INTERNSHIP ON KSRTC

CENTRAL WORKS
PAPPANAMCODE
 INTRODUCTION
 Begun in 20 February 1938

 Providing excellent service to the people both with

in the state and the neighboring states
 Ordinary, Limited stop, fast and super fast buses ,
Super Deluxe which caters to the different
sections of the society
 Comparatively cheap and the innovative
 KSRTC CENTRAL WORKSHOP
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 Main one, which deals to complaints at a
large scale
 Assembly of parts for the launch lf new
buses
 Overhauling and assembly sections
which engage in the maintenance of
machine parts
 ORGANIZATION STRUCTURE
  ENGINE OVERHAULING

 Cylinder block from the dismantled engine is cleaned

 Then boring and honing is done to remove wear
 The valve is grinded to proper finish and valve seat is lapped
 The damaged pistons is replaced by a new one
 The wearied crankshaft is ground so that modality and taper are within
permissible limits
 Crankshaft is coated with recommended lubricant
 After all maintenance or repairing process the engine is tested for four hour
  ENGINE PARTS
 ENGINE BLOCK

 It is a metal casing made from high carbon steel in

which the cylinder s are placed. They can withstand
high pressure and temperatures. Each part of the
engine is placed correctly and accurately inside the
engine block.
 CYLINDER SLEEVE OR BORE

It is the cylinder holes that are present in an

engine body in which power is produced. Diesel or any
other required fuel is sprayed to the required cylinder in
the order and power is produced. The number of
cylinder increase according to the requirements of
power.

 PISTON

It is a cylindrical material placed inside the cylinder.

Since the engine is an air tight device, the fuel inside the
cylinder had to be compressed for ignition and the burnt
gases are to be pushed out of the engine cylinder. Piston
helps in the compression and expansion of area inside the
cylinder. The piston acts as a movable end of the combustion
chamber.
 CRANKSHAFT

 It is a shaft that converts the reciprocating motion of the cylinder –piston

arrangement into the rotational motion
 This crankshaft is then connected to gearbox to deliver the necessary torque
to the automobile wheels
 The crankshaft is placed inside the engine block perpendicular to the motion of
piston heads
  CONNECTING ROD

 This is the part that joins the piston with crankshaft

 The rod is connected to piston using piston pin
 The connecting rod heads are kept at position and
tightened using bolts and are torqued to the desired
value

 CYLINDER LINER

 They are cylindrical lining placed inside the

cylinders for the smooth movement of piston
inside the cylinders.
 VALVES

 Certain valves are present in the engine block for

allowing passage of fuel ,and air into the system
 The inlet valve allow the passage of air-fuel mixture
or fuel in the system
 The valve is made with ‘’high-strength austenitic
nickel-chromium-iron alloys’’

 CAMSHAFT

 It is a specially designed shaft which is kept

parallel to the crankshaft
Cam
 The spraying of diesel ,inlet of air into the
cylinder before combustion and the outlet of
exhaust after combustion etc are done
precisely and in an order in the combustion
process by the help of this shaft

Camshaft timing sprocat

 CYLINDER HEAD

 It is well designed block paced above the

cylinder holes
 Valves and atomizer are placed on the cylinder
head
 Rocker arm is placed above the cylinder head

 ROCKER ARM

 It is a lever arrangement that converts power to the

pushrod to valve
 Pushrod from the tappet is connected to one end
of the rocker arm which in turn pushes down the
corresponding valve
  ATOMISER

 Diesel can’t mix with air efficiently so

it is sprayed to air
 It is specially designed nozzle to spray
diesel to the cylinder

 TURBOCHARGER

 Turbo chargers are works using the exhaust gases from

the cylinders are fed to the one portion of the turbo which
helps to rotate an impeller at high speeds
 Turbocharging is common in modern car and truck diesel
engines to produce higher power outputs, with lower
emission, and improving efficiency from the similar
capacity of engine
 AIR COMPRESSOR

 The piston is connected to the camshaft

for its working
 Air is stored in compressed chamber and
supplied varies parts of the vehicle for
different functions

BEARING
There are a number of bearing used inside the
engine block
Bearing are used where smooth movement of parts
are mandatory
Bearing with required oil clearence help in the
smooth working of the engine
  OIL PUMP

Oil pump circulates engine oil under pressure to

the rotating bearing, the sliding pistons and the
camshaft of the engine
This lubricates the bearings, allows the use of
higher –capacity fluid bearings and also assists in
cooling the engine

 FEED PUMP

 It is to pump water to the engine sides for the purpose

of cooling
 It is operated by the camshaft
  GASKET

 Gasket is the mechanical seal which fills the space

between two or more mating surfaces
 Generally it is used for preventing leakage from or
into the joined objects while under compression
 Gasket allows less-than-perfect mating surfaces on
the machine parts where they can fill irregularities

FLYWHEEL

 A heavy revolving wheel in a machine which is used

to increase the machine momentum and thereby
provide greater stability or a reserve of available
power
 It is usually connected to the other side of the
crankshaft
 ENGINE TEST
Engine is tested for temperature generated inside it
Testing the working of all components in the engine
This testing process is go on for four hours
 FUEL INJECTION SYSTEM

 Fuel has to be injected into the combustion chambers at

high pressures
 For vehicles having more than one cylinder, the timing for
spraying is also an important factor
 The FIS section in KSRTC deals mainly with the
inspection and repair of two fuel injection pumps
 It also tests the device that is used to spray diesel to the
combustion chamber called Atomiser
 FUEL INJECTION SYSTEM
  PARTS

 FUEL TANK
 A fuel tank is a safe container for flammable fuel
 Fuel tanks range in size and complexity from the
small plastic tank of a butane lighter to the multi-
chambered cryogenic Space Shuttle external tank
 FUEL FEED PUMP

 The fuel feed pump used for the diesel engine is similar to
that of a fuel lift pump for the petrol engine
 It delivers the fuel from the tank to the injection pump
continuously and at a reasonable pressure
 It is necessary because there is possibility of formation of
vapour bubbles and subsequently cavitation in the pump
due to suction of the rapidly moving plungers of the
injection pump. This would lead to uncontrolled variations in
the rate of delivery of fuel to the cylinders, causing rough
running and possibly even mechanical damage to the
engine. Also cavitation could cause mechanical damage in
the injection pump.
 Generally delivery pressures of between about 29 and 98
kpa adequate for preventing vapour formation on the
suction side of in-line type injection pumps. This pressure
also ensures adequate supply of fuel for filling the plunger
elements at high speeds in a rotary or distribution pumps
  DISTRIBUTION PUMB(injection pump)

 An injection pump is the device that pumps diesel (as the fuel) into the
cylinders of a diesel engine
 Traditionally, the injection 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 diesel
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)
 Distribution pump is classified into two, they are inline distribution pump
and distribution pump
 INLINE PUMP

These are fuel distribution pump which distribute the fuel to the
injectors in high pressure

The rotary motion for this pump is taken from engine

Inside the pump rotary motion of the engine is converted to

reciprocating motion by using a cam
  ROTARY DISTRIBUTION PUMB

These pumps are used to pump the diesel to fuel injectors with
high pressure
It is usually used with automotive or agricultural engines that have
lower performance and durability requirement than the heavy duty
truck diesels
These pumps are luburicated by the diesel inside it,bychance if the
fuel got empty .The pump will damaged
WORKING OF ROTARY FUEL PUMP
  IMPORTANT PARTS IN ROTARY DISTRIBUTION
PUMP
 ECCENTRIC DISK: A disk with some thickness inside where the rotor
of the pump is kept.
 ROTOR: The rotor has 4 slots for installing blades in them. In the
centre the rotor has a hole for the driving shaft. It acts as a vane pump
when driving shaft drives the rotor.
 SUPPORTING PLATE: It is a circular plate to support the rotor and
badges
 DRIVING SHAFT: It is specially designed shaft that goes through the
centre of the pump. It is driven by belt from cam shaft. It is placed
perpendicular and connected with the rotor of the pump.
 GOVERNOR: It is a gear system driven by the driving shaft which
governs the amount of diesel to be pumped
 ROLLER ASSEMBLY: A specially designed circular plate for free
rotation of cam plate.
 CAM PLATE: An accurately designed plate with a curvy design for the
perfect timing for opening and closing of element
 ELEMENT: Instead of having 6 elements in inline injection pump, the
rotary pump has only one element. It has hole in it which allows the
flow of diesel to different cylinders. The top portion of element has
6 specially designed small holes. They are differently oriented. As
the cam plate moves, some holes get closed and others get opened.
This helps in pumping the fuel to different cylinders at different
times. The cam plate is so adjusted that the right firing order is
acquired
 HYDRAULIC HEAD: The top portion of element is connected to this
head. It has 6 holes in them which are connected to the delivery
valves of each cylinder. 
 FULCRUM LEVER: It is the part that varies the amount of diesel to
be pumped by raising and lowering the element head.
 TD PISTON: Time delay piston is small cylinder kept connected with
the roller assembly to govern the movement of cam plate.TD piston
is actuated by the pressure of diesel
  ATOMISER
ATOMISER :Atomize or break the fuel oil into fine particles

Diesel can't mix with air so it atomized and spray on the chamber

It is directly spray into the combustion chamber so that every fuel
particle mixes with the air
 THREE TESTS ARE DONE ON ATOMISER TO TEST THEIR PROPER
WORKING
 SPRAY TEST: to check if all the holes of the atomiser is open.
Diesel is sprayed through the atomiser for this.
 PRESSURE TEST: the pressure at the time of spraying is measured
and checked with the required value. Placing or removal of
required shim solves the petroleum.
 LEAK TEST: it is to check the leakage of diesel in atomiser.
  CALIBRATION OF FUEL INJECTION PUMP

After the assembly of fuel injection pump, by using

testing oil the assembled pump is calibrated.
  RETRIVEL
 In RETRIVEL, the workers are doing the maintenance of clutch
 The clutch is an essential part in a transmission system, which
engage and disengage the power from engine to the gearbox
 In retrivel the main problem is the wearing of clutch disc, these
weared clutch are replaced by new one and it is passed to the
engine overhauling section
  CLUTCH
 Found on vehicles with manually shifted transmissions
 Disengages engine from transmission
 Releases engine from transmission during gear shifts
 Driver controls clutch application from inside the vehicle with a
clutch pedal
 Engine does not make sufficient torque at lower rpm to be able to
move the car
 Clutch must gradually couple rear wheels to engine
  CLUTCH DISC
CHARACTERISTICS
 CLUTCH HUB: inner part of disc and has splines
 Torsional dampers: absorb shock
 Clutch disc has facings made of friction material
 Contain molded or woven asbestos
 Facings riveted to both sides of cushion plate
 Cushion plate is riveted to disc plate
 Clutch is engaged: air is trapped in grooves
 Clutch is released: trapped air pushes disc away from
pressure plate and flywheel
 PRESSURE PLATE

 Pressure plate is cast iron plate

 Part of cover assembly
 Cover assembly is bolted to the flywheel
 Clutch disc is wedged between pressure plate and
flywheel
 Space between pressure plate and flywheel is less
than thickness of clutch disc
 Engine and transmission are physically connected
when clutch pedal released
  TYPES OF CLUTCH COVERS

 Clutch covers types

 Coil spring
 Diaphragm
 Other designs are less common
WORKING OF FRICTIONAL CLUTCH
 GEAR BOX
 The gear box is necessary in the transmission system to
maintain engine speed at the most economical value under all
conditions of vehicle movement
 An ideal gear box would provide an infinite range of gear ratios,
so that the engine speed should be kept at or near that the
maximum power is developed what ever the speed of the
vehicle. Function of a gear box
 Torque ratio between the engine and wheels to be varied for
rapid acceleration and for climbing gradients
 It provides means of reversal of motion
 Transmission can be disconnected from engine by neutral
position of gearbox selective type gear box
 Central workshop deals with the service and testing of TATA and
LEYLAND gearbox. In these buses synchromesh gearbox is
commonly used
 TYPES OF GEAR BOX
AUTOMATIC
SYNCHRONIZED
TRANSMISSION
TRANSMISSION
GEARBOX
 MANUAL TRANSMISSION

 It uses a driver-operated clutch engaged and

disengaged by a foot pedal (automobile) or
hand lever (motorcycle), for regulating torque
transfer from the engine to the transmission;
and a gear selector operated by hand
(automobile) or by foot (motorcycle)

 SYNCHROMESH GEARBOX
 Synchromesh gearbox is commonly used in all
buses
 This type of gearbox is similar to constant mesh
 The gear on the lay shaft are fixed to it while those
on the main shaft are free to rotate on the same
PROPLER SHAFT
Propeller Shaft is the shaft that transmits power from the
gearbox to the differential gear in a vehicle
Propeller shaft, sometimes called a cardan shaft
In most of the automotive vehicles, the engine is located at the
front and the rear wheels of the vehicle are being driven. This
arrangement stipulates a longer propeller shaft to be used. In
some arrangements two or three propeller shafts are used to
make up the length
In some other vehicles, the engine is at the rear and the rear
wheels are being driven. For such arrangements a short propeller
shaft is used to drive each wheel
 REQUIREMENTS OF PROPELLER SHAFT

 High torsional strength: Therefore, they are made of solid or

hollow circular cross section
 Toughened and hardened: Therefore, they are made of superior
quality steel and are induction hardened
 Efficiently jointed: Therefore they are generally welded by
submerged are carbon dioxide welding process.
 Dynamically balanced: Since the phenomenon of whirling may
be critical at higher speeds, therefore, propeller shafts are
tested on electronic balancing machine.
 Reduced thrust loads: Since resonance is dangerous for the life
of shaft. It also transmits excessive dynamic force to the shaft's
end supports, and so its occurrence should be avoided.
 UNIT
 DIFFERENTIAL
 POWER STEERING
 WABCO
  DIFFERENTIAL
 While the vehicle take a turning, the outer wheels have to
travel greater distance as compared to the inner wheels in
the same time
 If we use a solid rear axle only and no other devices, then
there is chance to skid
 Differential should reduce the speed of the inner wheels and
increase the speed of the outer wheels when taking turns
 PARTS
PINION DRIVE GEAR: transfers power from
the driveshaft to the ring gear.
RING GEAR: transfers power to the
Differential case assembly.

SIDE/SPIDER GEARS: help both wheels

to turn independently when turning.

DIFFERENTIAL CASE ASSEMBLY: holds the

Ring gear and other components that drive the rear axle.

REAR DRIVE AXLES: steel shafts that transfer torque from the differential assembly
to the drive wheels.

REAR AXLE BEARINGS: ball or roller bearings that fit between the axles and the inside
of the axle housing.

AXLE HOUSING: metal body that encloses and supports parts of the rear axle
assembly.
 HYPOID GEAR

•Most of the modern differentials have

Hypoid Gears.
•Pinion gear sits offset, lowered from the
centerline of ring gear.

•Improved gear mesh because of larger gear tooth contact area.

•Improves gear life and reduce gear noise.
 PINION GEAR

One side is attached to the ring gear and the other to yoke(drive
shaft).

Either a crushable sleeve or

shims are used to preload the
pinion bearings.

Preload: a small amount of

pressure applied to the bearings to
remove play and excess clearance.

Ring gear and pinion gears are a

matched set.
 DIFFERENTIAL CARRIERS

REMOVABLE CARRIER:
can be serviced at a workbench.

INTEGRAL OR UNITIZED CARRIER

formed as a part of axle housing.
DIFFERENTIAL LUBRICATION

•Uses 80W-90 hypoid oil (distinct smell).

•Remove fill plug (mostly with 3/8” ratchet) insert finger;

if you are able to touch oil, level is good.
 POWER FLOW IN DIFFERENTIAL

Drive shaft spins the Pinion gear.

Pinion gear turns the larger ring gear to produce

gear reduction.

Ring gear attached to differential case, hence it

rotates with the ring gear.

Differential case spins the sun gears which are attached to the axles.

Axles transfer the power to the wheels.

  STEERING SYSTEMS
Power steering section of KSRTC deals with the service and
testing of the steering box
Larger amount of torque is required to be applied by the driver for
steering of medium and heavy vehicles. The power steering system
provides automatic hydraulic assistance to the turning effort applied
to the manual steering system. the power system is designed to
become operative when the effort at road wheel exceeds a
predetermined value. It is operated by fluid under pressure . The
principle of working of all the power steering system is dame. The
slight movement of the steering wheel actuates a valve so that the
fluid under pressure from the reservoir enters on the appropriate side
of a cylinder there by applying pressure on one side of a piston to
predate the steering linkage which steers the wheel in the appropriate
direction
Ksrtc use rane steering box in buses
 Hand brake

Spring Brake Actuator

For Hand brake
MACHINE SHOP
 MACHINE SHOP PROCESS

In machine shop, no new part is manufactured and

there is reconditioning the used parts for reuse

The flywheel is refaced by lathe

Brake drum is reconditioned by DRUM BRAKE LATHE

The damaged threads are rethreaded

  FACING OF FLYWHEEL

 Here the flywheel is faced for reuse

 The face is machined to get smooth face
 There is a limit in machining process and if it exceed,
by using shim it managed clutch
 RECONDITIONING OF BRAKE DRUM
 The inner surface of brake drum have some
irregularities, these irregularities must be smooth for
the better braking
 For that the brake drum is resurfaced by using DRUM
BRAKE LATHE
 Both rear brake drums should be resurfaced whenever
new brake shoes are installed
  TYRE
The tyre section of KSRTC deals the removal of
old tyres and replacing them with the new or re-
threaded tyres
Radial tyres are usually used in KSRTC
A bus needs 6 tyres, 2 in front and 4 in the rear
 BUFFING OF TYRES

TYRE BUFFING is a process of shaving a

portion of tread off a tyre in order to gain
increased traction in dry tarmac conditions
Tyres are rethreaded at a temperature of 150
degree Celsius
around 3-5 hours will take for rethreading a tyre
  RETHREADING OF TYRES

 Retreading is a process for tyres that replace worn

out tyres
 Retreading process is applied for tyres that have
been worn so that they can be reused after proper
inspection
 Through rethreading we can save the cost to buy a
new tyre
 TIRE COMPONENTS
 VEHICLE OVER HAULING
Here the complaints of the parts of bus are identified
and that are dismantled and repair it on the repairing
section and assembled on the bus
The brake test are done here
The body of buses, floor, roof and glasses are fixing
here
 ELECTRICAL
In this section mainly the maintenance and
repairing of starter motor and alternator is
done
the maintenance done mainly on the
carbon bushes and the armature coil
The week battery are recharger