Experiment No.

:2
Objective:
Study of various engine components and systems (Transmission System, Suspension
System, Fuel Injection System, Lubrication System, Cooling System).
Apparatus:
Engine Chassis Model.
Theory:
Fuel Injection System
Types of Fuels:
1. Solid Fuels:
Primary: wood, coal, peat, dung, etc.
Secondary: Coke and Charcoal
2. Liquid Fuels:
Primary: Petroleum
Secondary: diesel, gasoline, kerosene, LPG, coal tar, naptha, ethanol
3. Gaseous Fuel:
Primary: Natural Gas
Secondary: hydrogen, propane, methane, coal gas, water gas, blast
furnace gas, coke oven gas, CNG.
Fuel Properties:
Fuel properties includes:
Low Moisture Content
Low Cost
Low Reactivity
Octane Number/Cetane number
Moderate Velocity od combustion
High calorific value
Moderate velocity of combustion
Volatility.
Viscosity.
Flash Point.
Sulphur Content

Fuel Supply System:

Fuel Supply system includes:
 Air Filters
Fuel Filters
Air Cleaner
Oil Filter
Fuel Filter Seal
Air Filter Assembly
Carburetor
Fuel Injection system

Fuel Tank:
A fuel tank (or petrol tank) is a safe container for flammable fluids. Though
any storage tank for fuel may be so called, the term is typically applied to part of an
engine system in which the fuel is stored and propelled (fuel pump) or released
(pressurized gas) into an engine. Fuel tanks range in size and complexity from the
small plastic tank of a butane lighter to the multi-chambered cryogenic Space Shuttle
external tank.
Fuel Pump:
A fuel pump is a frequently (but not always) essential component on a car or
other internal combustion engined device. Many engines (older motorcycle engines in
particular) do not require any fuel pump at all, requiring only gravity to feed fuel from
the fuel tank or under high pressure to the fuel injection system. Often, carbureted
engines use low pressure mechanical pumps that are mounted outside the fuel tank,
whereas fuel injected engines often use electric fuel pumps that are mounted inside the
fuel tank (and some fuel injected engines have two fuel pumps: one low pressure/high
volume supply pump in the tank and one high pressure/low volume pump on or near
the engine).
Fuel Filters:
A fuel filter is a filter in the fuel line that screens out dirt and rust particles from
the fuel, normally made into cartridges containing a filter paper. They are found in
most internal combustion engines. Fuel filters serve a vital function in today's modern,
tight-tolerance engine fuel systems.
Air Cleaner:
A particulate air filter is a device composed of fibrous materials which removes
solid particulates such as dust, pollen, mould, and bacteria from the air. A chemical air
filter consists of an absorbent or catalyst for the removal of airborne molecular
contaminants such as volatile organic compounds or ozone. Air filters are used in
applications where air quality is important, notably in building ventilation systems and
in engines.
Throttle Body:
A throttle is the mechanism by which fluid flow is managed
by constriction or obstruction. In fuel injected engines, the throttle body is the part of
the air intake system that controls the amount of air flowing into the engine, in
response to driver accelerator pedal input in the main.
Intake Manifold:
An inlet manifold or intake manifold is the part of an engine that supplies
the fuel/air mixture to the cylinders.
Electronic Fuel Injection:
Fuel injection is the introduction of fuel in an internal combustion engine, most
commonly automotive engines, by the means of an injector. All diesel engines use fuel
injection by design. Petrol engines can use gasoline direct injection, where the fuel is
directly delivered into the combustion chamber, or indirect injection where the fuel is
mixed with air before the intake stroke.
Carburetor:
Venturi flow device which meters the proper amount of fuel into the air flow by means
of a pressure differential.

Diesel Pump:
An Diesel Injection Pump is the device that pumps diesel (as the fuel) into the
cylinders of a diesel engine. Traditionally, the injection pump is driven indirectly from
the crankshaft by gears, chains or a toothed belt (often the timing belt) that also drives
the camshaft. It rotates at half crankshaft speed in a conventional four-stroke diesel
engine.

Exhaust System
Exhaust Manifold:
Piping system which carries exhaust gases away from the engine cylinders, usually
made of cast iron.

Muffler:
A device that is used to reduce engine noise.

Exhaust Gas Recirculation:

In internal combustion engines, exhaust gas recirculation (EGR) is a nitrogen oxide
(NOx) emissions reduction technique used in petrol/gasoline and diesel
engines. EGR works by recirculating a portion of an engine's exhaust gas back to the
engine cylinders.

Catalytic Converter:
Chamber mounted in exhaust flow containing catalytic material that promotes
reduction of emissions by chemical reaction.
 Engine Lubricating System

Lubricating oil properties:

An Excellent Lubricant possesses following properties:
High boiling point and low freezing point
High viscosity index.
Thermal stability.
Hydraulic stability.
Corrosion prevention.
High resistance to oxidation.

Oil Pump:
Pump used to distribute oil from the oil sump to required lubrication points. The oil
pump can be electrically driven, but is most commonly mechanically driven by the
engine. Some small engines do not have an oil pump and are lubricated by splash
distribution.

Oil Cooler:
Oil cooling is the use of engine oil as a coolant, typically to remove surplus heat from
an internal combustion engine. The hot engine transfers heat to the oil which then
usually passes through a heat-exchanger, typically a type of radiator known as an oil
cooler.

Oil Filter:
An oil filter is a filter designed to remove contaminants from engine oil,
transmission oil, lubricating oil, or hydraulic oil. Oil filters are used in many different
types of hydraulic machinery.

Engine Cooling System

Water Jacket:
System of liquid flow passages surrounding the cylinders, usually constructed as part
of the engine block and head. Engine coolant flows through the water jacket and keeps
the cylinder walls from overheating. The coolant is usually a water-ethylene glycol
mixture.

Water Pump:
Pump used to circulate engine coolant through the engine and radiator. It is usually
mechanically run off of the engine.

Engine Fan:
Most engines have an engine-driven fan to increase air flow through the radiator and
through the engine compartment, which increases waste heat removal from the engine.
Fans can be driven mechanically or electrically, and can run continuously or be used
only when needed.

Radiator:
Liquid-to-air heat exchanger of honeycomb construction used to remove heat from the
engine coolant after the engine has been cooled. The radiator is usually mounted in
front of the engine in the flow of air as the automobile moves forward. An engine-
driven fan is often used to increase air flow through the radiator.

Antifreeze Coolant:
An antifreeze is an additive which lowers the freezing point of a water-based liquid.
An antifreeze mixture is used to achieve freezing-point depression for cold
environments and also achieves boiling-point elevation ("anti-boil") to allow
higher coolant temperature.

Engine Transmission System

Clutch Construction
The clutch assembly consists of the following components:
Clutch disc
Flywheel
Clutch cover assembly
Clutch release bearing
Clutch release fork
The clutch disc is connected to the input shaft of the transmission, and is located
between the flywheel and clutch cover assembly. The flywheel is connected to the
engine crankshaft and the clutch cover assembly is attached to the flywheel. The
clutch release fork forces the clutch release bearing against the diaphragm spring of
the clutch cover assembly.
Clutch Operation:
When the clutch pedal is pressed, a cable or hydraulic piston pushes on the release
fork, which presses the throw-out bearing against the middle of the diaphragm spring.
As the middle of the diaphragm spring is pushed in, a series of pins near the outside of
the spring causes the spring to pull the pressure plate away from the clutch disc (see
below). This releases the clutch from the spinning engine.

Manual Transmission System:

A manual transmission, also known as a manual gearbox or stick shift is a type
of transmission used in motor vehicle applications. It uses a driver-
operated clutch engaged and disengaged by a foot pedal (automobile) or hand lever
(motorcycle), for regulating torque transfer from the engine to the transmission and
a gear selector operated by hand (automobile) or by foot (motorcycle).

Automatic Transmission System:

An automatic transmission, also called auto or self-shifting transmission is a type
of motor vehicle transmission that can automatically change gear ratios as the vehicle
moves, freeing the driver from having to shift gears manually. Like other transmission
systems on vehicles, it allows an internal combustion engine, best suited to run at a
relatively high rotational speed, to provide a range of speed and torque outputs
necessary for vehicular travel.