INDUSTRIAL DEPARTMENT OF MECHANICAL ENGINEERING

TRAINING
REPORT

Trainee name- PRANJAL

PADALIYA
 INDUSTRIAL TRAINING REPORT

FIELD EXPOSURE
REPORT
REGIONAL WORKSHOP
KATHGODAM, NAINITAL
( Uttarakhand Transport Corporation)
(2017-2018)

DEPARTMENT OF MECHANICAL ENGINEERING

UNDER GUIDED BY : SUBMITTED BY :

Mr. Gajendra Singh PRANJAL PADALIYA

Vth SEMESTER
H.O.D. MECHANICAL ENGG.
MECHANICAL ENGG.

ii
INDEX-

S.No. TOPIC NAME Page No.

1 PREFACE 1

2 ACKNOWLEDGEMENT 2

3 CERTIFICATE OF DEPARTEMENT 3

4 CERTIFICATE OF INDUSTRIES 4

5 NAME AND ADDRESS OF INDUSTRIES 5

6 DATE OF JOINING AND RELEASING 6

7 INTRODUCTION/NATURE OF INDUSTRIES 7

8 SECTION OF UNIT VISITED AND ACTIVITIES 8

9 DETAIL OF MACHINE / TOOL AND INSTRUMENT USED IN THE 9

SECTION OF THE UNIT VISITED

10 WORK PROCEDURE IN THE SECTION 10

11 SPECIFICATION OF THE PRODUCT AND MATERIAL USED 11

12 WORK OF REPAIR AND MAINTENANCE 12

iii
 PREFACE

I am very grateful to our honorable H.O.D Mr.GAJENDRA SINGH and lecturer

mr. sachin saxena 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-1/11/2017
PRANJAL PADALIYA
MEchanical Engineering (5thsemester)

iv
 ACKNOWLEDGEMENT

It is my pleasure to be indebted to various people, who

directly or indirectly contributed in the development of
this work and who influenced my thinking, behavior, and
acts during the course of study.
I express my sincere gratitude to Dr. Rajesh updhyaya
worthy Principal for providing me an opportunity to
undergo summer training at Roadways Regional Workshop
Kathgodam, Nainital (Uttarakhand.
I am thankful to Mr.Mukesh kumar pant senior foreman for
his support, cooperation,
and motivation provided to me during the training for
constant Inspiration, presence and blessings.
I also extend my sincere appreciation to Mr.Gajendra
singh H.O.D and who provided his valuable suggestions
and precious time in accomplishing my project report.

v
Lastly, I would like to thank the almighty and my parents
for
their moral support and my friends with whom I shared my
day 19/06/2017 to 18/07/2017 day experience and
received lots of suggestions that improved my quality of
work.

PRANJAL PADALIYA
(Name of the student)

UTTARAKHAND TRANSPORT CORPORATION,

ROADWAYS WORKSHOP (REGIONAL)

ADDRESS: KATHGODAM, NAINITAL (U.K.)

vi
 DATE OF JOINING:19/06/2017

DATE OF LEAVING:18/07/2017

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. Ranikhet Depot

vii
 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.

viii
 CERTIFICATE

This is to certify that Mr Pranjal Padaliya is a student of Mechanical

Engineering Semester 5th in the season 2017-2018 of Govt. polytechnic
Kashipur Send has successfully completed the exposure report based on the
Uttarakhand Board of technical education Roorke 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.
Mr. Gajendra singh

ix
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:

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.

x
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

xi
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.
8. Radiator.
9. Valve Mechanism.
10. Self-Starter.

xii
 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.

xiii
 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 -:

xiv
 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
bearingto 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.

xv
3. Tappet cover should always fix.

4. Lubrication oil should be replaced in regular intervals.

xvi
2. GEAR BOX SECTION:-
Manual transmissions often feature a driver-operatedclutchand a movable gear
stick. Most automobile manual transmissions allow the driver to select any
forwardgear ratio("gear") at any time, but some, such as those commonly
mounted onmotorcyclesand 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 theflywheel 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
thethrow 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
engineso 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, mostautomatic transmissions feature epicyclic (planetary) gearing
controlled by brake bands and/or clutch packs to select gear ratio. Automatic
transmissionsthat allow the driver to manually select the current gear are
calledManumatics. A manual-style transmission operated by computer is often
called anautomatedtransmission 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

xvii
keep the engine running in thepower 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 isvariedas 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)

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

xviii
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
5. Fifth Gear – 36

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

Working-:

xx
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.

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-:

xxi
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.

xxii
3. Fuel Injection Pump Suction-:

xxiii
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.
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

xxiv
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

xxv
 |
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.

xxvi
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.
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.

xxvii
 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.

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-

xxviii
 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.

xxix
 4.AXLE SECTION-:

REAR AXLE-: Powerfrom 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

 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 thetransmission, to a drive shaft (British
term: 'propeller shaft', commonly and informally abbreviated to 'prop-shaft'),
which runs to the final drive unitthat contains the differential. A spiral

xxx
bevelpiniongear 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 cauge, 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 with the engine off, and the drive shaft is held (say leaving the
transmission 'in gear', preventing the ring gear from turning inside the

xxxi
differential), manually rotating one driven roadwheel causes the opposite
roadwheel to rotate in the opposite direction by the same amount.

When the vehicle is travelling 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.

xxxii
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

xxxiii
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
|

xxxiv
 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.

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

xxxv
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.

xxxvi
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.

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.

xxxvii
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.

xxxviii