time
4 - Vehicle being tested and vehicle owner
data
5 - Vehicle being tested manufacturing data
6 - Vehicle being tested diagnosis data
7 - Vehicle being tested data after adjustment
8 - Front axle data table
9 - Rear axle data table

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#

Prelab Questions :

1. Define caster, camber, Toe-in and Toe-out.

2. What is meant by steering angle inclination?
3. What is meant by road crown pull?
4. What are problems caused by wheel misalignment?
5. What are the effects of positive and negative caster?

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Observation Tabulation:

Result :
Castor, camber and toe values of the given car was measured and rectified.

42 | P a g e AUTOMOBILE ENGINEERING
 DATE:

8. MEASUREMENT OF HC, CO, CO2, NOx AND O2 USING EXHAUST GAS


ANALYZER.

Aim :
To perform exhaust gas analysis on a two stroke/four stroke petrol engine Importance/
Significance :
Crypton 285 OIML-spec analyzer is a fully microprocessor controlled exhaust gas
analyzer employing Non-Dispersive infra –Red (NDIR) Techniques. This analyzer measures
carbon monoxide, Hydrocarbons, Carbon dioxide and Oxygen. Zero calibration may be
commanded at any time by the operator and automatically executed by the analyzer. An
automatic auto zero check is performed every thirty minutes when the analyzer is switched on.

Apparatus required & Specifications :

S.No
Specifications
Apparatus Required

1 Five gas analyzer AVL

Procedure :
1.Carefully insert the sample probe into the vehicle exhaust pipe noting that is not
necessary to insert the whole length of the flexible section.

43 | P a g e AUTOMOBILE ENGINEERING
 2.Do not allow the flexible steel probe end to be kinked. Use the adjustable clip to secure
the probe to the exhaust pipe.

3.Do not force the probe, some vehicles have very short tail pipe section and it is possible
to damage the probe.

4.Take care when removing the probe from the exhaust at the end of the test.

5.Do not roll up the sample pipe while it is still connected to the analyzer as excessive
amounts of water may enter the filter unit.

6.The Greek letter Lambda (λ) is a comparative measurement of the Air/fuel ration (AFR).
Every fuel type has a specific AFR at which chemically correct combustion occurs i.e.,
all the fuel is burned and all the oxygen in the air is used so that the mixture is neither
rich nor lean.

7.This is the “Stoichiometric” AFR and for leaded petrol it in approximately, 14.7: 1. At
this point λ=1 when λ is less than 1, the AFR is rich and when it in more than 1 the A/
FR is lean.

Prelab Questions :

1. What is meant by LAMBDA sensor?

2. What are the four gases that can be measured by this 4 gas analyser?
3. What is meant by light off period?
4. What is meant by 3-way catalytic converter?
5. What is meant by fuel stoichiometry?

44 | P a g e AUTOMOBILE ENGINEERING
Observation Tabulation :

S.N O2
o. Engine speed HC CO CO2
(rpm)

Inferences :

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Result :
The measurement of the gases HC, CO, CO2 and O2 was measured using the 4gas
analyzer.

DATE:

9. SMOKE DENSITY TESTER

Aim :
To measure the smoke density of the given diesel engine using a smoke meter.

Importance/Significance :
The smoke meter uses a photoelectric cell pick-up has a source of light which throws a
beam on the soot-impregnated filter paper disc which is held in the filter slide. The
unabsorbed portion of light is reflected back on to an annular photo electric cell which
surrounds the light source. The intensity of this reflected light generates a current which is
measured by a sensitive ammeter mounted on the front of the unit and graduated from 0 to
10. The records the reflection from a filter paper while 10 indicates total absorption.

Apparatus required & Specifications :

S.No
Specifications

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 Apparatus Required
1 Smoke meter Paper filter type

Procedure :
Test:
1. Attach the sampling pump to the exhaust pipe with the clamp, so that the sampling pipe
rises continuously without bends from the probe to the pump.

2. Fit the probe centrally in the end of the exhaust pipe and clamp securely.

3. Push in the pump piston until if engages.

4. Loosen the locking nut at the other end of the pump and insert the filter slide with one
clean filter paper.

5. Connect the sampling pump to the probe.

6. With the engine at the required running condition, take a gas sample by squeezing the
rubber uniform staining.

7. Disconnect the sampling pipe at the probe between tests in order to avoid condensation

8. Store filter papers for evaluation of a convenient time.

Note: the first filter papers are usually darker than subsequent ones.

Evaluation of filter paper

1. Before evaluating, the unit must becalibrated

47 | P a g e AUTOMOBILE ENGINEERING
 2. With the instrument switched off and the protective cover on the photo cell, set the
pinter to ‘10’ with the adjusting on and leave to stabilise

3. Switch the instrument on and leave to stabilise for two minutes.

4. Remove the protective cover and place the photo-cell against the calibration paper
provided which should be placed on a stack of at least 10 clean filter papers.

Adjust the calibration knob to give a meter reading of 5.0+0.2

If this cannot be done, the internal batteries may need replacement more rarely, the
phot-cell bulb may need replacement.

5. Following the vehicle test, place the stained filter paper, stained side upper-most, on
top of a stack of ten clean filter papers.

Place the photo-cell centrally over the stack and note the meter reading.

6. Calculate the final reading as the mean of satisfactory readings taken at each test
condition.

7. Use charts,(supplied) to obtain corrected reading the temperature and pressue if

required.

If the readings are less than 2.0 (or) more than 5.5 units, no corrections should be
applied.

If the corrected readings are less than 2.0 (or) more than 5.5 units, the reading should
be quoted as less than 2.0 (or) more than 5.5

NOTE:

The meter calibration should be checked frequently during readings, use a clean cloth
to clean the rim of the photo-cell.

The stack of filter papers should always have a clean disc on top.

48 | P a g e AUTOMOBILE ENGINEERING
 Used test papers should be kept in envelops before and after evaluation and should
not be touched in the measuring area.

Prelab Questions :

1. What is meant soot?

2. What are causes of excessive smoke
3. What are the effects of particulate emission?
4. What is meant by 3-way catalytic converter?
5. What is the effect of fuel stoichiometry in the particulate emission?

Inferences :

Result :
The measurement of the density of the smoke from the given diesel engine is done using
a smoke meter.

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