Professional Documents
Culture Documents
Thorold May
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
Thorold MAY
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
English for Mechanics will ideally be used by a skilled language teacher who
also has a good mechanical understanding and can bring the content to life.
The material is intended to be presented orally at first, without students seeing
the text (although they may look at the labeled diagrams). Each topic is
presented in a paragraph of seven to ten sentences. When the topic has been
presented, explained and discussed, a series of oral questions can be asked.
The teacher may choose to ask some questions, especially when a
grammatical point is being made and exact responses are important. A better
system for much of the time is to have students question each other in pairs.
One member of the pair stands, and when he doesn’t know an answer, must
seek it from a copy of the text pinned to the wall some distance away. The
method is explained in detail below in the section entitles “Five Steps to
Learning a Text.”
English for Mechanics deliberately uses short texts to make learning effective
and easy. An appendix briefly explains why short texts are so useful as a
learning and teaching tool. Teachers can use the principles involved to shape
their own curriculum material.
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
TABLE OF CONTENTS
ENGLISH FOR MECHANICS .......................................................................... 1
English for Mechanics .............................................................................. 2
Introduction .................................................................................................. 3
TABLE OF CONTENTS .................................................................................. 4
CHAPTER 1 Tools and Materials .................................................................... 8
1.1 Equipment: shape, strength, complexity, design, function ..................... 8
1.2 Tools (1) ................................................................................................ 9
1.3 Jacks and Hoists ................................................................................. 10
CHAPTER 2 Welding .................................................................................... 11
2.1 Welding Safety (1) ............................................................................... 11
2.2 Welding Safety (2) ............................................................................... 12
2.3 Oxy Welding Components ................................................................... 13
2.4 Oxy Welding: Torch Adjustments ........................................................ 14
2.5 Welding Flames ................................................................................... 15
2.6 Gas welding processes ....................................................................... 16
2.7 Arc Welding Procedures ...................................................................... 17
CHAPTER 3 Friction Control & Seals ........................................................... 18
3.1 Friction ................................................................................................. 18
3.2 Lubrication ........................................................................................... 19
3.3 Plain Bearings ..................................................................................... 20
3.4 Anti-Friction Bearings .......................................................................... 21
3.5 Seals (1): Application; O-rings & Lip Seals .......................................... 23
3.6 Seals (2): Felt Seals, Wick Seals, Slings, Scrolls ................................ 24
3.7 Gaskets ............................................................................................... 25
3.8 Adhesives and Sealants ...................................................................... 26
CHAPTER 4 Fluid Systems .......................................................................... 27
4.1 Radiator Check .................................................................................... 27
4.2 Brakes ................................................................................................. 28
4.3 Anti-Lock Braking Systems (ABS) ....................................................... 29
4.4 Hydraulics (1): Overview & Pascal's Law ............................................ 30
4.5 Hydraulics (2): Brakes ......................................................................... 31
4.6 Hydraulics (3): displacement ............................................................... 33
4.7 Pneumatics (1) .................................................................................... 34
4.8 Pneumatics (2): Vacuums & compressed air ....................................... 35
4.9 The Air Conditioning Cycle .................................................................. 36
4.10 Refrigerant gases .............................................................................. 37
4.11 Heat transfer ...................................................................................... 38
CHAPTER 5 Vehicle Body Construction & Paint ......................................... 39
5.1 Vehicle Specifications .......................................................................... 39
5.2 The Car Body ...................................................................................... 40
5.3 The Instrument Panel .......................................................................... 41
5.4 Automotive paintwork (1) ..................................................................... 42
5.5 Automotive paintwork (2): From bare metal ......................................... 43
5.6 Automotive paintwork (3): Colour coats ............................................... 44
CHAPTER 6 Underbody & Suspension ....................................................... 45
6.1 Tyres ................................................................................................... 45
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
~~~
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
[1] Many familiar mechanical tools are quite robust. [2] They are normally
made to withstand harsh treatment over many years. [3] An alloy such as
chrome-vanadium steel in spanners is both hard and highly tensile. [4] Hand
tools must be adapted to the strengths and limitations of the human body. [5]
This human need is matched against the need to gain access, leverage,
accurate alignment or cutting power on a piece of material or equipment. [6] A
hammer handle is long and light (in order) to give centrifugal power, but the
head is heavy and tough to maximize impact. [7] A screwdriver shaft is long
(in order) to access awkward spots, but has tensile strength to withstand
torque. [8] Ratchet mechanisms help human joints which are only able to twist
through a few degrees. [9] Some mechanisms, like micrometers, register very
small variations, and are therefore delicate, being easily knocked out of
adjustment. [10] The development of modern mechanics is a story of
increasing precision and complexity. [11] Fuel injectors, electronic control
units and sensors now require highly trained technicians using sophisticated
tools.
response:
1. Make a list of tools, from the very robust to the easily broken or easily
knocked out of adjustment.
2. What sort of materials can withstand harsh treatment?
3. Compare the properties of chrome-vanadium steel, copper and wood.
4. What is one very important human thing to consider in designing hand
tools?
5. What are some non-human criteria that hand tools design has to satisfy?
6. Describe how the design of a hammer handle helps the head to be
effective.
7. Make a question using these words: why / screwdriver shaft.
8. Make a sentence using these words: human joints / able / twist
9. Think of some general ways in which the design of mechanical things has
changed in your lifetime.
10. Compare a tool that your father might have used and a tool which has
been developed in the last ten or so years.
[1] robust; [2] harsh; [3] tensile; [4] ergonomic; [5] leverage; [6] centrifugal
power; [7] torque; [8] ratchet; [9] delicate; [10] precision; [11] sophisticated.
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] If you have a job to do on your car, buy the tool you need, don't borrow it.
[2] Soon you will start to accumulate a useful collection. [3] If you use a tool
once a year, a cheap version is probably OK. [4] If the tool earns your living,
buy good quality. [5] Quality will save you money in the end. [6] Shifting
spanners are sudden death to tight nuts. [7] A rounded nut is no good to
anyone. [8] A wrong sized spanner is nothing but trouble, but some Imperial to
Metric substitutions work, more or less. [9] You can try the following: 11 mm to
7/16", 13mm to 1/2", 14mm to 9/16", 16mm to 5/8", 17mm to 11/16", 19mm to
3/4", 21mm to 13/16" (spark plug size), 22mm to 7/8". [10] You will probably
need 12mm spanners more than any other size, so you should buy several
different kinds. [11] 10mm, 12mm and 14mm seem to be the commonest bolt
sizes.
response:
keywords:
[1] buy; [2] collection; [3] cheap; [4] quality; [5] save; [6] shifting spanner; [7]
rounded; [8] substitutions; [9] 11mm; [10] 12mm; [11] bolt sizes
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] To "jack up" literally means to lift from below, while to "hoist" means to lift
from above.[2] In practice, vehicle jacks are portable lifting devices while
hoists are much larger, fixed pieces of lifting machinery. [3] The small
mechanical jacks in car boots may be of scissor or telescopic design, and are
only meant for changing flat tyres. [4] Garage wheel jacks are usually
hydraulic, and will lift most standard vehicles. [5] Any jacked vehicle should be
supported by safety stands before working under it. [6] Every year people are
killed when small jacks tip over or cars fall off piles of bricks. [7] Jacks and
hoists have to be placed carefully under lifting points that are not weak, rusty
or unstable. [8] With jacks and four-post hoists, the wheels also have to be
chocked.[9] Since a two post hoist lifts the whole vehicle, the vehicle must be
placed centrally so that it is balanced. [10] Check to see if the hoist has an
automatic safety lock, or whether it must be locked manually.
response:
keywords:
[1] jack up; [2] portable; [3] tyres; [4] wheel jacks; [5] stands; [6] killed; [7]
lifting points; [8] chocked; [9] balanced; [10] safety lock.
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
CHAPTER 2 Welding
2.1 Welding Safety (1)
pattern: Imperatives; never do X; do not do Y; use/keep/ leave Y
text:
response:
key words
[1] accidents; [2] for granted; [3] rules; [4] trolley; [5] empty; [6] protect; [7] arc;
[8] leads; [9] oil; [10] key.
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Here are some more rules on welding safety. [2] Always leak-test
cylinders, regulators, gauges, hoses and the oxy-acetylene hand piece. [3]
Light the blowpipe with a spark lighter, never a cigarette lighter or matches. [4]
Always check that the surrounding area is safe by removing anything which
can burn. [5] Keep the right kind of fire extinguisher within reach. [6] Wear the
right safety equipment for the job. [7] Tinted goggles are needed for gas
welding and a mask for arc welding. [8] Full length gloves, a leather apron and
spats are the best protection. [9] Do not wear trousers with cuffs, or any good
garment that can be damaged by hot sparks. [10] Make a safety check a part
of your everyday welding routine.
response:
keywords:
[1] rules; [2] leak-test; [3] spark lighter; [4] surroundings; [5] extinguisher; [6]
wear; [7] goggles; [8] gloves; [9] cuffs; [10] routine.
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
response:
keywords:
[1] components; [2] black; [3] pressure; [4] red; [5] 1500kpa; [6] regulators; [7]
oxygen gauge; [8] pair; [9] shows.
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
[1] Gas pressure must be adjusted according to the welding tip size. [2] The
smallest tip, size 8, requires oxygen at 50 kpa, and acetylene at 50 kpa. [3]
The largest tip, size 40, requires oxygen at 200 kpa and acetylene at 100 kpa.
[4] To start the torch, open the acetylene valve less than a 3/4 turn, then light
it. [5] Adjust the flame to burn a little away from the torch with no soot. [6]
Begin to open the oxygen tap very slowly, until the orange flame breaks into
two cones. [7] The inner cone nearest the tip will be white and ragged. [8] The
outer cone will be blue and feathery. [9] You will have 50/50 oxygen and
acetylene when the inner cone is clearly marked. [10] This is called a neutral
flame.
response:
1. What decides the gas pressure you must use in oxy-acetylene welding?
2. What is the correct oxygen and acetylene pressure with a size eight tip?
3. Make a question using these words: What / correct pressure / size 40 tip
4. Which gas tap do you open first to light the torch?
5. Finish this sentence: Adjust the acetylene flame to burn ...
6. Explain how you must open the oxygen tap.
7. What does the inner flame cone look like?
8. What does the outer flame cone look like?
9. What is the gas mixture in a neutral flame?
keywords:
[1] adjusted; [2] size 8; [3] size 40; [4] start; [5] soot; [6] oxygen tap; [7] inner
cone; [8] outer cone; [9] 50/50; [10] neutral.
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] A neutral flame of 50% acetylene, 50% oxygen, welds steel cleanly. [2] A
neutral flame does not transfer carbon into or out of the metal. [3] Most
welding of soft steel is done with a neutral flame. [4] Metal to be cut is heated
to cherry red with a neutral flame, then burnt with high pressure oxygen. [5]
An oxidizing flame, with excess oxygen but low pressure, is used for braze
welding. [6] The flame is cooler than a neutral flame, and the inner cone has a
purple colour. [7] A carburising flame has excess acetylene, and transfers
carbon into the metal. [8] It is used for hard-facing steel and welding
aluminum. [9] The carburising flame is hotter than a neutral flame. [10] It
shows a short white inner cone in a blue envelope which becomes darker on
the outside.
response:
keywords:
[1] neutral; [2] carbon; [3] gas pressure; [4] cutting; [5] oxidizing; [6] purple; [7]
carburizing; [8] hard-facing; [9] hotter; [10] white
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
response:
keywords:
[1] different types; [2] braze welding; [3] parent metal; [4] thin sheets; [5] thin
sheets; [6] small tips; [7] cut; [8] cutting nozzle; [9] fusion welding; [10] filler
rod
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] An electric arc can fusion weld at up to 5000°C. [2] Flux on the welding rod
creates a gas shield (in order) to reduce oxidization and also creates
protective slag. [3] Select the right electrode (welding rod) and amperage for
the job. [4] Strike an arc, then shorten the arc to about 3mm. [5] Tack weld the
two ends of the metal pieces to be joined [6] Tilt the electrode to about 75° in
the direction of the weld path. [7] Move the electrode slowly along the weld
path, keeping a molten pool of metal at a constant width. [8] Break the arc at
the end of the bead run with a quick twisting motion. [9] Allow the weld to cool,
chip off slag, and clean the join with a wire brush.
response:
keywords:
[1] electric arc; [2] flux; [3] right electrode; [4] strike; [5] tack weld; [6] tilt; [7]
move; [8] break; [9] clean
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
response:
+ Uses of friction: brake pads; road wheel; steering wheel; driver's seat; fan
belt.
% Friction not wanted: mechanical bearings; piston cylinders; pumps; vehicle
body wind resistance
keywords:
[1]resistance; [2] affected; [3] roughness; kinds [4] different; [5] rolling; [6]
pressure; [7] coefficient; [8] COF; [9] lubrication; [10] heat
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
3.2 Lubrication
pattern: precise definition; passive voice; diagram construction
text:
[1] Two metal surfaces rubbing together cause both resistance to movement
and heat. [2] This effect is called friction. [3] Friction can be greatly reduced by
placing a thin film of oil between moving surfaces. [4] This is called lubrication.
[5] An engine has many moving parts. [6] It would quickly overheat and seize
up without lubrication. [7] The lubrication system of an engine consists of a
storage sump, many oil channels, a pump, an oil filter, a pressure sensor,
and, of course, oil. [8] Multigrade oil is able to act as a lubricant under a wide
range of temperature and pressure conditions. [9] Some components like the
gearbox and differential run in a permanent oil bath. [10] Grease is less
viscous than oil, and is useful for applications like wheel bearings.
response:
keywords:
[1] rubbing; [2] friction; [3] oil; [4] lubrication; [5] moving; [6] overheat; [7]
system; [8] multigrade; [9] oil bath; [10] viscous.
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] A plain or solid bearing has no moving parts. [2] Rather, it uses a softer
metal than the rotating shaft. [3] Two common alloys used in plain bearings
are babbit and bronze. [4] Babbit is an alloy of lead and tin, while bronze is an
alloy of copper and tin. [5] Plain bearings are usually strengthened by a solid
steel backing. [6] Some plain bearings, such as piston-pin bushes, are made
in one piece. [7] Other plain bearings, such as crankshaft main bearings, are
split into two shells. [8] Some solid bearings with flanges can support both
radial and thrust loads. [9] It is important to lubricate most solid bearings
constantly with oil or grease. [10] Solid nylon bearings in some small
machines do not need to be lubricated.
response:
1. Put the following words into a sentence: moving / plain / parts / bearing
2. What are the two most common alloys found in plain bearings?
3. Which of these metals combine to produce what alloys: copper / tin / lead ?
4. Put sentence 5] into the active voice.
5. Why is it necessary to back many solid bearings with a steel shell?
6. Give an example of a) a single piece solid bearing and b) a two section
solid bearing.
7. How can a solid bearing be made to support a thrust load as well as a
radial load?
8. What is a type of solid bearing which does not need lubrication?
9. Find sentences in the text with patterns shown in the PATTERN note (in the
heading). Make some other sentences like these.
keywords:
[1] no moving; [2] softer; [3] alloy; [4] babbit; [5] backing; [6] one piece; [7]
shells; [8] flanges; [9] lubricate; [10] nylon
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Anti-friction bearings reduce friction by letting hardened steel balls rotate
within a cage. [2] There are four main parts to anti-friction bearings. [3] They
include the cone, or inner race, and the cup, or outer race. [4] Balls or rollers
revolve between the cone and the cap. [5] A cage keeps the balls between
the cup and the cone. [6] There are six main types of anti-friction bearings. [7]
They are the annular ball bearing, the ball-thrust bearing, the cup & cone ball
bearing, the straight roller bearing, the tapered roller bearing and the needle
roller bearing. [8] When the load is both radial and thrust, two separate kinds
of bearing may be used together. [9] However, it is usually more economical
to use a tapered rolling bearing to take the load in two directions. [10] Most
road wheel axle bearings are tapered roller bearings.
response:
[1] reduce; [2] parts; [3] include; [4] revolve; [5] cage; [6] types; [7] annular; [8]
together; [9] economical; [10] axle
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
Addendum
Annular ball bearings: These have balls rotating in a groove. They are used
for completely radial loads, such as alternator shafts.
Ball thrust bearings: used for loads thrusting completely parallel to the shaft.
The clutch release bearing is an example.
Cup and cone ball bearings: The groove is replaced by a deeper gutter,
buttressed on one side. This means that the balls can carry a radial load, plus
some thrust load in one direction (only). Examples might be found in
transmissions and steering boxes, rear axles etc.
Straight roller bearings: Roller bearings can carry heavier loads than ball
bearings. Straight roller bearings are used to carry very heavy axial loads with
no horizontal thrust. Examples are found on transmission main shafts and
cluster gear shafts.
Tapered roller bearings: Both the rollers and the housings in these bearings
taper. This means that they can accept both axial and radial forces. Tapered
roller bearings are typically used in opposing pairs. They are found in wheel
hubs, crown wheel & pinions, transmission mainshafts and cluster gear shafts.
Needle roller bearings: These are identical to straight roller bearings except
for the very small roller diameters. The rollers are inserted directly between a
hardened shaft and the internal bores of gears etc. They may be held by a
nylon cage. Examples are found in constant mesh gears, and transmission
mainshaft.
Answers to questions 9] and 10]
One tapered roller bearing is more economical of weight, space and cost than
a radial bearing plus a thrust bearing, but cannot carry the same total load.
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Seals, gaskets and sealants contain vehicle operating fluids within their
circuits. [2] Operating fluids have different properties and include coolant, oil,
grease, gases, refrigerants and hydraulic fluid. [3] O-rings are very common
types of seals, and may be made of rubber or plastic. [4] O-rings may be static
or dynamic. [5] Examples of static O-rings are in pipe fittings, while examples
of dynamic O-rings are between pistons and cylinders in hydraulic systems.
[6] Lip (or edge) seals use a thin, flexible edge (in order) to make close
contact with a smooth, rotating shaft. [7] The three parts of a lip seal are a
pressed steel case, a rubber seal bonded to the case, and a garter spring to
increase pressure on the seal. [8] Examples of lip seals are found at the front
and rear of crankshafts, at the input and output of transmission shafts, in the
steering box, as well as on the front wheel bearing and rear axle. [9]
Hydrodynamic lip seals contain flutes which improve sealing when the shaft is
rotated only in a certain direction. [10] External lip seals are attached to a
shaft or piston rather than a cylinder, and are typically found in hydraulic
brake systems.
response:
keywords:
[1] seals; [2] fluids; [3] O-rings; [4] static; [5] examples; [6] lip seals; [7] parts;
[8] examples; [9] hydrodynamic; [10] external.
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Felt seals are used as dust seals in front of a lip seal, and sometimes as a
grease seal in wheel bearings. [2] Felt seals are actually like thick washers in
a steel case, but they must be soaked in oil before fitting. [3] Wick seals are
used for sealing the crankshaft at the rear of the engine. [4] A wick seal is
asbestos rope impregnated with a dry lubricant such as graphite or
molybdenum disulphide. [5] One unusual thing about wick seals is that they
have to be hand cut and hand fitted into a special machined groove. [6]
Slingers are used to prevent excess oil reaching a seal. [7] The design of a
slinger is usually a metal disc fitted to a rotating shaft. [8] As oil moves along
the shaft and builds up against the disc, it is thrown off by centrifugal force. [9]
A scroll is a machined thread cut into a shaft which passes through a
sleeve.[10] Scrolls are another way to prevent excess oil reaching a seal. [11]
The rotating scroll carries oil back, away from the seal, but it will only work
while the engine is turning over.
response:
keywords:
[1] felt; [2] washers; [3] wick; [4] asbestos; [5] unusual; [6] slingers; [7] disc; [8]
centrifugal; [9] scroll; [10] excess; [11] ; [12] rotating
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
3.7 Gaskets
pattern:
text:
[1] A gasket is a thin, flat layer of material fitted between two adjoining
surfaces. [2] The purpose of a gasket is to prevent fluid loss. [3] The
compressibility of a gasket is its ability to be pressed into the shape of uneven
surfaces, thus making a seal. [4] The resilience of a gasket is its ability to
withstand extremes of temperature and pressure. [5] The permeability of a
gasket is a measure of its ability to stop fluids passing through the gasket
material. [6] The right thickness of a gasket is often important for bolt tensions
and clearances. [7] Some materials used in gaskets include paper, cork,
synthetic rubber, asbestos, steel, copper and aluminum. [8] Metal gaskets,
with metal alone or with a sandwich of asbestos, are normally used in high
temperature, high pressure applications. [9] Paper is used for thin gaskets in
low pressure applications like thermostat housings. [10] Cork has excellent
compressibility but little strength, and is suitable for rocker cover and sump
gaskets. [11] Gaskets should always be stored flat, in a spot where they won't
dry out or distort.
response:
keywords:
[1] gasket; [2] purpose; [3] compressibility; [4] resilience; [5] permeability; [6]
thickness; [7] materials; [8] metal; [9] paper; [10] cork; [11] stored.
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] An adhesive bonds two materials together while a sealant forms a layer
between two surfaces to prevent fluid loss. [2] Many compounds have both
adhesive and sealant properties. [3] Powerful bonding compounds may use
heat or a two part mixture to force chemical reactions. [4] On the other hand,
caulking compounds, like silicon rubber sealing on windows, may be quite
soft. [5] Some gaskets are being replaced by RTV-type sealants. [6] That is,
the RTV sealant "makes" a gasket by curing on the joints. [7] RTV sealants
should never be used to mend old gaskets. [8] Care must also be taken that a
RTV sealant gasket which replaces a normal gasket still gives the right
clearances. [9] Both normal gaskets and RTV sealant gaskets must be fitted
carefully so that internal holes like oil or water passages are not blocked. [10]
It is a bad mistake to over-tighten bolts joining two surfaces which are sealed
by a gasket or sealant.
response:
keywords:
[1] adhesive; [2] compounds; [3] bonding; [4] caulking; [5] RTV; [6] makes; [7]
old; [8] clearances; [9] holds; [10] over-tighten.
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] This is a procedure to check for a blocked radiator. [2] Remove the radiator
cap and accelerate the engine suddenly to 2500 r.p.m.. [3] If the water gushes
suddenly out of the filler hole, then there is a problem of blocked radiator
cores. [4] If the cores are blocked, the cooling system should be reverse-
flushed, or the radiator dismantled for internal cleaning. [5] Check for rust and
scale by noting the appearance of the water. [6] If the water appears rusty, the
cooling system requires flushing. [7] Check the exterior of the radiator fins for
dirt, leaves, insects and corroded fins. [8] Clean the exterior radiator fins by
using a very soft bristle brush. [9] Even if a radiator is in good condition, it may
overheat for several reasons. [10] For example, the pressure cap may be
failing, or a hose may be leaking. [11] A blown gasket or cracked block may
put hot gases and oil into the water. [12] Finally, wrong engine timing or
engine overload may cause overheating.
response:
keywords:
[1] check; [2] accelerate; [3] gushes; [4] blocked; [5] scale; [6] rusty; [7] fins;
[8] brush; [9] overheat; [10] pressure cap; [11] hot gases; [12] timing.
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
4.2 Brakes
pattern: which (relative pronoun); should be + verb (passive)
text:
[1] Most vehicles have a dual braking system. [2] The handbrake is used
when parking, or starting on hills. [3] It works mechanically, with the driver
pulling a ratcheted handle. [4] The handle pulls on a brake cable which levers
the rear brake pads against the drums. [5] The footbrake works a hydraulic
system to all four wheels. [6] Often, the rear wheels have drum brakes and the
front wheels have disc brakes. [7] Disc brakes cool rapidly, which stops
brakes fading when the linings become hot under heavy use. [8] The high
temperature brake fluid (which is) needed for disc brakes absorbs moisture.
[9] It should be replaced completely about every two years.
response:
keywords:
[1] dual; [2] handbrake; [3] mechanically; [4] cable; [5] footbrake; [6] drum; [7]
disk brake; [8] brake fluid; [9] replaced
2
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] A road wheel has maximum grip on the road while it is still turning. [2]
Anything which breaks tyre grip, such as wheel lock-up, or a sudden change
of direction, will destabilize the vehicle. [3] Anti-lock brake systems are
designed to eliminate skidding by short, rapid, repeated brake applications. [4]
Most cars with ABS also have four wheel disk brakes. [5] ABS units generally
consist of an electro-hydraulic booster, a speed sensor on each wheel, an
electronic control unit and necessary wiring, relays etc. [6] The booster
contains an electric motor, pump, reservoir, accumulator, and valve block (or
hydraulic modulator). [7] The wheel sensors send information on speed and
acceleration to the microprocessor. [8] As soon as wheel lock-up is detected,
the microprocessor instructs the valve block to change hydraulic pressure to
the booster. [9] Note that the accumulator in some booster designs must be
depressurized before servicing, or high pressure hydraulic fluid could cause
an accident.
[10] Many ABS units have a self-testing function every time they are used.
[11] If a fault is detected, the unit switches itself off, and allows ordinary
braking to take over.
response:
key words
[1] grip; [2] destabilize; [3] ABS; [4] four wheel; [5] consist; [6] booster; [7]
sensors; [8] lock-up; [9] accumulator; [10] self-testing; [11] switch off.
2
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Hydraulics is the study of liquids under pressure. [2] Hydraulic principles
are used in many areas of automotive engineering. [3] Some examples are
brake systems, hydraulic clutches, automatic transmissions, shock absorbers,
power steering, hoists and presses. [4] An advantage of hydraulic systems is
that many cams, rods and gears are not needed. [5] Also, energy is not lost in
hydraulic transmission over distances. [6] Liquids do not wear like gears, and
do not need lubrication. [7] Another big advantage is that hydraulic forces can
be easily multiplied. [8] For example, 10kg of force applied to a 5cm2 input
piston will increase to 20kg of force on a 10cm2 output piston. [9] Since force =
pressure x area, equal pressure applied to a larger area increases force. [10]
Put in another way, pressure is force divided by the area over which it is
distributed. [11] The behaviour of liquids is governed by Pascal's Law, which
states that a force applied to a liquid is transmitted equally in all directions
throughout the liquid. [12] Liquid is therefore quite different to, say, a metal
rod which will transmit force in only one direction.
response:
1. Define "hydraulics".
2. Make a question using these words: where / hydraulic / principles
3. List some examples of hydraulic applications.
4. Why are the engineering components in a hydraulic system fewer than in a
mechanical system?
5. Why do you think that little energy is lost in hydraulic transmission1?
6. Make a sentence using these words: liquids / not /wear / gears /lubrication
7. What is the physical law which deals with the transmission of forces in
fluids?
8. Calculate the increase in force from 20kg applied to a 10cm2 input piston,
to an output piston of 15cm2.
9. What happens when the same liquid pressure is applied to a larger area
than an input piston?
10. What exactly is pressure?
11. State Pascal's Law.
12. How does a metal rod transmit force differently from a liquid?
keywords:
[1] hydraulics; [2] areas; [3] example; [4] advantage; [5] energy; [6] wear; [7]
multiplied; [8] output piston; [9] force; [10] pressure; [11] Pascal's Law; [10]
metal rod.
3
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
response:
keywords:
[1] simultaneous; [2] mechanical; [3] failure; [4] dual; [5] master cylinder; [6]
slave cylinder; [7] drum; [8] springs; [9] stepped; [10] disc.
3
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
notes
3
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
response:
1. Define displacement.
2. How can the weight of a ship be calculated?
3. What area measurement does the force needed to displace a liquid depend
upon?
4. Put the following words into a sentence: might / 25 lb. / 5 sq. inches / 5
inches
5. Calculate the lifting force applied by 5 psi to a piston face of 250 square
inches.
6. If a 5 sq. inch piston moves 5 inches at 5 psi, how far will a 250 square inch
piston move?
7. Make a question using these words: why / pistons / displace / same
8. Describe the displacement principle used by a hydraulic jack.
9. Finish this sentence: Hose jet nozzles use fluid displacement in .....
10. What is the effect on fluid displacement of a wide diameter open hose
end?
11. What is the effect on fluid displacement of a jet nozzle?
keywords:
[1] displacement; [2] ship; [3] surface area; [4] move; [5] lifting force; [6] large
piston; [7] same amount; [8] jacks; [9] nozzles; [10] wide diameter; [11] greater
distance.
3
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
response:
1. Define pneumatics.
2. Engines work on the expansion and compression of gases. How is the
compression ratio of an engine calculated?
3. What are some automotive applications of pneumatics?
4. What is a physical property that gases share with liquids?
5. How do gases differ from liquids?
6. Make a sentence using these words: design / air brakes / calculate /
compression
7. Make a question using these words: gases / weight
8. Why is air pressure greater at sea level than on top of a mountain?
9. What is an effect of high altitudes on carburetion?
10. Suggest why an EFI system might work better than a carburetor on a
mountain top?
keywords:
[1] pneumatics; [2] combustion; [3] applications; [4] fluids; [5] compressible; [6]
devices; [7] weight; [8] atmosphere; [9] mountain; [10] EFI.
3
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Atmospheric pressure of 14.7 psi (101.3 kpa) applies equally to all objects
on the earth's surface. [2] When pressure affecting one surface of an object is
altered, atmospheric pressure can have a powerful affect. [3] For example the
low pressure area of a venturi lets atmospheric pressure power carburetors
and lift aeroplane wings. [4] Low pressure in a drinking straw lets atmospheric
pressure force a liquid into your mouth. [5] The brake booster uses manifold
vacuum to allow atmospheric pressure to multiply foot pressure on the
brake.[6] The measurement of compressed air actually ignores atmospheric
pressure, (that is, 30 psi on the gauge is really 44.7 psi). [7] This is because
work can only be done by compressed air above 14.7 psi. [8] Air brakes move
a brake cylinder until the resistance of the friction pads equals the air
pressure. [9] Pascal's law affects the working of air brakes. (10) When you
calculate the force applied by an air brake, air pressure and piston size are
the important variables, not the amount of air.
response:
keywords:
[1] earth's surface; [2] altered; [3] venturi; [4] straw; [5] booster; [6]
compressed air; [7] work; [8] air brakes; [9] Pascal; [10] variables.
3
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Air conditioning systems make use of the relationship between pressure
and heat. [2] A special volatile refrigerant gas such as R12 is used to
exchange heat. [3] A compressor puts hot refrigerant gas under high
pressure, and sends it to a condenser. [4] Cool air passes over the
condenser, which is similar to a car radiator. [5] The condenser removes heat
from the refrigerant, which then moves as a liquid on to the receiver-dryer. [6]
The function of a receiver drier is to filter, de-moisturize and store the
refrigerant. [7] The expansion valve then allows a controlled amount of liquid
refrigerant into the evaporator. [8] As the liquid suddenly expands in the
evaporator coils its temperature drops. [9] However, warm air from the
passenger compartment passes over the coils, which absorb heat and
vaporize the refrigerant. [10] The warm, low pressure refrigerant vapour then
passes on to the compressor the begin the cycle again.
response:
keywords:
[1] relationship; [2] exchange; [3] compressor; [4] condenser; [5] heat; [6]
receiver-drier; [7] expansion valve; [8] evaporator coils; [9] vapourize; [10] low
pressure.
3
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Everyone knows that car exhausts cause pollution. [2] Not many people
realize that the refrigerant gases in automotive air conditioners are also
dangerous to the environment. [3] These CFC gases destroy the ozone layer.
[4]A common CFC gas used in cars is called R12 (Refrigerant 12), which is
also hazardous for mechanics. If [5] R12 gas is touched by an open flame it
forms a poisonous gas. [6] In addition, refrigerant gases can cause frostbite or
blindness if they are not handled carefully. [7] In spite of its drawbacks, R12 is
a very efficient refrigerant. [8] It takes 970 Btu's (British Thermal Units) to turn
one pound of water to steam, but only 69.5 Btu's to turn one pound of R12 to
vapour. [9] (One Btu is the amount of heat required to raise the temperature of
one pound of water one degree Fahrenheit at sea level pressure.) [10] In air
conditioners, pressure changes the point of R12, which boils at -30° at
atmospheric pressure, but only 0°C at 30.1 psi. [11] Automotive air
conditioners are heat exchange systems which work by manipulating pressure
and temperature.
response:
keywords:
[1] pollutant; [2] refrigerant gases; [3] ozone layer; [4] R12; [5] flame; [6] frost
bite; [7] efficient; [8] vapour; [9] Btu; [10] pressure; [11] heat exchange.
3
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Heat at a molecular level describes the energy level in electrons. [2] As
heat (energy) increases, some electrons move to higher orbit shells, and are
eventually freed from their nuclei. [3] Pressure compresses the orbit of
electrons in their shells, and therefore influences heat directly. [4] Heat may
transfer by conduction, convection or radiation. [5] Conduction occurs in solids
where the atoms are closely packed and energy transfers from atom to atom.
[6] Some metals like aluminum and copper are especially good thermal
conductors. [7] Convection occurs in liquids and gases when hot molecules
rise and are displaced by cooler molecules, creating a circular current. [8]
Radiation is heat transfer as a form of wave energy through space. [9] All
heated objects give off radiation waves, which will be reflected by light
coloured surfaces and absorbed by dark surfaces. [10] In car heating and air
conditioning systems heat is transferred by convection in the passenger
compartment. [11] In the engine and radiator heat is transferred by
conduction. [12] In an air conditioner, heat is changed by pressure.
response:
3
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
response:
1. Why would it have been difficult to manufacture a vehicle 200 years ago,
even with full specifications?
2. What does a mechanic have to interpret from vehicle specifications?
3. What are some of kinds of the measurements which vehicle specifications
state?
4. Explain what "dimension" and "service limit" mean.
5. Give two examples of clearances in an engine specification.
6. Make a sentence using these words: torque / setting /cylinder / might
7. Make a question using these words: what / displacement / minute
8. Why might a "backyard mechanic" sometimes find it hard to work to
specification?
9. Fill in the gaps in the following sentence: A mechanic must know how
..............., to what ............, using which ......... and in which ................
10. What are automotive trade tests based upon?
keywords:
[1] components; [2] interpret; [3] specifications; [4] dimension; [5] clearance;
[6] torque; [7] displacement; [8] specialist; [9] order; [10] tradesman; [11] tests
3
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Modern car bodies are made from pressed steel panels. [2] One set of
panels is welded together (in order) to make the floor pan. [3] Another set of
panels is welded together (in order) to make the upper body. [4] The whole
assembled unit is called a "unitary construction body". [5] Unitary construction
bodies are more rigid than the older vehicles built on a a chassis of channel
iron. [6] The front and rear of unitary bodies are usually weaker than the
passenger compartment. [7] This allows the body to collapse gradually in a
crash, in order to protect the driver. [8] Better quality vehicle bodies are zinc-
dipped to slow rusting. [9] Once a unitary welded body is coated with several
layers of acrylic or enamel paint, it is almost maintenance-free.
response:
keywords:
[1] panels; [2] pan; [3] upper body; [4] unitary; [5] rigid; [6] weaker ; [7]
collapse; [8] zinc; [9]paint
4
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] A good driver uses all of his senses to monitor the car. [2] He listens for
mechanical noises, interprets vibrations and senses how hard the engine is
working. [3] However, the instrument panel also gives him more exact
information. [4] The main gauges on a car instrument panel are the
speedometer, the odometer, the fuel gauge, the ammeter, the temperature
gauge, the oil pressure gauge, and various warning lights. [5] The
speedometer measures road speed by computing from drive shaft revolutions
after the gearbox. [6] Wrong replacement parts in a speedo' can lead to
speeding fines: watch it! [7] The odometer shows the total distance a car has
traveled, while a trip-meter is a special odometer that you can reset to zero.
[8] A tachometer indicates engine revolutions, and is mainly useful in high
performance cars. [9] The temperature gauge works from a thermocouple, two
strips of metal soldered together which generate a small current when they
are heated. [10] Every experienced driver keeps an eye on temperature and
oil pressure.
response:
keywords:
[1] senses; [2] listens; [3] instrument panel ; [4] gauges; [5] speedometer; [6]
fines; [7] odometer; [8] tachometer; [9] temperature gauge; [10] driver
4
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
response:
keywords:
[1] nitrocellulose lacquer; [2] similar; [3] lacquer; [4] enamel; [5] sealer; [6]
coats; [7] primer-surfacers; [8] primer; [9] scratches; [10] thinners.
4
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Apply a coat of primer-surfacer to the bare metal for adhesion. [2] Wait for
one hour. [3] Apply a coat of spray putty, wait two hours, and then apply a
second coat of spray putty. [4] If hand putty is used, work quickly and
thoroughly, because it dries rapidly. [5] Hand putty will lift off if it is reapplied
over putty that is not completely dry. [6] Wait one day after applying spray
putty. [7] Rub the putty back with a 150 grade paper. [8] Take care to keep the
sanding block flat on the surface. [9] Now hand rub the job with a 250 grade
paper. [10] No block is used in this hand rubbing. [11] Finally, remove all dust
from the surface with a tack rag.
response:
keywords:
[1] primer-surfacer; [2] one hour; [3] spray putty; [4] dries ; [5] lift off ; [6] one
day; [7] rub back; [8] flat ; [9] hand rub ; [10] no block; [11] dust.
4
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] When the bare metal preparation is finished, apply a primer coat. [2] Wait
one hour, then apply a second primer coat. [3] Primers should be applied as
"wet coats", covering the whole area thoroughly. [4] Wait for one day, then
apply a quick, thin coat of colour. [5] Remove all old masking, then put on new
masking. [6] The new masking should expose some of the old paint, so it can
be blended. [7] Hand sand the primer with 400 grade paper. [8] Apply wax
and grease remover (prepsol) with a clean tack rag. [9] Apply finishing coats
using long, even strokes and keeping an even distance from the surface.
response:
keywords:
[1] primer; [2] one hour; [3] wet; [4] thin; [5] masking; [6] old colour; [7] 400
grade; [8] prepsol; [9] long, even;
4
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] The main parts of a tyre are the carcass, the tyre wall and the tread. [2] In
addition, all tyres have a valve stem and valve, and some have an inner tube.
[3] The tyre must make an air-tight seal on the wheel rim. [4] What are the two
main kinds of tyres? [5] They are cross-ply and radial types. [6] Cross-ply
tyres contain several layers of cloth with the thread running diagonally. [7] The
diagonal thread gives a compromise between horizontal flexibility and stable
steering. [8] Radial tyres solve the same problem in a different way. [9] They
have layers of inner fabric with horizontal threads. [10] On the outside is a belt
of strong fabric to giver lateral stiffness for good steering. [11] The outer radial
belt may be woven with spun steel wires. [12] It is dangerous to mix cross-ply
and radial tyres because they behave differently.
response:
keywords:
[1] parts; [2] valve; [3] airtight; [4] kinds; [5] cross-ply; [6] layers; [7] diagonal;
[8] radial; [9] horizontal; [10 belt; [11] outer; [12] mix
4
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
[1] The suspension system of a car has two main functions. [2] Firstly it must
keep all four road wheels in contact with the road, so that steering, braking
and the transmission drive can operate properly. [3] Secondly, the suspension
system must offer passengers maximum comfort. [4] The two functions are
never quite compatible, so engineers always make a compromise. [5] The
main suspension components in modern cars are leaf springs, coil springs,
wishbones, torsion bars, shock absorbers and McPherson struts. [6] Leaf
springs are leaves of tempered steel clamped together and fastened to the
chassis by a shackle at one end, a pivot at the other. [7] Coil springs are often
used together with wishbones to give independent front suspension. [8]
McPherson struts also offer independent front suspension. [9] They use a coil
spring together with a shock absorber. [10] The spring absorbs bumps, while
the shock absorber dampens (stabilizes) up and down bouncing. [11] A
torsion bar is springy steel which absorbs bumps by twisting and untwisting.
[12] Torsion bars are often part of the front-end suspension unit.
response:
keywords:
[1] functions; [2] road wheels; [3] comfort; [4] compromise; [5] components; [6]
leaf springs; [7] coil springs; [8] McPherson struts; [9] together; [10] dampens;
[11] torsion bars; [12] front-end
4
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
6.3 Steering
pattern: may, must; listing, drawing diagrams
text:
[1] The steering system translates the driver's turning effort to turning the road
wheels. [2] It also gears down the effort required, and cushions shocks
coming back to the driver. [3] The main parts of a steering system are the
steering wheel, steering column, steering box, pitman arm & idler arm, tie
rods, and ball joints at the stub axles. [4] The steering box may use a rack and
pinion design, or a recirculating ball design. [5] Hydraulic power steering
systems may work through the steering box, or attach directly to the linkage
unit (tie rods). [6] A hydraulic system must still leave the driver with good
"road feel". [7] A rack & pinion steering box has a toothed rack which is moved
by a helical gear on the steering column. [8] The helical gear is quieter than
straight teeth, and absorbs shocks better. [9] A recirculating ball steering box
uses ball bearings which ride between a worm gear on the steering column
and a half-gear on the pitman arm.
response:
keywords:
[1] translates; [2] gears down; [3] parts; [4] steering box; [5] hydraulic; [6] road
feel; [7] rack & pinion; [8] helical; [9] recirculating ball
4
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Power rack and pinion systems are typically found on front wheel drive
cars, while integral power steering assemblies are typically found on rear
wheel drive cars. [2] The integral power steering unit is actually a recirculating
ball and worm gear. [3] Every power steering system also needs a pump,
driven by a belt to the engine. [4] It will also have hydraulic pressure hoses, a
return line and a control valve. [5] Some systems have variable ratio steering,
which increases the turning speed at high angles. [6] If the power steering
mechanism fails, it is always possible to steer the vehicle on manual override.
[7] The general operating principle is that a rotary valve directs fluid to one or
other side of a piston. [8] This fluid pressure has the effect of assisting
mechanical gear movements to turn the Pitman arm. [9] Three common types
of pumps used in power steering systems employ a vane impeller, a roller
impeller and a slipper impeller respectively. [10] Always check the hydraulic
fluid levels for the pump when servicing a power steering vehicle.
response:
1. Which kind of power steering systems are usually found on front wheel
drive cars, and which type on rear wheel drive cars?
2. What is the mechanical gearing system in an integral power steering unit?
3. List the main components in a power steering system.
4. Make a question using these words: what / hydraulic / needed / power
5. Explain what variable ratio steering does.
6. Complete the following sentence: If the power steering fails .....
7. What does the rotary valve do?
8. How does the fluid pressure assist the driver?
9. Name three hydraulic pump designs used in power steering systems.
10. What is an extra servicing requirement with power steering systems?
keywords:
[1] front wheel drive; [2] integral; [3] pump ; [4] hoses; [5] variable ratio; [6]
fails; [7] rotary valve; [8] assisting; [9] types; [10] check.
4
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Wheel alignment is the adjustment of front wheels (in order) to provide
stable steering and minimise tyre wear. [2] Each stub axle pivots about either
two metal king pins, or two ball joints [3] These king pins or ball joints are tilted
in two directions. [4] Firstly, the top, but not the bottom ball joint is moved a
little backwards. [5] This adjustment puts the centre of the axle (and point of
road contact) a bit behind the pivot point (like a supermarket shopping trolley).
[6] This angle of front to back tilt is called castor, and it makes steering easier.
[7] Secondly, the wheel is tilted from top to bottom. [8] Unloaded vehicles
usually have positive camber, which means that the wheels lean outward at
the top. [9] As the load increases, camber tilts to zero or negative camber. [10]
Finally, front wheels are given a slight toe-in of 3 to 5mm. [11] This means that
the two wheels are closer at the front than the rear at rest. [12] When the
vehicle is moving, the wheels splay out a bit, which can cause wheel wobble.
response:
keywords:
[1] wheel alignment; [2] stub axle; [3] tilted; [4] moved; [5] centre; [6] castor; [7]
top to bottom; [8] positive; [9] negative; [10] toe-in; [11] closer; [12] wobble.
4
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
[1] Combustion or hot gas engines include: gas turbines, rotary engines, and
free-piston engines, as well as two and four cycle reciprocating piston
engines. [2] Most reciprocating engines have pistons linked to a crankshaft
with a connecting rod ("con-rod"). [3] The crankshaft converts reciprocating
motion into rotary motion, and must be very carefully balanced to avoid
vibration. [4] The four cycles in a normal vehicle engine are a) fuel mixture
intake, b) fuel mixture compression, c) fuel mixture explosion and expansion,
and d) burnt gas removal (exhaust). [5] The fuel mixture in a petrol engine is
roughly one part of petrol to fifteen parts of air, with the mixture controlled by a
carburetor or fuel injectors. [6] In a two stroke engine, each engine revolution
becomes a power stroke, but only every second revolution is a power stroke
in a single cylinder four stroke engine. [7] Two stroke engines use ports in the
cylinder walls instead of poppet valves. [8] Most engines have several
cylinders, which are typically arranged in-line, in a V-shape or horizontally
opposed. [9] The angle of "throws" in a crankshaft are controlled by the
number of cylinders and their arrangement. [10] All the "throws" on a
crankshaft must be in equal parts of 3600 so that rotation remains balanced.
response:
keywords:
[1] gas engines; [2] link; [3] convert; [4] cycles; [5] mixture; [6] power stroke;
[7] ports; [8] cylinders; [9] throws; [10] 3600 .
5
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
response:
keywords:
[1] displacement; [2] bore; [3] calculation; [4] power; [5] uneven wear; [6] gas
tight; [7] cold piston; [8] aluminum alloy; [9] melt; [10] combustion chamber;
[11] surface area
5
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
[1] The cylinder head fits over the cylinders and contains the valves and valve
train. [2] The valve train consists of the push rods from the bottom end, and
the rocker arms. [3] The rocker arms push the valves open. [4] The valves are
returned to the closed position by the valve springs. [5] There are usually two
valves to each cylinder, one intake and one exhaust. [6] They are operated by
the valve train to let the fuel mixture into the cylinder (intake), and then let the
burned gases out after the cylinder is fired (exhaust). [7] Modern cylinder
heads are typically made of an aluminum alloy. [8] In addition to the cylinder
bore, the head contains passages for water and oil.[9] The head must make
an absolutely gas-tight seal with the head gasket and engine block. [10]
Cylinder head bolts are tightened in a certain order to a specified torque.
response:
keywords:
[1] cylinder head; [2] valve train; [3] rocker arms; [4] valves; [5] intake; [6] fuel
mixture; [7] aluminum alloy; [8] passages; [9] gas-tight; [10] bolt.
5
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] The function of an engine valve is to open or close an engine port. [2] This
controls the intake and exhaust of gases in the combustion chamber. [3] It
also controls the gas pressure at which combustion takes place. [4] The main
parts of a valve are the valve head, valve stem, valve face and valve seat. [5]
The valve head is the wide, mushroom-shaped part of the valve. [6] The valve
face is the beveled part of the valve head. [7] The long, pencil-shaped part of
the valve is the valve stem.[8] The valve face must make a gas-tight seal with
the valve seat. [9] The intake valve seat may be a machined part of the
cylinder head. [10] The exhaust valve seat is usually a special alloy insert,
made to withstand high temperatures. [11] Some other parts of the engine
valve system are valve guides, valve springs, push rods and rocker arms.
response:
keywords:
[1] function; [2] intake; [3] gas pressure; [4] parts; [5] valve head; [6] valve
face; [7] valve stem; [8] gas tight; [9] intake valve seat; [10] exhaust valve
seat; [11] other parts.
5
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] The decision to recondition a part depends upon cost, time and the
availability of spares. [2] Much reconditioning in technically advanced
countries is done in specialist workshops. [3] Any engine part should be
completely cleaned before it is reconditioned. [4] Cleaning can be done in a
hot detergent tank, with spray jets, by blasting with glass beads, or by an
ultrasonic machine. [5] The worst way to clean parts is with petrol. [6] The
cleaned part should be examined carefully and measured for damage or
wear. [7] A worn metal part can be enlarged or repaired by soldering, brazing,
welding, plating, metal spraying, or sometimes by expanding with heat &
pressure. [8] An oversized metal part can be cut, ground, etched, or
sometimes shrunk with freezing. [9] External cracks can be welded or brazed
with an electric arc, which is less likely to warp than oxy welding. [10] Metallic
plastic cannot be used in areas of high stress or temperature. [11] Fine
internal cracks can only be found in aluminum with special dies, and in iron
with magnetic or electrical detectors. [12] It is usually best to replace internally
cracked parts.
response:
keywords:
[1] decision; [2] specialist; [3] cleaned; [4] ultrasonic; [5] petrol; [6] examined;
[7] worn; [8] oversized; [9] cracks; [10] plastic; [11] internal cracks; [12]
replaced.
5
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] A lever is a rigid link between two opposing forces turning about a fulcrum.
[2] For example, as a point on one side of a wheel goes up, a point on the
opposite side of the wheel goes down. [3] The axle, or fulcrum of the wheel is
exactly halfway between each point on the rim. [4] If the fulcrum is moved
closer to one force point than the other, then the closer force point moves a
shorter distance with greater force. [5] Leverage is stated as a ratio like 4:1,
which means the fulcrum divides the lever and gives a lifting advantage of
four parts to one. [6] Gearing uses two fulcrums, at the centre of gear wheels
which mesh with each other. [7] The leverage or gearing advantage between
two gear wheels is a ratio of their diameters. [8] Many tools and machines
extend human physical power by using leverage. [9] Human bones and
muscles themselves make remarkable use of leverage and counter-balancing
forces. [10] However, both human structures and machines are easily broken
when leverage is applied in the wrong direction.
response:
keywords:
[1] lever; [2] wheel; [3] axle; [4] fulcrum; [5] leverage; [6] gearing; [7]
diameters; [8] physical power; [9] bones; [10] broken.
60
5
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] An engine gearbox is a device to multiply the torque from a crankshaft. [2]
In this way the engine can cope with a range of load conditions, such as
starting from rest, reversing, and so on. [3] The gearbox contains three shafts:
the input (clutch) shaft, the output shaft (main shaft) to the rear wheels, and a
counter-shaft (layshaft). [4] The output shaft contains two or more geared
clutches which can engage various combinations of main gears. [5] The
geared clutches also contain synchromesh units [6] Synchromesh makes the
main gears rotate at the same speed so that they can engage and disengage
without clashing. [7] Synchromesh works through friction cones on the geared
clutches. [8] The input shaft is permanently engaged with the countershaft.[9]
The countershaft can engage with the main shaft to produce toque ratios such
as 3:1, 2:1, or 1:1 (top gear). [10] For reverse, there is an idler gear between
the countershaft and the main shaft.
response:
keywords:
[1] multiply; [2] conditions; [3] shafts; [4] output shaft; [5] geared clutches; [6]
synchromesh; [7] friction cones; [8] input shaft; [9] countershaft; [10] reverse
5
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] The steps to changing gears are a) drop the engine revs', b) disengage the
clutch, c) select a gear, and d) accelerate and gradually re-engage the clutch.
[2] In first gear, the smallest gear on the countershaft drives the biggest gear
on the output shaft. [3] On a three speed gearbox this may give a torque ratio
of about 3:1. [4] The gears will be spinning at different speeds as you move to
engage second gear. [5] As the forked gear selector pushes the geared clutch
towards second gear, a friction cone will speed up the second gear. [6] The
second gear will increase speed until it is spinning at the same speed as the
gear on the counter shaft. [7] In top gear there is no gearing down and power
transfers straight from the input shaft to the output shaft. [8] The gearbox is
quieter in top gear because the countershaft is not transferring any power. [9]
Note however that the differential always changes torque between the final
drive shaft and the wheels.
response:
keywords:
[1] changing gears; [2] first gear; [3] torque ratio; [4] speeds; [5] gear selector;
[6] second gear; [7] top gear; [8] quieter; [9] differential.
5
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Three different systems work together (in order) to make an automatic
transmission work. [2] These systems are a fluid coupling, two sets of
planetary gears, and a hydraulic control system. [3] The fluid coupling
replaces a conventional clutch. [4] It consists of an input rotor (called a pump
or impeller), an output rotor (called a turbine), and a stator with fixed blades in
the middle. [5] Fluid thrown by the impeller forces the turbine to rotate also. [6]
The actual automatic gearbox contains a ring gear, planet gears and a central
sun gear. [7] Gearing ratios are changed by holding one or more of these
gears steady while others rotate. [8] The hydraulic control system includes a
governor on the final drive shaft. [9] It controls various pumps and valves
which hydraulically set the gear ratios.
response:
1. Finish this sentence: Three different systems work together (in order) to ...
2. What are the three main systems in an automatic transmission?
3. Add a beginning to this sentence: ... consists of an input rotor (impeller), a
stator and an output turbine.
4. Change this sentence to active voice: Fluid is thrown by the impeller.
5. Make a quick, labeled diagram showing the main gears in an automatic
gearbox.
6. How are gear ratios changed in an automatic gearbox?
7. What does the hydraulic governor do?
8. Find out how exactly the hydraulic governor works.
keywords:
[1] three systems; [2] planetary; [3] fluid coupling; [4] rotor; [5] impeller; [6]
automatic gearbox; [7] ratios; [8] governor; [9] controls.
5
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
response:
keywords:
[1] fluid clutch; [2] friction clutch; [3] flywheel; [4] clutch plate; [5] splined; [6]
torsion springs; [7] pressure plate; [8] diaphragm; [9] release bearing.
5
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] The two jobs a differential does are a) to transfer power at right angles to
the tail shaft, and b) to allow the drive wheels to rotate at different speeds. [2]
The road wheels turn at different speeds on corners because the outside
wheel travels further than the inside wheel. [3] The differential contains two
gear sets. [4] The first gear set comprises a pinion (which is) attached to the
tail shaft, and a large crown wheel which drives one of the rear axles. [5] The
second gear set comprises two sun gears, which are on the ends of the axles,
and two planet gears between the sun gears. [6] The sun & planet gear set
revolves freely in a cage until the car goes into a corner. [7] When the inner
road wheel turns more slowly than the outer road wheel, the difference is
taken up by the planet gears, which begin to rotate against the sun gears. [8]
Some vehicles have limited slip differentials which transfer drive to the wheel
which has most traction. [9] Various designs of limited slip differentials make
use of spring loaded clutches, or a floating differential pinion. [10] All the
differential gears operate in a bath of heavy oil.
response:
keywords:
[1] jobs; [2] road wheels; [3] gear sets; [4] pinion; [5] sun gears; [6] cage; [7]
planet gears; [8] limited slip; [9] design; [10] oil.
6
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] The fuel system delivers petrol, diesel or LPG from a tank to an engine. [2]
Delivery must be safe, reliable and carefully controlled for the needs of the
engine. [3] Fuel in petrol engines travels through a fuel line to a filter, a pump
and then to a carburetor or fuel injectors. [4] The carburetor mixes petrol with
air to make a fine vapour. [5] This mist is sucked through the inlet manifold
and inlet valve port into the combustion chamber of the cylinder. [6] In EFI
systems, either a single fuel injector may spray the fuel into the inlet manifold,
or an injector may spray directly adjacent to each inlet port (multiple injector
system). [7] The fuel pump in a carburetor system delivers just enough fuel for
the pistons to burn. [8] The fuel pump in an injection system delivers fuel at
constant high pressure (250-300kpa) to the fuel rail. [9] The injectors take
some fuel, but the rest is cycled back to the fuel tank. [10] Electronic fuel
injection [EFI] systems are much more complex than carburetor systems.
response:
keywords:
[1] fuel system; [2] delivery; [3] travel; [4] carburetor; [5] combustion; [6]
injector; [7] pump; [8] pressure; [9] cycled; [10] EFI.
6
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] All combustion engines run on hydrocarbon fuel, mostly petrol, diesel and
LPG. [2] Every fuel is a mixture of many different hydrocarbons, each with a
different volatility. [3] Highly volatile hydrocarbons have low boiling points, and
so vaporize easily. [4] Ordinary fuels contain that mixture of hydrocarbons
which will work best with average engines. [5] Engine knock occurs when the
octane rating (volatility) is not high enough to evenly burn all the fuel in the
combustion chamber. [6] Petrol also contains additives. [7] One additive stops
fuel deterioration. [8] Deterioration leaves a gum which blocks up fuel lines,
injectors and automatic chokes. [9] Some other additives are detergents to
clean the fuel system, and an anti-rust compound to stop corrosion.
response:
keywords:
[1] hydrocarbon; [2] mixture; [3] volatile; [4] ordinary fuels; [5] engine knock;
[6] additives; [7] deterioration; [8] gum; [9] detergents
6
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] All the fuel in an engine combustion chamber should be burnt. [2] Good
combustion burns evenly, giving a steady thrust to the piston right through the
power stroke. [3] When the flame spreads unevenly there is a series of
explosions, causing uneven pressure and engine knock. [4] Engine knock
causes loss of power, overheating and sometimes engine damage. [5]
Additives in petrol raise the octane rating, preventing engine knock. [6] Lead
additive is now being replaced by aromatic hydrocarbon additives. [7] Both
cause damage to human health. [8] Super petrol is for high compression
engines, having an octane rating of about 97. [9] Standard petrol is made for
lower compression engines, having an octane rating of about 92.
response:
keywords:
[1] burnt; [2] evenly; [3] knock; [4] damage; [5] additives; [6] lead; [7] health;
[8] super; [9] standard
6
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] The exhaust system has three important jobs. [2] Firstly it carries hot,
expanding gases away from the combustion chambers. [3] Secondly, it may
convert poisonous gases before they are released into the atmosphere. [4]
Thirdly, it quietens the terrible noise made by an unmuffled engine. [5] The
first job of carrying away gases is an engineering problem. [6] The engine is
actually happiest when it can exhaust straight into the air without back
pressure, but this is socially unacceptable. [7] The second job of converting
poisonous gases is done by a catalytic converter. [8] Older cars do not have
these. [9] Carbon monoxide takes oxygen out of your blood and poisons
whole cities. [10] Exhaust noise is quietened down by a muffler. [11] Most
mufflers contain baffles to slow down the gases. [12] The E.P.A.
(Environmental Protection Agency) in Australia imposes heavy fines on
drivers with vehicles which pollute with noise or smoke.
response:
keywords:
[1] three jobs; [2] carries; [3] converts; [4] quietens; [5] engineering; [6] back
pressure; [7] converter; [8] older cars; [9] carbon monoxide; [10] noise; [11]
baffles; [12] EPA
6
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] The need for emission controls on vehicles has been the greatest influence
on engine design for several years. [2] Motor vehicle noxious emissions are
carbon monoxide (CO), hydrocarbons (HC), and oxides of nitrogen (NOx). [3]
Precombustion controls limit the production of harmful emissions, while
postcombustion controls try to render emissions harmless. [4] There are at
least fourteen engine factors that contribute to pollution, and many engine
modifications to combat them. [5] Positive crankcase ventilation is a fairly
simple and effective system to recirculate crankcase fumes for combustion. [6]
Thermostatically controlled air cleaners allow air-fuel mixtures to be leaner
and burn more completely. [7] Early fuel evaporation systems aid engine
warming up to help reduce use of the choke. [8] A manifold heat control valve
can let exhaust gases warm the intake manifold. [9] Evaporative emission
control systems prevent the escape of fuel vapour from the fuel tank and
carburetor. [10] Exhaust gas recirculation systems mixes exhaust gases with
the air-fuel vapour, slows combustion, and helps reduce oxides of nitrogen.
[11] In EGR (exhaust gas recirculation systems) an electronic vacuum
regulator valve can regulate the amount of exhaust gas to be returned to the
intake manifold.
response:
1. What are three modifications to engine design that have occurred because
of emission controls?
2. Which noxious chemicals do internal combustion engines generate?
3. Explain the difference between precombustion and postcombustion
controls.
4. Make a list of engine factors that can contribute to pollution
5. Complete the following sentence: Positive crankcase ventilation is
..................
6. What does a thermostatically controlled air cleaner do?
7. Explain the function of early fuel evaporation devices.
8. Make a question using these words: why / manifold / heat / control / valve
9. How can the escape of fuel vapour from the petrol tank be diminished?
10. How does an exhaust gas recirculation system help reduce pollution?
11. What is the function of an electronic vacuum regulator valve?
keywords:
[1] engine design; [2]combustion; [3] precombustion; [4] engine factors; [5]
crankcase ventilation; [6] air cleaners; [7] evaporation; [8] heat control; [9]
vapour; [10] recirculation; [11] vacuum regulator
6
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
response:
keywords:
[1] oxygen; [2] efficient combustion; [3] high performance; [4] efficiency; [5]
supercharger; [6] Rootes; [7] turbine; [8] 100,000 rpm; [9] wastegate; [10]
compression ratio; [11] modifications.
6
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Electronic fuel injection systems are designed to make engines more
efficient, reliable and less polluting. [2] These are obvious advantages.[3] A
disadvantage is that very complex systems may be difficult for general
mechanics (let alone owners) to fix. [4] EFI systems marry the technology of
fuel injectors to a technology of solid state electronics. [5] Output from a
network of sensors is coordinated by an analogue computer which then
controls the delivery of air and atomized fuel for combustion. [6] Fuel delivery
is controlled through the swirl pot, fuel pump, fuel filter, fuel rail fuel injection
valve, and fuel pressure regulator. [7] Some engines also contain a cold start
injector and a fuel damper. [8] There are various designs of air flow sensors,
such as an air flap, platinum hot wire, or ultra sonic Karman vortex device. [9]
Some other parts of an EFI system include a manifold pressure sensor,
throttle unit, air flow duct and auxiliary air valve. [10] A further set of valves
and sensors controls idling.
response:
keywords:
[1] design; [2] advantage; [3]disadvantage; [4] marry; [5] analogue; [6] fuel
delivery; [7] airflow; [8] pressure; [9] idling.
6
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
About "technologies"
Note that every technology has more specialized branches. You can draw a
tree diagram to show how various sub-technologies fit into a larger scheme of
things.
For example:
6
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] The four main models of EFI systems used in Australia in 1995 are L-
Jetronic, D-Jetronic, Motronic and Delco. [2] Actual fuel injection design can
be Port Fuel Injection (PFI) or Throttle Body Injection (TBI; renamed from
Central Fuel Injection, CFI). [3] The PFI system has an injector at each
cylinder, above the inlet valve. [4] The TBI system is mounted like a
carburetor, but uses one or two injectors. [5] Three basic sub-systems make
up the EFI unit: fuel control, air flow, and electronic control. [6] The fuel control
provides petrol under pressure for all operating conditions. [7] The air flow
system controls and monitors all air flowing into the engine. [8] The electronic
control system manages information gathering from sensors. [9] It then
instructs EFI devices to adjust for optimum output. [10] Mechanics are trained
to repair fuel and air components, but most will be unable to fix serious faults
in the electronic control unit (which is an analogue computer).
response:
1. Make a question using these words: four main models / EFI systems
2. Explain what the letters PFI and TBI stand for
3. Where are PFI injectors located?
4. Where does a TBI injector insert its fuel spray?
5. What are the three basic sub-systems of an EFI unit?
6. Why will fuel pressure to the injectors vary?
7. Make a sentence using these words: air / controls / monitors
8. What is the input function of the electronic control system?
9. What is the output function of the electronic control system?
10. What will stop mechanics repairing certain faults in an EFI system?
keywords:
[1] models; [2] design; [3] PFI; [4] TBI; [5] sub-systems; [6] fuel control; [7] air
flow; [8] electronic control; [9] output; [10] mechanics.
6
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] EFI fuel systems operate under a pressure of 250-300 Kpa. [2] Fuel
pressure varies with inlet manifold pressure.[3] The fuel is thoroughly filtered
and directed to a fuel rail. [4] The fuel rail feeds the injectors. [5] At the end of
the fuel rail, a pressure regulator valve returns excess fuel to the petrol tank.
[6] Returning fuel is not under pressure, but must pass through a swirl pot. [7]
The swirl pot contains a venturi which speeds up the fuel as swirling pressure
forces out any air bubbles. [8] Fuel pump operation is controlled electronically
and always delivers more fuel than is needed. [9] The fuel pump motor is
immersed in, cooled and lubricated by the petrol itself. [10] Fuel injectors
atomize the fuel. [11] They are electronically controlled by a solenoid, and
open approximately 0.1mm for 1-1.5 milliseconds per pulse.
response:
1. What is the normal operating pressure at the fuel rail of an EFI system?
2. What can cause fuel pressure to vary?
3. Why is it important to filter petrol in an EFI system especially carefully?
4. Change the following sentence to passive voice: The fuel rail feeds the
injectors.
5. Explain the function of the fuel pressure regulator valve.
6. What is the pressure of fuel entering the swirl pot?
7. Make a sentence using these words: swirling pressure / air bubbles
8. How does fuel pump delivery in an EFI system differ from fuel delivery in a
carburetor system?
9. What is unusual about the lubrication of fuel pump?
10. Fuel injectors atomize fuel. What does that job in a carburetor?
11. Give a typical pulse period for an electronic fuel injector.
keywords:
[1] pressure; [2] manifold; [3] filtered; [4] fuel rail; [5] regulator; [6] returning; [7]
swirl pot; [8] delivers; [9] immersed; [10] atomized. [11] solenoid.
7
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] About 11,500 liters of air are needed to burn one liter of petrol in an
internal combustion engine. [2] EFI systems therefore contain many devices
to measure and control air passing to the combustion system. [3] Some EFI
units use an metal flap linked to a variable resistor to measure actual air flow.
[4] Another method uses a hot platinum wire which changes its electrical
resistance when cooled by air. [5] A more complex solution is the ultra-sonic
Karman Vortex air flow sensor. [6] This depends upon sending ultra-sonic
sound signals across vortices which change with air speed and temperature.
[7] Another device, the manifold absolute pressure sensor helps to regulate
the correct air-fuel ratio. [8] Driver input to the EFI system is via the throttle
valve. [9] This butterfly valve is physically moved by the accelerator pedal.
[10] Idling speed is controlled by an adjustable air passage which by-passes
the throttle valve.
response:
1. What is the ratio of air to fuel (by volume) in an internal combustion engine?
2. Make a sentence using the following words: EFI systems / contain / devices
/ air / combustion
3. How can a metal flap in the air duct measure air flow?
4. Explain how a platinum wire can measure air flow.
5. What is a third type of air flow sensor?
6. How can ultra-sonic signals actually measure air flow?
7. Make a question using these words: how / air-fuel / ratio / measured
8. How does the driver influence EFI operation?
9. What is the design of the throttle valve?
10. How is idling speed controlled in an EFI system?
keywords:
[1] air; [2] measure; [3] flap; [4] wire; [5] vortex; [6] ultra-sonic; [7] ratio; [8]
driver; [9] butterfly; [10] idle.
7
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] The EFI electronic system consists of an analogue computer plus an array
of sensors and actuators. [2] Mechanics can do little to repair the computer
(also called the control module) but can read "trouble codes" with the right
equipment. [3] The computer receives information, then stores, collates and
computes it. [4] Information is output to control devices in either analogue or
digital form. [5] Some control modules can be reprogrammed for different
engines. [6] A throttle position switch sends information varying from "idle" to
"high load", and gives a signal for increasing the injection valve pulse width.
[7] A throttle position sensor measures the throttle valve angle, and this is
used to calculate the crude air-fuel ratio. [8] Various sensors measure air and
coolant temperature, while a detonation sensor records ignition firing, hence
timing. [9] An oxygen sensor in the exhaust gives information for precisely
tuning the air-fuel mixture. [10] Both vehicle speed and crankshaft speed are
measured by other devices, which feed the information back to the control
module.
response:
keywords:
[1] EFI; [2] trouble codes; [3] computer; [4] control devices; [5] reprogrammed;
[6] throttle; [7] position sensor; [8] various; [9] oxygen; [10] speed.
7
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1]Natural liquid petroleum gas occurs as evaporation in most crude oil wells,
and some wells are almost completely gas deposits. [2] For many years LPG
was burnt off into the atmosphere, but now it is often liquefied by compression
and marketed. [3] LPG also occurs as a by-product of oil refining. [4] LPG is a
mixture of several gases, mostly propane, with smaller proportions of
propylene and butane. [5] At atmospheric pressure (101.3 kpa) propane has a
boiling point of -42°C, propylene -48°C and butane 0°C. [6] LPG is normally
stored in liquid form at about 706 kpa at 20°C. [7] Note that actual pressure is
proportional to temperature and the composition of the gases. [8] A litre of
liquid LPG will release about 270 liters of vapour to a car engine. [9] LPG is
naturally colourless, odourless and tasteless, but smell is added for the safety
of users.
response:
7
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
response:
1. Change this sentence from passive to active voice: LPG should always be
treated with respect.
2. Why will liquid LPG cause frostbite?
3. What is the effect of liquid LPG when it touches an eye?
4. What personal safety precautions should you take when using LPG?
5. Why can't you smoke when working near LPG?
6. Finish this sentence: LPG is heavier than air, so ...
7. Why is a special detector needed to locate LPG in the atmosphere?
8. Finish this sentence: LPG vapours increase cancer risks, so ....
7
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Take special precautions when working on a vehicle (which is) fitted with
an LPG tank. [2] Close the tank before any work. [3] Run the engine to empty
the pipes of all gas.[4] Do not proceed until you have checked for leaks. [5]
Read and understand all the regulations about working with LPG. [6] There
are regulations about fitting LPG equipment, the construction of LPG tanks,
the operation of LPG systems, and the adjustment of LPG-fuelled engines. [7]
LPG gases have slightly different effects on your body at different
concentrations. [8] At a high concentration, Propane and Butane will act as
asphyxiates. [9] That is, they will force air from the lungs, causing
unconsciousness and then death. [9] At a 2% concentration in the air,
propane and butane act as an unaesthetic.[10] That is, they will cause
dizziness, then possibly unconsciousness and death.
response:
7
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
pattern: for this reason; X includes A,B,C; X allows Y and does Z; if X, then Y
text:
[1] An LPG cylinder must store fuel under a pressure of about seven
atmospheres. [2] For this reason the tank is usually constructed of carbon
steel or stainless steel. [3] A number of valves and gauges are fitted to the
tank. [4] They include the service valve, the safety relief valve, the contents
gauge, the fixed liquid level gauge (for ullage), the filler valve, and the
automatic fill limiter. [5] The filler valve allows filling from a high pressure gas
source, and closes automatically when filling is complete. [6] If the gas source
is connected directly to the tank, a double non-return valve must be used. [7]
If the gas source is remote from the tank, a single non-return valve can be
used at the tank end, but a double non-return valve must be used at the gas-
source end. [8] The law requires an automatic fuel limiter (AFL) to prevent
filling the tank more than 80%.
response:
7
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] The service valve is also called the manual isolating valve. [2] The service
valve controls whether gas flows from the tank to the service line. [3] The
service valve should either be fully on or fully off. [4] If it is partially on, there
can be leakage to the atmosphere, which is dangerous. [5] An excess flow
valve is part of the service valve, and automatically cuts off if there is a break
in the fuel line. [6] The valve closes if there is a gas flow of more than 215
milliliters per second at fifty kilopascals. [7] However a small bypass hole
allows gas to flow at 3.3 ml/s at 350 kilopascals, even when the main valve is
closed. [8] This allows an empty fuel line to be refilled after repair.
response:
7
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] The function of the automatic fuel limiter (AFL) is to prevent over-filling of
the LPG cylinder. [2] A Katakura AFL consists of a float connected to a pilot
valve which is inside a main valve. [3] As the tank fills to 80% of capacity, the
float closes the pilot valve. [4] When the pilot valve is closed, pressure inside
the main valve forces it to close also. [5] When the main valve is closed, filling
is stopped. [6] A small bypass hole from the AFL to the Fill Valve prevents a
"lock up" of liquid in the AFL when filling is complete. [7] This allows the AFL
to reset for the next fill. [8] The internal design of the AFL uses an equalization
of pressure in different parts of the mechanism to operate it. [9] The design is
ingenious.
response:
7
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
11.7 LPG Systems (6): The Ullage Valve, Safety Valve and
Contents Gauge
pattern: X does Y when Z; When Z, X will do Y; X goes through Y; Xs like Y
must have Z; X uses a Y
text:
[1] Ullage is the unfilled space in a storage tank. [2] LPG tanks have an Ullage
Valve (also called a Fixed Liquid Level Gauge). [3] The Ullage Valve bleeds a
small amount of liquid into the atmosphere when the tank is 80% full. [4] This
bleed goes through a clear plastic tube which the operator can see, and then
knows he must stop filling. [5] On old LPG tanks with no AFL, the Ullage Valve
was the only way to know when the tank was full.
[6] Sealed pressure vessels like LPG tanks must have a safety release valve.
[7] When the pressure in an LPG tank rises above 2.55 MPa
(MegaPascals)the safety valve will open. [8] The Contents Gauge gives an
exact reading of fuel remaining in an LPG tank. [9] The Contents Gauge
commonly uses a direct reading magnetic float mechanism.
response:
1. What is ullage?
2. Finish this sentence: The ullage valve is also ....
3. When does the Ullage Valve operate?
4. How does an Ullage Valve help the operator?
5. What is one difference between old and newer LPG systems?
6. What is the safety valve relief pressure on an LPG tank?
7. Make a question using these words: What / exact reading
8. What is the usual operating mechanism for a Contents Gauge?
7
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] LPG systems have numerous valves and gauges in all parts of the unit. [2]
The lock-off valve filters and controls gas from the tank to the converter (also
called a vaporizer/regulator). [3] The LPG lock-off valve is regulated by the
manifold vacuum, and closes if the engine stalls. [4] The LPG safety switch
sits between the LPG lock-off and the converter. [5] It may be electrically or
vacuum driven, but always closes if the engine stalls. [6] The petrol lock-off is
a solenoid valve, but it can be overridden manually. [7] LPG converters may
be simple or complex, but their function is always to change fluid pressure. [8]
Liquid LPG enters the first converter stage and is changed to vapour. [9] LPG
vapour emerges from the second stage converter at roughly atmospheric
pressure.
response:
8
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
response:
keywords:
[1] electrical system; [2] alternator; [3] alternating current; [4] battery; [5]
wiring; [6] earthing; [7] regulators; [8] fuses; [9] car computers.
8
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
12.2 Alternators
pattern:
text:
response:
keywords:
[1] alternator; [2] induction; [3] parts; [4] rotor; [5] brushes; [6] connects; [7]
stator; [8] diodes; [9] phase winding; [10] current
8
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] An electric starter motor produces very high torque for a short time. [2] Its
job is to turn the flywheel quickly until the cylinders fire, then disengage. [3] A
typical motor might have four brushes, and four commutator coils wound in
series (although some have six). [4] The rotor of a series wound motor can
spin out of control with no load, so be careful. [5] The rotor shaft is connected
to a pinion gear which turns the flywheel. [6] The motor will not turn until the
pinion gear engages the flywheel. [7] When the flywheel turns faster than the
starter motor, an overrunning clutch disengages the starter. [8] A solenoid sits
on top of the starter motor, and moves a pivot lever to push the pinion gear
onto the flywheel. [9] A few starter motors use permanent commutator
magnets for more power. [10] Some starter motors use a special reduction
gear (sometimes sun and planet gears) for extra cranking speed.
response:
keywords:
[1] torque; [2] flywheel; [3] series; [4] no load; [5] pinion gear; [6] engage; [7]
clutch; [8] solenoid; [9] magnets; [10] speed.
8
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Disconnect the starter connecting strap from the solenoid cap. [2] Remove
the solenoid mounting screws. [3] Lift and pull the solenoid away from the
pivot lever and housing. [4]Remove the shaft end cap screws, cap, circlip and
spacing washers from the starter. [5] Remove the through bolts and the
commutator end housing. [6] Lift the brush holder off the armature, after
removing the brushes. [7] Remove the yoke and field coils. [8] Note the
position of the dust cover and pivot lever, then remove the armature. [9]
Remove the circlip from the drive shaft, then slide the collar off. [10] Slide the
pinion and clutch assembly off the armature (drive) shaft. [11] Remove the
solenoid cap, desolder the solenoid wires and then push the cap away from
the solenoid chips.
response:
keywords:
[1] connecting strap; [2] screws; [3] solenoid; [4] washers; [5] through bolts; [6]
brushes; [7] yoke; [8] armature; [9] circlip; [10] pinion; [11] solenoid cap
8
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Every automobile needs at least one lead-acid battery. [2] Firstly the
battery is a source of power for the ignition system, starter motor and other
systems. [3] Secondly, the battery stabilizes voltage in the whole electrical
system. [4] Thirdly, the battery provides a temporary current boost when
electrical demand is greater than the alternator output. [5] 12 volt lead-acid
batteries are made up of six cells (which are) connected in series. [6] The
cells are filled with an electrolyte of suphuric acid (which is) diluted with water.
[7] Each cell has an output of 2.2 volts. [8] Each cell will typically contain three
negative plates (which are) interlaced by two positive plates. [9] The negative
plates are welded into a plate group by a post strap, and similarly for the
positive plates. [10] The positive plates contain brown lead dioxide (PbO2),
while the negative plates contain grey sponge lead (Pb).
response:
8
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Electrolyte is the carrier which moves electric current between negative
and positive plates in a lead-acid battery. [2] The electrolyte is a solution of
sulphuric acid and water at a specific gravity of 1.265. [3] Specific gravity is
the weight of a liquid divided by the weight of an equal quantity of water. [4]
The specific gravity of water is 1. [5] During DISCHARGE, oxygen from the
positive plate(lead dioxide, PbO2) combines with hydrogen in the sulphuric
acid (H2SO4) to form water (H2O). [6] This dilutes the acid. [7] At the same
time, sulphate (SO4) from the acid combines with lead (Pb) in both the
negative plate and the positive plates. [8] The result is lead sulphate (PbSO4).
[9] The negative and positive plates become more and more similar. [10]
During battery CHARGING lead sulphate splits into lead (Pb) and sulphate
(SO4). [11] Water is split into hydrogen (H2) and oxygen (O). [12] Hydrogen
(H2) then combines with sulphate (SO4) to make sulphuric acid (H2SO4). [13]
Oxygen combines with lead to make lead dioxide (PbO2)on the positive plate.
response:
8
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] The best charging method for a battery is affected by at least four factors.
[2] Firstly, consider the electrical capacity of the battery and secondly, its
present charge state. [3] Thirdly the battery age and condition will affect
charging, and finally the temperature of the electrolyte is important. [4] Fast
charging should be limited to 60 amperes for 30 minutes for 12 volt batteries.
[5] A battery should not be fast charged beyond 75% of capacity (specific
gravity of 1.225). [6] Constant potential charging keeps the same voltage but
current drops automatically as the battery becomes full. [7] If a battery warms
up during charging it should be placed on a slow charge. [8] Constant current
slow charging sends about 3 amperes for up to 24 hours. [9] When the cells
are gassing freely the battery is charged. [10] A trickle charge of one ampere
is used to maintain battery stocks. [11] Trickle charges should be turned off
overnight or batteries may be damaged by overcharging.
response:
1. What are the first two factors affecting the best charging rate?
2. What are the third and fourth factors affecting the best charging rate?
3. Rewrite the following sentence in passive form: Battery age will affect the
charging rate.
4. What are the time and ampere limits on fast charging for a 12 volt battery?
5. When should fast charging be stopped?
6. What is constant potential charging?
7. If the battery becomes warm during charging, what should you do?
8. What sort of charging works on an input of about 3 amps?
9. How do you know when a battery is charged?
10. Finish this sentence: A trickle charge of one ampere is used ............
11. Why should a trickle charge be turned off from time to time?
keywords:
[1] method; [2] capacity; [3] age; [4] fast; [5] 75%; [6] constant; [7] warm; [8] 3
amperes; [9] gassing; [10] trickle; [11] damage
8
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] A high voltage spark ignites the fuel-air mixture in a cylinder's combustion
chamber. [2] This spark is produced by a special electrical circuit which is
called the ignition system. [3] Here is how an ignition system works. [4] The
battery stores DC current at only 12 volts. [5] An ignition coil boosts the 12 volt
current to about 20,000 volts for very short periods of time. [6] Between the
ignition coil and the spark plugs is a distributor, which has two jobs. [7] Firstly,
the contact breaker points in the distributor break the electrical circuit, which
creates a high voltage in the coil. [8] Secondly, the distributor passes current
to each of the spark plugs in turn. [9] The high voltages between the coil and
spark plugs are carried by special insulated leads which have cores of copper,
carbon or silicon.
response:
keywords:
[1] spark; [2] ignition; [3] works; [4] battery; [5] coil; [6] distributor; [7] points; [8]
in turn; [9] leads
8
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
[1] The distributor in an ignition system has several important functions. [2] It
switches the current flow through the coil on and off. [3] It distributes high
voltage pulses from the coil to alternate spark plugs. [4] It controls the timing
of ignition sparks according to speed and engine load. [5] Each part of the
distributor has a job to do. [6] The distributor cap works with the rotor button to
form a rotary switch. [7] Except for metal and carbon contacts, these parts are
made of insulating material. [8] The contact set (distributor points) has a fixed
contact and a moveable breaker arm. [9] The contact points open and close
the ignition coil circuit. [10] The vacuum advance controller is linked to the
contact breaker plate, and varies the ignition timing. [11] The distributor body
is clamped to the engine and adjusted (in order) to set initial ignition timing.
[12] The condenser is a special capacitor which speeds collapse of the
magnetic field in the coil, and also helps prevent arcing across the distributor
contact points.
response:
8
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
[1] An ignition coil consists firstly of a laminated iron core. [2] About 20,000
turns of fine wire around the core make up the secondary winding. [3] About
500 turns of heavier insulated copper wire then make up the primary winding.
[4] The core and coils are packed in bitumen or oil, and stored in a metal
jacket. [5] The metal jacket dissipates heat[6] An insulated ignition coil cap
contains terminals for the low tension battery circuit, and a central contact for
the high tension lead.[7] The primary winding stores energy in a magnetic
field. [8] When the distributor contact points open, the magnetic field collapses
and induces a high voltage in the secondary windings. [9] An ignition coil is
really a step-up transformer which generates from 4,000 to 30,000 volts at 50
to 150 times a second.
response:
9
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] An automotive ignition system contains two main circuits. [2] The primary
ignition circuit is the path for low voltage current from the battery. [3] It
includes the ignition switch, coil primary winding, distributor contact points and
condenser. [4] When the contact points are closed, battery current sets up a
magnetic field in the primary winding. [5]When the contact points open the
magnetic field collapses. [6] Current would arc across the small contact point
gap if the condenser did not provide an alternate path. [7] The points are
mechanical, so they open slowly (in electrical terms). [8] However, the
condenser diverts the current very quickly. [9] Current stored in the condenser
reverses back through the coil when battery voltage drops. [10] This helps the
magnetic field in the coil to collapse very quickly for maximum effect.
response:
9
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
[1] The secondary ignition circuit is the path for high voltage current from the
coil. [2] It includes the coil secondary winding, the distributor rotor arm, the
distributor cap, high tension leads and spark plugs. [3] Induced voltage in the
coil secondary circuit depends upon several factors. [4] Firstly it depends
upon the number of windings in the primary and secondary coils. [5] Secondly
it depends upon the voltage in the primary winding, and hence the strength of
the magnetic field. [6] Thirdly it depends upon the speed with which the
primary magnetic field collapses. [7] Conventional ignition systems have some
limitations because of dwell time and a maximum of about 4 amperes in the
primary circuit. [8] Dwell angle is the number of degrees the distributor cam
turns while the contact points are closed. [9] At high speeds the points cannot
stay closed long enough for the coil to reach magnetic saturation. [10]
Because the primary circuit is not fully charged at high speed, the secondary
circuit does not receive optimum voltage.
response:
9
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
pattern: Some problems are ..; X uses so much Y that Z; One solution is to Y;
A does B except on Y when Z occurs; X is so strong that Y;
text:
[1] Some marginal problems which affect ignition systems are voltage drop,
tracking and electrical interference. [2] The starter motor uses so much
current that not enough is left for the coil. [3] A common solution is to use a
coil (which is) designed to permanently run on a lower current. [4] A ballast
resistor stops full battery voltage from reaching the coil, except on startup
when the resistor is short-circuited. [5] Running such a coil without a ballast
resistor will damage it. [6] Tracking means low resistance leakage paths
across insulators because of dirt or moisture. [7] Tracking is found most often
in spark plugs and distributor caps. [8]The high tension ignition circuit is so
strong that it can induce voltages in other electrical devices. [9] Induced
voltage especially affects nearby radio and television receivers. [10] One
solution is to add resistance ("suppressors") to the secondary circuit, which
reduces the strength of the magnetic field at the spark gap. [11] A second
solution is to put capacitors between an area of interference and earth. [12] A
third solution is to encase high tension components in a metal shield, called
screening.
response:
9
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] An electronic ignition system does not use breaker points and a
condenser. [2] Instead, it contains a reluctor and a sensor in the distributor,
and an ignition control unit. [3] The reluctor is a rotor with teeth equal to the
number of cylinders, and is found in place of the old distributor camshaft. [4]
As the reluctor passes the sensor a signal is sent to a demodulator in the
ignition coil. [5] The demodulator switches off the primary circuit, causing the
magnetic field in the primary coil to collapse. [6] The ignition control unit has
solid state components, including an oscillator. [7] When the ignition is
switched on, the oscillator excites a magnetic field in the sensor. [8] This
makes the sensor sensitive to the revolving metal teeth of the reluctor.[9] Note
that electronic ignition systems look similar to breaker point systems, but they
operate at higher voltages. [10] Therefore parts cannot be exchanged
between the two kinds of systems.
response:
9
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
response:
keywords:
[1] semiconductor; [2] silicon; [3] shell; [4] valence; [5] crystal; [6] bonding; [7]
bias; [8] N-type; [9] P-type; [10] electron short; [11] diode
9
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
14.2 Diodes
pattern: X is a Y, made from Z; P becomes Q because R; A becomes B.
However, Y;
text:
[1] A semiconductor diode is a solid state electronic device made from two
parts. [2] One part of the diode is made from P-type material, and one part is
made from N-type material. [3] "P" refers to positive (a shortage of electrons)
and "N" refers to negative (an excess of electrons). [4] A thin layer on each
side of the PN junction becomes electrically near-neutral because the atoms
in this region achieve stable valence. [5] However, impurity atoms (e.g. of
aluminum) in the stable layer make a charged barrier to the passage of many
free electrons. [6] This "internal barrier potential" can be overcome by a
potential of 0.7V for silicon or 0.3V for germanium. [7] When the small barrier
voltage is varied exactly a much larger current is allowed to flow through the
PN junction. [8] This means that the junction is a sort of tap. [9] Electron flow
will only pass through a diode from the N-type material to the P-type material.
[10] This means that the PN junction is a valve with many uses. [11] One
important use of diodes is to rectify AC current to DC current.
response:
9
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
14.3 Transistors
pattern: T work on the same U as V. However … ; P has a low Q, but a high
R
text:
[1] Transistors work on the same principle as diodes. [2] However their design
makes it possible to control a wider range of circuit needs more accurately. [3]
A transistor contains three elements, which may be NPN or PNP. [4] An NPN
transistor is forward biased for current, and a PNP transistor is reverse
biased. [5] The transistor elements are called the collector, the base and the
emitter. [6] The emitter supplies electrons to the base in an NPN transistor, or
hole charges* in a PNP transistor. [7] The collector removes charges from the
base. [8] The base is forward biased and very thin. [9] It has very low
resistance to the emitter circuit, but high resistance to the collector circuit. [10]
When a small control current is sent into the base, almost all the electrons go
to the emitter. [11] At the same time, barrier potential at the PN junctions is
overcome and a large current flows between the emitter and collector circuits.
hole charge: when an electron moves from one atom to another it leaves a
"hole" which can be filled by another electron. Thus these "holes" are moving
from positive to negative, in the opposite direction to the electrons. This is
called hole flow. A PNP transistor uses hole flow.
response:
keywords:
[1] principle; [2] design; [3] elements; [4] biased; [5] collector; [6] supplies; [7]
removes; [8] base; [9] resistance; [10] control; [11] barrier
9
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Silicon controlled rectifiers (SCRs) are widely used in electronic ignitions
and battery chargers. [2] SCRs combine two diodes in an arrangement of
NPNP, which give three junctions. [3] The second junction is reverse biased
and the third junction is forward biased. [4] This normally prevents the SRC
from conducting through the main circuit. [5] However, another circuit called a
gate is introduced after the first junction. [6] A small voltage from the gate
overcomes barrier potential at the junctions. [7] A large current will then flow in
the main circuit, even if the gate current is stopped. [8] If the main current
stops, the gate trigger is needed to start it again. [9] Another kind of electronic
trigger is a sensor. [10] A sensor controls electron flow as its temperature or
pressure changes. [11] Car air conditioners are a typical use for this kind of
sensor.
response:
keywords:
[1] widely used; [2] NPNP; [3] biased; [4] prevents; [5] gate; [6] voltage; [7]
main; [8] stops; [9] sensor; [10] controls; 11] air
9
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] You have to sell your personality and skills in a job interview. [2] Be
punctual, neatly dressed and keep a good posture. [3] Don't slouch, don't
smoke, and don't be negative in any way. [4] Speak clearly, but don't say
more than you need to. [5] If asked, describe your qualifications and career
history in the first two minutes. [6] Explain your skills in the second two
minutes. [7] Come with some examples of SUCCESSFUL things you have
done in the past. [8] Be ready to explain how you solved some work problem
in the past. [9] Be ready to explain how you can help this new employer. [10]
Think up a harmless answer to questions such as "what is your greatest
weakness". [11] Keep all your personal doubts private. [12] Be ready to ask a
couple of sensible questions about the new job.
response:
keywords:
[1] sell; [2] punctual; [3] slouch; [4] say; [5] two minutes; [6] skills; [7]
successful; [8] solved; [9] help; [10] questions; [11] doubts; [12] ask.
9
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Your voice is your strongest link with the rest of humanity. [2] You should
try to speak in an interview with authority, certainty, consideration, credibility
and empathy. [3] You show that you are in control when you speak with
authority and certainty, and this impresses people. [4] Be careful not to
confuse authority with arrogance. [5] Always show consideration for the
feelings of people you talk to, and people you talk about.[6] It makes you look
weaker when you talk badly about somebody else. [7] You must make other
people feel that they are credible. [8] If you believe in them, they will believe in
you. [9] Empathy is the ability to put yourself in another person's shoes, and
share their feelings. [10] This is a great gift in human relationships.
response:
keywords:
[1] voice; [2] authority; [3] control; [4]arrogance; [5] consideration; [6] talk; [7]
credible; [8] believe; [9] empathy; [10] gift.
1
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] My name is Samir and I come from Basra in Southern Iraq, where my
family had lived for generations. [2] At high school I attended the technical
stream and graduated with training in automotive repairs. [3] I wanted to study
more, but my family was not rich. [4] For six months I worked in a garage,
then my country went to war with Iran. [5] Every man in Iraq is forced to serve
in the army. [6] Luckily I spent most of the next six years repairing tanks and
trucks, which gave me more mechanical experience. [7] I was very unhappy
with conditions in Iraq, and eventually I was able to flee to Turkey with my
family. [8] After some time in a refugee camp I came to Australia. [9] For a
year I worked in a vehicle assembly plant for Ford in Melbourne. [10]
However, I really wanted to improve my technical and English language skills.
[11] Therefore I have been doing a six months full time Certificate in
Occupational Studies (Automotive) with John Batman Institute of TAFE.
response:
key words:
[1] Samir; [2] high school; [3] study; [4] worked; [5] army; [6] mechanical
experience; [7] flee; [8] refugee; [9] assembly; [10] Certificate.
1
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] From a very early age I liked to take things to pieces. [2] It was a sort of
joke in my family. [3] However this habit gave me a natural advantage as a
mechanic. [4] I seem to have a real talent for problem solving, especially when
it comes to machines. [5] Of course, I have also learned to understand metals
very well. [6] In Iraq I often had to make parts which couldn't be bought. [7] I
can use a lathe and weld most jobs. [8] I have had experience with trucks,
farm machinery, military vehicles and cars. [9] In Iraq I also had licences to
drive all these vehicles. [10] In Australia I have a car licence at present, and
have also done a course to obtain a forklift licence.
response:
keywords:
[1] pieces [2] joke [3] advantage [4] talent [5] understand [6] make [7] lathe [8]
experience [9] licences [10] forklift
1
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
response:
dialogue:
1
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
reconstruction a)
Clln s n * pprntc. H s * hldng * 6mm spnnr nt rsty mntng blt wth hs tstrtchd rm.
Hs shldr s chng * nd h cn't s th * blt, bt hs bg wrry s Bll Pttgrw, th bss. Pttgrw s
sppsd t ht th spnnr wth * blck hmmr, bt h cn't b trstd. mnt g Pttgrw tk chnk t f
Clln's knckl, thn swr * t hm whn h * drppd th spnnr.
reconstruction b)
(speak the dialogue aloud with a partner, using the vowel-less words as a
cue)
1
English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] The shipyard night crew was on a double shift and it was 2am in the
morning. [2] Earny Onions, the foreman, had told them to finish off the tail
shaft on the Alice Star. [3] She was a 12,000 ton freighter under the Liberian
flag, and the owners had driven her into the ground. [4] Old Pita was
struggling with a chain block on the shaft when a chain link suddenly broke
and the 3 ton shaft dropped with a sickening thud. [5] "Bloody Yugo'", snarled
a drunken Australian, who had come onto the shift late. [6] Pita slipped his
hand down to his boot and pulled out a knife. [7] The Australian lunged for a
heavy spanner. [8] It looked ugly. [9] Suddenly, everyone became very alert.
response:
reconstruction a):
(read the text aloud using the vowel-less words as a cue)
reconstruction b)
(read the text aloud, using the first letter of words as a cue)
Tsncwoadsaiw2itmEOtfhtttfottsotASSwa1tfutLfato
hdhitgOPwswacbotswaclsbat3tsdwastBYsadA
whcotslPshhdthbapoakTAlfahsIluSebva
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] Customer quotations for vehicle repair may be oral or written. [2]
Knowledgeable customers will insist upon a written quotation since this can
more easily be enforced as a legal contract. [3] A quotation should accurately
list the estimated time for work, the labour cost and the parts cost needed for
a repair. [4] Customers are more likely to accept a quotation which is detailed
than one which is vague.[5] Prices quoted will be retail prices, while the hourly
labour rates are up to the proprietor. [6] Other information needed on the
quotation includes: i) the name and address of the customer; ii) the make and
registration number of the vehicle; iii) any discount for cash payment. [7]
Before quoting, a mechanic should try to estimate the work as carefully as
possible. [8] Customers do not like to be rung up with the news that expensive
extra work is required! [9] The garage proprietor who refunds any
overestimate from a quotation will win great customer loyalty. [10] Treating
customers honestly is as important for repeat business as doing a good job.
response:
keywords:
[1] oral; [2] legal; [3] list; [4] accept; [5] prices; [6] registration number; [7]
estimate; [8] extra; [9] refund; [10] honestly.
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
text:
[1] If ever there was a hopeless vehicle, it was the Trabant. [2] Even the name
sounded like a crippled ant. [3] The Trabant couldn't race a moped downhill.
[4] Its cranky little two stroke motor gave off more fumes than an oil refinery,
and needed a wizard to start it on cold mornings. [5] The body was narrow
and cramped, the seats were primitive, and the suspension was barbaric. [6]
The Trabant was East Germany's gift to engineering. [7] Now it was
grandma's gift to Helmut after grandfather's death. [8] Helmut could take it
when he moved to Hamburg, the old lady said. [9] Helmut managed a sickly
smile.
response:
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
Fluency
English for Mechanics is firstly about improving language skills, and secondly
about reinforcing technical knowledge in automotive engineering. All kinds of
skill and knowledge can be judged from the fluency of an individual's
behaviour.
Fluency is measured by ....
a) the speed of a student's comprehension and response
b) the precision of comprehension and response
c) the amount of information the student can hold in consciousness at a
given time.
Learning
For most of us, the hardest part of study is not the content of a topic itself, but
managing the learning process. Successful learning is often controlled by
whether information is mentally digestible, or can be made digestible.
Students will only learn and retain ...
a) what they can hold in short-term memory .
b) what they can grasp conceptually.
c) what has some "emotional reality" for them
Teaching
This book will be used by both teachers and students. Teachers are a
resource, but they don't know everything, and they can't do the job of learning
for anyone else. The best way to teach and be taught is to start with a clear
understanding of what the teacher can offer. A teacher is more than a trainer,
but less than a god. Dogs are trained, and angels know it all anyway. Mere
human beings have to be coaxed with cunning and laughter to do their best.
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
a) burn off
some compounds
vapourize b) liquify by sell
crude petroleum compression
natural
LPG
refining by-product
Note: Step 5 is the hardest step, but also the most useful.
______________
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
CHAPTER 2
WELDING
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
CHAPTER 3
CHAPTER 4
FLUID SYSTEMS
Radiator Check if X then Y; imperative
procedural Language
Brakes which (rel. pro); should
be + V (passive)
Anti-Lock Braking
Systems (ABS)
Hydraulics (1): Overview
& Pascal's Law
Hydraulics (2): Brakes
Hydraulics (3):
Displacement
Pneumatics (1)
Pneumatics (2):
Vacuums & Compressed
Air
The Air Conditioning
Cycle
Refrigerant gases active/passive voice;
technical language
Heat transfer
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
CHAPTER 5
CHAPTER 6
CHAPTER 7
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
CHAPTER 8
CHAPTER 9
CHAPTER 10
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
CHAPTER 11
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
CHAPTER 12
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
CHAPTER 13
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
CHAPTER 14
CHAPTER 15
CHAPTER 16
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
CHAPTER 17
End
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English for Mechanics . copyright Thorold May 1996-2009 SINGLE USER LICENCE thormay@yahoo.com
Thor May has been teaching English to non-native speakers, and lecturing linguistics, since
1976. During the 1990s he ran a program to train immigrant mechanics to Australia in the
English needed for their profession. This gave rise to English for Mechanics, which has also
been sold and used successfully in environments as diverse as Indonesia, Poland, Hungary
and South Korea. Thor’s other work has taken him to seven countries in Oceania and East
Asia, mostly with tertiary students, but with a couple of detours to teach secondary students
and young children. He has trained teachers in Australia, Fiji and South Korea. At the moment
(2007) he is teaching in Chungju National University, South Korea. Many of his papers,
essays and stories may be seen on his website at http://thormay.net ; e-mail
thormay@yahoo.com