Summer Training Report

Submitted in partial fulfilment for the award of Diploma in Mechanical Engineering.

Project Title
Maintenance Department (Engine Section).

Training Organization
UPSRTC
Place
Kaiserbagh, Lucknow, Up.
Training Duration
From:- 01 / 06 / 2017 To:- 30 / 06 / 2017.
Name of Officer: - Mr. K M Chauhan.
Internal Guidance: - Mr. Abdul Khalique & Mr. Zafaruddin.
Diploma (Mechanical)
Roll No.: 1501063094.

NAME : MOHD ARMAN

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 INDEX
S.N CONTENTS PAGE REMARK
O
1. Acknowledgement 2
2. History 4-7
3. Infrastructure 8-9
4. Depots & Busses 10
5. Basic Concepts of Auto Mobile 12
6. Engines & Classifications 13-14
7. Main Components of Engines 15-31
8. Report 33-35
9. Flow Chart of Vehicle 36-40
Maintenance
10. C Conclusion 41
11. Reference 42
12. Summary 43

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 AKNOWLEDGEMENT
It’s a great pleasure to present this report of summer training
in UPSRTC, LUCKNOW in partial fulfilment of Diploma
Programme under the Guidance of INTEGRAL UNIVERSITY
(POLYTECHNIC), LUCKNOW.
At the outset, I would like to express my immense gratitude
to my training guide guiding me right from the inception till
the successful completion of the training. I am falling short of
words for expressing my feelings of gratitude towards him for
extending their valuable guidance about market and support
for literature, critical reviews of project and the report and
above all the moral support he had provided me with all
stages of this training. I would also like to thank my friends
and all my group members for their help and cooperation
throughout the training.

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 Slogan: "Aapka Apna Saathi".
Founded: 15 May 1947; 70 years ago.
Headquarters: Lucknow, Uttar pradesh, India.
Service type: Ordinary, Rural, Express, Volvo & Scania.
Fuel type: Diesel
Website: www.upsrtc.com.

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 UTTAR PRADESH STATE ROAD TRANSPORT CORPORATION

At a Glance
UPSRTC is a public sector passenger road transport
corporation providing services in the state of Uttar Pradesh
and other adjoining states in North India.
With a fleet size of over 11851 buses we operate over 3
million kilometres catering to the travel needs of over 1.4
million people and earing over 70 million every day.
Provision of adequate, efficient, well-co-ordinated,
comfortable and economical services to our passengers,
while earning enough for self-sustenance & growth, is our
Moto.

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 HISTORY
Passenger road transport services in the state of U.P. started
on 15th May, 1947 with the operation bus services on the
Lucknow – Barabanki route by the erstwhile
U.P.Government Roadways .
Subsequently, during the fourth Five Year Plan, rechristened
as Uttar Pradesh State Road Transport Corporation (UPSRTC)
On 1-6-72 under the provision of the Road Transport Act,
1950 with the following objectives.
For the development of the road transport sector correlated
to which would be overall development of trade & industry.
For coordination of the road transport services with the
other modes of transport.
For providing or causing the provision of an adequate,
economical & efficiently coordinated road transport services
to the residents off the state.

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At the time of establishment 0f the corporation it had a fleet
of 4253 buses which were operating on 1123 routes. The
corporation’s earned kilometre operated at the time was
228.8 million kilometres. While the total number of
passengers carried by its buses totalled 251.3 million.
By the end of decade the fleet of the corporation had
attained strength off 5679 buses, the operation had
increased to 1782 routes. As a result of this increases in
operation, the earned kilometres totalled about 395.3 million
kilometres , while the total numbers of passengers carried
totalled over 449.1 million.
The end of VI five year plan saw further increase in all
operational parameters being achieved by the corporation
rose to 425.7 million kilometres.

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During the VII five year plan 2722 buses were replaced with
new buses however 3142 buses were auctioned and the fleet
at the end of 1996-97 became 7463 buses.
During Xth five year plan 5274 buses were inducted and 4818
buses were removed from fleet. At the end of 2006-07 the
corporation had 6561 buses apart from 784 hired buses
operated under its control.
During the XIIth five year plan period the Corporation targets
to purchase 8450 new buses to bring itd fleet size to 13040
by the end of plan period in 2017.
The Corporation has also commenced the operation of high
end buses and non stop inter city services (PLATINUM &
GOLD LINE).

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 INFRASTRACTURE
The corporate office of the corporation is situated at
Lucknow. The Corporation has been reconstituted on
30.10.03 with the service in the state of Uttaranchal firming a
separate corporation.
For efficient functioning the corporation has been divided in
to 20 regions of which 1 region operates urban & sub-urban
services. Each regions has a regional workshop where major
repair and maintenance work as well as assembly
reconditioning work is performed.
Each region has been further divided into operational units
called depots. The total depots in the corporation is 108,
including car-section. Each depot has a depot workshop
attached to it to provide supporative maintenance facilities.

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For heavy maintenance and repair of vehicles, reconditioning
of major assemblies, renovation of buses and construction of
new bodies on new chassis, two central workshop have been
established in Kanpur: Central Workshop, Rawatpur and Dr.
Ram Manohar Lohia Workshop, Allen Forest.
Eight tyre retreading plants are established at Agra,
Lucknow,Gorakhpur , Ghaziabaad, Bareilly, Kanpur,
Sharanpur, Allahabad, Moradabad and Etawah to provide in
house tyre retreading facilities.
For repairs and maintenance of staff cars belonging to the
state Government and the Corporation, a separate unit
named Car Section is established in Lucknow.
For imparting training to drivers and technical staff, a
Training School is established in Kanpur.

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 Depots & Bus Station
The Corporation has 300 bus stations and of which 249 are
owned premises and 51 in rented premises. For the
convenience of the passengers the corporation the
Corporation generally has rest rooms, canteens, booking
offices, toilets, drinking water, time table & fare chart
display, enquiry counters, public address system, lights, fans,
seats & benches and PCO etc.
Cleanliness of the bus stations and buses are accorded
priority. Suggestion &/ or complaint books have been made
available to station incharges and passengers feedback
through them is invited and monitored. Tv’s have been fitted
in passenger lounge of important bus stations.

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 FUTURE PLANING
Soon UPSRTC may introduce 'poo bus' that runs on human
and household waste.
In March this year, the first 'poo bus' rolled out in the UK,
powered by human and household waste. Now, Uttar
Pradesh State Road Transport Corporation is mulling over the
introduction of these buses for intra-city services, across all
75 districts.
The corporation has been in talks with Swedish bus maker
Scania, which produces vehicles fuelled by human waste. If
this project sees the light of day, UP will be the first state in
the country to have bio-fuel powering buses.
Top road transport officials said all cities across the 75
districts could have these buses. The poop of 100 humans,
they said, was all it would take to fuel a 200-km ride.
Buses that run on poop already ply the streets of Britain,
Italy, Sweden and Poland. Ravinder Singh, service manager,
Agra division of UPSRTC, said, "The Swedish bus maker
showed a presentation to our representatives on how human
excreta and household waste could provide a sustainable
way of fuelling public transport, while also improving urban
air quality."

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NAME : MOHD ARMAN
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 BASIC CONCEPT ABOUT AUTOMOBILE
About fifteen thousand separate parts are put together to
make an automobile automative vehicle are produced in
large variety of sizes and shapes, all have the same basic
parts and systems. This includes-:
 Basic structure.
 Engine or power plant.
 Transmission system.
 Control system.
 Super structure.

Basic Structure of bus

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 ENGINE
A heat engine is a machine which converts heat energy into
mechanical energy. The combustion of fuel such as coal,
petrol, diesel generates heat. This heat is supplied to
working substance at high temperature. By the expansion of
this substance in suitable machines, heat energy is converted
into useful work.

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 INTERNAL COMBUSTION ENGINE (I C ENGINE)
 IC engine is a type of engine in which combustion of fuel
takes place inside the engine as shown in below fig. In
these engines there is a sequence of processes.
 Compression
 Combustion
 Expansion
 Exhaust / induction.
There are two basic mechanical designs to achieve these four
processes in either:
Four stroke IC engine & Two stroke IC engine

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 MAIN COMPONENTS OF I C ENGINE
 Cylinder Block
 Cylinder Head
 Piston
 Piston Rings
 Connecting Rod
 Crankshaft
 Engine Bearing
 Crankcase
 Valves
 Spark Plug
 Injector
 Manifold
 Camshaft
 Gudgeon Pin or Piston Pin
 Push Rod
 Flywheel

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 CYLINDER BLOCK

Cylinder is the main body of IC engine. Cylinder is a part in

which the intake of fuel, compression of fuel and burning of
fuel take place. The main function of cylinder is to guide the
piston. It is in direct contact with the products of combustion
so it must be cooled. For cooling of cylinder a water jacket
(for liquid cooling used in most of cars) or fin (for air cooling
used in most of bikes) are situated at the outer side of
cylinder. At the upper end of cylinder, cylinder head and at
the bottom end crank case is bolted. The upper side of
cylinder is consists of a combustion chamber where fuel
burns. To handle all this pressure and temperature generated
by combustion of fuel, cylinder material should have high
compressive strength. So it is made by high grade cast iron. It
is made by casting and usually cast in one piece.

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 CYLINDER HEAD

The top end of cylinder is closed by means of removable

cylinder head. There are two holes or ports at the cylinder
head, one for intake of fuel and other for exhaust. Both the
intake and exhaust ports are closed by the two valves known
as inlet and exhaust valve. The inlet valve, exhaust valve,
spark plug, injector etc. are bolted on the cylinder head. The
main function of cylinder head is to seal the cylinder block
and not to permit entry and exit of gases on cover head valve
engine. Cylinder head is usually made by cast iron or
aluminium. It is made by casting or forging and usually in one
piece.

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 PISTON

A piston is fitted to each cylinder as a face to receive gas

pressure and transmit the thrust to the connecting rod. It is
the prime mover in the engine. The main function of piston is
to give tight seal to the cylinder through bore and slide freely
inside of cylinder. Piston should be light and sufficient strong
to handle the gas pressure generated by combustion of fuel.
So the piston is made by aluminium alloy and sometimes it is
made by cast iron because light alloy piston expands more
than cast iron so they need more clearances to the bore.

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 PISTON RINGS

A piston must be a fairly loose fit in the cylinder so it can

move freely inside the cylinder. If the piston is too tight fit, it
would expand as it got hot and might stick tight in the
cylinder and if it is too loose it would leaks the vapour
pressure. To provide a good sealing fit and less friction
resistance between the piston and cylinder, pistons are
equipped with piston rings. These rings are fitted in grooves
which have been cut in the piston. They are split at one end
so they can expand or slipped over the end of piston. A small
two stroke engine has two piston rings to provide good
sealing but in a four stroke engine has an extra ring which is
known as oil ring. Piston rings are made of cast iron of fine
grain and high elastic material which is not affected by the
working heat. Sometimes it is made by alloy spring steel.

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 CONNECTING ROD

Connecting rod connects the piston to crankshaft and

transmits the motion and thrust of piston to crankshaft. It
converts the reciprocating motion of the piston into rotary
motion of crankshaft. There are two end of connecting rod
one is known as big end and other as small end. Big end is
connected to the crankshaft and the small end is connected
to the piston by use of piston pin. The connecting rods are
made of nickel, chrome, and chrome vanadium steels. For
small engines the material may be aluminium.

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 CRANKSHAFT

The crankshaft of an internal combustion engine receives the

efforts or thrust supplied by piston to the connecting rod and
converts the reciprocating motion of piston into rotary
motion of crankshaft. The crankshaft mounts in bearing so it
can rotate freely. The shape and size of crankshaft depends
on the number and arrangement of cylinders. It is usually
made by steel forging, but some makers use special types of
cast-iron such as spheroidal graphitic or nickel alloy castings
which are cheaper to produce and have good service life.

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 ENGINE BEARING

Everywhere there is rotary action in the engine, bearings

need. Bearings are used to support the moving parts. The
crankshaft is supported by bearing. The connecting rod big
end is attached to the crank pin on the crank of the
crankshaft by a bearing. A piston pin at the rod small end is
used to attach the rod to the piston, also rides in bearings.
The main function of bearings is to reduce friction between
these moving parts. In an IC engine sliding and rolling types
of bearing used. The sliding type bearing which are sometime
called bush is use to attach the connecting rod to the piston
and crankshaft. They are split in order to permit their
assembly into the engine. The rolling and ball bearing is used
to support crankshaft so it can rotate freely. The typical
bearing half is made of steel or bronze back to which a lining
of relatively soft bearing material is applied.

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 CRANK CASE

The main body of the engine to which the cylinder are

attached and which contains the crankshaft and crankshaft
bearing is called crankcase. It serves as the lubricating system
too and sometime it is called oil sump. All the oil for
lubrication is placed in it.

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 VALVES

To control the inlet and exhaust of internal combustion

engine, valves are used. The number of valves in an engine
depends on the number of cylinders. Two valves are used for
each cylinder one for inlet of air-fuel mixture inside the
cylinder and other for exhaust of combustion gases. The
valves are fitted in the port at the cylinder head by use of
strong spring. This spring keep them closed. Both valves
usually open inwards.

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 SPARK PLUG

It is used in spark ignition engine. The main function of a

spark plug is to conduct the high potential from the ignition
system into the combustion chamber to ignite the
compressed air fuel mixture. It is fitted on cylinder head. The
spark plug consists of a metal shell having two electrodes
which are insulated from each other with an air gap. When
high potential current supply to spark plug it jumping from
the supply electrode and produces the necessary spark.

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 INJECTOR

Injector is usually used in compression ignition engine. It

sprays the fuel into combustion chamber at the end of
compression stroke. It is fitted on cylinder head.

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 MANIFOLD

The main function of manifold is to supply the air fuel

mixture and collects the exhaust gases equally form all
cylinder. In an internal combustion engine two manifold are
used, one for intake and other for exhaust. They are usually
made by aluminium alloy.

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 CAMSHAFT

Camshaft is used in IC engine to control the opening and

closing of valves at proper timing. For proper engine output
inlet valve should open at the end of exhaust stroke and
closed at the end of intake stroke. So to regulate its timing, a
cam is use which is oval in shape and it exerts a pressure on
the valve to open and release to close. It is drive by the
timing belt which drives by crankshaft. It is placed at the top
or at the bottom of cylinder.

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 GUDGEON PIN OR PISTON PIN

These are hardened steel parallel spindles fitted through the

piston bosses and the small end bushes or eyes to allow the
connecting rods to swivel. It connects the piston to
connecting rod. It is made hollow for lightness.

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 PUSHROD

Pushrod is used when the camshaft is situated at the bottom

end of cylinder. It carries the camshaft motion to the valves
which are situated at the cylinder head.

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 FLYWHEEL

A flywheel is secured on the crankshaft. The main function of

flywheel is to rotate the shaft during preparatory stroke. It
also makes crankshaft rotation more uniform.

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 REPORT
On 1st June, it was my first day. As it was my first day I was
very excited about the workshop, workers, and all the other
things related to the training.
I reached there at sharp 8 o’clock in the morning. After the
attendance under the guidance of FOUR MAN Mr. K.M
chauhan we visit the whole workshop.
There are the following shops:
 Welding shop
 Painting shop
 Electrical shop
 Sheet metal shop
 Engine section
 Air filling station
 Automatic washing station
And many other small works also done in various other
shops.
In the first week we only got knowledge about all shops and
their respective operations perform in them.
In the workshop many buses comes for maintenance work
but approx. 4-5 buses are completed successfully.

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There are two categories of Maintenance.
 Half Maintenance (Servicing)
 Full Maintenance (Servicing)

HALF MAINTENANCE
In the Half Maintenance or servicing the buses generally who
completed their 40000 km trip comes under this category
In this servicing following operations are done:
 Gear & clutch servicing
 Oil seal checked and change if required
 Lubrication of various parts are done
 Mobile oil changed
 All the wheels are examined
 Head light, indicator, back light, battery are repaired
 And many other small works are done.
Finally after Washing the vehicle at the automatic washing
station, the vehicle are tested and handle to their respective
drivers.

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 FULL MAINTENANCE
In this, generally the maintenance or servicing of vehicles
are done who completed their 80000 km trip.
In this the complete servicing of the vehicle are done. This is
time taking process than the half one.
In this maintenance following operations are done.
 Mobile oil change
 Lubrication is done (full)
 Rear and front wheel greasing is done
 Oil seal are changed
 Inspection of breaking system
 Gear and clutch inspection and repairing
 Servicing of gear box
 Maintenance of gear system
 Engine is also opened if required
 Head light, back light, indicator, horn are also checked
properly
 Self-start system and battery are also examined
 Inspection of seats, windows, and their covers are
changed if required also etc. are done.

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 FLOW CHART OF VEHICLE MAINTENANCE
ENTRY

AIR FILLING STATION

MECHANICAL SERVICE STATION

ELECTRICAL SERVICE STATION

WELDING SHOP

SHEET METAL SHOP

PAINTING SHOP

AUTOMATIC WASHING STATION

EXIT

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 AIR FILLING STATION
At this station the amount of air checked and also inspection
of tyre, tubes are also done.
They may change as per requirement.

MECHANICAL SERVICE STATION

At this station, servicing of all the mechanical components of
the vehicle such as gear, clutch, axle, break, suspension
system, rear and front wheel etc are done.
If required that the some parts are are also replaced with
new one.

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 ELECTRICAL DEPARTMENT
In this department, generally the self-starting system of the
vehicle is inspected.
There are also battery gravity, head light, indicator, horn, etc
are checked.

WELDING SHOP
As the name referrers in this shop welding of the various
broken part of the vehicles are done such as frame, seat
foundation, windows, etc.Generally electric arc welding and
gas welding are used for welding.

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 SHEET METAL SHOP
This is smallest shop, in this shop generally the broken body
of the vehicle are fabricated by using G.I sheets.
This shop acts as the body maker of the vehicles.

PAINTING SHOP
The vehicles which are old or their painted surface becomes
rough n ugly are treated under this shop.
Generally the painting is done manually and also with the
help of machine also such as spray painting machine.

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 AUTOMATIC WASHING STATION
This is the last stage of every maintenance after all the
procedure. Finally, vehicle comes at that stage.
In this the washing of vehicle is done automatically.

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 CONLUSION
 While working on this project during four weeks, I have
study complete detail of I C engines.
 This specification and learned by me from the
employees of each division of engine and these method
production add a gem in my knowledge.
 The employees know their work very well and very
helpful in guided us.
 I tried to learn to my best and make the most of it and I
will carry this knowledge for my future experience and
studies.

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 REFERENCE
 www.upsrtc.com
 Economics times
 The Times of India
 www.wikipedia.com

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 SUMMARY
I had successfully completed my four weeks Industrial
Summer Training at UPSRTC Kaiserbagh Workshop, Lucknow.
Where I had been Visited the Whole Workshop & also got
Knowledge about the each Shop as discussed later.
Especially in Engine Section I Took Interest & Studied the
detail about the IC Engine & its Components deeply.
During my Industrial Summer Training I showed much
Interest in Learning.
As the Working Staff were Experienced & also had knowledge
about theory & Practical.
Under their Guidance I had learned some new techniques like
how to deal with the Workers, Punctuality, Responsibilities,
& Dedication towards the work

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 THANK

YOU….!!

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