INDUSTRIAL TRAINING REPORT

FIELD EXPOSURE REPORT REGIONAL WORKSHOP KATHGODAM, NAINITAL (Uttarakhand Transport Corporation) 2012-2013
DEPARTMENT OF MECHANICAL ENGINEERING

SUBMITTED BY Vishal Bishawakarma

SUBMITTED TO Mr. Hitendra Bankoti

INDEX

CERTIFICATE PREFACE NAME AND ADDRESS DATE OF JOINING AND LEAVING NATURE OF INDUSTRY SECTION OF THE UNIT VISIT AND ACTIVITIES THERE IN DETAIL OF MACHINE/TOOL AND INSTRUMENTS USED IN THE SECTION OF THE UNIT VISITED WORK PROCEDURE IN THE SECTION USE OF COMPUTERS SAFETY MANON WORK PLACE AND WORKING CONDITIONS SPECIFICATION OF THE PRODUCT AND MATERIAL USED WORK OF REPAIR AND MAINTAINANCE

CERTIFICATE
This is to certify that Mr Vishal Bishawakarma is a student of Mechanical Engineering Semester 6th in the season 2012-2013 of A.I.T.S Sand has successfully completed the exposure report based on theUttarakhand Technical University Dehradun and satisfactory action of it. In the report containing a record of 4 week industrial training. I wish him on the success in life.

H.O.D. Dr. R Belwal

PREFACE
I am very grateful to our honorable H.O.D Dr. R Belwal that he gave me a golden chance in the working process, management, machines and advanced technologies used in industries by this field exposure. It was a 30 days training period in which I joined Roadways Regional Workshop Kathgodam, Nainital (Uttarakhand), which is a major workshop of U.K Transport Corporation. There I learned about the parts and working process of buses as well as repairing and assembling of parts. I wish I had the chance to assemble the parts. I wish I had some more time to develop my technical knowledge by this training process. Thank You Vishal Bishawakarma
DATE-05/07/2013

Mechanical Engineering 6th semester

UTTARAKHAND TRANSPORT CORPORATION, ROADWAYS WORKSHOP (REGIONAL)

ADDRESS: KATHGODAM, NAINITAL (U.K.)

DATE OF JOINING: 03/06/2013

DATE OF LEAVING: 02/07/2013

U.T.C REGIONAL WORKSHOP, KATHGODAM OVERVIEW-:

WORK OVERVIEW Service center for uttrakhand roadways buses is situated in kathgodam ad also known as UTTRAKHAND MANDALIYA KARYALAYA. In the workshop, the repairing of damaged parts of buses is carried out by the workers. Also repaired/new bus parts are assembled. The servicing of buses is also carried out in the workshop. For these operations the workshop is divided into different sections.

Most of job of maintenance like replacement, assembling, inspection etc is done manually and is based on past experience.

SERVICES-:
The constructed parts are supplied to the following Roadways Depots as per the need.
1. 2. 3. 4. 5. 6.

Ranikhet Depot Kashipur Depot Bhowali Depot Almora Depot Haldwani Depot Ramnagar Depot

WORKING HOURS -:
In Roadways Workshop Kathgodam the work scheduleis as follows: Working Time Tea Time Working Time Lunch Time Working Time : 8:00 AM TO 10:00 AM. : 10:00 AM TO 10:30 AM. : 10:30 AM TO 12:00 PM. : 12:00 PM TO 01:00 PM. : 01:00 PM TO 05:00 PM.

SECTIONS:

The Roadways Workshop Kathgodam has the following sections-:

1) Engine Section. 2) Gear Box and Clutch Section. 3) Spring Section. 4) Fuel Injection Pump Section. 5) Axel Section. 6) Electric Section.

1. Engine Section:-

In this section tuning and testing of engines of is carried out. The engine is repaired and damaged engine parts are replaced. All the engine parts are then assembled and engine is then tested to check if it is functioning properly. Any functional errors encountered are removed before approving the engine for installation on buses. All the engines are turbocharged. Engines of the following buses are repaired in the workshop
1. 2. 3. 4.

TATA- 1312 TATA- 1520 TATA- 1210 LEYLAND

PARTS OF ENGINE:There are following parts of an Engine-:

1.

Cylindrical Head.

2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Oil Pump. Cylinder Block. Piston. Crank Shaft. Cam Shaft. Cooling Fan. Radiator. Valve Mechanism. Self-Starter. Fly Wheel. Cooling Plate. Dumper Pulley. Vibration Dumper Pulley. Water Pump. Timing Plate Housing. Push Rod. Diesel Filter. Tappet. Gudgeon Pin. Alternator. Turbo Charger.

SPECIFICATIONS OF ENGINE-:
1. MODEL T.C. 1312 (TATA). 2. NUMBER OF CYLINDER 6. 3. BORE SIZE 102 mm.

4. FUEL USED- DIESEL. 5. FIRING ORDER- 1, 5, 3, 6, 2, 4 6. INJECTION PRESSURE- 175-180. 7. AVERAGE 5-6 km/lt.

ASSEMBLY OF T.C.1312 (TATA)-:

First of all Engine Block is used in assembling of Engine. Then bush bearing is fixed in Engine Block. Then Crank shaft is fixed; now Crank Shaft is clamped by Crank Shaft Head. Then Crank Shaft is connected with Piston by Connecting Rod and Gudgeon Pin. Then Oil Ring and Compressor Ring are attached with Piston. Now by the Connecting Rod Head the Piston is clamped to Crank Shaft. Now the Timing Plate Housing is clamped in the front part of Engine Block and Rear oil Seal is fixed in back side, which prevents leakage of oil. Now Oil pump is fixed in front of Timing Plate. Oil Pump contains two gears, small size gear is attached with Crank Shaft and big size gear is attached with small size gear. Than we clamp Cam Shaft whose gears mesh with Crank Shaft. Than we use a Timing Pin in between Oil Pump and Cam Shaft to control the fuel supply. Than Side Plate is clamped, after that Push Rod is inserted than Injectors are clamped over the Inlet and Outlet Valve then Tappet Covers are fixed.

WORKING PRINCIPLE-:
In Roadways Buses Four Stroke Diesel Engines is used. The strokes are -:

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1. 2. 3. 4.

Suction Stroke. Compression Stroke. Combustion/Power Stroke. Exhaust Stroke. When the engine starts crank shaft rotates. And this rotates the cam shaft because they both are fixed together by a soft Timing Pin. Cam rotates because it is a part of cam shaft, rotating of cam uplifts the tappet. Tappet uplifts the push rod by which some action goes to Rocker Arm, the timbre end of Rocker Arm goes down, and this applies pressure on valve stem. Valve Phase comes down from valve seat and ports open. Through the ports fuel enters into the engine cylinder.

LUBRICATION OF DIESEL ENGINE:Different engine parts are lubricated using pressure to deliver lubricating oil. Through Oil Pump or Oil Sump, oil is sucked under pressure (200 to 400 KPa). It passes through gallery. After reaching to main gallery some amount of oil reaches to big end bearing then through cross holes it passes through main bearing to reach the piston and gudgeon pin. The oil used for lubrication of engine is 15W40.

PRECAUTION & SAFETY FEATURES:1. Tappet clearance should be clean. a. When inlet is hot >> 0.10 inch b. When outlet is hot >> 0.20 inch 2. Rocker Arm & Lubrication of Rocker Arm should be checked. 3. Tappet cover should always fix.

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4. Lubrication oil should be replaced in regular intervals.

2. GEAR BOX SECTION:Manual transmissions often feature a driver- operated clutch and a movable gear stick. Most automobile manual transmissions allow the driver to select any forward gear ratio ("gear") at any time, but some, such as those commonly mounted on motorcycles and some types of racing cars, only allow the driver to select the next-higher or next-lower gear. This type of transmission is sometimes called a sequential manual transmission. The way a manual transmission works is that the flywheel is attached to the engine, clutch disk is in between the pressure plate and the flywheel. When running, the clutch disk is spinning with the flywheel and when pressure is applied

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to the clutch pedal the throw out bearing is pushed in and it makes the pressure plate stop applying pressure to the clutch disk and making it stop receiving power from the engine so the gear can be shifted without any problems and when pressure stops being applied to the clutch pedal the clutch disk is allowed to start receiving power from the engine. Manual transmissions are characterized by gear ratios that are selectable by locking selected gear pairs to the output shaft inside the transmission. Conversely, most automatic transmissions feature epicyclic (planetary) gearing controlled by brake bands and/or clutch packs to select gear ratio. Automatic transmissions that allow the driver to manually select the current gear are called Manumatics. A manual-style transmission operated by computer is often called an automated transmission rather than an automatic. Contemporary automobile manual transmissions typically use four to six forward gears and one reverse gear, although automobile manual transmissions have been built with as few as two and as many as eight gears. Transmission for heavy trucks and other heavy equipment usually have at least 9 gears so the transmission can offer both a wide range of gears and close gear ratios to keep the engine running in the power band. Some heavy vehicle transmissions have dozens of gears, but many are duplicates, introduced as an accident of combining gear sets , or introduced to simplify shifting. Some manuals are referred to by the number of forward gears they offer (e.g., 5-speed) as a way of distinguishing between automatic or other available manual transmissions. Similarly, a 5-speed automatic transmission is referred to as a "5-speed automatic." Gear box is fixed with Clutch Plate Housing behind Clutch. Gear box is used to drive vehicles in different load conditions. With the help of gears the speed of vehicles is varied as required. In this section the assembly and repairing of gearbox is done. In this section following type of Gear Box are assembled-:
1. 2.

GBS-40--------- T.C(TATA) GBS-30--------- T.C(TATA)

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PARTS OF GEAR BOX-:

1. Main Shaft 2. Counter Shaft 3. Shifting Rod 4. Gear Box Housing 5. Cover Plate 6. Bearing and Sleeve 7. Fork 8. Cylindrical Bin 9. Mug Drain Pin 10.Spring Washer 11.Oil Seal 12.Front Cover 13.Butt Rings 14.Hub and Bush 15.Synchronizer 16.Carrier and Compressor Pin 17.Drive Shaft 18.Gear Box Cover Rear

ASSEMBLY-:
Counter Shaft adjusts in Gear Box which is made up of Cast Iron by Casting. There are Five Gears in counter shaft. Main shaft acts as a base purpose shaft. The main shaft is assembled in which there are 6 helical gears. There are 5 forward and 1 reverse gear. In these sleeve fork fits after the shifting rod.

Number of Teeth in each Gear-: A. In Main Shaft-:

1. 1. 2. 3. 4.

First Gear - 39 Second Gear 32 Third Gear 25 or 26 Fourth Gear 19 or 20 Fifth Gear 17

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B. In Counter Shaft-:
1. 2. 3. 4. 5.

First Gear 11 Second Gear 17 Third Gear 23 or 24 Fourth Gear 29 Fifth Gear 36

C. Number of Teeth in Back/Reverse Gear = 21

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Working-:
1) Neutral Position-: The power of Engine reaches to Counter Shaft. But because of no Pinion meeting of Main and Counter Shaft, power doesnt go forward and the Vehicle remains unmoved.

2) First Gear-: With the help of Gear Lever Shaft the First Gear of Main Shaft meshes with the First Gear of Counter shaft. The power of Engine comes to Counter Shaft than goes to Main Shaft. Main Shaft Rotates clockwise and gives movements to Propeller Shaft and the vehicle start to move.

3) Second Gear-: By taking Gear Lever to downwards the Second Gear of Main and Counter Shaft mesh together, movements has already send to the Propeller Shaft, by the Second Gear the speed of vehicle increased, because the pinion of the Main and Counter Shaft decreases & increases respectively.

4) Third, Fourth and Fifth Gear-: There working is just like the Second Gear, but in Fourth Gear Main Shaft starts taking power directly from Clutch Shaft.

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5) Reverse Gear-: When Gear Lever takes Gear to the Reverse Gear position the small tooths of Reverse Gear mesh with the First Gear of Main Shaft and big tooths mesh with the Reverse Gear of Counter Shaft, Main Shaft rotates anticlockwise and the vehicle comes backward.

Lubrication of the Gear Box-:

80W90 lubricating oil is used for the lubrication of gear box. Splash lubrication method is used.

Precaution and Safety features-:

1. Lubrication of the all Gear box is necessary. 2. Gear selection should happen according to the nature of load.

3. Gear shifting should be done according to the speed of vehicle and engine.

4. Gear shifting should be done softly.

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3. Fuel Injection Pump Suction-:

In Diesel Engine F.I. Pump is used for carrying the in correct amount time, high pressure and reaches it to injector in it the injection pressure is 7 to 30 M Pa.

Parts of F.I. Pump-:

1. Delivery Valve. 2. Delivery valve spring. 3. Plunger. 10. Air Nipple. 11. Hand Primer. 12. Cotton Glassy.

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4. Pump housing. 5. Control pack. 6. Plunger Return spring. 7. Control sleeve. 8. Cam Shaft. 9. Feed Pump.

13. Paper Glassy. 14. Idling. 15. Lever Washer 16. Control Rod 17. Sluing Lever 18. Fly Weight

SPECIFICATION OF F.I. PUMP-: Model Injection Pressure CAM Sequence Direction of Rotation

-Bosh Type F.I. Pump - 7 to 30 M Pa. - 1-5-3-6-2-4. -Clock Wise.

WORKING PRINCIPLE-:
Fuel by suck fuel pump from the tank at low pressure with the help of filter. Fuel is supplied to unit injector where its pressure is increased. And the high pressure fuel is then supplied to the engine cylinders at appropriate time. Any extra fuel goes again to tank through relief valve.

FLOW DIAGRAM FOR F.I PUMP-:

Hand Primer |

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Fuel Supply | Feed Pump | Glassy | Strainer | Diesel Filter | Pump | Air Nipple | Self-Start

Precaution & Safety Features-:

1. 2. 3.

Pump should remain clean always. Mountings should be tight.

Do not clamp retainers very tight.

4. Spring Section-:
Because of the ups and downs encountered in the road, the vehicle experiences many shocks. To prevent damage to the vehicle due to these shocks leaf springs are employed. They are semi-elliptical in shape. The length of these springs is different for both Axles. In front axle the length of spring is 74 Inch and decreases 4 inch downwards, and in Rear Axle the length of spring is 78 Inch decreases as in the front axle. The width of Leafs is 3 inch. The total number of the Road Spring in a vehicle is 4, and one spring contains 15 leafs.

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Krampe Hydraulic Machine is used for the bending of road springs. The machines type is HKTG. In the vehicle these Road Springs are hanged in a Chassis Hanger Bracket, and then with a U Bolt.

Working-:
When a vehicle experiences a shock, the shock is transmitted to the springs through the axel, and spring tend to get to straight position, Shekel helps them to do this. So the maximum part of the shock is absorbed by the spring and little by the body.

Precautions And Safety Features -:

1. 2. 3. 4.

There is no breakage in the Leaf. Mounting should be tight. Weekly Lubrication is required for the Shekel pin. Too much play in shekel is not permissible.

In Roadways Workshop Kathgodam the following tools are used for repair and assembly-:
1. 2. 3. 4. 5. 6. 7.

Spanner. Hammer. Chisel. Pliers. Screw Drivers. Anvil. F.I Pump Testing Machine.

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8. 9. 10.

Hydraulic Krampe Machine. Micrometer. Lathe machine.

In Roadways Workshop Kathgodam mainly assembly and repairing is done. It is done follows-:
1.

At first the damage parts of automobile from various Depots send to Roadways Workshop Kathgodam. Here they are classified and send to suitable Workshop Section. In every section the automobile parts are dissemble. Dissembled parts washed by Dermal. The washed part replaces the damaged part. Now the assembly is done. The washed parts checked carefully from where it damaged. In this way after repairing new assembled part supply to the depot.

2. 3. 4. 5. 6. 7.

In the Roadways Workshop Kathgodam there is a limited use of computers. The use of computers is as follows-:
1. 2.

The data related to Purchase and Selling of parts is stored. To prepare the list of automobile parts and their costs and from which company they have been purchased. In the Registration of Roadways Buses. Details of spare parts stored in the depot.

3. 4.

The following step should be taken for safety on the work place-

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1.

The workshop should be clean and there will be security apparatus must be given to the workers. The Workshop System of air must be managed. Do not smoke and peep away of the fire substance from working place. Use Apron, Shoes, and Glassware during work. The wiring of the Workshop should be done properly.

2. 3. 4. 5.

In This Roadways Workshop there is no production work is done. Only the assembling work is done in the respect of production. The damage part of the bus is changed by new part and the assembling is done. In the assembling there are various sections in the Workshop and the assembling of various parts in the respective section is done. For example: In the Engine Section , assembling for its part like Crank Shaft , Cam Shaft etc., is done and the new assembled Engine is prepared by various parts of various companies.

5. AXLE SECTION-:
REAR AXLE-: Power from the engine is delivered to the rear axle through
propeller shaft. In the rear axle a differential is mounted which distributes the power from the engine in between the two tires as per the requirement. The differential has three jobs:

To aim the engine power at the wheels

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To act as the final gear reduction in the vehicle, slowing the rotational speed of the transmission one final time before it hits the wheels To transmit the power to the wheels while allowing them to rotate at different speeds

Torque is supplied from the engine, via the transmission, to a drive shaft (British term: 'propeller shaft', commonly and informally abbreviated to 'propshaft'), which runs to the final drive unit that contains the differential. A spiral bevel pinion gear takes its drive from the end of the propeller shaft, and is encased within the housing of the final drive unit. This meshes with the large spiral bevel ring gear, known as the crown wheel. The crown wheel and pinion may mesh in hypoid orientation , not shown. The crown wheel gear is attached to the differential cage, which contains the 'sun' and 'planet' wheels or gears, which are a cluster of four opposed bevel gears in perpendicular plane, so each bevel gear meshes with two neighbours, and rotates counter to the third, that it faces and does not mesh with. The two sun wheel gears are aligned on the same axis as the crown wheel gear, and drive the axle half shafts connected to the vehicle's driven wheels. The other two planet gears are aligned on a perpendicular axis which changes orientation with the ring gear's rotation. In the two figures shown above, only one planet gear (green) is illustrated, however, most automotive applications contain two opposing planet gears. Other differential designs employ different numbers of planet gears, depending on durability requirements. As the differential carrier rotates, the changing axis orientation of the planet gears imparts the motion of the ring gear to the motion of the sun gears by pushing on them rather than turning against them (that is, the same teeth stay in the same mesh or contact position), but because the planet gears are not restricted from turning against each other, within that motion, the sun gears can counter-rotate relative to the ring gear and to each other under the same force (in which case the same teeth do not stay in contact). Thus, for example, if the car is making a turn to the right, the main crown wheel may make 10 full rotations. During that time, the left wheel will make more rotations because it has further to travel, and the right wheel will make fewer rotations as it has less distance to travel. The sun gears (which drive the axle halfshafts) will rotate in opposite directions relative to the ring gear by, say, 2 full

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turns each (4 full turns relative to each other), resulting in the left wheel making 12 rotations, and the right wheel making 8 rotations. The rotation of the crown wheel gear is always the average of the rotations of the side sun gears. This is why, if the driven roadwheels are lifted clear of the ground with the engine off, and the drive shaft is held (say leaving the transmission 'in gear', preventing the ring gear from turning inside the differential), manually rotating one driven roadwheel causes the opposite roadwheel to rotate in the opposite direction by the same amount. When the vehicle is traveling in a straight line, there will be no differential movement of the planetary system of gears other than the minute movements necessary to compensate for slight differences in wheel diameter, undulations in the road (which make for a longer or shorter wheel path), etc.

FRONT AXLE-: Power to the front axle comes from the rear axle. The Front
Axle and suspension consists of I- Section beam, to which the stub Axle is connected at each end.

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MAIN PARTS OF AXLE-:

1) I- Beam 2) Crown 3) Sun & Star gears 4) Pinion 5) Bearing Cone 6) Distance Piece washer 7) Thrust Washer 8) Chuck Washer 9) King Pin 10) King Pin Sims 11) Staff Axle 12) Cutter Pin 13) Split Nut 14) Second Arm 15) Third Arm 16) Oil seal ring

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Assembly of Axle-:
I-Beam | Staff Axle | King Pin | King pin Sims | Roller Bearing | Cutter Pin | Inner Bearing | Break Richet I Break-Shoe | Lining | Break Cam shaft | Plastic Slip | Hub

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SPECIFICATION OF AXLE-:
1. I-beam- 34801UZ164142. 2. Roller bearing- 19 Balls. 3. Inner Bearing- 1888400-565/562 no. 4. Outer Bearing- 32308no.

Precaution and Safety features-:

1. Lubricates King Pins every week. 2. Always use the specified Lubricant. 3. Always wipe the nipples clean before filling grease. 4. Grease has to be pumped in through top/bottom grease nipples.

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6. Electric Section-:
Electric Section consists of:
1. 2.

SELF STARTER ALTERNATOR

1. SELF STARTER Self-starters only work is to start vehicle. By pressing self the operator starts the vehicle

Main parts of Self Starter-:

1. 2. 3. 4. 5. 6. 7. 8. 9.

Main field. Auxiliary Field. Clutch. Armature. Pinion. Solenoid Switch. DE and CE Switch. D Plate. Trip Plate.

WORKING-:
When the Self Start is pressed, current comes to auxiliary field; auxiliary field presses armature forward, the trip plate of armature presses the lever of solenoid switch by which the current comes in main field, then current goes to Commutator.

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2. ALTERNATOR -: It is used to charge the battery for various purposes.

MAIN PARTS-:
1. 2. 3. 4. 5.

Pulley. Straighter. Regulator. Rectifier. Slip Ring.

WORKING-:
Dynamo sends D.C Current to the straighter and the rectifier fixed in straighter changes the current to A.C and imparts movement to the Rotor. This generates the electricity. The electricity generated travels to the regulator. The regulator sends current to the battery. Thus battery is charged by the alternator. When battery has sufficient Charge the regulator cuts the power supply between alternator and battery.

Precautions and safety features-:

1. 2. 3. 4.

Connections should be tight and clean. Saves the wires from Grease and Oil. Do not let the wires hanging. The insulation should be correct.

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