Vehicle Servicing

NTQF Level - 1

Learning Guide -31

Unit of Competence: -Apply Automotive Mechanical System
Fundamentals

Module Title: -Applying Automotive Mechanical System

Fundamentals

LG Code: EISVHS1 M10 0919 LO1-LG-61

TTLM Code: EISVHS1 TTLM 0919v1

LO 1: Identify system fundamentals

 Instruction Sheet Learning Guide #-31

This learning guide is developed to provide you the necessary information regarding the
following content coverage and topics –

 Locate suitable relevant sources of information.

 Identify general automotive system fundamentals

 Refer to and identify mechanical/electrical terminology and operating principles of

systems andcomponents

This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to –

 Suitable relevant sources of information are located to assist with mechanical

fundamentals research
 General automotive system fundamentals are identified in relation to modern vehicle
platforms
 Mechanical/electrical terminology and operating principles of systems and components
are referred to and identified for a particular application

Learning Instructions:
1. Read the specific objectives of this Learning Guide.
2. Follow the instructions described in number 1 to 7.
3. Read the information written in the “Information Sheets 1”. Try to understand what are
being discussed. Ask you teacher for assistance if you have hard time understanding them.
4. Accomplish the “Self-check 1” in page -.
5. Ask from your teacher the key to correction (key answers) or you can request your teacher
to correct your work. (You are to get the key answer only after you finished answering the
Self-check 1).
6. If you earned a satisfactory evaluation proceed to “Information Sheet 2”. However, if your
rating is unsatisfactory, see your teacher for further instructions or go back to Learning
Activity #1.
7. Submit your accomplished Self-check. This will form part of your training portfolio.
 Information Sheet-1 Locate suitable relevant sources of information.

Sources of information

Information can come from virtually anywhere; personal experiences, books, articles, expert opinions,
encyclopaedias, the web. The type of informationneeded will change depending on its application .individuals
generate information on daily basis as they go about their work. In academic institution, staff and students consult
various source of information. The choice of the source to consult is usually determined by the type of information
sought.

In general there are three types of sources of information;primary, secondary and tertiary.it is important to
understand these types and to know what type is appropriate for your coursework prior to searching for information.
 Primary sources
They are the original documents of an event or discovery such as results of research, experiments or surveys,
interviews, letters, diaries, legal documents, and scientific journals articles. Primary sources are also records of
events as they are first described.
Primary source are the first formal appearance of results in print or electronic formats example of primary source
are: eyewitnessaccount, journalistic report, financial report, government document, archeological and biological
evidence, court records, ephemerals (posters, handbills), literary manuscript and minutes of meetings etc.
 Secondary sources
Are offer an analysis or is statement of an event or discovery described in primary sources. They interrupt, explain
or summarize primary sources. Some secondary sources are used to persuade the reader. Secondary sources
may be considered less objectives .Example of secondary source include dictionaries, encyclopedias, textbooks,
articles and editorials
 Tertiary sources
Definition: tertiary sources consist of information which is a distillation and collection of primary and secondary source
generally, tertiary sources are not considered to be acceptable material on which to base academic research. Tertiary sources
are usually not credited to a particular author. They are intended only to provide an overview of what the topic includes its
basic terminology, and often references for further reading. Some reference materials and textbooks are considered tertiary
sources when their chief purpose is to list, summarized or simply repackage ideas or other information. Tertiary source
include

 Work which list primary and secondary resources in a specific subject area
 Work which index, organized and compile citations to, and show secondary and sometimes primary source can be
used
  Material in which the information from secondary sources has been “digested” reformatted and condensed, to put
into a convenient, easy to read form
 Source which are once removed in time from secondary sources
sourc
Difference between primary, secondary and tertiary sources of information

 Timing of the event recorded

 Rhetorical aim of the written item
 Context of the researching scholar

Vehicle workshop manuals

Continuousinnovationsinadvancedautomo motivetechnology,controlsystemsandnewaccessoriesaredeveloped,testedandintroduc
newaccessoriesaredeveloped,testedandintroduc
ed in the latest vehicle
models.Itbecomesverydifficultforthetechnicianstodependontheirexperiencesandpersonalju
orthetechnicianstodependontheirexperiencesandpersonaljudgme gmentwhentroublediagnosingandr
epairingthetroublesinthelatesttechnologyado
adoptedonthevehicle.
Inordertofulfillthecustomersatisfaction,ser
erviceandpartspersonnelshouldhaveup-to-
dateproductknowledge,technicalinformation,skillsintroublediagnosisandrepairt
ation,skillsintroublediagnosisandrepairtechniques.
Toovercomethisconcern,manufacturersarepub publishingvarioustypesofmanualsandcatalogstoserve
serve asreferencematerials.

The followingaretheclassifications ofservice operationpublications :

(a)Publicationsforthecustomer
(b) Publications for
or the service operation
(c)Otherservicepublications

Manufacturers are publishing manuals to provide detailed information to the customer on theoperation of instrument and
controls, features and specification of the new vehicle.The following are the manuals distributed to the sales and distribution
distributi
sectors :

(1) Owner’s manual

(2) Warranty booklet

(3) Sales brochure

Owner’s ManuaIs

Owner’s Manual provides important information to ensure the proper operation of the vehicle.It is published for every model,
given to the owner of the vehicle and reference for modelinformation and technical specifications.A source of information on
vehicle control systems and contain some information not found inthe repair manual, such as break - in procedure of new
vehicle, approved fuel and lubricantsand vehicle interior care.

Normally the owner’s manual includes the following information :

(1) Operation of instruments and controls

(2) Information before driving vehicle

(3) Starting and driving of vehicle

(4) What to do in case of an emergency

(5) Corrosion prevention and appearance care

(6) Maintenance requirements

(7) Do it yourself maintenance

(8) Specifications

Warranty BookIet

Warranty Booklet is a supplemental to the owner’s manual and provides the following detailedinformation:

(1) Repair covered by warranty

(2) What is not covered by warranty

(3) Where to go for warranty service

(4) Regulation in relocation to another country

(5) Obtaining warranty service

(6) Maintenance record

(7) Owner's responsibilities

(8) General information from the manufacturers

Brochure for New VehicIe

Brochure or catalog describes and illustrates the recent features, components, accessories,

mechanism or control systems adopted in the new vehicle.

Service bulletins
What is a technical service bulletin?

A TSB is a service bulletin issued by the manufacturer and communicated to its dealerships whose purpose is to remedy a
known problem or defect associated with an automobile, but if and only the owner takes the vehicle to a certified dealer.
Technical service bulletins frequently address a recurring problem and include illustrated instructions for repair, a list of the
parts needed the warranty status and the labor change. Unlike a formal recall where the manufacturer makes a public
announcement and sends out recall notifications to owners of the vehicles informing them of the recall and the steps to take
to get the vehicle repaired, the manufacturer or dealership will rarely make a public announcement or directly or directly
inform the consumer about the TSB – hence, the term, “silent recall.”

If a problem addressed in a TSB is particularly widespread, the manufacturer may decide to send out “owner notification
“letters. Unlike TBS s, repairs under owner notification leeter are made free change to the consumer owner notifications have
milege and time restrictions which, under some circumstances, may disquality aconsumer from the free repair.

Automotive texts

Magazine technical articles

Special service tools(SST)

Document workplace procedures

 Self-Check -1 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next
page:

1. Discuss about source of information?

2. What are primary, secondary and tertiary source of information?
3. List 6 primary, secondary and tertiary sources of information?

Score = ___________
Answer Sheet
Rating: ____________

Name: _________________________ Date: _______________

1. _____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
____________________________________________________________________
2. _____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
____________________________________________________________________
3. _____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
______________________________________________

Note: Satisfactory rating - 2 points Unsatisfactory - below 2 points

You can ask you teacher for the copy of the correct answers.
 Identify general automotive system fundamentals
Information Sheet-2

General Automotive system fundamental

1. Engine system fundamental
1.1 Air induction system
1.2 Fuel system
1.2.1 conventional fuel system
1.2.1.1 gasoline fuel system
1.2.1.2 diesel fuel system
1.2.2 electronic fuel injection(EFI) system
1.2.2.1 electronic gasoline fuel injection
1.2.2.2 electronic diesel fuel injection
1.3 Ignition system
1.3.1 Conventional ignition system
1.3.1.1 contact breakpoint ignition system
1.3.1.2 transistorized ignition system
1.3.2 Electronic ignition system
1.3.2.1 West spark ignition system
1.3.2.2 Coil in plug spark plug(direct ignition) system
1.4 Cooling system
1.4.1 direct (air) cooling system
1.4.2 indirect(liquid) cooling system
1.5 Lubrication system
1.5.1 splash lubricant system
1.5.2 pressurized(pump) lubricant system
1.6 Exhaust system
2. Electrical system fundamental
2.1 Electric Source system
2.1.1 Battery
2.1.2 AC generator
2.2 Charging system
2.2.1 conventional charging
 2.2.2 electronic charging
2.3 Starting system
2.4 Ignition system
2.5 Lighting system
2.6 Body management system
2.6.1 immobilizer system
2.6.2 Power window system
2.6.3 Cruse control system
2.6.4 Alarm and central lock system
2.7 Air conditioning system
3. Power train system fundamental
3.1 Clutch system
3.2 Transmission system
3.3 Drivetrain and differential system
4. Under chassis system fundamental
4.1 Break system
4.2 Steering system
4.3 Suspension system
5. Body system fundamental
5.1 Body repairing system
5.2 Painting system
 Self-Check -2 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next
page:
1. Write the main catagorie of automotive?
2. Write the engine system fundamental?
3. Write the vehicle electrical system fundamental?
Answer Sheet Score = ___________

Rating: ____________
Name: _________________________ Date: _______________
1. _____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
____________________________________________________________________
2. _____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
___________________________________________________________________
3. _____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
__________________________________________________________________

Note: Satisfactory rating - 2 points Unsatisfactory - below 2 points

 Refer to and identify mechanical/electrical
Information Sheet-3 terminology and operating principles of systems and
components

1.WhatisanAutomobiIe?
Theterm“auto”meansseIfand“mobiIe“meansmoving.
Automobileisacommontypeofselfmovinglocomotiveusedtocarry passengersand
cargos.

A.DeveIopmentofearIyautomobiIe

On thehistory ofautomobile development,

someoftheremarkablevehiclesshownin
Fig. 1-5to1-9 becomesthe benchmarkin
theearlydevelopmentstageofproduction
andmanufacturingofautomobiles.

Fig.1-5
1886byBenzfirstgasolineautomobilethree
wheelcar

Fig.1-6
1894byBenzfirstgasolineautomobilefour
wheelcar
B. Featuresandfunctions

Automobileisdesignedasatransport
machinewiththethefollowingfunctions:

Engine (a)Consistsofon-boardenergysource
andengine
(b)Drivenonroadsbywayofrubbertires
(c)Cancarrypeopleandcargo
(d)Canbedrivenbyaperson

FueItank(gasoIine)
(a)Consistsof on - boardenergy
sourceandengine
 Avehicledrivenbyinternalcombusttion
engineandanalternateelectricmottors.
RefertoFig.1-10

Enginerunsbyusingdifferenttypessoffuels
asfollows:

1)Gasoline
2) Diesel
3)LPG-LiquefiedPetroleumGas
umGas
4)CNG-CompressedNaturalGas
Gas

Avehicledrivenbyelectricmotorpoowered
byseriesofautomotivebatteries.
RefertoFig.1-12

Thefirstdevelopedelectricmotorsdr
driven
vehicleistheBakerElectricCarin1902.
in1902.
Onbo
nboardenergy
sou
urce(Battery)
Fig.1-12

(b)Driveonroadbywayofrubbertires
Movethevehiclethroughfrictionresistancceontheroadsurface.

Fig.1-13

tires
(c)CancarrypeopIeandIightcargo
Busescancarrygroupofpeopleandlightccargos.

Fig.1-14

Bus
(d) Can carry peopIe and heavy cargo
Truckscancarrypeopleandheavycargoss.
Truck

Fig.1-15
(e) Canbedriven byaperson
Automobileisakindofmachinethatcanbe
bedrivenbyaperson.RefertoFig.1-16
Automobileisdesignedwiththree(3)majorope
oroperationstoprovidearemarkabledrivingperforman
ance.Itsmajorfunc
tionistoRun,TurnandStop.RefertoFig.1
.1-17

Fig.1-16

Fig.1-17
C. SomebrandsofmodernautomobiIes
modernautomobiIes
Variousvehiclemodelsaredesignedandmdmanufacturedtosatisfytheincreasingdemandsofcust
ustomersinter
msofdrivingperformance,comfort,safety
etyandfuelefficiency.
RefertoFig.1-18to1-22
 TOYOTA NISSAN
Fig.1-18 Fig.1-21

HONDA Fig.1-22
MITSUBISHI
Fig.1-19

Fig.1-20
D. CIassificationofmodernautomobiIes
Automobilesarecommonlyclassifiedaccordingtothefollowingdesignandconfigurations:

(1)Sourceofenergy
(2)Engineconstruction
(3)Enginemountingposition
(4)Application
(5)Bodystyleandshape
(6)Space
(7)Bodyconstructionandnumberof doors
 (1) Sourceof energy

Thefollowingarethecommonclasssification
ofvehiclesaccordingtothesourceofpo
ceofpower
generationsandoperations:

(A)Battery
Avehicledrivenbyelectricmotorsppowered
byseriesofautomotivebatteries.
Thefirstdevelopedelectriccaristhe
theBaker
producedin1902.

(B)GasoIineengine
Avehicledrivenbythepowergeneraatedby
internalcombustionengineusingaagasoline
fuel.
Gasolineengineproduceshighpow werin
anyspeedrange.
Itiscommonlyusedforpassengercrcarsand
SportsUtilityVehicle(SUV).
RefertoFig.1-24and1-25

(C)DieseIengine

Avehicledrivenbythepowergenerratedby
internalcombustionengineusingdiieselfuel.
DieselInjector
DieselInject
Dieselengineproduceslargetorquueand
consumeslessfuel.

Itiscommonlyusedinmostoftrucks,L
usedinmostoftrucks,Light
Commercial Vehicles(LCV)andSpoportsUtil-
ityVehicles(SUV).

RefertoFig.1-26and1-27

(D)AIternativefueIs

Avehicledrivenbythepowergeneraatedby
internalcombustionengineusingthe
thefollow-
ing alternativetypesoffuels:
Fig.1-26
(a)CNG-CompressedNaturaIGas
uraIGas
(b)LPG-LiquefiedPetroIeumGas
roIeumGas
 (E)EIectricvehicIe

Powercontrol
Avehicledrivenbyelectricmotorspowered
Unit byseriesofautomotivebatteries.

Thebatteriesrequirerecharging,doesnot
emitpollutantsandquiteduringoperation.

RefertoFig.1-28

Battery
Battery (F)HybridvehicIe
Fig.1-28
Avehicledrivenbybothgasolineengineand
Inverter electricmotor.

Thegasolineenginegenerateselectricityto
charge the batteries anddoes notneed an
externalsourceofenergyforthecharging.

Thevehicleinitiallymovebythepowerof
electricmotorandasthevehiclerunsathigher
Transaxles
Converter speed thegasolineenginewillstarttooper-
Fig.1-29 atetodevelopmorepower.
Secondarybatterytype
Thevehicleconsumeslessfuelandnoise
(nickelmetalhydridebattery)
duringoperation.

RefertoFig.1-28and1-29

(G)FueICeIIHybridVehicIe(FCHV)
Hydrogenstorage
FuelceIIstack Avehiclethatisdrivenbyfuelcellsthat
generateselectricitybychemicalreaction
Powertrainunit
(electricmotorandtransaxles)
betweenhydrogenandoxygen.

Fig.1-30
It produces low level ofpollutants in the air
andnonharmfulemissions.
RefertoFig.1-30
 (2)Constructionandcombustion
combustion

Thefollowingaretheclassificationssof
vehiclesaccordingtothetypesofengngine
constructionsandcombustion.

(A)ExternaIcombustionengine
aIcombustionengine

Inasteamengine,fuelisburntoutsideth
dethe
cylindersandpowerisgeneratedbyythe
Highpre
ressuresteam
expansionofanotherliquidorgasheeated
bycombustionorburning.
RefertoFig.1-31

(B)InternaIcombustionengine

a)Reciprocatingengine

Anenginethatproducesitspowerbbythein-
ternalburningoffuelinsidethecylinde
nders.
Combustion
Fig.1-31 Thecreatedcombustionorpressurrepushes
thepistondownandcrankshaftmecha
aftmechanism
forcetomoveupthepistoninacycle.
e.

Thereciprocatingmovement ofthepistons
convertedintorotarymotionbythecranks
ankshaft.

Itcanbeeithergasolineordieselengginede-
pendingonthefuelused.

GasoIineengine
Amixtureofgasolineandairisburneedinside
thecylindersofanengine.

RefertoFig.1-32
Gasolineengine
Dieselengine
DieseIengine
Fig.1-32
Anatomizeddieselfuelsprayedintoth
ntothecom-
bustionchamberandselfignitedbyyheatof
compression.RefertoFig.1-32
 (C) Rotaryengine

Acompactandlightweightenginethat
generallyconvertsthepressuregenerated
inaspaceinsideofovallikeshaped
housingandtriangularrotortoarotating
motion.

RefertoFig.1-33

Fig.1-33

(D) Turbocharge engine

Anenginewithaturbocharger,aforced
inductioncompressoroperatedbyturbine
impellerthatisdrivenbyengine’sexhaust
gas.

Turbochargerincreasestheamountofair
thatenterstotheenginetoproducemore
power.
Fig.1-34
RefertoFig.1-34

(3)Enginemountingposition

Thefollowingareclassificationsofvehicles
accordingtoenginemountinganddrive
traincomponentspositions:

(A)Frontengine,FrontwheeIdrive(FF)

Figure 1-35 FF vehicIehas nopropellershaftthatpro-

videsspaciousinteriorsandcomfortableride.
RefertoFig.1-35

(B)Frontengine,RearwheeIdrive(FR)

FRvehicIeiswellbalancedthatprovides
thebestcontrolanddrivingstability.
Figure 1- 36 RefertoFig.1-36
 (C)Rearengine,RearwheeIdrive(RR)

RRvehicIehasanenginemountedatthe
rearthatdrivestherearwheels.

RefertoFig.1-37

Figure 1-37\
(D)Midshipengine,RearwheeIdrive
(MR)

MR vehicIehasanenginemountedonthe
middlethatallowsgoodweightdistributionon
thefrontandrearaxlesthatmakesiteasyto
control.RefertoFig.1-38

Figure 1-38
(4)AppIication

Thefollowingaretheclassificationsof
vehiclesaccordingtoitsapplications.

(A)PassengervehicIe
Fig.1-39
Designedtomainlytransportsmallnumber
ofpassengersandcarrylightluggages.
RefertoFig.1-39

(B)CommerciaIvehicIe

Fig.1-40
Designedforcommercialpurposestocarry
cargoortransportgroupofpassengers.
RefertoFig.1-40

(C) Bus

Designedtotransportgroupofpassengers
Fig.1-41
andcarrytheirluggages.
RefertoFig.1-41

(D)Truck
Designedtocarryheavyandlargecargos.
RefertoFig.1-42

Fig.1-42
 (E)SpeciaIpurposevehicIe

Designedandmanufacturedforitsspecial
purposeandparticularapplications.
RefertoFig.1-43

FireTruck
(5) Body styIe and shape

Thebodyisthepart ofvehiclethatcarries
peopleorluggage.

Thefollowingarethecommontypesof
bodystyles.

(A)Sedan
Fig.1-44

Mostcommon passenger carwhich is de-

signedforthecomfortofdriverandpassen-
gerwithrowsofseatsinthefrontand atthe
back.RefertoFig.1-44

(B)Coupe

Fig.1-45 Sportylookwith2seatsforthedriverand
passengerthatemphasizesstyleandperfor-
mance

Theroofissmallerandheightof thevehicle
islower.RefertoFig.1-45

Fig.1-46 (C)HatchbackorLiftback

Similartocoupeinwhichthepassengerand
luggageareasareopentooneanother.
Reardoorandwindowcanbeliftedupor
openedlikehatchofaship.
RefertoFig.1-46
(D)Hardtop
Sedanwithoutwindowframes(nodoorsash)
andcenterpillars.RefertoFig.1-47
Thebackandfrontwindowsopenupasone
Fig.1-47
thatofferswideorgoodviews.
The style with centerpillars withoutsash is
calledthe“pillaredhardtop”.
 (E)ConvertibIe

Passengersedanorcoupethatcanbe
hatcanbe
drivenwithitsroofinupordownconddition.

RefertoFig.1-48
Fig.1-48

(F)Pickup

Compacttruckwithenginecomparrtment
extendsinfrontofthe driver’sseat.
eat.

RefertoFig.1-49

Fig.1-49
(G)Wagonandvan

Ithasintegratedpassengersand
and luggages
space.
Wagonmainlycarriesgroupofpasssengers.
Vanmainlycarrieslightluggages.

RefertoFig.1-50
Fig.1-50

(H)Limousine

Longpassengervehiclewithapartiition
betweenthedriverandpassengerc
ercabinsto
provideprivacyontheoccupantsofftherear
seats.

RefertoFig.1-51
Fig.1-51

6. Space

Thefollowingaretheclassificationso
nsof
engine,passengerandluggagespac paces:
(A)3 box type
Ithasseparatepartitionspaceforengine,
ngine,
passengersandluggages.
RefertoFig.1-52
aEnginespace
bPassengersspace
cLuggagespace

Fig.1-52
 (B)2 box type
Compact vehicle with integratedspace
integratedspac for
passengersandluggages.
Ithasaseparateenginespace.
RefertoFig.1-53

a Enginespace
b Passengersandlu
ersandluggage’sspace
c Passengersandlu
ersandluggage’sspace

Fig.1-53
(C)1boxtype

Ithasintegratedspaceforengiine,
pasengers,luggagesandcargos.

Commonlyusedforcommercialpuurposes
intransportinggroupofpassenggers,
luggagesandcargos.

RefertoFig.1-54
a. Enginespace
b.Passengersandluggagesspace
c. Passengersandlugg
ggagesspace

Fig.1-54

(7) Body construction

Thefollowingarethecommononlytypesof
vehiclebodyconstructions:
(1) Framebody
Constructedwithseparatebo
odyandframe.
Engine, transmissionandsuspensionare
mountedintheframe.

Fig.1-55RefertoFig.1-55
 (2)Monocoquebody

Constructedwithintegratedb
bodyand
frame.
Bodyandframearejoinedtog gethertoform
astrongsingleunitbox.

RefertoFig.1-56

(7)Numberofdoors
Fig.1-56

Thefollowingaretheclassificationso
nsof
vehiclesaccordingtothenumberof ofdoors:

(A)2door

Vehiclewithdriverandpassengerddoors.
Fig.1-57
RefertoFig.1-57

(B)4door

Vehiclewithdriver,frontandrearpasssengers
doors.

RefertoFig.1-58
Fig.1-58
(C)5door

Vehiclewithdriver,frontandrearpasssengers
andreardoors.

RefertoFig.1-59

Fig.1-59
 3. Basicfunctionofanau
unctionofanautomobiIe
Adrivershallbeabletocontrol thevehiclet
eto“RUN”,“TURN”,and“STOP”accordingtothe
requireddrivingsituations.
Thefollowingarethemajordriveabilityfunnctionsofvehicles:
1)EnabIethevehicIetorun
Theenginepowerallowsthevehicletorun un.Thedrivetraintransmitsthepowerfromthe
enginetothedrivingwheels.Thedrivetrainsyste
ThedrivetrainsystemconsistsofcIutch,transmission,propeIIers
rshaft,differe
ntiaI,axIeshaftordriveshaft.RefertoFiig.1-60

PropeIIershaft Driveshafts
Dri

CIutch
utch Transmission
Fig.1-60 Differrential

DriveTrain
2)EnabIethevehicIetoturn
Thetireismountedontheaxlebymeansof
meansof
thediscwheel.
Theaxleismountedtothebodythrooughthe
suspensionsystemandsupportedb
edbysprings
andotherpartstoabsorbthebounccingeffect
duetotheunevenessoftheroadsuurface.
(a)Steeringsystem
Fig.1-61
Mechanismthatenablesthevehicletoturnn.
Ithassteeringwheelthatcontrolsbyth
thedriver
anddevicesthattransmitsthismovvementto
thetiresinordertochangethedirection
directionof
thevehicle.
RefertoFig.1-61

Fig
g.1-62
 (b) Suspension system
Undercarriagemechanismthatsupportsthe
bodytoprovideacomfortableride.

RefertoFig.1-62

3)EnabIethevehicIetostop

Brakesystemenablesthevehicletostopand
slowdown.

Brakingforcetakesplacewhenthedriver
appliespressureandcontinuousapplication
Fig.1-63 tothebrakeswillenablethevehicletostop.
The following are the methods ofstopping
therotationalmovementofthetires:

(a)Footbrakes
Footbrakesareusedtocontrolthespeed
andstopthevehicle.

Generally,discbrakesareusedinthefront
wheelsanddiscordrumbrakesareusedin
therearwheels.
RefertoFig.1-64
Fig.1-64Drum brakes

(b)Parkingbrakes

Parkingbrakesorhandbrakesaremainly
usedwhenthecarisparked.

Themechanicalbrakesystemlockstherear
wheels.
RefertoFig.1-65

Fig 1-65
(c)Enginebrake

Enginebrakeusedtheretardingeffectof
enginewhenthevehicleisingearandthrottle
valveisclosed.
RefertoFig.1-66

Fig.1-66
4. AutomobiIesafetyandcomfort
Anautomobilemustprovidethefollowingvariousfunctionsinordertobedrivensafelyand
comfortably.
Thedrivermustbeabletocontrolthevehicleaccordingtohisneeds.
Thedriverneedsdevicestoinformotherdriversofhisintentions.
Devicesthatmakedrivingatnight,infog,rainorsnowpossible.
Safetydesignanddevicesthatpreventinjuryinacollision.
Aircoolingandheatingconditioners.
Comfortablerideandquietoperation.

Thefollowingarethecomponentsofvehicle
thatprovidescomfortandsafety:

1)Seats

Itsupportsthedriverandpassengersbody
tomaintainacomfortableride.

PartsofvehicIeseat

1Headrest

2Seatback
Fig.1-67 3Lumbarsupport

4Seatcushion
2)SeatbeIts
Whenthebrakesaresuddenlyappliedor
whencollisionoccurs,thebodyofpassengers
moveforwardwithstronginertialforce.

Seatbeltssecuredthebodyofdriverand
passengerstotheirseatstopreventfrom
collidingtosteeringwheel,front windshield
orbeingthrownoutofthevehicle.

2 pointtype 3-pointtype Thetwotypesofseatbeltsare2pointtype

thatsupportsonlythehipsand3pointtype
thatsupportsboththehipsandchestarea
Fig.1-68RefertoFig.1-68
3)DoorIocks

Doorlockspreventthedoorstoopeneasily
byvibrationorimpact.

Itpreventspeoplefromopeningthevehicle
withoutpermissionoftheowner.

Itcanprotectluggageandvaluablepersonal
 belongingsinsideandtrunkofthevehicle.

Thefollowingaretheconditionsofthedoor
Fig.1-69 lockingmechanism:

ADoorisopen

BDoorispartlyopened
CDoorisclosed
4)Airconditioner

Airconditionersystemregulateshumidityand
temperatureinsidethecabinof vehicle.

Adehumidifier,controlsheatingandcooling
conditions.
Fig.1-70
Removesobstructionsoffrost,iceand
condensationfromtheinteriorsurfacesofthe
windows.

RefertoFig.1-70
5. Economy/vehicle durability

1) FueI economy
Fig.1-71
Representsthevolumeoffuelthatengine
consumes whenthevehicletravelsagiven
distance.

Thetwomethodsofcalculatingthefuel
consumptionrate:
(a)Volumeoffuelconsumed(used)while
travelingagivendistance(L/100km).

L/100km=fueI(L)/distance(100km)

(b)Distancetraveledwhileconsuminga
Fig.1-72 givenvolumeoffuel(km/L).

Km/L=distance(km)/fueI(L)

2)VehicIedurabiIity

Aconditionofthevehiclefreefromrust,
corrosion,wearandexhaustion.

Paintisafilmthatisappliedtothebody
surfaces.
 Itsprimarypurposeistoenhancetheappear-
anceofthebodyandprotectsthevehiclefrom
rust,sunraysdustandrain.
RefertoFig.1-72

3)ServiceabiIityandrepairabiIity
Theserviceabilityandrepairabilityareindex
whichshows degreeof easinesstoservice
orrepairthevehicle.
Incasethevehiclehasgoodserviceabilityand
Fig.1-73
repairability,itmeansthatthetotallaborcost
willbeless.RefertoFig.1-73

6.EnviromentaIprotection
Exhaustma
nifoId 1)Exhaustsystem
Thefollowingarethemajorfunctions:

MuffIer (a)AirpoIIutionprotection
(CataIyticConverter)

Exhaustpipe Theexhaustsystemequippedwithcatalytic
convertermakes theengine moreeffective
CataIyticconverter byreducingexhaustgasemission.
Fig.1-74
Thecatalyticconverterislocatedinthemiddle
ofexhaustsystemtofilterandremovethe
harmfulelementsfromtheexhaustgases.
RefertoFig.1-74and1-75

Theharmfulelementsintheexhaustgases
areasfollows:
MonoIithiccataIyst (1)CO(CarbonMonoxide),
Fig.1-75 (2)CO2(CarbonDioxide)-nonharmfulbut
itleadstoincreaseglobalwarning
(3)HC(Hydrocarbons),
(4)NOx(NitricOxides)

(b)Quietoperation
Theexhaustsystemreducesthesoundsof
explosioncreatedbytheexhaustgases.
Theexhaustgasesaredischargedfromthe
engineatahightemperatureandpressure.
Exhaustgasesmakesexplosivesoundsifre-
Fig.1-76 leaseddirectly,toreducethenoiseamuffler
isinstalled.
Itisprovidedtomufflethesoundbyreducing
thepressureandtemperatureoftheexhaust
gases.RefertoFig.1-76
7. VehicIeIdentification
1)Location
FramenumberorVehicleIdentification Number(VIN)isstampedontheenginecompart-
mentorchassis.
Nameplateisusuallystampedontheenginecompartmentorbodypanel.
VehicleIdentificationandnameplatearecommonlystampedindifferentpartsofthevehicles
andvariesaccordingtothetypesandconstructionofvehicles.
Usetheserviceorrepairmanualtofindtheproperlocation.
RefertoFig.1-77for the location ofVINAand NameplateB

Fig.1-77

2)NamepIate

Thenameplateisalsoknownas“Manufacturer’sPIate”.

Thecontentsvaryaccordingtothedestinationofthevehicle.

Thenameplateofapassengercarislocatedonthecowlpanel.

Theserviceorrepairmanualshowstheexactlocationofthenameplate
RefertoFig.1-78
 TOYOTAMOTORCORPORATION JAPAN
1
MODELNZE-121R-AEPEK
2
ENGINE1NE-FE149cc

3 FRAMENO.JTC8122E403033487

COLORTRIM 6
4
109Y803 GUM(KG)

5 TRANS/AXLEU340E-02A

PLANT/BUILDM2
9

Fig.1-78 7 8

Thefollowingarethedescriptionofthe
numberindicators:RefertoFig.1-78

1.Modelcode
2.Enginetypeandpistondisplacement
3.Framenumber
4.Vehicleidentificationnumber
5.Bodycolorcode
6.Trimcode
7.Transmissioncode
8.Axlecode
9.Plantnamecode
8.Componentnames
1)ExteriorstructuraIparts

Fig.1-79
Thefollowingarethedescriptionofthenumberindicators:
RefertoFig.1-79
1.Bumper 12.Outsiderearviewmirror(Doormirror)
2.Radiatorgrille 13.Doorpanel
3.Enginehood 14.Frontfenderpanel
4.Windshieldglass 15.Protectionmoulding
5.Frontpillar 16.Mudguard
6.Slidingroofglass 17.Quarterpanel
7.Roofpanel 18.Rearfenderpanel
8.Doorframe 19.Fuellid
9.Centerpillar 20.Backwindowglass
10.Doorwindowglass 21.Rearspoiler
11.Outsidedoorhandle 22.Trunkpanel
2)InteriorstructuraIparts

Fig.1-80

Thefollowingarethedescriptionofnumberindicators:
RefertoFig.1-80
1.Vent 12.Seat(cushion)
2.Centerconsole 13.Recliningadjustmentlever
3.Instrumentpanel 14.Seatback
4.Innerrearviewmirror 15.Headrest
5.Sunvisor 16.Seatbelt
6.Doortrim
7.Assistgrip
8.Centerarmrest
9.Glovebox
10.Scuffplate
11.Seatsliderlever
Fig.1-81

Thefollowingarethedescriptionofnumberindicators:
RefertoFig.1-81

17.Insidedoorhandle
18.Doortrimboard
19.Doorwindowregulatorhandle
20.Doorarmrest
21.Doorlockbutton
22.Weatherstrip
23.Doorpocket
 Self-Check -3 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next
page:
1. What is automotive?
2. Write the Classificationofmodernautomobiles?
3. Write Enginemountedposition?
Score = ___________
Answer Sheet
Rating: ____________

Name: _________________________ Date: _______________

1. _____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
2. _____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
3. _____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Note: Satisfactory rating - 2 points Unsatisfactory - below 2 points

 List of Reference Materials

1- BOOKS
IntroductiontoAutomotiveTechnoIogyThirdEdition7/2010
Vehicle Service Manual ThirdEdition7/2010
 Vehicle Servicing
NTQF Level - 1

Learning Guide -32

Unit of Competence: -Apply Automotive Mechanical System
Fundamentals

Module Title: -Applying Automotive Mechanical System

Fundamentals

LG Code: EISVHS1 M10 0919 LO2-LG-32

TTLM Code: EISVHS1TTLM 0919 v1

LO 2: Identify operation of system or component

 Instruction Sheet Learning Guide #-32

This learning guide is developed to provide you the necessary information regarding the
following content coverage and topics –
 Identify component or system
 Research information
 Identify safety hazards

This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to –
 Component or system to be researched is identified
 Information is researched to ensure sufficient understanding of component or system to
assist with its further identification and application
 Potential for unsafe conditions or safety hazards is identified

Learning Instructions:
8. Read the specific objectives of this Learning Guide.
9. Follow the instructions described in number 1 to 7.
10. Read the information written in the “Information Sheets 1”. Try to understand what are
being discussed. Ask you teacher for assistance if you have hard time understanding them.
11. Accomplish the “Self-check 1” in page -.
12. Ask from your teacher the key to correction (key answers) or you can request your teacher
to correct your work. (You are to get the key answer only after you finished answering the
Self-check 1).
13. If you earned a satisfactory evaluation proceed to “Information Sheet 2”. However, if your
rating is unsatisfactory, see your teacher for further instructions or go back to Learning
Activity #1.
14. Submit your accomplished Self-check. This will form part of your training portfolio.
 Information Sheet-1 Identify component or system

The main system and component of automotive

Intake system
Which include the Air filter (air cleaner), carburetor; intake manifold and intake valve (combustion chamber) this
system allows pure & fresh air to enter the engine it consists of
Air cleaner: -Which cleans & filters the air before interring the combustion chamber of an engine
Superchargers: -it increases the air pressure into the engine so that more fuel can be burnt & the engine output
increases
Intake manifold: -is required to deliver into the cylinder either a mixture of fuel & air From the carburetor or only
from the air Cleaner.
Fuel system components
Fuel system: -which includes the fuel tank, fuel line, fuel filter, fuel pump, carburetor and combustion chamber.
Carburetor: - it is a device to mix air with fuel in the proper ratio for the purpose of combustion Petrol is the fuel
used in the gasoline engine.
Fuel tank is used as a reservoir & for the reason of safety it is placed at the rear of the car, to prevent it from fire
hazards. There is a small filter which is placed in the tank at the end of the line. (Two filter is called strainer)
Which is used to filtered out large particle out of the fuel
The fuel line which allow fuel to reach to the pump & to the carburetor
The full filter is used to filtered out dust particle out of the fuel generally it is located b/n the pump & carburetor, in
some model it may be b/n the fuel tank & fuel pump.
Fuel pump: - Which feeds the fuel from the tank to the carburetor through the filter.
Diesel Fuel System
Fuel tank, fuel line, fuel filter, fuel feed pump, injection pump, high pressure line, injector nozzle and combustion
chamber. For diesel engine (distributors type)
Fuel tank: - It is a reservoir of fuel which is made of sheet metal of sufficient capacity
Fuel Line: - which allow fuel to reach to the pump & to the injector nozzle
Fuel Filter
Feed pump It maintains the fuel pressure in the system at a sufficient high level to circulate the fuel
Injection Pump the pump supplies fuel to the injectors according to the firing order at the constant stroke correct
time in the cycle.
Nozzle: - A single unit used to meter, atomize & inject the required amount of fuel into the combustion chamber of
the cylinder
Ignition system
This includes the battery, start/ignition switch, ballast resistor, ignition coil, high tension cable, distributor, H.T.C and
spark plug.
Ignition coil: -is used to step up the battery voltage to 20000 & above
High tension cable: - It connect the secondary voltage the step up voltage to the distributor & spark plug
Distributor: --It distributed the high voltage to each spark plug & time the spark
Spark plug: -Convert the electrical volt/current to spark by making the high voltage jumped between to gap
Cooling system
Which include the radiator, lower house; water pump, water jacket, thermostat, upper hose and radiator also fan.
Water Pump: -Is a centrifugal type pump, it increases the flow rate of the water
Fan It draws fresh air through the radiator and thus increases the efficiency of the radiator in cooling hot water
Radiator: -The purpose of the radiator is to cool down the water received from the engine, it has three main parts: -
upper tank, Lower tank and Tubes
Thermostat:-It is a kind of check valve which opens & closes with the effect of temperature The normal operating
temperature of an engine is 80-900c.
Water Jacket: -It provided a way for the coolant to circulate & take off the heat from the engine component.
Lubrication System
The engine uses a combination pressure/splash lubrication system, delivering oil under pressure to crankshaft,
connecting rod and main bearing surfaces. Other component areas are splash lubricated. A high-efficiency greater
oil pump maintains high oil flow and oil pressure, even at low speeds and high operating temperatures. A pressure
relief valve limits maximum pressure of system. Oil pan must be removed to service oil\ pickup and oil pump.
Starting system
This includes the battery, ignition switch, starting motor and ring gear of flywheel.
Battery: -provide electrical power to the starter motor
Switch: -it controls the starter circuit
Starter Motor: -It converts the electrical energy to mechanical energy & rotates the crank shaft with a minimum
cranking speed
Ring gear at fly wheel: -it takes the starter motor torque to the engine crank shaft
Charging system
This includes the battery, ignition switch and alternator (generator) regulator. It is the system which supply
electricity to the electrical load & charge the battery after the engine is started
Battery: -It is the primary sources of electricity to the vehicle
Switch: -Which operate the circuit of the charging system
Alternator: - Which convert the mechanical energy of the engine to electrical energy
Regulator: - It makes the output of the alternator not mover than 12v.
Steering System
In front wheels can be turned to left and right by steering system so that the vehicle can be steered. The steering
wheel is placed in front of driver. It is mechanically linked to the wheels to provide the steering control. The
primary function of the steering system is to provide angular motion to front wheels so that vehicle can negotiate
a turn. It also provides directional stability to vehicle when the vehicle moves ahead in straight line. Now-a-days,
many vehicles are equipped with power steering which uses pressure of a fluid to reduce steering effort. When
driver turns the steering wheel, a hydraulic mechanism comes into play to provide most of the effort needed to
turn the wheel.
Suspension System

Suspension system of an automobile separates the wheel and axle assembly of the automobile from its body. Main
function of the suspension system is to isolate the body of the vehicle from shocks and vibrations generated due to
irregularities on the surface of roads. Shock absorbers are provided in the vehicles for this purpose. It is in the form
of spring and damper. The suspension system is provided both on front end and rear end of the vehicle.
A suspension system also maintains the stability of the vehicle in pitching or rolling when vehicle is in motion.It
supports the body on the axles and maintains the proper geometrical relationship between the body and wheels
Brake system
Brakes are used to slow down or stop the vehicle. Hydraulic brakes are generally used in automobiles, where
brakes are applied by pressure on a fluid. Mechanical brakes are also used in some vehicles. These brakes are
operated by means of leavers, linkages, pedals, cams, etc. Hand brake or parking brake is known usually
mechanical brake. These are used for parking the vehicles on sloppy surfaces and also in case of emergency.
Brake Pedal:-When the brake pedal is depressed, force is applied to the master cylinder.The force that the
pushrod applies to the master cylinder piston is, therefore, much greater than the force applied to the brake pedal.
Master Cylinder Reservoir:The reservoir may be cast as one piece with the cylinder body, or it may be a separate
molded nylon or plastic container.
Hydraulic Tubes And Hoses
Steel tubing and flexible synthetic rubber hosing serve as the arteries and veins of the hydraulic brake system.
These brake lines transmit brake fluid pressure(the blood) from the master cylinder (the heart) to the wheel
cylinders and calipers (the muscles and working parts) of the drum and disc brakes.
hydraulic brake system with a booster unit located between the brake pedal and the master cylinder to help
activate the brakes
Master cylinder (Structure and operation)
Master cylinder generates hydraulic pressure as brake pedal is pressed and consists of cylinder body, oil reservoir
tank and cylinder components such as piston, piston cup, check valve, piston return spring etc. There are 2 types
of master cylinder: single master cylinder of one piston and tandem master cylinder of 2 pistons. Currently tandem
master cylinder is used. Newer master cylinders have a metal or plastic reservoir mounted above the cylinder. The
reservoir will have one or two caps.
The dual master cylinder contains two separate pressure chambers in a single bore. The master cylinder has two
holes between each chamber and the brake fluid reservoir. The holes provide a supply of fluid duringbraking.
Exhaust system
Exhaust system: - The exhaust system collects exhaust gases from the engine & expels them out. It consists of: -
 Exhaust valve
 Exhaust port
 Turbo charger
 Muffler
 tail pipe
 Exhaust manifold:-The exhaust manifold collects exhaust gases from the exhaust of various cylinders &
conducts them from each and to a central exhaust passage
 Turbo Charger: - Is an exhaust gas driven turbine which drives a centrifugal compressor wheel
 Muffler: -reduces the noise of the exhaust gases by reading the pressure of the used gases by low
expansion & cooling. The muffler must not cause any appreciable restriction to the flow of oil that could
raise back pressure excessively.
 Self-Check -1 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next
page:
1. List fuel system component?
2. List lubrication system component?
Answer Sheet Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

1. _____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
________________________________________________________________
2. _____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_______________________________________________

Note: Satisfactory rating - 1 point Unsatisfactory - below 1 point

Information Sheet-2 Research information

SUPPLEMENTS
The Automotive Technology package offers a full complement of supplements.
Student Online Companion
Each textbook provides access to the new Student Online Companion, which includes the following components:
■ PowerPoint—StudyStudy outlines with images for each textbook chapter.
■ ASE-Style Practice Questions—self self check questions
qu to help students review chapter material and get familiar with the
question types they will see on certification exams.
■ Web Links and Activities—Links
Links to industry Web
W resources/reference material with related research activities for many.
■ Challenging Concepts— videos, eos, narration, and questions to help students comprehend more challenging topics.
■ Interactive Online Game—A self-reviewreview Q&A game to help students comprehend the chapter material.
Tech Manual
The Tech Manual (ISBN 1428311505) offers stude students opportunities to strengthen their comprehension of key concepts and to
develop their hands-on, practical shop experience. Each chapter includes Concept Activities
Activities and Job Sheets, many of which
are directly correlated to specific NATEF tasks.
tasks Service manual report sheets, case studies, and review questions also are
included to offer a rounded approach to each lesson.
Instructor Resources
The Instructor Resources DVD (ISBN 1428311521) for the fifth edition includes the following components to help minimize
instructor prep time and engage students:
■ PowerPoint—Chapter
Chapter outlines with images, animations,
animation and video clips for each textbook chapter.
■ Computerized Test Bank in Exam View View—Hundreds of modifiable questions for exams, quizzes, in in-class work, or homework
assignments. All applicable questions are correlated to the 2008 NATEF Automobile Standards.
■ Image Library—A A searchable database of hundreds of images from the textbook that can be used to easily customize the
PowerPoint outlines.
■ Challenging Concepts—45 45 videos, narrati
narration, and questions help students comprehend more challenging topics.
■ End-of-Chapter Review Questions—Word Word files of all textbook review questions are provided on the DVD.
■ Instructor’s Manual—an an electronic versio
version of the Instructor’s Manual is included in the Instructor Resources.
■Operation Sheet Template—for for instructors who develop their own job sheets, a template is provided to help with their
formatting.
Instructor’s Manual
This comprehensive guide provides lecture outlines
outlines with teaching hints, answersto review questions from the Learning guide,
and answers to Tech Manual questions, as well as guidelines for using the Tech Manual.. A correlation
corr chart to the 2008
NATEF Task List provides refers
If you need research information use the following
 Self-Check -2 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next
page:

1. Discuss about Research information?

Score = ___________
Answer Sheet
Rating: ____________

Name: _________________________ Date: _______________

1. _____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_______________________________________________________________

Note: Satisfactory rating - 1 point Unsatisfactory - below 1 point

 Information Sheet-3 Identify safety hazards

Electricity and water

Electrical safety is a system of organizational measures and technical means to prevent harmful and dangerous
effects on workers from electric current, electric arc, electromagnetic field and static electricityAvoid water at all
times when working with electricity. Never touch or try repairing any electrical equipment or circuits with wet hands.
It increases the conductivity of the electric current.
Electric shock safety
 Turn off power at the main breaker.
 Call an ambulance.
 Don't touch the victim until you are certain there is no live electricity. (Never move someone if
they are touching a power line or other high-voltage current.)
 If the victim is not breathing, begin mouth-to-mouth.
 If the victim has no pulse, begin CPR
Electrical Tool Safety
1. Do not use power equipment or tools on which you have not been trained.
2. Keep power cords away from the path of vacuum cleaners, floor polishers and grinders.
3. Do not carry plugged in equipment or tools with your finger on the switch.
4. Do not carry equipment or tools by the cord.
5. Disconnect the tool from the outlet by pulling on the plug, not the cord.
6. Turn the tool off before plugging or unplugging it.
7. Do not leave tools that are "On" unattended.
8. Do not handle or operate electrical tools when your hands are wet or when you are standing on wet floors.
9. Turn off electrical tools and disconnect the power source from the outlet before attempting repairs or
service work. Tag the tool "Out of Service".
10. Do not drive over, drag, step on or place objects on a cord
Electricity and Water: A Dangerous Combination
Electricity would travel through the water and through you to the ground. This is why it's so important to keep all
electrical appliances away from water, and to make sure your hands are dry and you are not standing in water
when you touch anything electrical
Depending on the job task to be performed, PPE for the electric power industry generally includes safety glasses,
face shields, hard hats, safety shoes, insulating (rubber) gloves with leather protectors, insulating sleeves, and
flame-resistant (FR) clothing.
10 Tips – How to avoid getting shocked when working with electricity at home?
 1. Never mix water and electricity. ...
2. Pay attention to what your appliances are telling you. ...
3. Install Ground Fault Circuit Interrupters (GFCI). ...
4. Make sure you're using the right size circuit breakers and fuses. ...
5. Protect kids with outlet covers
Toxic substances
There are generally four types of toxic entities; chemical, biological, physical and radiation: The R.M.Yassine Scale
is the main scale used to measure toxicity
Here are some examples of natural toxic chemicals:
 Mercury.
 Snake venom.
 Caffeine in coffee, tea, kola and cocoa.
 Arsenic.
 Ricin from castor beans.
 Petroleum.
 Hydrogen sulfide.
 Chlorine gas.
Broken or damaged equipment
Defective equipment. A manufacturing or design defect in the equipment can increase the risk of an accident.
Workers who have been injured by a piece of defective equipment may have another source of compensation.
They may be able to name the manufacturer or distributor of the equipment in a third party lawsuit.
Faulty equipment is any type of mechanical or electronic equipment that is dangerous or unsafe to use. This
usually refers to equipment used in the workforce for producing or manufacturing products. Faulty equipment is
responsible for several types of on the job injuries each year
Identifying faulty portable electrical tools and equipment
 a competent person regularly electrically testing and inspecting tools, extension leads and portable
electrical equipment — inspection tags should be fitted;
 recording inspection details in an equipment register;
 tagging out and removing all faulty equipment for repair or disposal; and
Faulty equipment Harm can be caused when exposed to 'live parts' or through conducting objects or materials.
Faulty or overloaded equipment can lead to fires which can cause damage, injuries and loss of life.

Flammable materials and fire hazards

Flammable liquids and fire risk. Petrol and other fuels, as well as many common products like solvents, thinners,
cleaners, adhesives, paints, waxes and polishes, are highly flammable and there's a high risk of fire and/or
explosion if there is a source of ignition nearby.
Flammable and combustible liquids are liquids that can burn Under the Workplace Hazardous Materials Information
System (WHMIS) 1988, flammable liquids have a flashpoint below 37.8°C (100°F)
Lifting practices
Automotive Lifts
1. Remove all tools, cords, hoses, trash and any other debris from the lift area and wipe up all grease and oil
spills before driving a car or truck into the service bay.
2. Position the lift arms, adapters and supports to the center of the lift out of the way of the car's tires before
driving the vehicle into the service bay.
3. Do not stand in front of a vehicle being driven into the service bay.
4. Do not use any lift that has cracked contact pads, cracked lift arms or any other visible damage.
5. Do not use wood or concrete blocks as a substitute for an extended.
6. Use wheel blocks to chock the wheels of any vehicle on a runway lift while the vehicle is on the lift.
7. Do not leave the controls unattended while the lift is in motion.
8. Do not block or "tie open" the lift's control while the lift is in motion.
9. Do not use the engine or transmission supports or stands as a substitute for jack stands.
10. If the vehicle begins to slip off of the lift, run in the opposite direction of the fall, but not toward a wall or work
bench that might trap you between the object and the vehicle.
11. Before you lower the vehicle, remove tool trays, jack, engine and transmission stands, and any other
obstructions from under the vehicle.
12. Before removing the vehicle from the service bay, position lifts arms and supports to the center of the lift away
from the wheels of the vehicles.
13. Do not "tie down" or override the air or control valves of the lift.
14. Do not raise vehicle with anyone inside it.
15. When raising a vehicle, use the following procedure:
1) Use the lift to raise the vehicle about one foot off the ground, then moderately push the rear or
front bumper of the vehicle to ensure that the vehicle frame is stably mounted on the lift support's
contact pads.
2) If the frame of the vehicle is not firmly touching a support contact pad, or is slipping, immediately
lower the vehicle and start over.
3) Once the vehicle is secure on the lift, lift the vehicle to the desired work height and visually check
those contact points for misalignment before going under the vehicle.
16. As you raise the vehicle, you will hear a "clicking" noise which indicates that the lift's locking device is
engaging. If you do not hear the "clicking" noise, stop the lift, fully lower the vehicle and use another lift. Place
an "Out of Service" tag on the control switch of the damaged lift and do not use it.
17. If you will be working under a lift that will be positioned at a point below where the lift's locking device engages,
place four jack stands under the vehicle's frame or suspension for additional support before working under the
vehicle.
18. Wear safety goggles when working underneath vehicles.
A useful lifting technique for rescuers with weak knees or thighs is them: If both legs and knees are strong, you can
use the: Squat lift. The technique of the power lift includes: Bending your knees to bring your center of gravity
closer to the object
Keep in mind:
 Do not attempt to lift by bending forward. Bend your hips and knees to squat down to your load, keep it
close to your body, and straighten your legs to lift.
 Never lift a heavy object above shoulder level.
 Avoid turning or twisting your body while lifting or holding a heavy object
Check out these safe lifting and handling tips, recommended by the Health and Safety Executive.
 Think before you lift. ...
 Keep the load close to the waist. ...
 Adopt a stable position. ...
 Ensure a good hold on the load. ...
 Don't bend your back when lifting. ...
 Don't bend the back any further while lifting. ...
 Don't twist when you lift.
Spillages
In industrial production, spillages is a loss of production output due to production of series defective or an
acceptable product which must be rejected
The following steps should be taken during spill cleanup.
 Prevent the spread of dusts and vapors. ...
 Neutralize acids and bases, if possible. ...
 Control the spread of the liquid. ...
 Absorb the liquid. ...
 Collect and contain the cleanup residues. ...
 Dispose of the wastes. ...
 Decontaminate the area and affected equipment
 Self-Check -3 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next
page:
1. List natural toxic chemicals?
2. Write rules of electric shock safety?
Answer Sheet Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

1. _____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________
2. _____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
______________________________________________________________

Note: Satisfactory rating - 1 point Unsatisfactory - below 1point

 List of Reference Materials

1. BOOKS