INDUSTRIAL TRAINING REPORT

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

DEPARTMENT OF MECHANICAL ENGINEERING

SUBMITTED BY SUBMITTED TO
Vishal Bishawakarma Mr. Hitendra Bankoti

INDEX

● CERTIFICATE

● PREFACE

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 ● 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.

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 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 DATE-05/07/2013
Vishal Bishawakarma
Mechanical Engineering
6th semester

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 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

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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. Ranikhet Depot
2. Kashipur Depot
3. Bhowali Depot
4. Almora Depot
5. Haldwani Depot
6. Ramnagar Depot

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

SECTIONS:

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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:-

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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. TATA- 1312
2. TATA- 1520
3. TATA- 1210
4. LEYLAND

PARTS OF ENGINE:-
There are following parts of an Engine-:
1. Cylindrical Head.
2. Oil Pump.
3. Cylinder Block.
4. Piston.
5. Crank Shaft.
6. Cam Shaft.
7. Cooling Fan.

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 8. Radiator.
9. Valve Mechanism.
10. Self-Starter.
11. Fly Wheel.
12. Cooling Plate.
13. Dumper Pulley.
14. Vibration Dumper Pulley.
15. Water Pump.
16. Timing Plate Housing.
17. Push Rod.
18. Diesel Filter.
19. Tappet.
20. Gudgeon Pin.
21. Alternator.
22. 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.

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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 -:
1. Suction Stroke.
2. Compression Stroke.
3. Combustion/Power Stroke.
4. 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.

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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.
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

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

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PARTS OF GEAR BOX-:
1. Main Shaft 10.Spring Washer
2. Counter Shaft 11.Oil Seal
3. Shifting Rod 12.Front Cover
4. Gear Box Housing 13.Butt Rings
5. Cover Plate 14.Hub and Bush
6. Bearing and Sleeve 15.Synchronizer
7. Fork 16.Carrier and Compressor Pin
8. Cylindrical Bin 17.Drive Shaft
9. Mug Drain Pin 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. First Gear - 39
1. Second Gear – 32
2. Third Gear – 25 or 26
3. Fourth Gear – 19 or 20
4. Fifth Gear – 17

B. In Counter Shaft-:
1. First Gear – 11
2. Second Gear – 17
3. Third Gear – 23 or 24
4. Fourth Gear – 29

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 5. Fifth Gear – 36

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

Working-:

1) Neutral Position-: The power of Engine reaches to Counter Shaft. But

because of no Pinion meeting of Main and Counter Shaft, power doesn’t go
forward and the Vehicle remains unmoved.

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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.

5) Reverse Gear-: When Gear Lever takes Gear to the Reverse Gear position
the small tooth’s of Reverse Gear mesh with the First Gear of Main Shaft and big
tooth’s mesh with the Reverse Gear of Counter Shaft, Main Shaft rotates anti-
clockwise 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.

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4. Gear shifting should be done softly.

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. 10. Air Nipple.
2. Delivery valve spring. 11. Hand Primer.

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 3. Plunger. 12. Cotton Glassy.
4. Pump housing. 13. Paper Glassy.
5. Control pack. 14. Idling.
6. Plunger Return spring. 15. Lever Washer
7. Control sleeve. 16. Control Rod
8. Cam Shaft. 17. Sluing Lever
9. Feed Pump. 18. Fly Weight

SPECIFICATION OF F.I. PUMP-:

Model -Bosh Type F.I. Pump
Injection Pressure - 7 to 30 M Pa.
CAM Sequence - 1-5-3-6-2-4.
Direction of Rotation -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
|
Fuel Supply
|
Feed Pump
|
Glassy

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 |
Strainer
|
Diesel Filter
|
Pump
|
Air Nipple
|
Self-Start

Precaution & Safety Features-:

1. Pump should remain clean always.
2. Mountings should be tight.
3. Do not clamp retainers very tight.

4. Spring Section-:
Because of the up’s and down’s 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.
Krampe Hydraulic Machine is used for the bending of road springs. The
machine’s 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. There is no breakage in the Leaf.
2. Mounting should be tight.

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 3. Weekly Lubrication is required for the Shekel pin.
4. Too much play in shekel is not permissible.

In Roadways Workshop Kathgodam the following tools are used for repair and
assembly-:
1. Spanner.
2. Hammer.
3. Chisel.
4. Pliers.
5. Screw Drivers.
6. Anvil.
7. F.I Pump Testing Machine.
8. Hydraulic Krampe Machine.
9. Micrometer.
10. 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.
2. In every section the automobile parts are dissemble.
3. Dissembled parts washed by Dermal.
4. The washed part replaces the damaged part.
5. Now the assembly is done.
6. The washed parts checked carefully from where it damaged.
7. In this way after repairing new assembled part supply to the depot.

In the Roadways Workshop Kathgodam there is a limited use of computers.

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The use of computers is as follows-:
1. The data related to Purchase and Selling of parts is stored.
2. To prepare the list of automobile parts and their costs and from which
company they have been purchased.
3. In the Registration of Roadways Buses.
4. Details of spare parts stored in the depot.

The following step should be taken for safety on the work place-
1. The workshop should be clean and there will be security apparatus must be
given to the workers.
2. The Workshop System of air must be managed.
3. Do not smoke and peep away of the fire substance from working place.
4. Use Apron, Shoes, and Glassware during work.
5. The wiring of the Workshop should be done properly.

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 'prop-
shaft'), 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 half-
shafts) will rotate in opposite directions relative to the ring gear by, say, 2 full
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

20
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 9) King Pin
2) Crown 10) King Pin Sims
3) Sun & Star gears 11) Staff Axle
4) Pinion 12) Cutter Pin
5) Bearing Cone 13) Split Nut
6) Distance Piece washer 14) Second Arm
7) Thrust Washer 15) Third Arm
8) Chuck Washer 16) Oil seal ring

Assembly of Axle-:
I-Beam
|
Staff Axle

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 |
King Pin
|
King pin Sims
|
Roller Bearing
|
Cutter Pin
|
Inner Bearing
|
Break Richet
I
Break-Shoe
|
Lining
|
Break Cam shaft
|
Plastic Slip
|
Hub

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.

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4. Grease has to be pumped in through top/bottom grease nipples.

6. Electric Section-:
Electric Section consists of:
1. SELF STARTER
2. ALTERNATOR

1. SELF STARTER – Self-starter’s only work is to start vehicle. By pressing

self the operator starts the vehicle

Main parts of Self Starter-:

1. Main field.
2. Auxiliary Field.
3. Clutch.
4. Armature.
5. Pinion.
6. Solenoid Switch.
7. DE and CE Switch.
8. D Plate.
9. 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

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switch by which the current comes in main field, then current goes to
Commutator.

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

MAIN PARTS-:
1. Pulley.
2. Straighter.
3. Regulator.
4. Rectifier.
5. 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. Connections should be tight and clean.
2. Saves the wires from Grease and Oil.
3. Do not let the wires hanging.
4. The insulation should be correct.

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