CHAPTER 1

INTRODUCTION
1.1 Introduction to workshop
As stated in our syllabus we have prepared our report on our industrial training. As being
Mechanical Engineering student in present we need to be an acquainted with practical
exposure about components of industrial field procedure and practical so as have an operation
of size and scale of operation. To develop comprehension regarding concepts, principals
taught in the classrooms and their application involving field/industrial task problems.
To have first-hand knowledge culture and to mentally prepared them before actually joining
word of work services. So for this very purpose, I went to HRTC R/W Hamirpur.
On feedback we prepared following report. All data taken in this report such as specification
various parts etc. is about TATA LP/LPO 1512TC vehicle manufactured by TELCO where
quality is the watchword. Workshop is a place where repair or change of the parts of vehicle
is done or in other words it is place where theory or laws changes practically to original
structure. In R/W Hamirpur there is about 50 staff members of which mechanics are about 30.
The others are related to clerical staff or other officers such as R.M. and Dy. R.M. works
manager, head mechanics. There are about 50 buses and one recovery van. About 10 buses
remain present at every time. There is a big store in the workshop in which every part of
buses or every equipment is available. Storekeeper keeps every part in its place, he use
catalogue to give a part to the worker, Works Manager and Head Mechanic check the
working of every worker and told workers how to make procedure, if any trouble comes to a
worker..

1.2 Organization structure

Himachal Road Transport Corporation is head by a Board of Directors with Transport
Minister as the Chairman. Managing Director is the Chief Executive of the Corporation.
Himachal Road Transport Corporation has a three tier structure. The Corporate Office at
Shimla controls 4 Divisional Offices located at Shimla, Mandi, Hamirpur and Dharamshala.
These 4 Divisions controls 23 Regional Office
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Depots under them.

Devision

Regions

1. SHIMLA

1. Taradevi
2. Rural Unit
3. Local Unit, Dhalli
4. Rekong Peo
5. Rampur
6. Rohroo
7. Solan
8. Nahan

2. MANDI

1. Mandi
2. Kullu
3. Keylong
4. Sarkaghat
5. Sunder Nagar

3.HAMIRPUR

1. Hamirpur
2. Dehra
3. Una
4. Bilaspur
5. Nalagarh
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4.DHARAMSHALA

1. Dharamshala
2. Pathankot
3. Chamba
4. Palampur
5. Baijnath
6. Jassur

Fig.1.1 Flow diagram of organization structure [1]

1.3 History
At the time of Independence, Himachal was formed as a "C" class State by merger of 33 hilly
States of North-Western Himalayas on 15th April, 1948. Passenger and goods services were
nationalized in the Pradesh in July, 1949. During the year 1958, a Corporation, "Mandi-Kullu
Road Transport Corporation" was floated jointly by the Govt. of Punjab, Himachal and
Railways under the Road Transport Corporation Act, 1950 basically to operate on the joint
routes in the States of Punjab and Himachal. With the reorganization of Punjab State in 1966,
few hilly areas of Punjab were merged in Himachal and operational areas of Mandi-Kullu
Road Transport Corporation came entirely in the expanded State of Himachal. On
02.10.1974, Himachal Govt. Transport was merged with Mandi-Kullu Road Transport
Corporation and was renamed what even today is known as Himachal Road Transport
Corporation.
1.4 Growth
After the formation of Himachal on 15th July, 1948 the network of roads had received topmost priority of the Government. At present the road network is widely spread in Himachal.
In 1974 total routes operated by HRTC were 379 which have grown to 2325 in March 2016
and the fleet strength has grown from 733 to 2645 in March 2016. Bus remains the sole
mode of passenger transportation in the state as railways have a negligible presence in the
State. The narrow gauge lines connecting Pathankot with Jogindernagar and Kalka with
Shimla are so slow moving that a very small percentage of traffic is carried by them at
present; thereby leaving the onus of carrying the passenger traffic on to bus transport.
1.5 Bus types
HRTC is operating five types of buses.
Ultra Luxury AC Buses - HIMSUTA
Deluxe Buses
Mini buses (JNNRUM)
Ordinary Buses
Semi Deluxe Buses

Volvo buses or Ultra Luxury Air Conditioned Buses (HIMSUTA)

HRTC is operating Ultra Luxury AC Buses (Volvo & its equivalent) from Delhi to Shimla,
Manali and Dharamsala vice versa. Theses buses are equipped with latest and comfortable
facilities to the passengers
12000 mm length, 2600mm width, 3620mm height and 6200mm wheelbase bus developed
for passenger transport. The bus is comfort for long distance travel. Full air suspension. This
bus is provided with good branded Carrier make air-conditioner with excellent cooling
effect to make the journey comfortable & cool. This bus is provided with 44 nos 2X2
comfortable, luxurious passenger seats. Mobile and Lap Top chargers are provided for
passengers use. For the entertainment of the passengers 21 TV &CD player is provided.
Window glasses are toughened and provided clear vision to passengers. Front panel is
designed to increase the drivers vision area and aesthetic look of the bus. Luggage space is
provided under passenger seating area. The bus is fitted with powerful, fuel efficient and
electronically controlled engine with a turbocharger and intercooler, Euro III compliant.

Fig 1.2 Volvo bus [2]

Deluxe buses
Constructed on 166WB & 218 WB Chassis. The bus is provided with 2X2 comfortable,
luxurious passenger seats. Emergency door is provided behind the Rear Axle at right side of
the bus for more safety to passengers. Lights have been provided above each twin seat along
with speaker and call bell switches. Fitted with single windshield laminated glass. Heavy
duty fans of 8 size provided. 21 TV and Music system is provided for the entertainment of
passengers

Fig.1.3 Deluxe bus [2]

Mini buses (JNNURM)
Good looking blue Colour buses. The bus is provided with 2X2 comfortable passenger seats.
Emergency door is provided behind the Rear Axle at right side. Fitted with digital destination
board. Fitted with Air Brakes, power steering. Fitted with Euro-III Diesel Engine.

Ordinary Buses

Ordinary Buses (2X3) are equipped with latest comfortable hi-tech seats. These buses are
plied on long and intra-state routes on ordinary fare.

Fig.1.4 Ordinary bus [2]

Semi Deluxe Buses

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Semi-deluxe Buses (2X2) are equipped with comfortable push back seats. These buses are
plied on long and intra-state routes with an additional fare of Rs. 20/- more than the ordinary
fare to provide the passengers economic comfortable journey.

Fig.1.5 Semi deluxe Bus [2]

1.6 Safety Guidelines

To avoid accident and to keep them from happening following safety guidelines should be
allowed:
1. Provide your attention at most to the job quietly.
2. Keep the tool within your convenient reach under your control.
3. Arrange neatly without scattering them around and out of way. Always keep jack handles
pointing up to avoid tripping up to wheel creepers are not in use stand them against the wall
to avoid stumbling over them.
4. Be serious about your work never including in horseplay or other foolish activities to avoid
injury to other.
5. Never put sharp objects like screw driver in your pockets otherwise you will cut yourself
or get stabbed.
6. Always wear suitable clothes for the job otherwise serious injuries can be caused by
sleeves or ties getting caught by the machine or full leathers shoes with non-skid rubber heel
should be worn.

7. To provide good grip on tool or part always wipe excess oil and grease up hand tool as
required.
8. To avoid slipping and falling to the ground due to spilt oil or grease or any liquid clean up
immediately the ground.
9. Compressed air should never be used to blow dust from your clothes. Compressed air
should never be pointed to any person because flying particles or chips may harm him

2.7 The lathe

2.7.1 Introduction
The lathe is one of the oldest machine tools and came into existence from the early tree lathe
which was then a noble device for rotating and machining a piece of work held between two
adjacent trees. This device continued to develop through centuries and in the year 1797 Henry
Mau slay, an Englishman, designed the first screw cutting lathe which is the forerunner of the
present day high speed, heavy duty production lathe, a machine tools which has practically
given shape to our present day civilization by building machines and industries.
2.7.2 Function of lathe machine
The main function of the lathe is to remove metal from a piece of work to give it the required
shape and size. This is accomplished by holding the work securely and rigidly on the machine
and then turning it against cutting tools which will remove metal from work in the form of
chips. To cut the work piece, should be rigidly held on the machine and should be fed or
progressed in a definite way relative to work.
2.7.3 The lathe uses
The centre lathe: This lathe is the most important member of the lathe family and is the most
widely used. The term engine is associated with the lathe owing to the fact that early lathes
were driven by steam engines. Similar to the speed lathe, the engine lathe has got all the basic
part e.g. bed, headstock, and tailstock. But the headstock of an engine lathe is much more
robust in construction and it contains additional mechanism for driving the lathe spindle at
multiple speeds.

2.8 Boring machine

2.8.1 Introduction
The boring machine is one of the most versatile machine tool used to bore holes in large and
heavy parts such as engine frames, steam engine cylinders, machine housings etc. Which are
practically impossible to hold and rotate in an engine lathe or a drilling machine. Boring
machine has, therefore, been developed primarily to do this. In addition to its primary
purpose of boring the range of speeds and feeds provided to the various traversing
components allow drilling, milling and facing to be performed with equal facility. By the
fitting of simple attachments, the use of the machine can be extended still further to include
screw cutting, turning, planetary grinding, or gear cutting.

Fig.1.6 Boring machine [3]

CHAPTER NO 2
9

MAIN COMPONETS OF AUTOMOBILE

2.1 Chassis
A chassis consists of an internal vehicle frame that supports a manmade object in its
construction and use. It is analogous to an animal's skeleton. An example of a chassis is the
under part of a motor vehicle, consisting of the frame (on which the body is mounted). If the
running gear such as wheels and transmission, and sometimes even the driver's seat, are
included, then the assembly is described as a rolling chassis.
Chassis is the basic framework of the automobile. It supports all the parts of the automobile.
Chassis a French term which means the complete Automobiles without
Body and it includes all the systems like power plant, transmission, steering, suspension,
wheels tyres, auto electric system etc. without body. If Body is also attached to it them it is
known as the particular vehicle as per the shape and design of the body.

Fig 2.1 Chassis [4]

The Functions of the Chassis frame

1. To carryall the stationary loads attached to it and loads of passenger and cargo carried in it.
2. To withstand torsional vibration caused by the movement of the vehicle
3. To withstand the centrifugal force caused by cornering of the vehicle
4. To control the vibration caused by the running of the vehicle
5. To withstand bending stresses due to rise and fall of the front and rear axles.
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Main parts of Chassis

1. Radiator
2. Engine
3. Fly wheel
4. Clutch
5. Gear box
6. Universal joint
7. Propelled shaft
8. Differential
9. Axle shaft
Some other main parts of Chassis are:
1. Leaf spring
2. Oil tank
3. Battery
4. Tyre
5. Seat

2.2Radiator
Radiators are heat exchangers used to transfer thermal energy from one medium to another
for the purpose of cooling and heating. The majority of radiators are constructed to function
in automobiles, buildings, and electronics. The radiator is always a source of heat to its
environment, although this may be for either the purpose of heating this environment, or for
cooling the fluid or coolant supplied to it, as for engine cooling. Despite the name, most
radiators transfer the bulk of their heat via convection instead of thermal radiation (the main
exception to this rule being the radiators on spacecraft, see spacecraft radiators below),
though the term "convector" is used more narrowly; see radiation and convection, below.

11

Fig.2.2 Cooling System [5]

Inter cooler:
Intercooler is any mechanical device used to cool a fluid, including liquids or gases, between
stages of a multi-stage compression process, typically a heat exchanger that removes waste
heat in a gas compressor. They are used in many applications, including air compressors, air
conditioners, refrigerators, and gas turbines, and are widely known in automotive use as an
air-to-air or air-to-liquid cooler for forced induction (turbocharged or supercharged) internal
combustion engines to improve their volumetric efficiency by increasing intake air charge
density through nearly isobaric (constant pressure) cooling.
2.3 Engine

An engine or motor is a machine designed to convert one form of energy into mechanical
energy. Heat engines, including internal combustion engines and external combustion engines
(such as steam engines), burn a fuel to create heat, which then creates a force. Electric motors
convert electrical energy into mechanical motion; pneumatic motors use compressed air and
otherssuch as clockwork motors in wind-up toysuse elastic energy. In biological
systems, molecular motors, like myosins in muscles, use chemical energy to create forces and
eventually motion.
They are Two Types: external combustion engines and internal combustion engines
We are classified the internal combustion engines into two categories
1st is EURO Stage
12

2nd is BS- Bharat Stage

At this time we use EURO 3 in Tata Buses and Bharat Stage 3 in Ashok Leyland buses

Fig 2.3 Engine [6]

Main parts of Engine:
2.3.1. Cylinder Block & crank case: Cylinder block is the basic frame work of the engine. In this there are cylinder in which
pistons reciprocates. The basic frame work of the engine is formed by the cylinder block, it
houses the engine cylinders which serve or bearings and guides for the pistons reciprocating
in them. Around the cylinder there are passages for the circulation of coolant.
2.3.2. Cylinder head:
To form a combustion chamber above each cylinder thecylinder head is above the engine.
2.3.3. Oil sump
It is at the lower of the engine. It is used to store the oil to collect the return oil.
2.3.4. Manifolds:
There are two types of manifold. i) Inlet manifold ii) Exhaust manifold
2.3.5. Gaskets: These are used to provide a tight fitting joint between two surfaces. The cylinder head form a
combustion chamber above each cylinder. It also contains valve guides, valve seals, ports,
coolant jackets and threaded holes for spark plugs or injections.
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Material: - Cast iron and aluminium alloy.

2.3.6. Cylinder liners:
To remove the cylinders wear in the engine cylinder liners are used.
There are of two types:i)Wet liner ii) Dry Liner
In buses dry liner is used and wet liner is used in heave commercial vehicles.
2.3.7. Pistons:i) To transmit the force of explosion to the crankshaft.
ii) To serve as a guide and a bearing for small end of the connecting rod
Function: 1. To transmit the force of explosion to the crankshaft.
2. To serve as a guide4 and a bearing for small end of the connecting rod.
3. To form a seal so that the high pressure gases in the combustion chamber do not escape
into the crank case. The top of the piston is called head or crown. It is close to the valves. It is
used in some high powered engines and has a raised dome which is used to increase the
compression ratio as well as to control combustion.
2.3.8. Piston rings:
Function: i) To form as a seal for the high pressure gases from the combustion chamber against leak
into the crank case.
ii) To provide easy passage for heat flow from the piston crown to the cylinder walls.
These are of two types:
i)
ii)

Compression rings
Oil control rings

14

2.3.9. Connecting rod: Main function of the connecting rod is to convert the reciprocating
motion of the piston into the rotary motion of the crankshaft.

Fig.2.4 Connecting rod [6]

2.3.10. Piston pin:
It is used to connect the piston and the connecting rod.
2.3.11. Crank shaft: It is the engine component from which the power is taken. It receives the power from the
connecting rods to the clutch and to the wheels.

Fig.2.5 Crank shaft [6]

2.3.12. Viscous fan: It is attached in the front of the engine. Its main function is cooling the engine.
It is driven by a V-belt from the crankshaft pulley. It may have four to seven blades.
It is generally made of sheet metal but these days mounted plastic material e.g. nylon or
polypropylene are also being used for making fans.
15

2.3.13. Oil galleries

Cylinder block also carries lubrication out to various component through drilled passages
called oil galleries.
Function:
Its main function is to provide support for the main journals and bearings of the crankshaft.
Top of the cylinder block is attached the cylinder head. Other parts like timing gear, water
pump, ignition distributor, flywheel, fuel pump etc. are also attached to it.
2.3.14. Camshaft:A camshaft is a shaft with a cam for each intake and exhaust valve. Each cam has high spot
called cam bob which control valve opening. It rotates half of the crankshaft. One four stroke
cycle is complete in two revolution of the crankshaft each cam must open and close the inlet
and exhaust valve once every two revolution of the crankshaft

Fig.2.6 Camshaft [6]

2.3.15 Minor engine repair: or engine servicing
To keep the motor vehicle in a condition of safety, reliability, comfort, cleanliness
performance and economy automobile service is very necessary in modern fast moving time.
Type of Automobile can be broadly decided in like following two types:
1. Self-diagnosed services
In these services are include the lubrication, washing body and being repair of brakes tires,
steering alignment etc. these services are necessary for efficient running and maintenance of
automobile.
2. Performance services
For correcting engine performance and electrical troubles, the performance services are
carried out. Performance services are quite different from self-diagnosed services before
carrying out and of performance services.
16

2.3.16 Basic requirements of engine service

The basic requirement of engine services is to find out the following information:
1. To determine what is wrong in the engine.
2. To find exactly as to what type of services is required for correcting the fault and restoring
the normal performance economy.
3. A full and proper test of engine is necessary for establishing the exact cause of trouble
experienced as well as the repair and parts required to replace. In modern engine, which are
complicated and critical to restore normal performance fully and accurately some extra
operation in addition to personal skill and experience is required for testing the engine with in
economic limits of time and corrective service required.
It will be seen that when the motor vehicle has been properly run in it would provide new
performance of the reconditioning it is due to fact that original setting limits and specification
gradually change because of long hour of use causing wear in moving parts deterioration in
cable insulation weak springs corroded terminal and clogged passage the troubles like lack of
power, poor acceleration, hard
starting missing king pin poor idling rough running as well as heavy fuel consumption are the
indication of loss in performance
2.3.17 Engine services procedure
Before servicing an automobile engine it is necessary to determine the cause of the trouble in
the engine. This is done by observing the symptoms produced by and indicated in the
instrumental check visual examination should produce by the engine and this sound of the
engine emission the analysis of the symptoms of troubles and troubleshooting charts are very
helpful for this purpose generally these are two types of engine troubles:
1. Internal troubles.
2. External troubles.
2.3.18 Engine disassembly
The dismantling and removing is done for finding the cause of troubles in engine parts such
as:
a) Manifolds
b) Cylinder head
c) Cylinder block
d) Piston and connecting rod
17

e) Shaft
f) Sump or oil chamber
g) Turbo charger
h) Sub assembly
2.3.18 Cleaning of parts
Parts disassemble and in repairable condition should be cleaned. These are in general two
types of cleaning done on an engine:
I) Degreasing
ii) De carbonizing

2.3.19 Inspection of parts:

Inspection of parts is very necessary for fine working of an engine. Inspection of parts should
be done carefully. In common there are two types of inspection mentioned as below:
a) Visual inspection:
From visual inspection we mean that inspection of any crack or any addition to part. If part is
faulty another one should replace it.
b) Dimensional inspection:
It is meant for the inspection of dimension of a part. It should be checked.
2.3.20 Condition of engine parts:
Condition should be remembered and they should be in working. Some conditions are such
as:
a) Valve
b) Valve train
c) Camshaft
d) Lifter
e) Rocker arm
f) Push rod
g) Valve spring
h) Valve retainer
i) Rocker shaft
Piston:

18

A vertical wear on the thrust surface and slight looseness of the top ring in groove is common
wear visible and piston with the type of wear can be reconditioned usually.
Servicing the piston:
a) Ring grooves
1) Compression ring
2) Oil ring
b) Skirt
c) Piston pin
d) Cylinder wall
e) Piston assembly
Shaft and bearing:
a) Crank shaft
b) Cam shaft
c) Bearing
d) Cylinder block
e) Cylinder wall
f) Main bearing
g) Oil pump
h) Water pump
i) Covers

2.4 FUEL FILLTER AND OIL FILLTER:

2.4.1 Fuel Filter:

19

Fig.2.7 Fuel filter [3]

A fuel filter is a filter in the fuel line that screens out dirt and rust particles from the fuel,
normally made into cartridges containing a filter paper. They are found in most internal
combustion engines.
2.4.2 Oil filter:
An oil filter is a filter designed to remove contaminants from engine oil, transmission oil,
lubricating oil, or hydraulic oil. Oil filters are used in many different types of hydraulic
machinery. A chief use of the oil filter is in internal-combustion engines in on- and off-road
motor vehicles, light aircraft, and various naval vessels. Other vehicle hydraulic systems,
such as those in automatic transmissions and power steering, are often equipped with an oil
filter.

20

Fig.2.8 Oil filter [3]

2.5 FUEL INECTION PUMP (FI PUMP)
An Injection Pump is the device that pumps fuel into the cylinders of a diesel engine.
Traditionally, the pump is driven indirectly from the crankshaft by gears, chains or a toothed
belt (often the timing belt) that also drives the camshaft. It rotates at half crankshaft speed in
a conventional four-stroke engine. Its timing is such that the fuel is injected only very slightly
before top dead centre of that cylinder's compression stroke. It is also common for the pump
belt on gasoline engines to be driven directly from the camshaft. In some systems injection
pressures can be as high as 200 MPa (30,000 PSI).

Fig 2.9 FI pump [3]

Mechanical pumps are gradually being phased out in order to comply with international
emissions directives, and to increase performance and economy. Alternatives include
common rail diesel systems and electronic unit direct injection systems. These allow for
21

higher pressures to be developed, and for much finer control of injection volumes compared
to mechanical systems.
2.6 Flywheel
A flywheel is a rotating mechanical device that is used to store rotational energy. Flywheels
have an inertia called the moment of inertia and thus resist changes in rotational speed. The
amount of energy stored in a flywheel is proportional to the square of its rotational speed.
Energy is transferred to a flywheel by the application of a torque to it, thereby increasing its
rotational speed, and hence its stored energy. Conversely, a flywheel releases stored energy
by applying torque to a mechanical load, thereby decreasing the flywheel's rotational speed.
2.6.1Common uses of a flywheel include:
Providing continuous energy when the energy source is discontinuous. For example,
flywheels are used in reciprocating engines because the energy source, torque from the
engine, is intermittent.
Delivering energy at rates beyond the ability of a continuous energy source. This is achieved
by collecting energy in the flywheel over time and then releasing the energy quickly, at rates
that exceed the abilities of the energy source.
Controlling the orientation of a mechanical system. In such applications, the angular
momentum of a flywheel is purposely transferred as a torque to the attaching mechanical
system when energy is transferred to or from the flywheel, thereby causing the attaching
system to rotate into some desired position.

Fig.2.10 Flywheel [7]

22

2.7 Clutch system

2.7.1 General
Clutch is the mechanism interposed between engine and the gear box which enables engine
power as well as torque of the engine to be transmitted at WILL to the gear box through
friction drive. When clutch pedal is depressed the clutch is disengaged and motion & power
flow from engine to gear box and hence to road wheels is disconnected.
Important functions of clutch within the power train are as follows:
1. Moving the vehicle from rest:
Engine gives sufficient power required for moving the vehicle from rest only at high rpm.
Therefore, it is necessary to run the engine on no load up to such rpm and then connect to the
gear box. This is achieved by disengaging the clutch upon which engine is separated from
gear box.
2. Shifting in to gears:
While changing gear it is necessary that the gears in the gear box should not be under the load
of transmitted power. Therefore, during each up or down gear shift it is necessary to interrupt
the power flow from engine to the gear box. This is achieved by disengaging clutch before
shifting in to gears.
3. Protection within the power train:
Clutch is the only flexible link between the engine and the power train as the power
transmission is only through the friction drive. There is no rigid connection between driving
and driven members which provides safety within the power train against the abnormal
load/power transmission.

Fig 2.11 Dry clutch [3]

2.8 Gear system
23

2.8.1 Synchromesh Gear Box:

This type of Gear Box is similar to the constant mesh type in that all the gears on the main
shaft are in constant mesh with the corresponding gears on the lay shaft or counter shaft. The
gears on the counter shaft are fixed to it while those on the main shaft are free to rotate on the
same. This is the provision of synchromesh device which avoids the necessity of double
declutching. The parts which ultimately are to be engaged, first brought into frictional contact
which equalizes their speed, after which these may be engaged smoothly.

Fig.2.12 Gear box [6]

The gear box are of two types : i) Constant mesh gear box
ii) Synchromesh gear box
Constant mesh gear box is not used in the present vehicles only the synchromesh gear box is
used. This is used in every vehicle, because of the following.
i) Easy to operate.
ii) There is no wear and tear in the gear box or gears.
iii) Because of the synchromesh the gear shifting is easy.
After this they told us about the complete parts of the gear box when they are working over
there we also done the dismantling and assembly of the gear box.
Main parts: i). Main shaft - Drive gear
ii) Counter shaft - Driven gear
iii) Housing
iv) Driving flange
v) Oil Retainer
24

2.8.2 For dismantling of the gear box following tools are used.
i.) Hammer
ii) Chisel
iii) Tommy bar
iv) Open end spanner
v) Extension rod
vi) Iron stick
vii) Socket set
viii) Ring spanner
ix) Nose pliers
x) Speed handle
All of the above tools are used for the dismantling and assembly of the gear box.
2.8.3 Disassembly of a gear box
1. Gear box housing
2. Coupling Plunger
3. Shifting fork
4. Shaft
5. Shifting Sleeve
Primary shaft
Main shaft
Counter shaft
Idle or reverse shaft
Counter shaft has one fixed gear, if the counter shaft has small gear than main shaft in its
opposite mashes its big gear. Arrangement of counter shaft and main shaft there is a lock nut
between the counter shaft and main shaft first of all we can remove it and opens the shaft.
2.8.4 Assembly of gear box:
After dismantling the g ear box first the gear box is washed with the help of diesel and other
components are also washing with it. Then with the help of pressured water all the
components and g ear box is washed for complete cleaning Jan is fixed in the gear box cover
and grease is also used to prevent the leakage of oil. Five litter of lubricating oil is pour in the
gear box.
2.9 Propeller shaft

25

Propeller shaft, sometimes called a carden shaft, transmits power from the gearbox to the rear
axle. Normally the shaft has a tubular section and is made in one- or two-piece construction.
The two-piece arrangement is supported at the midpoint by a rubber mounted bearing. Short
drive shafts are incorporated for the transmission of power from the final drive assembly to
the road wheels in both front and rear wheel drive layouts.

Fig.2.13 Propeller shaft [8]

2.10 Differential
When the bus is taking turn the outer wheels will have to travel greater distance as compared
to the inner wheels in the same time. If therefore, the car has a solid rear axle only and no
other device; there will be tendency for the wheels to skid. Hence of the wheel skidding is to
be avoided. Some mechanism must be incorporated in the rear axle, which should reduce the
speed of inner wheels and increase the speed of all the wheels same when going straight
ahead. Such a device, which serves the above function, is called differential. To understand
the principle on which differential works consider figure. To the crown wheel of the final
drive is attached a cage, which carries a cross pin and a spider. To sun gears mesh with
the two or four planet pinions. Axle half-shafts are splinted to each of these sun gears. The
crown wheel is free to rotate on the cross pin or the spider arm, they cannot apply different
torque to the teeth on one side, therefore, they act as balance and divide the torque between
the two wheels on axle, even when their speeds are different.

26

Fig.2.14 Differential [9]

2.11 Axle

Fig 2.15 Axle [10]

2.12

Braking system

2.12.1 Brakes:
It goes without saying that brakes are one of the most important control components of the
vehicle. They are required to stop the vehicle within the smallest possible distance and this is
done by converting the kinetic energy of the wheels into the heat energy which is dissipated
into the atmosphere.

27

Fig.2.16 Drum brake [11]

2.11.2 Requirements:
1. The brakes must be strong enough to stop the vehicle within minimum distance in an
emergency.
2. The brakes must have good anti fade characteristics.
Types:
1. Mechanical brakes
2. Hydraulic brakes
3. Vacuum brakes
4. Electric brakes
5. Air brakes
But here we have to study only three types of brakes which are discussed below:
2.12.3 Mechanical system
These are absolute known as service brakes. However these are still used on rear wheels in
many cars, as parking or emergency brakes.
Linkages
When the pedal is pressed, the brakes are applied. This simple linkage system however has
the advantage that it is very difficult to obtain. Equal effect at the wheels for which the
compensators have to be used in heavier vehicles. This is done either in one or two stages for
lesser reduction say up to 71 single reduction is used in two steps. The final drive in practice
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consists of a bevel pinion and crown wheel or alternatively worm and wheel arrangement.
The bevel pinion is mounted on a shaft, which is connected to the propeller shaft generally
through a universal joint. From the crown wheel the drive goes to the differential. Three types
of gears are used for the final drive bearing.

Fig 2.17 Mechanical brake [12]

2.12.4 Hydraulic brakes:
Most of cars today use hydraulic operated foot brakes on all the four wheels with an
additional brake mechanically operated on the rear wheels.
Master cylinder is the main component of the hydraulic locking system. This can be rightly
name as heart of the hydraulic linking system wheel cylinder is the 2nd fluid under pressure
forces the piston apart there by applying the brakes.

Fig 2.18 Hydraulic brakes [13]

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2.12.5. Air brakes:

In this the compressor takes air from the atmosphere through the filter and the compressed air
is sent to the reservoir through the unloaded valve which gets lifted at a predetermined
reservoir pressure and also to the brake chambers also called diaphragm units at each wheel
through the brake valve. Valve is with the driver who can control the intensity of braking
according to the requirements.

Fig.2.19 Air brakes system [14]

2.12.6. Main component of air brake
1. Unloaded valve
2. Brake valve
3. Hand control valve
4. Brake chamber
5. Chamber air brake
2.13 Leaf spring and suspension system
Suspension is the system of tires, tire air, springs, shock absorbers and linkages that connects
a vehicle to its wheels and allows relative motion between the two. Suspension systems serve
a dual purpose contributing to the vehicle's road holding/handling and braking for good
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active safety and driving pleasure, and keeping vehicle occupants comfortable and a ride
quality reasonably well isolated from road noise, bumps, vibrations etc.
The automobile suspension system is having the following requirement

To have minimum deflection to the vehicles with required stability

To have minimum wheel hop.
To safe guard the occupants and cargo against road shocks
To minimize the effects of stresses due to road shocks on the mechanism of the

vehicle.
To keep the body perfect in level while travelling over rough and uneven roads.
To keep the body of the vehicle safe from road shocks

Fig.2.20 Leaf spring [15]

There are different types of suspension system provided in different vehicles. Those are
(i) Conventional suspension system
(ii) Independent suspension system

2.14 Steering System

The steering system of a vehicle is having the following requirements
(1) It should be able to turn the vehicle with more mechanical advantage and less efforts.
(2) It should turn the wheel within shortest possible time
(3) There should be self-cantering action in the steering geometry

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(4) It should be certain degree irreversible so that the shocks of the roads surface are not
transmitted to the hands of the driver.

Fig.2.21 Steering system [16]

2.14.1 Power Steering
The power steering system provides additional assistance to the turning effort applied to the
manual steering system. The power steering is of two types Hydraulic and electric/
electronic. A hydraulic electric hybrid system is also possible. A hydraulic power steering
(HPS) used hydraulic pressure applied by on engine driven pump to assist the motion of
turning the steering wheel.
Electric power steering (EPS) is more effects than the hydraulic power steering since the
electric power steering motor only needs to provide assistance when the steering wheels
turned whereas the hydraulic pump must run constantly. The main components of an integral
power steering system consist of a hydraulic pump assembly connected with hoses. A rotary
valve power steering gear for the integral system using recirculating ball type worm and
wheel steering gear is most commonly used one.

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CHAPTER NO 3
MAINTENANCE PROCEDURE
3.1 Maintenance procedure daily
3.1.1Engine oil level:
Before starting or at least 5 minutes after the engine is shutdown check the oil level and top
up if necessary never particles engine with the oil level below mark or above the high mark.
3.1.2Marking on dipstick:
Low mark to high marks capacity 2.1 litters
Grade SAE 15W-40
Confirming to classification API CE/SG
3.1.3Fuel level:
Check fuel in fuel tank. Top up if necessary and secure cap capacity 160 liters.
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Removing radiator pressure cap:

Removing the pressure cap when the coolant is cold (below 50*C)
Failure to do so can result personal injury.
3.1.4Coolant mixture:
50% water
50% ethylene glycol (antifreeze)
3.1.5Fan:
Rotate the crankshaft and visually inspect the fan for cracks.
Proper mounting, replace fan if damaged.
3.1.6Drive belt:
Visually inspect the belt, replace the belt if frayed or pieces of material missing or
longitudinal.
3.1.7Water separator:
Lift the spring load valve as shown above and drain the water until clear fuel is visible.
3.1.8Caution:
Excessive draining will introduce and into the system causing the engine to be hard to start.
3.1.9Draining condensed water:
Drain off condensed water from air tank (1) by operating drain valve.
3.1.10Brakes:
Check for proper functioning of brakes

3.1.11Tyre pressure:
Check and inflate the tyre in cold condition
Front tyre pressure

5.3 bar (75 psi)

Rear tyre pressure

6.0 bar (85 psi)

3.1.12Leaks:
Check for leaks of water, air, fuel and oil at gaskets hose connections flexible pipes and pipe
connections. If there is any fault replace the part.
3.1.13Electrical system:
Check the functioning of light, horn, wiper blinker, switches and gauges.
3.2 Inspection after 1000 kms
3.2.1Clutch pedal free play:
Check free play at clutch pedal, it should be 5 to 10 mm
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3.2.2Adjusting free play:

If free play is less adjust by loosening check nut on push rod of master cylinder check and
free play and lock the nut. Vary the free play at pedal again.
3.2.3Gear box:
Open oil drain plug and check oil level play. Check level of gear box oil top up if necessary.
Grade APIGLA-SAE 80
3.2.4Rear axle:
1. Oil drain plug.
2. Oil level plug.
Check level of rear axle oil top up if necessary
Grade

AIPGL5

SAE90 (up to 9*C)

SAE75 (9 to 45*C)

3.2.5Power steering fluid level:

Check oil level in the power steering tank with engine switched off just place the dipstick in
position while checking. The oil level should be 1 to 2 cm above the mark on dipsticks for
topping up use oil conforming ATF-type A.
3.2.6 Steering system hoses:
It fitted check for leaks of oil from the pipe and connection of power steering system
necessary.

3.2.7 Battery check:

Check electrolyte level it should be between 10 to 22 mm above the top of the battery plates.
Battery mounting clamps and starter motor terminals must be kept clear and firm. Apply
Vaseline/petroleum jelly on battery terminals.
3.2.8 Wheel nuts:
Check wheel nuts and tight them. If necessary when the wheel on the rear axle care must be
exercised to insure that between the drum and inner wheel rim spherical washers are placed
in the wheel studs with flat surface towards the wheel. After lifting the inner and outer wheel
spherical washers should be placed in such a way that the spherical surface is towards the
wheel rim and the drum. Torque (non-spigot Ted: 45-55m/kg wheel rims are fitted the
spherical washers and spherical spring washer is not required torque (spotted wheel rim nuts
50-60 mugs)

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3.2.9 Brake system:

1. Check free movement of spindle in dual brake valve.
2. Check brake system for leaks and rectify if necessary.
3.2.10 Leaf spring U bolts:
The U bolt nuts and check nuts of front and rear the spring should be regularly tightened with
at torque wenches or with a socket wrenches or with a socket and handle of at least 60 cm
length torque (U bolt nut 35 mkg) torque (check nut 35 mkg).
3.2.11 Lubricate linkage bushes and pins:
Lubricate oilcan brake chamber fork and pinball joins of exhaust brake linkage clutch
linkages pivots linkage of foot brake.
3.2.12 Grease with gun:
Brake pedal bush brake double level block adjuster and camshaft bushes (AAL) clutch pedal
bushing accelerator linkages support bush gear shifting linkage propeller shaft U joint sliding
yoking pins tie rod ends drag link end front spring pins rear spring pins helper spring brackets
rear grade purpose grease no 2.
3.3 Inspection after every 72000 km
3.3.1 Vibration damper:
Check the index line on the damper hub and the inertia member if the lines are more than 1.5
mm out an alignment replace the damper.
3.3.2 Inspecting rubber member:
Inspect rubber member for deterioration if pieces of rubber are missing.
If elastic member is more than 3.13 mm below the metal surface replace the damper. Also
look for forward movement of the damper ring on the hub. Replace the damper if any
movement is detected.
3.3.3 Schematic circuit of hydraulic clutch actuation:
1. Clutch master cylinder.
2. Clutch fluid screw.
3. Bleeding screw.
4. Clutch sleeve cylinder.
3.3.4 Clutch system:
Dismantle clean inspect and reassemble clutch sleeve cylinder and master cylinder. Replace
damaged/worn out parts.
3.3.5 Bleeding clutch system:
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Remove the dust cap from slave cylinder bleed screw and attach the bleed tube to bleed
screw. Place the other end of the tube in clean glass for containing sufficient brake fluid to
submerge the end of the tube. Pump the clutch pedal twice/thrice slowly throughout its spoke
and by holding the pedal pressed loosed the bleed screw and watch then air bubbles in the
glass jar. Retighten the bleed screw. Repeat the procedure until air bubbles cease to appear at
the end of bleed tube. Replace the dust cap on the bleed screw total system.
Capacity of clutch fluid 210 cc
Grade SAEJ 1703 E/F
3.3.6 Steering oil and filter change:
Drain off hydraulic oil of power steering big loosing drain. Plug remove carrier and insert
new filter cartridge with metal colour in upward direction. Fill this oil into this oil tank crank
the engine and add oil to mark up the oil level to the top mark of dipstick.
Recommended oil:
Confirming to ATF-type-A
System capacity 3 litters
Bleeding power steering system:
Jack up the front only and run the engine at idle speed turn the steering wheel several times
from lock to lock so that air escapes from the cylinder keep adding oil until oil level remains
at upper mark at dipstick and air bubbles are no longer rising in the oil tank when steering
wheel is turned shut the engine off and lower front axle. Check oil level and add if necessary.
To bring the oil level 1 to 2 cm above the top mark of dipstick.
3.3.7 Spring:
Dismantle front and rear spring clean and apply graphite grease while reassembling grease
spring pin with grease plan
3.3.8 Butterfly valve in exhaust:
Dismantle and clean bitterly valve. Do not lubricate.
3.3.9 Gear box:
Dismantle clean inspect and reassemble the gear box
1. Drain gear oil while still hot clean magnetic and rain plug.
2. Check and tighten left hand nut to specified torque if necessary dismantle drive shaft.
Reassemble and replace left hand nut and tighten it to specified torque replace bearing if
required.

37

3. Check bearing on main shaft counter shaft and needle roller bearing on main shaft for
scoring/pitting mark replaces bearing needed roller bearing if necessary.
4. Adjust endplay of bearing on counter shaft main shaft and drive by selecting shims.
5. Check backlash on speed gears it should be within 0.25 mm. inspect gears replace
worn/scored/pitted gears.
6. Refills the gearbox with recommended oil.
7. Test the gearbox for gear noise and smooth gear engagement.

CHAPTER NO 4
CONCLUSION
When I first began my Industrial Training but went by ever so quickly and have left me
craving for much more. I would have to say that it is an absolutely fabulous part of the
curriculum and perhaps will remain the most memorable one.
Needless to say that this experience was a highly enriching and educative one as I went on
from one department to another and met and got the opportunity to train under several highly
respected senior professionals. I learnt that every individual is different and that every one
has something unique to offer. I learnt that every job has its nuances and its value and that no
job is superior to the other. I learnt that on needs to constantly improve and improvise. I
38

learnt hat this is just the beginning of a long road ahead full of challenges. But I know that
I will be able to run along because I have my foundations firmly built in. It is here that I got
the opportunity to continuously introspect and improve as a budding professional and as a
human being. I will always look back at the time spent here with fondness and with pride.
I cannot but thank all the people who have helped me in several different ways that will go a
long way in facilitating the commencement of a wonderful journey.

REFERENCE
1. http://hrtchp.com/hrtc/page/Organisational-Structure.aspx
2. http://hrtchp.com/hrtc/page/Bus-Services.aspx
3. https://www.scribd.com/document/194372295/Summar-Training-Report-HRTCTRAINING-REPORT
4. https://www.google.co.in/url?
sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKE
wjy9LL9q6zOAhXFuI8KHdHgADMQjRwIBw&url=http%3A%2F
%2Fwww.wheelmela.com%2Fnew-trucks
%2Ftata&psig=AFQjCNGoi1XrwWv9UEzh4X9WOS7BkKIVQA&ust=1470557
560149978
39

5. https://www.google.co.in/url?
sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKE
wi_wI7ArKzOAhVBPo8KHQoYA_UQjRwIBw&url=https%3A%2F
%2Fcatiatutorialv5.wordpress.com%2F2012%2F02%2F23%2Fengine-coolingsystem
%2F&psig=AFQjCNEkLFxnQEz0BjLniFQRrsbXCIDQMA&ust=14705576949
68762
6. https://www.scribd.com/doc/110871126/Industrial-Training-Project-Report-onH-R-T-C
7. https://www.chicagocorvette.net/diagram_view.php?d=1799&rc=1341
8. http://enginemechanics.tpub.com/14081/css/Propeller-Shaft-Assemblies-59.htm
9. http://www.mrclutchnw.com/services/differential-rebuilding/
10. http://blog.nexttruckonline.com/truck-news/press-release/navistar-selects-danaaxles-driveshafts-for-newest-vehicle/
11. http://themechunicorn.blogspot.in/2014/04/brakes-drum-brakes-part2.html
12. http://www.seminarsonly.com/EngineeringProjects/Mechanical/Mechanical_Braking_System.php
13. http://mechanicalmania.blogspot.in/2011/07/hydraulic-brake.html
14. http://oppositelock.kinja.com/air-brakes-and-truck-safety-1515446684
15. http://www.trailersauce.com/equipment/suspension/
16. http://www.buzzle.com/articles/how-does-power-steering-work.html

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