DEPARTMENT OF MECHANICAL ENGINEERING

GRAPHIC ERA UNIVERSITY

DEHRADUN, INDIA

INDUSTRIAL TRAINING REPORT

AN INDUSTRIAL TRAINING REPORT IN PARTIAL
FULFILMENT OF THE REQUIREMENTS FOR THE
DEGREE OF
BACHELOR OF TECHNOLOGY
IN

Mechanical Engineering
FOR THE TRAINING COMPLETED IN
NEEL METAL PVT.LTD.HARIDWAR
FROM 25.06.2013 TO

03.08.2013

SUBMITTED BY
PRASHANT GORLA
(2002775)
BATCH 2010- 2014
1

INDUSTRIAL TRAINING REPORT

on
Repairing and Maintenance of different parts of Roadways Buses
at

UTTAR PRADESH STATE ROAD TRANSPORT CORPORATION

Major workshop PEETALNAGHRI, (MORADABAD)
MORADABAD -240001
Submitted in the partial fulfillment of industrial training program

CHITRESH LAHIRI
(UNIV. Roll No.: 2002706)
Department of Mechanical Engineering
GRAPHIC ERA UNIVERSITY
DEHRADUN

ACKNOWLEDGEMENT

I take this opportunity to express deep gratitude to the management of UTTAR

PRADESH STATE ROAD TRANSPORT CORPORATION Major Workshop,
PEETALNAGHRI, (MORADABAD) for providing me the opportunity to get an
exposure of their esteemed unit. I am sincerely thankful to the MAINTENANCE
DEPARTMENT which Co-ordinate the training and especially express my thanks to
Mr. MUKUL KUMAR (Service Manager, SM) for their continued help and guidance.
Last but not the least I express my deep gratitude to our Director Dr. M. P.
Singh for sending me to such a large integrated industry for summer training and giving
chance to acquire an experience of lifetime.
I also express my sincere thanks to parents and family members for providing
their continued moral support.

CHITRESH LAHIRI
B.Tech. : M.E
TH
4 Year, VIIth Semester
GRAPHIC ERA UNIVERSITY
DEHRADUN, Uttarakhand

Head Of Department
Date
Student
Class Coordinator

CONTENT
Certificate
Acknowledgement
Content
S.NO
1

INTRODUCTION
1.1 Profile of the industry
1.2 Introduction
1.3 Nature of industry
1.4 Section of unit visited and activities
1.5 Details of Machine
1.6 Tools and Instrument
1.7 Work procedure in different section
1.7.1Engine section
1.7.2 Brake section
1.7.3Gear section
1.7.4 Pump section
1.7.5 Front and Rear Axle

SPECIFICATION OF PRODUCTS
2.1Work of repair and maintenance

DETAIL OF THE SHOP

3.1 Machine shop
3.2 Tyre shop
3.3 welding shop
3.4 Fitting shop
3.5 Sheet Metal working shop
3.6 Painting Shop

DISCRIPTION OF BRACKDOWN
5

4.1 Storing manners of the items

5

SAFETY MEASURE OF WORKPLACE

CONCLUSION

PROFILE OF THE INDUSTRY

Work:

Regional Workshop
UTTAR PRADESH STATE ROAD TRANSPORT
CORPORATION
Moradabad Zone
PEETALNAGHRI, (MORADABAD)

Head Office:

Lucknow, India

Year of Establishment:

1947

Types of production:

Automobile Parts Assembly &Repairing

Area Benefittted:

Bijnore,Rampur,Chandausi,Amroha,
Dampur,Sambhal Depot.

INTRODUCTION:
This workshop is established in PeetalNaghri District Moradabad Operated by
UttarPradesh Transport Corporation. It was established by Govt.of Uttar Pradesh in the
year 1952.
In roadways workshop parts of buses are repaired for the assembling and repairing of
automobile parts it is divided into engine section, gearbox, F.I.Pump spring front and
rear axle section and staring section.
Disassembled parts of Roadways workshop are prepared by ASHOK LEYLAND and
TATA Industry.

1.3 Nature of the Industry:

In this unit all type of maintenance and lubrication of a vehicle is done. here parts
assembly also worked in this unit. There are following type of maintenance, repairing
and assembly of different parts of buses is done by mechanics .Different parts of bus
are as follows:
1. Engines Work
2. Gear Box
3. Brake System
4. Clutch Plate
5. Front Axle and Rear Axle
6. Oil Pump
7. Water Pump
8. Welding
9. Painting
10. Air Dryer
11. Tier Body Repair

Working HourThe working schedules are divided into two shifts, A Shift and B Shift. Every
workers work in 8 Hrs.
The Timing Of A Shift Is 8:00 AM -12:00 PM
The Timing Of B Shift Is 1:00 PM- 5:00 PM

Working StaffIn each section 15-20 mechanics works and 7-10 helper helps to them and works going
easily.
1.4 SECTION OF THE UNIT VISITED AND ACTIVITIES
SECTION IN UNIT
In this unit all maintenance and repairing in vehicle divided into different section. Each
section has its own work of repairing and assembles of parts. In all these sections,
particular work has done.

In MORADABAD Roadways has following section

1. Engine Section
2. Gear Box Section
3. Rear Axle Section
4. Front Axle Section
5. Pump Section
6. Electrical Section
7. Welding Section
8. Painting Section
9. Brake Section
10. Other Repair Section
1. Engine SectionThis section is the most important section of the workshop. In this shop engine is
assembled. All necessary parts for the assembly of engine available in the store room.
This assembly completed by trained and expert mechanics. After checking of working

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of assemble engine. It used to vehicle and replaced the damage engine. All the assemble
repairing and checking work are completed in this section.

Fig. 6 cylinder engine

Main parts of engine:
1. Cylinder blocks &crank case
2. Cylinder head
3. Piston
4. Piston ring
5. Piston pin
6. Connecting rod
7. Crank Shaft
8. Cam shaft
9 Fly wheels
10. Silencer
11. Air compressor
12 . Oil Filter
2. Gear Box Section-

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In this section gear system is assembled. All the gear arrangement of gear system are
adjusted during the assembly. After checking the gear system by the experience of
mechanics gear box is prepare for using in to replaced damage gear box in vehicle.
3. Rear Axle SectionIn this section Rear axle of vehicle which connects to back wheel from front wheel
through the popular shaft is assemble. Rear axle having two parts 1 st body and another
is crown case. Both the parts assemble separately. After there assembly they assemble
together and Rear axle is completed. After checking Rear axle by mechanics experience
its prepare for work.

Fig. Rear Axle

4. Front Axle SectionIn this section Front axle assembly is completed. After checking the assembly prepare
for working.

12

Fig. Front Axle

5. Pump Section- This section is divided into two parts
5.1-Water Pump Section
5.2-Oil Pump Section
5.1.Water Pump SectionIn this section Water Pump assembly is completed. Air Vessel assembly is also
completed in this section.
5.2- Oil Pump SectionOil pump used for delivering the fuel in engine. It is so important that Oil pump
assembly is complete in this section. In this unit, there is two type of Oil pump which
are assembled in workshop. First is inlined fuel pump and another is rotatory pump.
After the assembly, pumps are checked in oil pump testing machine. If pump works
properly then it used in engine.

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Fig .Oil Pump

6. Electrical SectionIn this section electrical part of engine ALTENATOR is assemble, repair and checked.
Electrical function in breaking system of vehicle is also completed with the help of
electrical section.
7. Welding SectionIn this section the broken body broken spare part are jointed by arc and gas welding.
8.Painting SectionIn this section the painting work in the body of vehicle or in the parts are be done.
9.Break DownIn this section brake system in Rear axle and Front axle is assemble and also in the
vehicle this brakes arrangement is most complicated work in all

10.Other Repair Section

In this section engine is repaired in such place which can not repair in engine
section like cylinder head, fuel pump, and alternator etc.

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1.5 DETAILS OF MACHINE

(a)Press Fit MachinesThe press fit machine are used for bearings are tight fit in shaft by press fit machine.
(b)Micro Machine(Testing Machine For F.I. Pump)
It is used for testing of F.I. Pump. It is an electrical machine.
(c)Lathe Machine- This machine used for the entire Lathe operations in vehicles part
according to their needs like brake drum

Fig. Lathe Machine

1.6 TOOLS & INSTRUMENTS

There are various type of tools used in this workshop such as.
1. Screw Driver
2. Spanner, wrenches
3. Ratchet
4. Pliers
5. Hammers
6. Drilling Machine
7. Chain Pulley Block
8. Hydraulic Jack
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9. Axle Stand
10. Gripper
11. Tools For Tire
12. Brake Checking Instrument
13. Engine Analyzer Etc.

(a )Air Compressor Torque ringIt is used for fast tightening of bolt. A dia is used in the torquring. It is fix in it.

(b) High Pressure Speed InstrumentIt is a special type of machine which is used for maintain the speed of bus.
(c)Vulcanization MachineIt is used for repairing the damage tubes of tire.
(d)Tire LeaverIt is used for fit the tire on rim and remove it for rim.
(e )Q DiaIt is used in different of fix torque ring as a square hole dia, hexagonal hole dia. It is
used according to bolt head. It is made f Cast Iron.
1.7 Work Procedure In Different Section
1.7.1

Engine Section-

Repairing of engine, assembly of engine are done in the unit. The maintenance of
vehicle has often 18000 K.M. running. In which checked also. If any default in engine
they repair it. Engine having 2 lakh K.M. life. After running this distance engine can be
damage. It depends on its maintenance.
This unit new engine is assemble. Its different parts for assemble if
available in store room of this unit. These required part such as

16

Cylinder Block
Cooling Plate
Piston
Rocker Arm
Crank Shaft
Timing Plate
Cam Shaft
Outlet Manifold
Fly Wheel
Inlet Manifold Housing
Oil Pump
Cylinder Head
Air Compressor
Clutch Fork
Piston
Overflow pipe
Injector Pipe
Tapped Cover
Radiator
Water Pipe
Turbo
Turbo Fan
Diesel
Air Filter
Starter Motor
Lubrication Filter
Dumper Pulley
Atomizer
Push Rod
The assembly of engine done by expert and trained mechanics. They have all required
tools and facility. After assembly engine checked also. If the engine works properly
then it used in vehicle. Engine also assemble in vehicle in this unit.
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1.7.2 Brake SectionBrake assembly in Front and Rear axle and in the vehicle also done by expert
mechanics in this unit. All required part such as brake shoe, brake drum, lining brake
cam, ratchet, roller bearing etc. are available in store room.

1.7.3 Gear SectionIn this section gear box and clutch plate are assembled by the mechanics.

Gear Box AssemblyGear box assembly also done in this unit. All required parts such as:
Different Gears (1st, 2nd, 3rd,4th ,5th and back gear)
Synchronize Cone,
Hub
Different Knobs,
Fork
Bearings,
Collar Bush
Counter Shaft,
Oil Ring
Main Shaft,
Lock Nut
Drive Shaft,
Shifting Slave
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Buttering,
Back Cover or Speedo cover
Front Cover
Available in the unit. Different gear can be identified by no of teeth. Engine power
transmits to counter shaft through drive shaft and it transfer to main shaft and wheel
driven system.
Clutch Plate-Clutch plate fitted between the fly wheel and pressure plate. It connects
and dis-connects the power of engine.
1.7.4 Pump Section- Pump section divided into two section
1-Water PumpIn this section water pump assembly is completed. All required parts such as1- Water pump-1510
2- Water pump shaft
3- Water pump bearing big
4- Water pump bearing small
5- Seal assembly
6- Water pump rotor
7- Water pump packing

2 Oil Pump or F.I. Pump- There are two type of Oil Pumps that are
used in Vehicle,

a.
b.

Inline FI Pump
Rotary Pump

19

Fig. S.I Pump

(a) IN LINE FUEL INJECTION PUMP

Consists of pump main body, governor, feed pump and timer. It has the same number of
plungers as cylinders of the engine and supplies fuel to all cylinders with one rotation of
the camshaft.
As this type of pump has the longest history of usage, it is widely used. It is now used
in trucks, agricultural machines and construction machines, while the distributor type is
used for small engines.
The inline fuel injection pumps are of different types such as Inline 500 type, Inline 620
type, Euro 1 type , HINO type fuel injection pumps. The working principle of all the
Inline fuel injections pumps is the same, but they are different in the construction.

(b) PARTS OF IN LINE FUEL INJECTION PUMP

1. Delivery-valve holder
2.

Filler piece

3.

Delivery-valve springs

4.

Pump barrel

5. Delivery valve
6. Inlet port and spill port
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7. Control helix
8. Pump plungers
9. Control sleeve
10. Plunger control arm
11. Plunger return spring
12. spring seat
13. Roller tappets
14. Cam
15. Control rack.

1.

Delivery-valve holder: he delivery valve holder acts as a support for

delivery valve spring. The delivery valve holder is placed above the copper
filler piece which is not re usable because it gets pressed during the delivery.

2. Filler piece: The filler piece is made up of copper and is present in between
the delivery valve holder and delivery valve spring. The filler piece is not
useable because it gets damaged due to the delivery pressure.
3. Delivery-valve spring: The spring is used to cut off the delivery of the fuel
at reduced pressures. There is a lock plate present below the spring used to
lock the element.
4. Delivery valve: The function of the delivery valve is to deliver the fuel from
the pump at high pressures to fuel injectors through high pressure pipe lines.
Inlet port and spill port : The function of the inlet port and spill port is to
draw the fuel from the plunger during the cam rotation and delivers it at high
pressure from the spill port.
5. Control helix: The control helix is present on the plunger and it is a helical
groove which connects the inlet port and spill port for the delivery of fuel.
6. Pump plunger: The pump plunger reciprocates inside the barrel and it has
an helical groove on it. The plunger is driven by cam and tappet mechanism.
21

7. Control sleeve: The control sleeve is used to fit the element (plunger and
barrel) and it acts as a grip for the element.
8.

Plunger control arm: Plunger control arm is used to control the movement
of the plunger inside the barrel.

9. Spring seat: Spring seat acts as a support or grip to the plunger return
spring.
10. Cam and Roller tappet :

Cam and roller tappet drives the plunger

according to the rotation of the cam .

11. Control rack : Control rack consists of control rod which is used prevent
dust from entering. The clearance between control rod and the upper plate of
plunger spring is generally 0.13mm
.

(d) DESIGN AND CONSTRUCTION

The standard in-line injection pumps consists of camshaft, and a plunger- andbarrel assembly (element) for each engine cylinder (above FIG.).The complete
fuel-injection system is comprised of:
A fuel-injection pump,
A mechanical flyweight or electronic

governor for control of engine-speed

and injected fuel quantity,

A timing device for varying the start of delivery as a function of

engine

speed,
A fuel supply pump for delivering the
fuel filter and the fuel line, to the injection

fuel from the fuel tank, through the

pump,

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 A number of high-pressure fuel-injection

number of engine cylinders, connecting

lines, corresponding to the

the injection pump and the injection

nozzles,
The injection nozzles.
The injection pumps camshaft is driven by the diesel engine. Injection- pump
speed and crankshaft speed are identical for 2-stroke engines. For 4-stroke
engines, pump speed is the same as engine camshaft speed, in other words half
crankshaft speed.
The drive between injection pump and engine must be as torsionally rigid as
possible if todays high injection pressures are to be generated. There are a
number of different sizes of in-line injection pumps for the various engine
outputs. The injected fuel quantity depends upon the volume of the injectionpump barrel, and maximum injection pressures are between 400 and 1,200 bar.
To lubricate the moving injection-pump components (camshaft, roller tappets
etc.) there must be a certain amount of oil in the injection pump. The injection
pump is connected to the diesel engines lube-oil circuit, and oil circulates
through the pump during operation. Each pump type is allocated to a given type
series, which in some cases overlap with respect to their power ranges.
The power outputs of diesel engines equipped with in-line injection pumps
range from 10 to 70 kW per cylinder. This broad power-output range is made
possible by the availability of a wide variety of different pump versions.
21

(e) METHOD OF OPERATION :

In line fuel injection pump consist of a plunger driven by a cam and tappet
mechanism at the bottom. The plunger reciprocates in the barrel. The quantity of
plunger varies with the number of cylinder in the engine. The plunger has a
rectangular vertical groove which extends from the top to another helical
groove. The delivery valve can be lifted off its seat under the pressure of liquid
fuel and against the force of the spring. The passage is connected to the fuel
atomizer
23

When the plunger is at the bottom of its stroke and supply as well as spill ports
are uncovered, oil from fuel feed pump, after filtration is forced into the barrel.
The supply and the spill port are sealed at certain stage when the plunger is
pushed away with the help of cam and tappet mechanism which is provided at
bottom. During the further movement of plunger the fuel above it gets
compressed and the high pressure developed, lifts the delivery valve off its seat
and fuel starts flowing through the passage to the atomizer. As the plunger rises
up still further, at a particular moment the helical groove connects the spill port
through the rectangular vertical groove, to the fuel in the upper part of the
plunger. Consequently there is a sudden pressure drop due to which the delivery
valve falls back on its seat under the force of spring. This increases the
volumetric capacity of the delivery system resulting in sudden pressure drop in
the delivery pipe. Thus the discharge from nozzle of the injector is cut off
suddenly and the fuel is prevented from dribbling into the cylinder even after the
injection ceases. The cycle is repeated frequently.
During each stroke of plunger, the duration of the delivery is more or less;
according to the spill port is made to communicate, earlier or later, with the high
pressure fuel in the upper part of the barrel. This depends up on the position of
the helical groove which can be changed by rotating the plunger with help of
rack. When engine at full load, the position of the helical groove on the plunger
is kept below the passage. At partial load or normal delivery, the plunger is
rotate to a position near by passage, in which the delivery takes place for shorter
period. When the engine is stopped, the plunger is rotate to the position where
helical groove is opposite to the passage, in which rectangular slot is in line with
the spill port. There is no pressure built up above the top of the plunger, the
delivery valve is not at all lifted and hence no delivery of fuel to the atomizer
takes place. The bore of the pump ranges in eight sizes from 5 mm to 10 mm but
the stroke of the plunger is standardized at 9 mm.

Inclined pump are rear in use in modern time. Rotatory pump used more now. Both type
of pump assemble in this unit. All required parts such as1. Body
2. Cam Shaft
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3. Rotor
4. T.D. Piston
5. Cam Plate
6. Fly Wheel Assembly
7. B.D. Holder
8.

Vane Pump

9. Pin
10. Tidbit Assembly
11. Cross Disk
12. Fulgum Leaver
13. Hydraulic Head
F.I. pump is work as fuel injection pump. After assembly it checked and after checking
it used if it work properly.

Fig. Description of F.I pump

5. TYPES OF IN LINE FUEL INJECTION PUMP

There are different types of in line fuel injection pumps but the basic principle of
operation is same. The different types are :
1. EURO 1 pump
2. IN LINE 500 type pump
3. IN LINE 620 type pump
4. HINO pump
25

The basic working of all these pumps is the same but they differ in their construction
and their overall efficiencies. The difference between In line 500 , in line 620 type of
fuel pumps from EURO 1 type fuel pump is that the In line 500 and 620 boost pressure
is supplied to the pump which increases the efficiency of in line 500 and 620 when
compared to EURO 1.the fly weight of in line 500 and inline 620 type is bigger than the
fly weight of EURO1.
25
ROTARY FUEL INJECTION PUMP
The injection pump is a single-plunger mechanical pump which distributes fuel to the
injectors in the correct firing order. The pump is driven by the camshaft spur belt or
gear at one-half crankshaft speed. All moving parts inside the pump
1.7.5 Front Axle And Rear AxleFront axle & Rear axle is assemble in there. Front axle having two parts as Eye beam
and Brake system.
Rear axle having there parts such as Eye beam, brake system and differential wheel.
Differential wheel having a different part. It assembles in this section also. Required
parts for the axle assembly are such as-

I beam
King pin
Staff axle
Adjusting seem
Brake cam shaft
Outer inner bearing
Set screw
Bush
Fork plate
Brake steel spring
26

Chuck nut,
Distance pin,
Taper bearing,
Coupling,
Coupling lock nut,
Washer,
Tail pinion.
Side bearing cone
Fig. Parts of Axle

Fig Painted Rear Axle

Roadways workshop Kathgodam, repairing work of vehicle and assemble of different
part of vehicle are done usually but it also supplied those assemble part to other sub
workshop in Kumaun regions like Bhowali Roadways etc. In the under of Uttarakhand
Parivahan Nigam, Kumaun Zone Kathgodam. Those supplied parts used in repairing
work in sub workshop of Roadways.
2. SPECIFICATION OF PRODUCTS
Roadways workshop kathgodam is a repairing centre. This work shop is repair normal
damage and problems. But in this shop damage parts replaced by new parts which
assemble in the unit. In this unit different parts of vehicle assemble and its replace
damage parts of vehicle and vehicle works properly.
27

In this shop not only product are to be produced but in this unit products sub-parts
are also used with the help of these subparts assemble. These parts used to replace
damage parts. This assembly is done by trained and expert workers under the officers.
So that parts we can say material in this shop could not harm the workers.
These sub parts produced by any automobile company like TATA, LAYLAND etc. and
Roadways workshop got its to company by legal government order.

(a) WORK OF REPAIR AND MAINTENANCE

Repair WorkIn repair department, if any part of the machine or tool is braked up. The broken part
are send to the repair department to be repaired.
Maintenance WorkThe maintenance department acts on the bases of Prevent Maintenance Inspection
(P.M.I). every machine has its fixed P.M.I. and maintain by its P.M.I.
The last week of the February is an eventry day. In these day the worker
and the repair department and the checking department check the whole machine and
repairs it. They are use only five days of the February last week.

3. DETAILS OF THE SHOP:

3.1 Machine Shop:
In machining shop there are different types of machines such as different types of lathe
machines such as Bombay lathe , bed lathe etc. , various types of drilling machines,
grinding machines, boring machines, shaping machines, slotting machines, milling
machines
In the machining shop the parts of the vehicle such as components of engine are
machines on boring machine, the gears of the vehicle are machined on lathes or
grinding machine depending upon requirements, front and rear axles are machined on
lathes or shaping machine according to the requirements of the components. There are
28

other sections such as electrical section, turbo charger shop, battery section, brake shop.
In these shops most are the components are machined and replaced .

3.2 TYRE SHOP

In tyre shop the worn out tyres of the bus are bought and are recycled by attaching a
rubber grip to the worn out tyre and is user again for the vehicle . Here the process of
recycling is very economical when compared to replacing it.
3.3Welding ShopThis shop is mainly used to joint up the broken parts. In this shop mainly used two type
of welding machine
1-Arc Welding
2- Forge Welding
3-Gas Welding
3.4 Fitting ShopThis shop is used for fitting, cutting and hammering on the iron part of bus.
3.5 Sheet Metal Working ShopThis shop is mainly used for repair that part which want to sheet layer.
3.6 Painting ShopThis shop is mainly used for paint the bus. In this shop the number plate also renew. In
this shop mainly black, white, yellow and green paint is used.
(a) Checking InstrumentTo measure the level of mobile oil in it used mobile oil gauge, also in it brake oil
gauge and water check gauge. By this we know the level of the oils and water.For
the lubricant checking they use also the instrument, and so many other thing as oil,
heat speed etc. are also checked by the other instrument.
(b) Quality ControlThe quality is measured by its capacity condition and b leaveness the vehicle needs
the regular maintenance.
29

4. DESCRIPTION OF BRAKE DOWN & RESTORING

Whenever any machine of the unit is brake down then the unit supervisor reported to
the maintenance department. The maintenance department checked the brake down of
the machine and confirm the brake down problem is electrically or mechanically. Then
they restore the machine for solving the problem. The government should do many
work. He increase many workers in a workshop. These workers are working in different
shifts.
4.1 STORING MANNERS OF THE ITEMS
All the items are store in store room. The store room is divided in many blocks and all
items keep in separately in the blocks. The name of every items written in every block
bottom in which keep them. The store room is divided into parts. There names are
electrical store room and other is mechanical parts of vehicle, engine, clutch, gear box ,
front axle, rear axle, tiers, fuel pump, fan, alternator, water pump and many other parts
of a vehicle. The store room should be without moisture. One day in a week. The
worker sprinkle the drug to kill the rat and other insects.

5. SAFETY MEASURE ON
The following points are followed by the workers on work place

All the machine should be properly greased.

Every worker should wear their working dress.

In the working condition the workers should be used gloves, ear plug and apron.

First aid box should be provided in the workshop.

Hospital should be near the workshop.

The work place should be cleaned and swept.

There should be cylinder of fire extinguisher

30

6 CONCLUSION
[1] In this report we discussed about the working of different section in roadways
workshop.
[2] Basically the organization deals with repair of engine , F I pump , gear box
and axles.

7 REFERENCE
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[1] Maintenance Engineering and Management ( Shubhash Chandra )

[2] www.Google.com
[3] I.C Engine ( Ganeshan )
[4] UttarPradesh Transport Corporation (Information Book)

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