A PROJECT REPORT

ON

SERVICE OF A CAR
( WHEEL ALIGNMENT AND TIRE
CHANGING) CHEVROLET WORKSHOP
UNDER IPS SCHEME
Submitted in fulfillment for the award of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted By

MD RAZAULLAH (20120194)
Under the Supervision of

Mr. Ashish Kumar(Ass. Professor, MU)

DEPARTMENT OF MECHANICAL ENGINEERING

INSTITUTE OF ENGINEERING AND TECHNOLOGY
MANGALAYATAN UNIVERSITY
BESWAN, ALIGARH 202145
YEAR: 2015-16

A PROJECT REPORT

ON

SERVICE OF A CAR
( WHEEL ALIGNMENT AND TIRE
CHANGING) CHEVROLET WORKSHOP
UNDER IPS SCHEME
Submitted in fulfilment for the award of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

Under Supervision
Mr. Ashish Kumar

Head of Department

Submitted By

Dr. AnkurSagar

(Ass. Professor)

MD RAZAULLAH
(20120194)

DEPARTMENT OF MECHANICAL ENGINEERING

INSTITUTE OF ENGINEERING AND TECHNOLOGY
MANGALAYATAN UNIVERSITY
BESWAN, ALIGARH 202145

INDUSTRIAL TRAINING REPORT

BACHELOR OF TECHNOLOGY

Mechanical Engineering

SUBMITTED BY

MD RAZAULLAH (20120194)

MAY, 2016

Department of Mechanical Engineering

INSTITUTE OF ENGINEERING & TECHNOLOGY,
MANGALAYATAN UNIVERSITY,
BESWAN, ALIGARH, U.P.

INDEX

Page no.

1. Introduction to CHEVROLET

2. Service of A Car

3. Machines used for service

4. Tools Used for service

5. Conclusion

10

6. References

11

1. INTRODUCTION
Chevrolet colloquially referred to as Chevy and formally the Chevrolet Division of General
Motors Company, is an American automobile division of the American manufacturer General
Motors (GM). Louis Chevrolet and ousted General Motors founder William C. Durant started

the company on November 3, 1911 as the Chevrolet Motor Car Company. Durant used the
Chevrolet Motor Car Company to acquire a controlling stake in General Motors with a reverse
merger occurring on May 2, 1918 and propelled himself back to the GM presidency. After
Durant's second ouster in 1919, Alfred Sloan, with his maxim "a car for every purse and
purpose," would pick the Chevrolet brand to become the volume leader in the General Motors
family, selling mainstream vehicles to compete with Henry Ford's Model T in 1919 and
overtaking the Model T as the best-selling car in the United States by 1929.
1.1 HISTORY

Fig 1.1(a):- First logo of the company (1911).

On November 3, 1911, Swiss race car driver and automotive engineer Louis Chevrolet cofounded the Chevrolet Motor Company in Detroit with William C. Durant and investment
partners William Little (maker of the Little automobile) and Dr. Edwin R. Campbell (son-in-law
of Durant) and in 1912 R. S. McLaughlin CEO of General Motors in Canada.
Durant was cast out from the management of General Motors in 1910 for five years. He took
over the Flint Wagon Works, incorporating the Mason and Little companies. As head of Buick
Motor Company prior to founding GM, Durant had hired Louis Chevrolet to drive Buicks in
promotional races. Durant planned to use Chevrolet's reputation as a racer as the foundation for
his new automobile company. Actual design work for the first Chevy, the costly Series C Classic
Six, was drawn up by Etienne Planche, following instructions from Louis. The first C prototype
was ready months before Chevrolet was actually incorporated. However the first actual
production wasn't until the 1913 model. So in essence there were no 1911 or 1912 production
models, only the 1 pre-production model was made and fine-tuned throughout the early part of
1912. Then in the fall of that year the new 1913 model was introduced at the New York auto
show.

Fig 1.1(b):- Current logo of CHEVROLET

1
2. SERVICE OF A CAR
A motor vehicle service is a series of maintenance procedures carried out at a set time interval
or after the vehicle has travelled a certain distance. The service intervals are specified by the

vehicle manufacturer in a service schedule and some modern cars display the due date for the
next service electronically on the instrument panel.
The completed services are usually recorded in a service book which is rubber stamped by the
service centre upon completion of each service. A complete service history usually adds to the
resale value of a vehicle.
Maintenance tasks commonly carried out during a motor vehicle service include:

Change the engine oil

Replace the oil filter

Replace the air filter

Replace the fuel filter

Replace the spark plugs

Tune the engine

Check level and refill brake fluid

Check level and refill power steering fluid

Check level and refill Automatic Transmission Fluid

Grease and lubricate components

Inspect and replace the timing belt if needed

Check condition of the tires

Mechanical parts that may cause the car to cease transmission or prove unsafe for the road are
also noted and advised upon.
3. MACHINES USED FOR SERVICE A CAR
Generally there are two machines which are used for service a car. These are following
i. Tire Changer Machine
ii. Wheel Alignment Machine
3.1 TIRE CHANGER MACHINE
A tire changer is a machine used to help tire technicians dismount and mount tires with
automobile wheels. After the wheel and tire assembly are removed from the automobile, the tire
changer has all the components necessary to remove and replace the tire from the wheel.

Different tire changers allow technicians to replace tires on automobiles, motorcycles and
heavy-duty trucks.
2

3.1.1 COMPONENTS OF WHEEL CHANGER MACHINE

Foot pedals

Fig 3.1.1(a):- Foot pedals on a tire changer

The tire changer has two foot pedals. The left pedal is called the clamp control pedal, a three
position pedal that opens and closes the rim clamps. Once pressed, pneumatic pistons move the
4 rim clamps together or apart simultaneously. The right pedal is the table top pedal, which is a
three position pedal that controls the rotation of the table top. When the table top pedal is
pressed down, the table top spins clockwise. The table top spins counter clockwise when the
pedal is raised.
Mount/demount mechanism

Fig 3.1.1(b):- Mount/Demount mechanism

The mount/demount mechanism consists of the duckhead, swing arm, and vertical slide. The
duckhead is at the bottom end of the vertical slide. The duckhead is uniquely shaped, like a
tapered bill, to fit next and surround the rim of a wheel. It can either be made of metal or plastic.
The duckhead mounts and demounts the tire from the wheel. The swing arm moves left and
right. The purpose of the swing arm is to move the duck head near or away from the rim. The
last component of the mount/demount mechanism is the vertical slide. The vertical slide moves
up and down so that the duck head can fit onto the rims of different size wheel widths. The

vertical slide has a spring and locking handle above the swing arm to set the duckhead and
maintain a stable position around the rim.

3
Air pressure system

Fig 3.1.1(c):- Valve system including air inflation gauge, air hose, and air pressure
bleed valve
The air pressure system on a tire changer provides the air to inflate tires mounted on wheels. The
air pressure system consists of 4 components: air hose, air inflation gauge, inflation pedal and
manual pressure bleed valve. The air hose is located near the top of the tire changer, and it allows
compressed air to travel into the tire. A specialized end is used on the air hose to clamp firmly
onto valve stems of the wheels. The air inflation gauge displays the air pressure within the tire
when the air hose is connected to the valve stem. The air inflation gauge displays the pressure in
pounds per square inch (psi). Directly below the air hose on the side of the tire changer is the
inflation pedal that enables the inflation of the tire.When the inflation pedal is raised, a burst of
air is released from valves next to each rim clamp toward the bottom bead of the tire to help with
inflation. The manual bleed valve is located next to the air hose and air inflation gauge. The
manual bleed valve allows the manual release of air pressure from tire.
Table top and rim clamps

Fig 3.1.1(d):- Table top with the rim clamps on each end
The table top and rim clamps hold and rotate the wheel to mount or dismount a tire. The table top
is directly above the foot pedals and below the mount/demount mechanism.
4
The table top is able to rotate clockwise and counter clockwise. The table top is shaped as the
letter "X", but it can be a circle in different tire changer models. On each end of the table top,
there are pneumaticpowered rim clamps. These rim clamps move in unison to secure wheels
onto the table top. Each rim clamp can be adjusted closer or further away from the center of the
table top to accommodate smaller or larger wheels.
Bead loosening system

Fig 3.1.1(e):- The bead loosener on the right side of a tire changer
The bead loosening system releases the tire bead from the rim of the wheel. The bead loosening
system consists of an arm near the bottom right side of the tire changer. There is a shovel shaped
metal piece at the end of the arm called the bead loosener shoe. The bead loosener shoe pivots
and is rounded to accommodate the shape of a wheel. On top of the arm, there is a handle with a
button on top to engage the bead loosening system. Across from the shovel shaped metal piece,
there are rubber squares to protect the wheel from scratches during the loosening procedure
Tire installation

Fig 3.1.1(f):- Tire installation

5

The following list provides an explanation of an operator installing a tire onto a wheel using a
tire changer.

3.2

The operator centers the wheel and securely fastens it onto the table top with the
rim clamp mechanism with the narrow bead-ledge up of the wheel.
The operator pushes the bottom bead first in the well of the wheel.

The operator pushes the top bead down into the center well of the wheel under the
duckhead and rotates the table top using the table top pedal.

The operator installs a valve core.

The operator slowly inflates the tire until the beads "pop" on the bead ledge of the
wheel.

The operator releases the rim clamps and inflates the tire to manufacturer
specifications.

WHEEL ALIGNMENT MACHINE

Fig 3.2(a):- wheel alignment machine

It is a machine by which we can find out the problems related to wheel alignment. Wheel
alignment is important to the health of your car or truck. If you hit a massive pothole, you might
bump your suspension out of the carefully calculated locations that the components have been
set. All of the elements that make your car go straight are called "alignment." Some shops try to
make it seem like rocket science, but wheel alignment is a fairly straightforward affair. The
inclusive term "wheel alignment" involves three main measurements -- caster, camber, and toe.

Fig 3.2(b) :- Clamper mount on tire

3.2.1

CAMBER

Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle.
When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward
at the top, the camber is negative (-).

Fig 3.2.1(a):- Camber

3.2.2 CASTER
Caster is the tilting of the uppermost point of the steering axis either forward or backward (when
viewed from the side of the vehicle). A backward tilt is positive (+) and a forward tilt is negative
(-).

Fig 3.2.2(a):- Caster

3.2.3 TOE

Toe is a measurement of how much the front and/or rear wheels are turned in or out from a
straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are
turned out, toe is negative (-).

Fig 3.2.3(a):- Toe

3.2.4 HOW TO ALIGN A WHEEL

TOE: - by adjusting tie rod of steering system.

CAMBER:- by adjusting front shockers

CASTER:- fixed

But in case of TAVERA camber can be manage by adjusting HIGH TENSION ROD.

Fig 3.2.4(a) :- Arrangement of steering system and wheel assembly

4. TOOLS USED FOR SERVICE

Monkey plier
Nose plier

Filler gauge

Special tool kit

Center punch

Screw driver

Adjustable spanners

Hammer

Mallet

Ring

Socket and accessories

Nylon hammer

Universal

Vices and clamps

Wrenches

Files

9
5. Conclusion

I have completed wheel alignment and changing of tires of a car successfully with the help of wheel
alignment machine, tire changer and tools.

10
7. Reference

o www.chevorlet.com
o http://www.merriam-webster.com/dictionary/wheel%20alignment
o Vehicle Dynamics By Milliken and Milliken
o http://www.bendpak.com/wheel-service/tire-changers/

11