AUTOMONBILE CHASSIS & BODY ENGINEERING

A Text Book on
Automobile Chassis and Body Engineering
(A text book for +2 Vocational and Diploma Students of Mechanical
Engineering)
Author
Sri. N.R.HEMA KUMAR
Lecturer in Vocational,
Department of Vocational Education,
Government Junior College, PALAMANER.
Editor
Sri. P.L.N. PRAKASA RAO PATNAIK,
Lecturer in Engineering (Automobile),
Department of Vocational Education,
Government Junior College AMADALAVALASA

contents
1.0 Chassis, Frame and Body
1.1 Introduction of Chassis frame
1.2 Layout of the Chassis and its main components
1.3 Functions of the Chassis frame
1.4 Types of Chassis frames
1.5 Various loads acting on the frame
1.6 State the different bodies used in automobiles
1.7 Explain the requirements of bodies for various types of
vehicles viz. private, commercial etc.
2.0 Steering Sytem
2.1 Requirement of the Vehicle steering
2.2 Types of Steering ears, systems and power steering
2.3 Steering linkages mechanism under steering, over steering
2.4 Turning radius
2.5 Wheel alignment of Ackerman’s & Devis Steering gear,
Mechanism
2.6 Steering geometry – Caster, Camber, King pin inclination, toe
in and toe out
2.7 Steering defects – wheel woubble and shimmy
2.8 List our the type of steering system used in various vehicles
3.0 Braking system
3.1 Explain Functions of brakes
3.2 Requirements of automobile brakes
3.3 Explain stopping time and stopping distance
3.4 Type of Braking systems – Disc and Drum braking system
3.5 Construction and working of Mechanical, hydraulic, and air
brakes
3.6 List out the types of brakes used in various vehicles
4.0 Suspension System
4.1 Requirement of a automobile suspension system
4.2 Types of suspension system – conventional and Independent
4.3 Types of springs – Laminated spring, coil spring, helical spring
4.4 Need of Shock absorber – construction and working of
different types of shock absorbers
4.5 Stabilizer bar and torsion bar
4.6 List out the type of suspension system used in various vehicles
5.0 Seat, Door and Window mechanism
5.1 Construction and working of door lock mechanism
5.2 Construction and working of manual window regulating
mechanism

5.3 Construction and working of power window regulating
mechanism
5.4 Construction and working of seat adjusting mechanism
6.0 Air Conditioning of motor vehicles
6.1 Necessity of automobile air conditioning
6.2 Construction and working of passenger car air conditioning
7.0 Painting of automobiles
7.1 Body painting
7.2 Different types of painting – Spray painting – hand painting
procedures
8.0 Automobile Pollution
8.1 Effects of automobile pollution on environment and human
beings
8.2 Types of automobile emissions
8.3 Treatment of exhaust gases by using catalytic convectors
8.4 Measurement of percentage of pollutants from petrol &
Diesel vehicles with the help of exhaust gas analyzers
9.0 Legal aspects of motor vehicles
9.1 Traffic signs and signals
9.2 Registration requirements
9.3 Necessity of permits for commercial vehicles
9.4 Insurance coverage
9.5 Procedure for obtaining driving licenses
‘

Chapter 1 Chassis Frame And body 1
CHAPTER 1
CHASSIS FRAME AND BODY
Introduction of Chassis Frame: Chassis is a French term and was initially used
to denote the frame parts or Basic Structure of the vehicle. It is the back bone
of the vehicle. A vehicle with out body is called Chassis. The components of
the vehicle like Power plant, Transmission System, Axles, Wheels and Tyres,
Suspension, Controlling Systems like Braking, Steering etc., and also electrical
system parts are mounted on the Chassis frame. It is the main mounting for all
the components including the body. So it is also called as Carrying Unit.
Layout of Chassis and its main Components:
The following main components of the Chassis are
1. Frame: it is made up of long two members called side members
riveted together with the help of number of cross members.
2. Engine or Power plant: It provides the source of power
3. Clutch: It connects and disconnects the power from the engine fly
wheel to the transmission system.
4. Gear Box

2 Automobile Chassis And Body Engineering.doc Chapter 1
5. U Joint
6. Propeller Shaft
7. Differential
FUNCTIONS OF THE CHASSIS FRAME:
1. To carry load of the passengers or goods carried in the body.
2. To support the load of the body, engine, gear box etc.,
3. To withstand the forces caused due to the sudden braking or
acceleration
4. To withstand the stresses caused due to the bad road condition.
5. To withstand centrifugal force while cornering
TYPES OF CHASSIS FRAMES:
There are three types of frames
1. Conventional frame
2. Integral frame
3. Semi-integral frame
1. Conventional frame: It has two long side members and 5 to 6 cross
members joined together with the help of rivets and bolts. The frame sections
are used generally.
a. Channel Section - Good resistance to bending
b. Tabular Section - Good resistance to Torsion
c. Box Section - Good resistance to both bending and
Torsion
2. Integral Frame: This frame is used now a days in most of the cars. There is
no frame and all the assembly units are attached to the body. All the
functions of the frame carried out by the body itself. Due to elimination of
long frame it is cheaper and due to less weight most economical also. Only
disadvantage is repairing is difficult.
3. Semi - Integral Frame: In some vehicles half frame is fixed in the front end
on which engine gear box and front suspension is mounted. It has the
advantage when the vehicle is met with accident the front frame can be
taken easily to replace the damaged chassis frame. This type of frame is
used in FIAT cars and some of the European and American cars.
VARIOUS LOADS ACTING ON THE FRAME:
Various loads acting on the frame are
1. Short duration Load - While crossing a broken patch.

2. Momentary duration Load - While taking a curve.
3. Impact Loads - Due to the collision of the vehicle.
4. Inertia Load - While applying brakes.
5. Static Loads - Loads due to chassis parts.
6. Over Loads - Beyond Design capacity.
STATE THE DIFFERENT BODIES USED IN AUTOMOBILES:
The Automobile bodies are divided in two groups
Body
Passenger Body Commercial body

According to Chassis design the body can divided into
1. Conventional Type
2. Integral Type
3. Semi- Integral Type
According to other usage:
1. Light vehicle Bodies - cars, jeeps
2. Heavy vehicle Bodies – Busses, Lorries
3. Medium vehicle Bodies - Vans, Metadoors

REQUIREMENTS OF BODIES FOR VARIOUS TYPES OF VECHILE:
The body of the most vehicle should fulfill the following requirements:
1. The body should be light.
2. It should have minimum number of components.
3. It should provide sufficient space for passengers and luggage.
4. It should withstand vibrations while in motion.
5. It should offer minimum resistance to air.
6. It should be cheap and easy in manufacturing.
7. It should be attractive in shape and colour.
8. It should have uniformly distributed load.
9. It should have long fatigue life
10.It should provide good vision and ventilation.

Short Answer Questions:
1. List out the various components of chassis?
2. What are the functions of Chassis frame?
3. List out the types of Chassis frame?
4. What are the frame sections used in Automobiles?
5. What are the requirements of Bodies for various types of vehicles?
Essay Type Questions:
1. Draw the layout of conventional Chassis with a neat diagram and
explain about various parts on it?
2. What are the different classification of bodies used in Automobiles
and explain?

Chapter 2 Steering System 7
CHAPTER 2
STEERING SYSTEM
Introduction: This system provides the directional change in the movement of
an Automobile and maintain in a position as per the driver’s decision without
much strain on him.
REQUIREMENTS OF STEERING SYSTEM:
a. It must keep the wheel at all times in to rolling motion with out
rubbing on the road.
b. This system should associate to control the speed.
c. It must light and stable.
d. It should also absorb the road shocks.
e. It must easily be operated with less maintenance.
f. It should have self-centering action to some extent.

Functions of Steering System:
1. It helps in swinging the wheels to the left or right.
2. It helps in turning the vehicle at the will of the driver.
3. It provides directional stability.
4. It is used to minimize the tyre wear and tear.
5. It helps in achieving self-centering efforts.
6. It absorbs major part of the road shocks.
Main Components of Steering System:

The following are the main components of steering system are
1. Steering Wheel
2. Steering column or shaft
3. Steering Gear
4. Drop Arm or Pitman Arm
5. Drag Link
6. Steering Arm
7. Track-Arms
8. Track Rod or Tie-Rod
9. Adjusting Screws
Types of Steering Gear Boxes:
1. Worm and Wheel Steering Gear.
2. Worm and Roller Steering Gear.
3. Re-circulating Ball type Steering Gear.
4. Rack and Pinion type Steering Gear.
5. Cam and Roller Gear type Steering Gear.
6. Cam and Peg Steering Gear.
7. Cam and Double lever Steering Gear.
8. Worm and Sector Type Steering Gear.
Functions of Steering Gear Box:

1. It converts the Rotary movement of the steering wheel in to the
angular turning of the front wheels.
2. It also multiplies drivers efforts and give MEHANICAL ADVANTAGE.
1.Worm and Wheel Type: This type of steering gear has a square cut screw
threads at the end of the steering column; which forms a worm, at the end of
it a worm wheel is fitted and works rigidly with it. Generally covered shaft is
used for the worm wheel. The worm wheel can be turned to a new position
the drop arm can be readjusted to the correct working position.
2. Re-circulating Ball Type: In this type of gear box the endless chain of balls
are provided between the worm and nut members. The nut form a ring of
rack having an axial movement. So that the sector on the rocker shaft racks,
the balls roll continuously between the worm and nut. Being provided with
return chambers at the ends of the worm. This method reduces friction
between worm and nut members. This type of steering gear is used for heavy
vehicles.
3. Rack and Pinion Type: This is common manual type of steering gear box
is used in most of the vehicles. In this type of steering a pinion is provided the
bottom end of the steering column. The teeth of the pinion wheel in mesh
with corresponding teeth provided on the rack, the end of which are

connected to the stub axle through the rod. The rotating motion of the
pinion operates the rack in FORE and AFT direction which in turn operates the
stub axle.
4. Cam and Lever Type: The cam and lever steering uses one or two lever
studs fitted in taper roller bearing. When the worm in the form of helical
groove rotates the stub axle and it also rotates along with it. This imports a
turning motion to the drop arm shaft.
5. Worm and Sector Type: In this type the worm on the end of the steering
shaft meshes with a sector mounted on a sector shaft. When the worm is
rotated by rotation of the steering wheel, the sector also turn rotating the
sector shaft. Its motion is transmitted to the wheel through the linkage. The
sector shaft is attached to the drop arm or pitmen arm.
Power Steering: Power steering reduces much strain on the part of the driver
while negotiating sharp curves. It makes easy to turn sharp corners. It is usually

arranged to be operative when the effort of steering wheel exceeds a pre-determined
value. It is fitted on heavy commercial vehicles and medium
cars.
Steering Linkages: Steering Linkage is a connection of various links between
the steering gear box and the front wheels. The motion of the pitman arm
and steering gear box is transferred so the steering knuckles of the front
wheels through the steering linkages. The swinging movement of the pitman
arm from one side to the other side gives angular movement to the front
wheel through the steering linkages.
Types of steering Linkages:
1. Conventional steering Linkage.
2. Direct cross type steering linkage
3. Three piece steering linkage
4. center arm steering linkage
5. Relay type steering linkage.
Slip Angle: The angle between direction of the motion of the vehicle and the
center plane of the tyre is known as Slip Angle. It ranges from 8º to 10º.
Under steer: When the front slip angle is greater than that of rear, the vehicle
tends to steer in the direction of side force. Then it is known as under steer. This
provides greater driving stability, especially when there is a side wind.
Over Steer: When the rear slip angle is greater than that of front slip angle,
the vehicle tends to mover away from the direction of center path. This is
known as over stear. This is advantageous when the vehicle moving on the
road having many bends curves.
Steering Gear Ratio or Reduction Ratio: It has been defined as the “ number
of turns on the steering wheel required to produce on turn of steering gear
cross shaft to which the pitman arm is attached. Generally it varies between
14'.1 and 24'.1.
Turning Radius: It is the radius of the circle on which the outside front wheels
moves when the front wheels are turned to their extreme outer position. This
radius is 5 to 7.5 m for buses and trucks.

Wheel Alignment: It returns to the positioning of the front wheels and steering
mechanism that gives the vehicle directional stability, reduce the tyre wear
to a minimum.
Factors effects the wheel alignment:
1. Factors pertaining to wheel:- a. Balance of wheels(Static and Dynamic)
b. Inflation of tyre.
c. Brake adjustments.
2. Steering Linkages.
3. Suspension System
4. Steering Geometry –a. caster b. camber c. king pin inclination d. toe-in
and toe-out etc.,
Steering Geometry: It refers to the angular relationship between the front
wheels and parts attached to it and car frame.
The steering Geometry includes
1. Caster angle
2. Camber angle
3. King-pin inclination
4. toe-in
5. toe-out etc.,
Caster Angle: This is the angle between backward or forward tilting of the
king pin from the vertical axis at the top. This is about 2º to 4º. The backward
tilt is called as positive caster. The forward tilt is called negative caster.
Camber: The angle between wheel axis to the vertical line at the top is
called camber angle. It is approximately ½º to 2º.
King-pin inclination: It is the angle between vertical line to the king pin axis.
The inclination tends to keep wheels straight ahead and make the wheels to
get return to the straight position after completion of a turn. The inclination is
normally kept 7º to 8º.

Toe-in: It is the amount in minimum at the front part of the wheel points
inwards approximately 3 to 5 mm. It prevents side slipping excessive tyre
wear, proper rolling of front wheels and steering stability.
Toe-out: It is the difference in angles between two front wheels and vehicle
frame during turning. It is used to prevent dragging of tyre during turn.
Reversible steering: When the deflection of road wheels is transmitted
through the steering wheel to road surface, the system is called Reversible.
If every imperfection of road surface causes the steering to rotate, it
causes much strain on the part of the driver to control the vehicle. It causes
much strain on the part of the driver to control the vehicle. There fore such of
the reversibility is not desired. But, some degree of reversibility desired, so that
the wheel becomes straight after taking a curve.
Irreversible steering: If the front road wheels does not transfer any deflection
to the steering which is called irreversible steering. After negotiating a curve
and the steering wheel not returned easily, there causes the production of

un due stresses on the steering mechanism, therefore some degree of
irreversible also desired.
Steering Mechanism: There are two types of steering gear mechanisms
1. Davis Steering gear 2. Ackermann Steering gear]
1. Davis Steering Gear: The Davis Steering gear has sliding pair, it has more
friction than the turning pair, there fore the Davis Steering Gear wear out
earlier and become inaccurate after certain time. This type is mathematically
Accurate.
The Davis gear mechanism consists of cross link KL sliding parallel to
another link AB and is connected to the stub axle of the two front wheel by
levers ACK and DBK pivoted at A and B respectively. The cross link KL slides in
the bearing and cross pins at its ends K and L. The slide blocks are pivoted on
these pins and move with the turning of bell crank levers as the steering
wheel is operated. When the vehicle is running straight the gear is said to be
in its mid-position. The short arms AK and BL are inclined an angle 90 t α to
their stub axles AC and BD respectively. The correct steering depends upon
the suitable selection of cross arm angle α, and is given by
Tan α = b/2l Where b= AB = distance between the pivots of front axle.
l=wheel base
2. Ackermann Steering System: It has only turning pair. It is not
mathematically accurate except in three positions. The track arms are made
inclined so that if the axles are extended they will meet on the longitudinal
axis of the car near rear axle. This system is called ackermann steering.
STEERING DEFECTS AND THEIR CAUSES AND REMEDIES:
1. Wheel wobble: The oscillation of the front wheels at low speeds is
called wheel wobble.
Causes Remedies
a. In Correct Dynamic Balancing
of wheels.
a. Correct the wheel balance
b. Uneven Tyre pressure b. Check the tyre pressure
c. The camber may be incorrect or
c. Adjust suitably.
uneven
d. The ball joints may be worn out. d. Replace with a new one

e. Excessive caster e. Adjust
f. Steering gear or wheel bearing
may be loosen.
f. Adjust or Replace
g. Tyre may worn unevenly g. Replace
2. High Speed shimmy: The oscillation of the front wheels at high speed is
called high speed shimmy.
a. Wheel Rim may be buckled - Straighten or replace
b. Front wheel bearing may loose or worn out - Tighten or Replace
c. Faulty shock Absorber - Replace
d. Incorrect toe-in - Adjust
3. Excessive backlash in steering:
a. Steering gear base may be loose -Tighten
b. Drop arm may be loose on splines - Replace
c. Front wheel stub axle bearing loose or worn out-Tighten or Replace
d. Loose steering Linkages - Tighten Properly
4. Steering Wander: The moving of Vehicle slightly in one side is known as
wandering
a. Tyre pressure in two sides is not equal - Check and correct
b. Steering knuckle bearing tight -Adjust
c. Badly worn Tyre - Replace
d. Incorrect Toe-in - Correct it.
5. Hard Steering: When the effort required for steering is more it is called
hard steering.
a. Low Tyre pressure - Correct pressure
b. Excessive caster - Adjust
c. Steering gear too tight - Adjust
d. Incorrect wheel Alignment - Adjust

COMPARATIVE STEERING DATA OF SOME INDIAN AUTOMOBILES
S.
No
Vehicle make Type
of
Steeri
ng
Camber Casto
r
King
pin
inclin
ation
Toe-in(
mm
)
Steeri
ng
Ratio
1
2
3
Hindustan
Ambassador
Mark II
Fiat 1100
Jeep CJ3B
Rack
&
Pinion
Worm
&
Roller
Cam
&
Lever
½”
(0 to 30)
degrees
+/- 20’
11/2
degrees
8 1/4”
(2
degre
es 10
mts
+/- 10
mts 30
secs
3
degre
es
3”
7
degre
es
71/2
degre
es
24
1 to 9
un
laden
7
laden
1.2 to
2.4
14:1
164:1
14:1,
12:1

1. What are the Requirements of Steering systems?
2. Explain the functions of steering systems?
3. List out the main components of steering system?
4. What are the functions of steering Linkages used the Automobiles?
5. What are the types of steering linkages used the Automobiles?
6. What is meant by wheel wobbling?
7. What are the causes for high Speed Shimmy?
Long Answer Questions:
1. What are the types of steering gear boxes used and explain any one
of them?
2. What is meant by Steering Geometry and explain with neat sketches?
3. Explain about different Steering mechanisms i.e. Dan’s and Ackerman
steering with neat diagrams?
4. Explain the following in brief:
a. Slip Angle
b. Under Steer and Over Steer
c. Reversible Steering and Irreversible steering
d. Turning Radius

Chapter 3 BRAKING SYSTEM 19
CHAPTER –III
BRAKING SYSTEM:
INTRODUCTION:
Braking is the mechanism in the motor vehicle which is used
to slowing down and stopping the vehicle to rest in the shortest possible
distance.
Principle of Braking system: While operating the braking system the KINETIC
ENERGY of moving vehicle is converted in to HEAT ENERGY.
Functions of Brakes: Brakes have the following functions.
1.It is used to stop the vehicle.
2.It is used to control the speed where and when required.
3.It is used to control the vehicle while descending along the slope.
4.To park the vehicle and held it in stationary position without the presence of
Driver.
Requirements of Automobile Brakes:
1.It should work efficiently irrespective of road condition and quality.
2.The retardation must be uniform throughout its application.
3.The pedal effort must be within the convenient capacity of the driver.
4.It must be reliable and should not be effected by heat water and dust.
5.It should be in minimum weight.
6.It should have long life.
7.It should be easy to maintain and adjust.
8.Noise and vibrations are to be minimum.
9.There should be provision for secondary brake or parking brake.
Stopping distance and Braking efficiency:
For practical measure for braking efficiency that of the minimum
distance in which it can be brought in to rest after the brake is applied.
The stopping distance depends upon
1.Grip between the tyre and road surface.
2.Tyre tread condition.
3.Tyre inflation.
4.Nature of road surface.
The stopping distance is calculated by
D=kv2
Where d=stopping distance in kilometers.
K=Constant depending upon the road and tyre inflation.
V=velocity of the vehicle per hour.

The value of k is 1/25 for 4 wheel braking system.
1/12 for 2 wheel braking system.
The braking efficiency is calculated by the equation:
η=V2/3D where v=velocity of the vehicle
d=stopping distance.
Condition of Brake Braking efficiency in %
1.Perfect 90%
2.Excellent 77%
3.Good 70%
4.Fair 60%
5.Poor 50%
6.Bad 37%
7.Very bad 30%
Below Fair is very danger.
Classification of Brakes: The following are the classifications of Brakes:
1.By method of power
a) Mechanical brakes
b) Hydraulic brakes
c) Vacuum brakes
d) Air brakes
e) Electrical brakes
f) Magnetic brakes
g) Air assisted hydraulic brakes
2.By method of application:
a) Service or foot brakes
b)Parking or hand brakes
3.By method of operation:
a) Manual
b) Servo
c) Power operation
4. By method of Braking contact
a. Internal Expanding Brakes

b. External Contracting Brakes.
5. By Method of Applying Brake force:
a. Single Acting Brakes.
b. Double Acting Brakes.
Types of Mechanical Brakes:
a. Drum Brakes (Internal Expanding or External Contracting)
b. Disc Brakes (Single or Two caliper)
Drum Brakes:
Construction: The main components of drum brakes are
1. Brake drum
2. Back plate
3. Brake shoes
4. Brake Liners
5. Retaining Springs
6. Cam
7. Brake Linkages
In this system the wheel is attached to drum. There are brake shoes used to
contact the rotating drum for braking operation. The shoes provide lining on
their outer surface. The cam is used to lift the brake shoes at one end, other
end is connected by some method so as to make as the brake sleeve come
into contact in the brake drum. The retaining spring is provided for bringing
the brake shoes back to its original position, after releasing the brake pedal.
All these parts are fitted in the back plate and enclosed with brake drum. This
system .
Working: When the pedal is pressed the cam moves the shoes outwards
through linkages, there by coming in frictional contact with the rotating drum.
As soon as the brake pedal is released the retaining springs help the brake
shoes to brought back and release the brakes.
2. Disc brakes: There are two types of disc brakes:
1. Spot Type
a. Swinging Caliper Type
b. Sliding caliper type
2. Clutch Type
Construction: The discs are made of gray cast Iron. The brake pressure in
case of disc brakes have to be much lighter than the drum brakes.

It consists of rotating disc and two friction pads which are actuated by
the four hydraulic wheel pistons contain in two halves of an assembly is called
a caliper. The caliper assembly is secured to the steering knuckle in a front
wheel brakes. The road wheel is fashioned to the outer surface of the disc.
The friction pads rides freely on each side of the discs. They are in position
being the hydraulic systems.
Working:
When the brakes is applied hydraulic pressure is supply to the fluid inlet
tube, due to which the wheel cylinder piston force the friction pads against
the rotating disc. In the released piston, the spring hold the piston pads so
that they maintain contact with disc surface.
Construction and Working of Hydraulic systems:
Hydraulic brakes make used of hydraulic pressure to force brake shoes
out words against the brake drum based on PASCAL’S LAW.
Construction: The main components of the system is
1. Master Cylinder 2. Wheel Cylinder
The figure shows the master cylinder is connected by tubing to the
wheel cylinder, at each of the four wheels. The system is filled with the liquid
under light pressure when the brake is not in operation. The brake fluid
generally a mixture of glycerin and alcohol or caster oil, denatured alcohol
and some additives.
The brakes shoes which are mounted on the inner side of the brake
drum and do not rotate. The brake liners are fitted on the outer surface of the

brake shoes. The brake pedal is connected to the master cylinder piston by
means of a piston rod.
Working: When the brake pedal is pressed the piston is forced in to the
master cylinder, the hydraulic pressure is applied equally to all wheel
cylinders. The pistons in the wheel cylinders pushed outwards against the
brake drum.
When the driver release the brake pedal, the piston in the master
cylinder returns back to its original position due to the return spring pressure.
Thus the pistons in the wheel cylinder come back in its original inward position.
Thus the brakes are released
Construction and working of Master Cylinder
Master Cylinder: The Master Cylinder is the heart of the hydraulic brake
system. It consists of two main chambers. The fluid reservoir which contains
the fluid to supply to the brake system, and the compression chamber in
which the piston operates. The reservoir supplies fluid to the brake system
through two ports. The larger port is called the filler or intake part and is
connected to the hollow portion of the piston between the primary and
secondary cups which act as piston seals. The smaller port is called the relief,
bypass or compensating port which connects the reservoir directly with the
cylinder and lines when the piston is in the released position.
When the brake pedal is depressed, the master cylinder piston moves
forward to force the liquid under pressure into the system. The relief port is
sealed out of the system. The liquid pressure is conducted to the wheel
cylinders, where it forces the wheel cylinder pistons out wards. These pistons
force the brake shoes out against the brake drums.

When brake pedal is released, the return spring quickly forces the
master cylinder piston back against the piston stop. Because the fluid in the
lines returns rather slowly, a vacuum tends to form in the cylinder in front of
the piston. This causes the primary cup to collapse to allow the liquid to flow
from the reservoir through the filter port past the piston to fill the vacuum.
Construction and working of Wheel Cylinder
WHEEL CYLINDER: Wheel cylinder is the second important hydraulic brake
system. It consists of two pistons which can move in opposite directions by the
fluid pressure. It is rigidly mounted on the brake shield or backing plate. The
boots protect the cylinders from foreign substances. Bleeder valves are
provided in the cylinder to permit air and liquid to be pumped out of the
system during of the bleeding operation .
Piston cup fits tightly in the cylinder against each piston and seal the
mechanism against leakage of the brake fluid. A Spring serves to hold the
cups against the piston when the pressure is decreased.
When the brakes are applied the brake fluid enters the cylinder from a
brake line connection inlet between the two pistons. It causes to force out
the two pistons in opposite directions. This motion is transmitted to the brake
shoe. Directly or through links force them against the brake drum, thus
applying the brake.
Construction and working of Tandem master Cylinder
In this master cylinder there are two pistons in the and hydraulic
pressure developed in two chambers one for the front left, and rear right
brakes and other for the front right and rear left brakes.
In tandem master cylinder one cylinder operates the front brakes while
the other cylinder operates the rear brakes.

Construction and working of Air Brake System:
The air brake system consists of two-stage air-compressor driven by the
crankshaft or gearbox shaft. It takes air from atmosphere, compresses it and
delivers to the air reservoir through un-loader valve. Where the pressure of
the reservoir reaches the maximum degree, the un- loader valve opens to the
atmosphere. Then the compressed air is directed in to the atmosphere
directly.
Each of the four wheels fitted with brake chambers consists of a
diaphragm, and which the air pressure is applied and pushes it. This force
operates the cam actuating lever and applies the brake. Each of the brake
chamber is connected to the brake pedal, and air filter is also fitted between
the brake valve and reservoir.
Working: When the brake pedal is pushed the brake valve opens and
compressed air is allowed in to the brake chamber. The brake valve consists
of three passages.
1. Air intake 2. Exhaust 3. Brake chamber
When the brake pedal is pressed the exhaust passage will be closed
and Air intake passage open and compressed air goes back to the chamber.
During return stroke the exhaust passage opens while intake closes and used
air goes to the atmosphere. This system fitted with an emergency mechanical
brake, which can be used when air supply fails the air brake system, which is
called air assisted hydraulic braking system.
Advantages:
1. This system used in heavy vehicles because they are more powerful
than hydraulic or mechanical brakes.

2. It simplifies the chassis design
3. The compressed air is used for purposes like tyre inflation; for horn,
windscreen wiper etc.
Disadvantage:
If there is any leakage in passage the entire system will be fail.
Therefore sealing of air is very difficult.

1. Explain the function of brakes?
2. What are the requirements of Automobile brakes?
3. What are the classifications of brakes?
4. What does stopping distance mean?
5. Explain about braking efficiency?
1. What are the types of mechanical brakes explain any one of them?
2. Explain the construction and working of Hydraulic brakes?
3. Explain the Construction and working of Air brakes?

CHAPTER-IV
SUSPENSION SYSTEM:
Introduction: The automobile frame and body are mounted on the front and
rear axle not directly but through the springs and shock absorbers. The
assembly of parts, which perform the isolation of parts from the road shocks,
may be in the forms of bounce, pitch and roll is called suspension system.
Functions of suspension system:
1. It prevents the vehicle body and frame from road shocks.
2. It gives stability of the vehicle.
3. It safeguards the passengers and goods from road shocks.
4. It gives the good road holding while driving, cornering and braking.
5. It gives cushioning effect.
6. It provides comfort.
Requirements of suspension system:
1. There should be minimum deflection.
2. It should be of low initial cost.
3. It should be of minimum weight.
4. It should have low maintenance and low operating cost.
5. It should have minimum tyre wear.
Components of Suspension system: Coil springs, Leaf springs, shock
absorbers, Spring shackles, stabilizer
Independent suspension system: The independent suspension system means
any arrangement that connects road wheels to the frame in which raise or
fall of the wheel has no direct effect on the other wheel. It eliminates wheel
wobbling.
Advantages: 1. It provides softer suspension.
2. It reduces wheel wobbling
3. It reduces the tendency of fitting of the wheel on one side due
to road vibration
4. It provides more space for engine accommodation.
5. It promotes under steer which results low un sprung weight.
6. The movement of the spring on one wheel is not transmitted to
the other wheel.
Sprung Weight: It is weight of all the parts supported by the spring including
weight of the spring.

Chapter 4 SUSPENSION SYSTEM 29
Un sprung weight: It is the weight of all the parts between the spring and rod
and the portion of spring weight it self.
Basic suspension movements:
1. Bouncing: The vertical movement of the complete body.
2. Pitching: The rotating movement of all the parts between the spring
and road and the portion of spring weight itself.
3. Rolling: The movement about longitudinal axis produced by the
centrifugal force during cornering.
Types of front Independent suspension system: There are three types:
1. Wish bone Type
2. Vertical guide type
3. Trailing Link Type
Wish bone Type of Front Independent suspension system:
In this type of suspension system coil springs are mostly used between
the two suspension arms and are controlled with frame and at the open ends
of the upper and lower wishbones which are connected to the chassis frame.
The upper arm is shorter than lower one. This keeps the wheel track constant.
The closed ends of the both arms are connected with steering knuckle,
supported by means of kingpin. A coil spring is placed in between the lower
suspension arm and frame.
Types of suspension springs:
1. Steel Springs : a. Leaf Springs
b. Coil Springs
c. Torsion bar Springs
2. Rubber Springs: a. Compression Springs
b. Progressive Springs
3. Plastic Srings
4. Air Springs: a. Bellow Type
b. Pestoon Type
5. Hydraulic Type
Construction and working of Leaf Springs:

Leaf springs are formed by bending. They are made of long strips of
steel. Each strip is named as Leaf. The long leaf is called Master Leaf, and it
consists of eyes at its both ends. One end is fixed to the chassis frame, the
other end is fixed to the shackle spring. The spring will get elongated during
expansion and shortened during compression. This change in length of spring
is compensated by the shackle. The U-bolt and clamps are located at the
intermediate position of the spring. The bronze or rubber bushes are provided
on both eyes on the master leaf.
Types of Leaf Springs: There are five types of leaf springs
1. Full – elliptic type
2. Semi – elliptic type
3. Three Quarter – elliptic type
4. Transverse Spring type
5. Helper Spring type
1. Full elliptic :
The advantage of this type is the elimination of shackle and spring. The
lubrication and wear frequently which are on of the main draw back of
this type of springs.
2. Semi – elliptic :
This type is more popular for rear suspension are used in 75% of cars.
3. Three – Quarter – elliptic type:
This type is rarely used in now-a-days. It gives resistance, but occupies
more space than other types.
4. Transverse Type:
This type of spring is arrange transversely across the car instead of
longitudinal direction. The transverse spring for front axle as shown in figure,

which is bolted rigidly to the frame at the center and attached to the axle by
means of shackle at both ends.
5. Helper Springs:
The helper springs are used in heavy vehicles for rear suspension. When
vehicle fully loaded the main sp[ring as well as helper spring to come in
action and absorb the road shocks. When the load of the vehicle is less the
helper spring will not act and the main spring only absorb the road shocks.
Need of Shock Absorber: If the suspension springs are rigid enough, they will
not absorb road shocks efficiently, and if they are flexible enough, they will
continue to vibrate for longer time even after the bump has passed.
Therefore, the springing device must be compromise flexibility and stiffness a
shock absorber needed in Automobile Suspension system.
Types of Shock Absorbers: They are mainly two types
1. Mechanical.
2. Hydraulic – a. Van type
b. Piston – i )Single Acting ii). Double Acting
c. Telescopic type
Construction and Working of Single acting Telescopic hydraulic shock
absorbers:

The telescopic shock absorber consists of a cylinder to which a head is
welded to screwed to the outer tube. The space between outer and inner
tube is called reservoir. A pressed steel cap and axle eye by means of which
cylinder is screwed to the axle are welded to the outer tube. A piston slides
inside the cylinder and screwed to the piston rod at which its upper end of
chassis eye, it is attached to the frame of the vehicle. The part of the piston
rod that is outside of the cylinder is protected by a cover which is welded to
the chassis eye. A piston rod gland packing prevent the leakage, when the
piston passes through the head and any fluid is trapped by it is supplied to
the reservoir through drain hole.

Working: If the axle eye moves upwards then the fluid must be displaced
from the bottom. Top side of the bottom side fluid through the outer ring of
the piston by lifting the non return valve. But since the increase in the volume
of upper end of the cylinder is less than the volume of the lower end. Fluid will
also displaced through the inner ring of holes of non return valve of foot
valve, and the level at the fluid will raise in the reservoir. The pressure setup will
depend on the size of hole in the piston and Foot valve and the squire of the
speed of which the cylinder is moved.
For downward motion of the cylinder the fluid will be displaced form
the upper end of the piston. In the leaver end through the inner ring of hole of
non return valve in the piston. The fluid will also be draw in the lower end of
the cylinder from the reservoir to the outer ring of hole of non return valve of
the foot valve.
Fig of shock absorber
Stabilizer Bar:
Stabilizer is necessarily used in all independent front suspension. It
reduces tendency of the vehicle to roll on either side when taking a turn. It is
simply a bar of alloy steel with arms at each end connected to the lower wish
bone of the independent suspension system. It is supported in bush bearings
fixed the frame and is parallel to cross member. When both the wheels
deflect up or down by the same amount, the stabilizer bar simple turns in the
bearings. When only one wheel deflects, then only one end of the stabilizer
moves, thus it acts as a spring between two sides of the independent front
suspension.
Torsion Bar
Torsion bar suspension is used in independent suspension system. It is a
rod acting in torsion and taking shear stresses only. It is made up of heat
treated alloy spring steel. This bar stores amount of energy nearly as same as
coil spring.
The bar is fixed at one end to the fr4ame, while the other end is fixed to
the end of the wheel arm and supported in the bearing. The other end of the
wheel arm connected to the wheel hub. When the wheel strikes a bump, it
starts vibrating up and down, thus exerting torque on the torsion bar which
acts as a spring.

Short Answer Questions
1. Explain the functions of suspension system?
2. List out the requirements of suspension system?
3. What are the types of suspension springs?
4. what are the basis suspension movements?
5. Explain about sprung weight and un sprung weight?
Long Answer Questions
1. What are the types of Independent suspension system and explain
about wish bone type of front independent suspension?
2. What are the types of leaf spring used in automobiles and explain with
neat sketches?
3. Explain the construction and working of single acting, telescopic,
hydraulic shock absorber with a neat sketch?
4. Explain briefly about following contents:
a. stabilizer bar
b. Torsion bar

Chapter 5 SEAT DOOR AND WINDOW MECHANISM OF CAR BODY 35
CHAPTER – V
SEAT DOOR AND WINDOW MECHANISM OF CAR BODY
Construction and working of door lock mechanism:
There are different methods to door lock or unlock mechanisms:
1. With a key
2. By pressing the unlock button inside the car
3. By using the combination lock on the outside of the door
4. By pulling up the knob on the inside of the door.
5. With a keyless – entry remote control.
6. By a signal from a control center.
In most of the cars having power door locks, the lock/unlock switch actually
sends power to the actuators that unlock the doors. But in more complicated
system having several ways to lock and unlock the doors, the body controller
decides when to do the unlocking. Body controller is a computer in the car.
Besides locks it takes care of many little things that makes your car friendlier
e.g., it make sure the interior lights stay on until the car is started, it beeps if
you leave your head lights on or leave the key in the ignition. Etc., In power
locks, body controller monitors all the possible sources ‘lock’ or ‘unlock’
signals e.g. it monitors a door – mounted touch pad and unlock the doors
when the correct mode is entered, it monitors a radio frequency and unlocks
the doors when it receives the connect digital code from the radio transmitter
in the key fob and also monitor the switches inside the car. When it receives a
signal from any of these sources, it provides power to the actuator that locks
or unlocks the doors.
The detailed power lock mechanism, in the door the actuator is
portioned bellow the latch. A rod connects the actuator to the latch and
another rod connects the latch to the knob that sticks up out of the top of
the door. When the actuator moves the latch up, it connects the outside
door handle to the opening mechanism. When the latch is down the outside
door handle is disconnected from the mechanism so that the door cannot be
opened. To unlock the door, the body controller supplies power to the door-lock
actuator for a timed interval. The door lock actuator is a simple device. It
consists of a small electric motor which turns a series of spur geans that
operate a rack. The rack pulls the knob up or pushes it down, thus opening or
closing the lock.
Construction and Working of Manual Window Regulating Mechanism:

The window glass winding mechanism included in the door
construction. When the handle is turning one direction, the toothed quadrant
which in turn moves the window carnivore. The glass fitted on the window
carrier which moves up and down as per the direction of rotation of the
toothed quadrant either clock wise or anti clock wise.
Construction and Working of Seat Adjusting Mechanism:
It is different form from the passenger seat . Bucket tupe of seat
commonly used. This type of seat is adjustable towards or away from the
steering wheel or control pedals in order to suit driver’s varying lengths of the
legs. In this arrangement rails are fixed to the frame. Frame is fixed with bolts
to slide on a rails squire to the floor. A lever projected to laterally to the seat
cushion. This engages with slide catch for seat position adjustment. The return
spring of the rocker again engages with the side catch. The lever is left free
after the adjustment of seat.

Chapter 5 SEAT DOOR AND WINDOW MECHANISM OF CAR BODY 37
Short Answer Questions
1. What re the different methods of door lock/unlock mechanism?
Long Answer Questions
1. Explain the construction and working of door lock mechanism with a
neat sketch?
2. Write the construction and working of Manual Window regulating
mechanism with neat sketch?
3. Explain about construction and working of power window regulating
mechanism?
4. Explain the construction and working of seat adjusting mechanism?

CHAPTER – VI
AIR CONDITIONING OF MOTOR VEHICLE:
Necessity of Automobile Air-Conditioning: Due to varying conditions of
heating, ventilating, cooling, dehumidification in the atmosphere at various
places, it is necessary to be conditioned the air in the automobiles. To
maintain human comfort and improve internal atmosphere in an enclosed
space, proper control of freshness temperature, humidity and cleanliness of
air is required. For this reason Automobile air-conditioning is necessary in the
vehicles.
Construction and working of Passenger car Air – Conditioning:
The main components of Auto Air- Condition are:
1. Compressor
2. Magnetic clutch
3. Condenser
4. Receiver or dehydrator
5. Expansion valve
6. Evaporator
7. Such on throttling valve
Compressor: The compressor in the Auto Air- Condition system is belt-driven
engine crankshaft pulley. A magnetic clutch engages the compressor shaft.
When the voltage is applied to the compressor clutch coil was sufficient the
compressor and pulley rotates together as one unit. When the voltage is

Chapter 6 Air Conditioning of Motor Vehicle 39
interrupted the pulley, disengages automatically, causes compressor to stop.
The low – pressured, high temperature, vaporized refrigerant enter in to the
compressor and it increases the pressure of about 20kg/cm² and 100ºc temp,
and pushes into the condenser. In the compressor the refrigerant never
reaches its liquid state.
Magnetic Clutch: The electrically controlled magnetic clutch is housed in
pulley assembly and a switch is on the controlling panel. This clutch is
engaged or disengaged depending upon the temperature of the air. Bellow
40 ºF. The compressor cannot be operated. Above 55ºF this switch closes and
completes the circuit to the compressor clutch.
Condenser: It is usually placed in front of the car and it is looks like a Fin-and-tube
radiator. The condenser receives heated and compressed gas from the
compressor and is cooled by the air passing across the condenser. The
refrigerant now in the form of high pressure liquid which is fed in to the
receiver drier Unit.
Reservoir or Dehydrator: The refrigerant stored under pressure in the Receiver-drier.
The drier removes any traces of moisture present in the system to avoid
freezing of moisture at low temperature and thus clogging the lines. It causes
running troubles.
Expansion Valve: In the expansion valve high pressure liquid is converted into
low pressure liquid then the refinement flow in to the evaporator
Evaporator: The evaporator unit where the cooling effect is obtained is
usually located inside the passenger compartment bellow the dash board. A
high capacity blower circulates the air in the in the car interior across the
evaporator coils, and the drops the temperature of the air inside the
passenger compartment. The heat picked by the refrigerant goes back to
the compressor in the vapour form, where the refrigerant is again
compressed to a high pressure and the cycle starts again.
Suction throttle valve: It ensures that the refrigerant the evaporator says at
such a pressure that the evaporator core surface temperature does not fall
bellow the freezing point of water (0°c), thus preventing ice formation in the
evaporator.

Short Answer Questions :
1.What is the necessity of automobile air-conditioning?
1. Write the construction and working of automobile Air-conditioning system
with a line
diagram?

Chapter 7 Painting Of Automobile 41
CHAPTER –VII
PAINTING OF AUTOMOBILE
Introduction: The corrosive nature of a metal used in a motor body
construction, necessitate the application of an anti corrosion coating. For this
reason the painting should be done.
Function of Painting:
1. It reduces the corrosion and protect the vehicle
body.
2. It is used for cleanliness.
3. It is used for esthetic appearance.
4. It is used to reduce the friction due to the
aerodynamic drag and allow the vehicle in stream
lining.
5. It is used for identification purpose.
Requirements of Good Painting:
1. It should be anticorrosive nature.
2. It should protect the hidden parts also from the corrosion.
3. It should have esthetic appearance.
4. It should be smooth finish for stream lining.
5. It must reduce the aerodynamic drag.
Main Constituents of paints:
1. Pigments
2. Drying oil
3. Thinners
4. Dry Extenders
5. Plasticizers
6. Resins.
Reason for failures of paints:
1. Not proper cleaning of body before painting
2. Not covering dents or spots.
3. Not using of proper good quality paint
4. Not applied the pretreatment with zinc phosphate
Different Types of Painting

1. Spray paint
2. Hand paint
Spray Painting procedure: Now-a-days spray paintings are largely use. The
procedure is as follows:
1. First of all the old paint should be scrapped with the help of scrappers
2. If there is nail or any obstruction they will be removed with the help of
pincers
3. The removal of old paint must be by application of caustic soda solution
and
spirit solutions.
4. In some portions heating is necessary with the help of blow lamp for
removal of old
paint.
5.The surface should be cleaned from dirt, dust, rust, grease etc.
6. The surface should maintain perfect level from any kind of bends.
7. Then once again clean with red oxide.
8. After wards duco paints or delux paints or required colour may be sprayed
on the vehicle as the primary coating.
9. After first coating is over we must see the variations of the surface clearly
and apply second coating and it will finish the painting job and gives
beautiful appearance.
10. Then decoration and letter writing finishes the body paint.
11. Finally polish the vehicle thoroughly.

Chapter 7 Painting Of Automobile 43
1. What are the functions of painting in Automobile body?
2. Explain the requirements for good painting?
3.What are the main constituents of paints?
4. What are the reasons for failure of the painting?
1. What are the different types of painting methods and explain the
procedure of spray painting?

CHAPTER – VIII
AUTOMOBILE POLLUTION
Introduction:- The major source of air pollution are flue gases, emissions from
refineries and factories etc.
on one hand and 60% of air pollution are due to automobile exhaust emission
in other hand. The I. C Engine exhaust contains several pollutants in the form
of oxides of Nitrogen (Nox) which are toxic and facing severe criticism. If the
concentration exceeds 100 ppm in enclosed space, if may even cause
death.
Effects of automobile pollution on environment and human beings:
The Oxides of Nitrogen together with hydro carbons react in the presence of
sunlight and form
Polto chemical smog. If effects the bad condition on crops
Animals,Birdscracking in rubber etc.
It Causes eyes irritation, objectionable odour.
It causes reduction in visibility, results traffic hazards.
The soot particles in the exhaust gases settle down on buildings and trees if
may thus spoils appearance of buildings in the long run.
The exhaust smoke is dangerous for health and causes troubles in breathing
Problems.
Types of Automobile emissions:
The vehicle emissions contains following types of pollutants
Exhaust emissions
Carbon Monoxide
Un burnt hydro carbons
Oxides of Nitrogen
Lead oxides
Sulphur dioxide
Smoke
Evaporative Emissions
Carburettor
fuel tank
petrol bunks
Crank case blow by from the crank case hydro carbons are emitted

Chapter 8 Automobile Pollution 45
Measurement of Percentage of Pollutions from petrol and Diesel Vehicles with
the help of exhaust gas analyzers
By using exhaust gas analyzer the measurement of percentage of
following pollutants from petrol and Diesel Vehicles
Pollut
Petrol
Diesel
ant
Engin
Engin
Consti
e
e
tuents
Carbo
n
Mono
xide%
9.9 2.9 2.7 3.9 - 0.01 - -
Hydro
Carbo
ns %
0.53 0.16 0.1 1.00 0.04 .0.01 0.01 0.03
Oxide
s of
Nitrog
en
PPM
30 1.020 650 20 60 8.5 240 30
Aldeh
ydes
PPM
30 30 10 290 10 20 10 30
Treatment of Exhaust gases by using catalytic converter
Fig Flow of gas through catalytic converter
The exhaust gases from the engine are passed through CATALYTIC
CONVENTER as shown in fig.,
A catalytic converter is a cylindrical unit about the size of small silencer and it
installed in to the exhaust system of a vehicle. It is placed between the
exhaust manifold and silencer in the exhaust system of a vehicle. Inside the
converter there is a honey corn structure of a ceramic or metal . Which is
coated with aluminum base material and there after a second coat of
precious metals platinum, palladium or rhodium or combination of the same.
The second coating serves as a catalyst. A catalyst is a substance which
causes a chemical reaction that normally does not happen in to the given
conditions. As a result catalytic reaction as the exhaust gases pass over the

converter substance, toxic gases such as co, the and NOX are converted in
to harmless CO2,H2 and N2 . There are two types of catalytic converters
A Two way converter which is used to control only CO and HC commissions
by oxidation
A Three way converter Which is used almost in all petrol cars It controls CO
and HC by oxidation
As well as NOX by reduction.

Chapter 8 Automobile Pollution 47
Short answer Questions:
What are the effects of automobile pollution on environment and human
beings ?
What are the types of Automobile emissions?
Long answer Questions:
Explain the treatment of Exhaust gases by using catalytic converters with a
neat SKETCH?

CHAPTER IX
LEGAL ASPECTS OF MOTOR VEHICLES:
Introduction: The motor vehicle act of 1977 is applicable and extends to the
whole of India. It was framed in 1939 and amended time to time according
to the requirements and necessities of roads and vehicles. This act as
amended up to 1977 has 10 chapters, 135 sections and 12 schedules.
The 10 Chapters as follows:
Chapter I – Preliminary Section 1-2.
Chapter II – Licensing of driver of motor vehicles (Sections 3-21)
Chapter IIA - Licensing of conductors of state carriage (Sections 21A-21J)
Chapter III – Registration of motor vehicles (Sections22-41)
Chapter IV – Control of transport vehicles (Sections 42-68)
Chapter IVA – Special provisions relating to state transport undertaking
(Sections 68A-68J )
Chapter V – Construction, equipment and maintenance of motor vehicles
(Sections 69-70)
Chapter VI- Control of traffic (Sections 71-91)
Chapter VII - Motor Vehicles temporarily leaving or visiting India (Section 92)
Chapter VIII – Insurance of motor vehicle against third party Risk (Section 93-
111A)
Chapter IX – Offences, penalties and procedure (Section 112-132)
Chapter X – Miscellaneous (Section 132A-135)
The Schedules are as follows:
First Schedule - Forms
Second Schedule I – Diseases and disabilities absolutely disqualifying a
person for obtaining a license to drive a motor vehicle
II – Diseases and disabilities absolutely disqualifying a person
For obtaining a license to drive Public vehicles.
Third Schedule - Test of competence to drive
Fourth schedule - Authorities entitled to grant Licenses to drive and to
register the motor vehicles, the temporary or time
being under the exclusive control of the central
Government and Registration makes for such vehicles.
Fifth Schedule - Offences on connection of an endorsement shall be
Made on the licence of the person affected
Sixth Schedule - Registration marks
Seventh Schedule - (omitted)

Chapter 9 Legal Aspects of Motor Vehicle 49
Eighth Schedule - Limits of speed for motor vehicles
Ninth Schedule - Traffic signs
Tenth Schedule - Driving Regulations
Eleventh Schedule - Signals
Twelfth Schedule - Repeat of certain enactments
Traffic Signals :
Signals:
1. When about to turn to the Right or to drive to the Right hand side of the
road in order to pas another vehicle or for any other purpose, a driver shall
extend his right arm in a horizontal position outside of and to the right of his
vehicle with the palm of the hand turned to the front.
2. When about to turn to the left of to drive the left hand side of the road, a
driver shall extend his right arm and rotate in an anti-clockwise direction.
3. When about to slow down, a driver shall extend his Right arm with the
palm downwards and to the right of the vehicle and shall move the arm so
extended up and down several times in such a manner that the signal can
be seen by the driver of any vehicle which may be behind him.
4. When about to stop, a driver shall rise his right Forearm vertically outside
and to the right of the vehicle, palm to the front.
5. When a driver wishes to indicate to the driver of a vehicle behind him that
he desires that driver to overtake him, he shall extend his right arm and hand
horizontally outside of and to the right of the vehicle and small swing arm
backwards and forwards in a semi- circular motion.
Registration Requirements : According to Chapter III section 22 to 28 the
following are the registration requirements
Section 22: Necessity for Registration:
No person shall drive any motor vehicle and no owner of a motor
vehicle shall cause or permit the vehicle to drive in any public place or in any
other place for the purpose of carrying passengers or goods unless the
vehicle is registered in accordance with this chapter and certificate of
registration of the vehicle has not been suspended or cancelled and vehicle
carries a registration mark displayed in the prescribed manner.

How to make Registration? What are the Requirements : Chapter III section
24.
1. An application by or on behalf of the owner of a motor vehicle for
registration shall be in Form E as set forth in the first schedule, shall contain the
information require by the Form, and shall be accompanied by the
prescribed fee.
Provided that where a motor vehicle is jointly owned by more persons
than one, the application shall be made by one of them behalf of all the
owners and such applicant shall be deemed to be the owner of the motor
vehicle for the purposes of this Act.
2. The Registration authority shall issue to the owner of a motor vehicle
registered by it a certificate of registration in Form-‘G’ as set forth in the First
Schedule and shall enter in a record to be kept by particulars of such
certificate.
3. The registration authority shall assign to the vehicle, for display there on in
the prescribe manner, a distinguishing mark (in the Act referred to as the
registration mark)
consisting of one of the groups or letters allotted to the state by the sixth
schedule followed by a number containing not more than four figures
Necessity of Permits for Commercial Vehicles: According to Chapter IV
section 42
1. No owner of transport vehicle shall use or permit the use of the vehicle in
any public place, ( whether or not such vehicle is actually carrying any
passenger or goods) save in accordance with the conditions of a permit
granted or countersigned by Regional or State Transport Authority or the
commission authorizing the use of the vehicle in the place in the manner in
which the vehicle is being used.
Provided that a stage carriage permit shall subject to any conditions that
may be specified in the permit, authorize the use of the vehicle as a contract
carriage.
Provided further that stage carriage permit may subject to any conditions
that may be specified in the permit, authorize the use of the vehicle as a
goods vehicle either when carrying passengers or not

Provided further that a public carrier’s permit shall subject to any conditions
that may be specified in the permit authorize the holder to use the vehicle for
the carriage of goods for or in connection with a trade or business carried on
by him.
2. In determining for the purpose of chapter IV whether the transport vehicle
is or is not used for the carriage of goods for hire or reward.
a. The delivery or collection by or on behalf of the owner of the goods sold,
used or let on hire or hire purchase in the course of any trade or business
carried on by him other than the trade of business of providing transport.
b. The delivery or collection by or on behalf of owner if the goods which have
been or which are to be subjected to a process or treatment in the course of
trade or business carried on by him.
c. The carriage of goods in a transport vehicle by a manufacture of or agent
or order in such goods while the vehicle is being used for demonstration
purpose, shall not be deemed to carrying of the goods for hire or reward, but
the carriage in a transport vehicle of goods by a person not being a dealer in
such goods who has acquired temporary ownership of goods for the purpose
of transporting them to another place and their relinquishing ownership shall
be deemed to constitute a carrying of goods for hire or reward.
INSURANCE COVERAGE: Chapter VIII section 93 and 94
a. Authorized insurance means an insurance in whose case the requirements
of the insurance Act, 1938(IV of 1938), the complied with;
b. “Certificate of Insurance” means a certificate issued by the authorized
insurer in persuade of sub – section(4) of section 95 and includes a cover note
complying with such requirement as may be prescribed, and where more
than one certificate has been issued in connection with a policy, or where a
copy, as the case may be;
c. Property includes roads, bridges, culverts, causeways, trees, pots and
milestones.
d. “ Reciprocating country” means any such country as may be on the basis
of reciprocity be notified by the central government in the official Gazette to
be a reciprocating country for the purpose of this chapter
e. “Third Party” includes the government.

Necessary for insurance against third party risk:
1. Not person shall use except as a passenger or cause or allow any other
person to use a motor vehicle in public place, unless there is in force in
relation to the use of vehicle by the person or that other person as the case
may, be a policy of insurance complying with the requirement of this
chapter.
Explanation: A Person driving motor vehicle merely as a paid employee,
which there is in force in relation to the use of the vehicle no such policy as is
required by this sub section, shall not be deemed to act in contravention of
the sub section unless he knows or has reason to believe that there is no such
policy in force.
2. sub section (1) shall not apply to any vehicle owned by the
central government of a state government and use for
Government purpose un connected with any commercial
enterprises.
3. The appropriate Government may be order exempt from the
operation of subs section (1)
any vehicle owned by any of the following authorities namely.
(a) the Central Government or a State Government if the
vehicle is use for Government purpose connected with any
commercial enterprise.
(b) any local authority
(c) any state Transport undertaking within the meaning of
section 68 – A
Provided that no such order shall be made in relation to any such authority
unless a found have been established and is maintained by the authority in
accordance with rules made in that behalf under this act for meeting any
liability arising out of the use of any vehicle of that authority which that
authority of any person in its employment may incur to third parties.
Explanation For the purpose of sub-section appropriate Government means
the central Government or the State Government as the case may be and
(1) In relation to any corporation or company owned by the Central
Government means that Central
Government or that State Government.

(ii) In relation to any corporation of company owned by the Central
Government an one or more State Government means the Central
Government
(iii) In relation to any other State Transport undertaking or any local
authority means the Government which has control over the under
taking or authority.
PROCEDURE FOR OBTAINING DRIVING LICENCE:
According to Chapter II Section 3 to 9
Section 3: Necessity of driving License: No Person shall drive a motor
vehicle in any public
Place unless he holds an effective driving License issued to
himself authorizing him to drive the vehicle .
Section 4: No person under the age or eighteen years shall drive a motor
vehicle in any public place.
Section 5 No owner or person in charge of a motor vehicle shall cause or
permit any person who
Does not satisfy the prohibition of Section 3 or Section 4 to drive
the Vehicles
Section 6 No holder of driving license shall permit it to be used by any other
person.
Section 7 Grant of Driving License
(i) Any person who is not disqualified under section 4 for driving
a motor vehicle and who is not for the time being disqualified for holding or
obtaining a driving License may apply to licensing authority have jurisdiction
in the area.
(ii) In which be ordinarily resides or caries on business
(iii) In which the school or establishment where he is reaching
or has received instruction in a driving a motor vehicle is
situated or
(iv) It the application is for a driving license to drive a paid
employee in which the employer resides or caries on
business for the issue to him a driving license.
2. Every application under sub section (1) shall be in a Form ‘A’ a set forth
in the First Schedule. Shall be signed by or bear the thumb impression of

the applicant in tow places, and shall contain the information required
by the Form.
3 When the application is for a driving license to drive a paid employee
or to drive a transport vehicle, or where in any other case the licensing
authority for reason to be stopped in writing so requires certificate in
Form ‘C’ as set forth in the First Schedule signed by a registered
medical Practitioner.
4 Every application for a driving license to drive a paid employee and
every application for a driving license to drive a transport vehicle shall
be accompanied by there clear copies of recent photograph of the
applicant.
5 If, form the application or from the medical certificate referred to in sub
section 3, it appears that the applicant is suffering from any disease or
disability specified in the second Schedule or any other disease or
disability which is likely to cause the driving by him of a motor vehicle of
the class which he would be authorized by the driving license applied
for to drive to be source of danger to the public or passengers the
licensing authority shall refuse to issue the driving license.
6 N driving license shall be issued to any applicant unless he passes to the
satisfaction of the
Licensing authority the test of competence to drive specified in Third
schedule.
7 The test of competence to drive shall be carried out in a vehicle of the
type to which the application returns, and for the purposes of part I of
the test.
(a) A Person who posses the driving test in driving heavy motor
vehicle shall be deemed
Also to have passed the test in driving any medium motor
vehicles or light motor vehicles.
(b) A Person who passes the test in driving a medium motor vehicle
shall be deemed also to
have passed the test in driving any light motor vehicles.
8 When application has been duty made to the appropriate licensing
authority and the applicant has
satisfied such authority of his physical fit ness and of his competence to
drive and has paid
to the authority such fee as the central Government may by rules
made under this Act. Specific the licensing authority shall grant the
applicant a driving is disqualified under section 4 for driving a motor
vehicle or is for the time being disqualified for holding or obtaining a
driving license.

Long answer Question
1. What are the different traffic signals and signals?
2. What are the requirements for registration?
3. What are the necessity permits for commercial Vehicles ?
4. Explain about insurance coverage for a License?
5. What are the procedure for obtaining driving License?

AUTOMONBILE CHASSIS & BODY ENGINEERING

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