PROJECT REPORT ON INDUSTRIAL TRAINING AT PATEL-L&T CONSORTIUM

Submitted To:ER. VIVEK GUPTA H.O.D (AE)

Submitted by :NITISH KUMAR CLASS ROLL NO.:- 7104013 BOARD ROLL NO.:-10051100225 Auto Engg.(5th sem.) 5TH Sem.

ACKNOWLEDGEMENT

Creating something new requires inspirations and these inspirations and this inspiration has some hidden forces which motivate to achieve the objective. Completion of any project requires combined efforts of many people. We would like to express our sincere thanks to all those, whose unending support helped us to perform our CONSTRUCTION SKILLS, REPARING & MAINTENANCE OF CONSTRUCTION EQUIPMENT named PARBATI HEP PROJECT SAINJ KULLU. We would like to place our deepest our sense of gratitude to Er. VIVEK GUPTA (H.O.D AUTOMOBILE) for providing necessary Infrastructure and Environment. We would specially like to mention Er. BRIJ BHUSHAN for his unending help and taking pain to provide answers to our queries. We would like to thankful to our teacher who gives extra time in the lab for the completion of the objective, they provide us necessary and helpful material related to our project. We are greatly indebted to all the officials of the AUTOMOBILE Department for their cooperation and timely help in one or the other way. At the last but least we would like to say thanks to all our friends for their co-operations and help they provided in accomplishment of the undertaken project.

INDEX

Basic requirement of engine services Engine service procedure Specification Maintenance schedule Engine section Gearing and gear box Power steering section Fuel injection pump Self starter Brakes Automobile shop equipment Maintenance procedures

SAFETY GUIDELINES
To avoid at to keep then happening following safety guidelines be allowed. 1. Provide your attention at most to the job and work quietly. 2. Keep the tool with in your convenient reach under your control arrange neatly without scattering then around and out of the way. 3. Always keep jack handles pointing up to avoid tripping up to when creepers are not in use stand then against the wall to avoid stumbling over them. 4. Be serious about your work never including in horseplay or other foolish activities to avoid injury to other. 5. Never put sharp objects like screw driver in your pocket otherwise you will cut yourself of get stabled. 6. Always wear suitable clothes for he job serious injuries are liable be caused by cleaning sleeve. 7. To provide good grip on tool or part always wipe excess oil- and grease up fly our hand tool. 8. To avoid one slipping and falling to the ground due to split oil or grease or any liquid clean up immediately. 9. Compressed air should never be used to below dust from your clothes compressed a hose should never be pointed to any poison because living panicles or chips may harm him. 10. While welding and grinding always water out for living speak when con set your clothes on fire.

BASIC REQUIREMENT OF ENGINE SERVICES

The basic requirement of engine services is to find our the following informationTo determine what is wrong in the engine

To find exactly as to what type of services is required for correcting the fault and restoring the normal performance economy.

A full and proper test of engine is necessary for establishing the exact cause of

trouble

experienced as well as the repair and parts required to replace. In modern engine, which are complicated and critical to restore normal performance fully and accurately some extra operation in addition to personal skill and experience is required for testing the engine with in economic limits of time and corrective service required.

It will be seen that when the motor vehicle has been properly run it would new performance of the reconditioning it is due to fact that original setting limit and specification gradually change because, of long hour of use causing wear in moving parts deterioration in cable insulation weak springs corroded terminal and clogged passage the troubles likes of power, poor acceleration, hard starting, missing pin king poor idling, rough running as well as heavy fuel consumption are the indication of loss in performance.

SEGINE SERVICE PROCEDURE

Before servicing an automobile engine its necessary to determine the cause of the trouble in the engine. This is done by observing the symptoms produced by and indicated in the instrumental check visual examination sound produced by the engine and this sound of the engine emission the analysis of the symptoms of troubles and trouble shooting charts are very helpful for this purpose generally these are two types1. Internal troubles. 2. External troubles.

The engine servicing procedure involves these following steps:Engine disassembly: - the dismantling
troubles in engine parts such as:i. Manifolds. ii. Cylinder head. iii. Cylinder block. iv. Piston and connecting rod. v. Shaft. vi. Sump or oil chamber. vii. Turbo charger. viii. Sub assembly.

and removing is done for finding the cause of

Cleaning of parts: - part disassembles and in repair condition should be cleaned these are
in general two types of cleaning done on enginei. ii. Digressing. De carbonizing.

Inspection of parts:-inspection of parts is very necessary for fine working of an engine.

Inspection of parts should be done carefully in common there are two types of inspection mentioned as below:-

a)

Visual inspection: - from visual inspection we mean that inspection of any crack
or any addition to part. if part is faulty another one should replace it.

b)

Dimensional inspection:-it is meant for the inspection of dimension of

should be checked.

a part. It

4. Conditon of engine parts:-condition should be remembered and thy should be in

working . some conditions are such as: A. valve B. valve train Camshaft Lifters Rocker arm Push rod Valve spring Valve retainer and locks Rocker shaft

5. Piston:- a vertical wear on the thrust surface and slight looseness of the top ring in
groove is common wear visible and Piston with this type of wear can be reconditioned usually.

Piston
6.

Servicing the piston:-

1. Ring grooves a. Compression Ring b. Oil Ring. 2. 3. 4. 5. Skirt. Piston Pin. Cylinder Wall. Piston Assembly.

Piston ring

7. Shaft

and bearing:-

A. Crankshaft. B. Camshaft. C. Bearing D. Cylinder block.

Shaft Bearing

Specification
1.

Engine:-

Cummins 6BT 5.9 TC water cooled direct injection

Model Type turbo charges diesel engine Bore stroke No of cylinder Max engine output Max torque Capacity Compression ratio Firing order Weight of engine 17:6:1

102/120mm 6 93.5kw (125.3hp) at 2500 rpm 410 nm (41.8mkg) at 1400-1700rpm 5883cc

1-5-3-6-2-4 413kg

Engine
2. AIR FILTER:-

Type

dry type remote mounted

AIR FILTER
3. FUEL Type

FILTER
per end fine filtration with water separator.

FUEL FILTER

4. OIL

FILTER

Type

full flow spin on paper type

Oil Filters
5. FUEL Type

INJECTION
MICO (A) Type

Fuel injectors 6. TURBO

CHARGER

Type

HOLSET

Turbo Charger

7. COOLING Capacity

SYSTEM
24 liters (totals)

Radiator frontal area

2887 sq cum

Cooling system

8. CLUTCH:Type single plate type

Outside diameter of clutch lining Friction area

310 mm 1030 sq cm (approx)

Clutch / Drive train / Flywheel

9.

GEARBOX:-

Model No of gears

GBS-40 Synchromesh 5 forward 1 reverse 1st -7.51 2nd -3.99 3rd -2.30 4th -1.39 5th -1.00 Rev.-6.93

Synchromesh gearbox

10. REAR AXLE:-

Type

single reduction, hyped Gears. 5.285:1(37/7) STD 5.857:1(41/7) OPTIONAL.

Rear axle

11. FRONT AXLE:Type heavy duty forged 1 be Am reverse Elliot type.

Front axle

12. STEERING:-

Type Steering gear box Ratio

manual steering stand. recalculating ball 34.2:2:1 for 1.p 151 TC 59 Wheelbases LPO 1512 TC

Parking brake Type

hand operated spring actuated Parking brake Acting on rear wheels

Engine exhaust brake

coupled with service Brake

STEERING

13. Frame:Type ladder type heavy Duty frame with Riveted / bolted cross Member.

Ankai Bus Frame

Channel section Depth Width side members 223 mm (max) 60 mm

14. Suspension:Type semi elliptical leaf Spring at front And rear Spring span front 14500 mm Rears -1600 mm Leaf width front- 70 mm Rear-80 mm hydraulic double acting

Shock absorber Telescopic

Suspension

15. Wheel and Tyres:Tyres Wheel rim No. of wheel 9.00 X 20-14 PR 7.00 X 20 front -2 Rear 4 Spare -1

Wheel and tyres

16. Fuel Tank:Capacity 160 liters 250 lit optional for 52,59 Wheel base.

Fuel tank
17. cab/cowl:Type all steel full forward Control cowl

18. Electrical system:System voltage Alternator capacity Battery 24 volts 45 amps 2*12v. 180 ah

Electrical system

19. Performance:Max geared speed in top Gear (with std. rear axle) 87 km/h standard 79 km/h optional Ratio of Ra

20. Main chassis dimension as per is 9435 in mm:Wheel base Track front Track rear Overall length Overall length (For 50%roh) Overall length (for 55%roh) Overall length (for 60%roh) Max width Front overhang 2434 1185 2434 1185 2434 1185 2434 1185 . . 9485 1615 . . 100325 3225 1950 1809 5860 4225 1950 1809 7380 5195 1950 1809 . 8975 5895 1950 1809 10025

21. Weight (kg):For IPO 1512 TC Wheel base m mm Bare chassis kern weight with Cowl (with spare wheel and tools) As per IS 9211 Max permissible FAW Max permissible RAW 4700 10160 4700 10160 4725 4190 5545 4380

22. Filling capacity of aggregates:Engine oil sump . max. 14.3 letters min. 12.3 liter Gear box GBS-40 5.2 liters Tear axle RA -108 RR.. 7.5 liter Steering gear housing 0.95 liter Hydraulic clutch actuation system . 0.21 liters Cooling system . 24 liter Front hub grease per hub 450 germs Rear hub grease per hub . 450 germs Water pump grease .. 80 germs

Maintenance schedule
Check:Daily
Engine oil level Fuel level Coolant level

weekly (after 1000kms)

clutch pedal free play oil level in gear box oil level in rear axle brake system

after 9000 kms

air system air cleaner steering system fan

Brakes fluid level for clutch Drive belt Water trap in air tank Brakes

power steering fluid level separator steering system battery

shocks absorber clutch

Axle pressure brakes system Brakes of coolant fuel oil Electrical system wheel nuts suspension bolts

After 1800 (Kms)

Antifreeze concentration Transmission system Body mounting Break system Rear axle Wheel alignment

o Lubricate

Linkage

o Change
Front hubcap grease Fuel filter Gearbox oil Engine oil filter Lubricate: wheel hubs

Overhaul:
Clutch System

MAINTENANCE PROCEDURE DAILY:Engine oil level:-Before starling or at least 5minutes after the engine IS shutdown check the
oil level and top up if necessary never particles with the oil level below mark or above the high mark

Marking on dipstick:Low mark to high Marks capacity Grade Conforming to classification SAE 15 W-40 APICE/SG 2 Liters

Fuel level:Check fuel level in fuel tank. Top up if necessary cap capacity 160 liters. Removing radiator pressure cap:Removing the pressure cap when the coolant is cold(below50C) failure to do so can result personal injury

Coolant level:Check coolant level Fill the cooling system to bottom of the radiator if necessary.

Coolant mixture- 50 % water

50% Ethylene glycol (antifreeze)

Fan:-

Rotate the crankshaft and Visually inspect the fan for

creaks

Proper mounting. Replace fan if damaged.

Drive Belt:Visually inspect the belt, replace the belt if frayed 01pieces of material missing or longitudinal. Cracks intersect with transverse cracks.

Water separator:Lift the spring load valve as shown above and drain the water until clear fuel is visible.

Caution:Excessive draining will introduce and into the system causing the engine to be hard to start.

Draining condensed water:Drain off condensed water from air tank (I) by operating till type drain value.

Brakers:Check for proper functioning of brakes.

Tye pressure:Check and inflate the Tyre in cold condition Front tyre Pressure Return tyre pressure 5.3 bar (75Psi) 6.0 bar (85Psi)

Laks:Check for laks of water an fuel and oil at all gaskets hose connect torn flexible pipes and pipe connection. If there is an/ fault replace that fault.

Electrical system:Check functioning of light horn, horn, wiper, blinker, switches and gauges.

INSPECTION AFTER 1000 KMS:Clutch pedal free play:Check free play at clutch pedal , it should be 5 to 10mm

Adjusting free play:If free play is less adjusts loosening check nut push rod of master cylinder check and free play and lock the nut. Very the free play at pedal again.

Gearbox:Open oil drain plug and checik oil levelplay. Check level of gearbox oil top up if necessary.

Grade Rear axle:1. Oil drain plug 2. Oil level plug

APIGLA-SAE 80

Check level of rear axle oil top up if necessary. Grade :APLGL 5 AE 90(UP TO9c) SAE 75 (0 TO 40C)

Power steering fluid level:Check oil level is the power steering tank with engine switched off place the dipstick in position while checking . the oil level should be 102 Cm above the mark on dispsticks for topping up use oil conforming ATF-Type-A.

Steering system hoses:If fitted check for leaks of oil from the pipe and connection of power steering system necessary.

Battery check:check electrolyte level it should be between 10 to 22 mm above the top of the battery plates . battery mounting clamps and starter motor terminals must be kept clear and firm. Apply Vaseline/petroleum jelly on battery terminals.

Wheel nuts:Check wheel and tighter, if necessary when changing the wheel on the rear axle caremust be exercised to ensure that between the drum and inner wheel rim spherical washers are placed in the wheel studs with flat surface toward the wheel . after lifting the inner and outer wheel spherical washers should be placed in such a way that the spherical surface is toward the wheel nut failure to do so will cause damage to the wheel rim and the drum. Torque (non-apigot Ted.45-55-Kgwheel rims are fitted the spherical washers and spherical spring wadher is not required torque (spigot Ted wheelmmnuts (50-60 mugs).

Brake system:1. check free movement of spindle in dual brake valve. 2. check brake system for leaks and rectify if necessary.

Leaf spring u bolts:The U bolt nuts and check nuts of front and rear the spring should be regularly tightened with at torque watches or with a socket wrench and handle of at least 60 cm length torque (U bolt nut 35 mkg) tor1que (check nut 35 mkg)

Lubricate linkage bushes and pins:Lubricate oilcan brake chamber fork and pinball joints of exhaust brake linkage clutch linkages pivots linkage of foot brake.

Grease with grease gun:Brake pedal bush brake double level block adjuster and camshaft bushes (AAL) clutch Pedal bushing accelerator linkages support brush gear shifting linkage propeller shaft U Joint sliding yoking pins tie rod ends drag link end front spring pms rear spring pins helper spring brackets rear grade purpose Grease NO.2

INSPECTION AFTER EVERY 9000 KM:Air intake system:Inspect the intake piping for damage cracked hoses loose clamps etc. Replace damages hoses and tighter loose clamps.

Service indicator check:The air cleaner service indicator reset the end flag if it is in the raised position operates the engine at max rpm load of check if the red flag rises. AGAIN in window , which indicates intake restriction.

Air filter change:Change the primary filter element when the red indicator flag rises again in the window because of intake resistance. Note:- the secondary filter is to be changed after replacement of primary filter for three times. After the air cleaner has been serviced push the button to reset the service indicator and check by operation the engine once again.

Steering system:Check and tighten if necessary. Pitman arm drag link tie rod steering gear box mounting bolts.

Break system
1. 2. Tighten brake torque plate mounting belts 10 to 11 mkg. Check for travel of brake chambers push the brakes have to be adjusted before it reaches 45 cm check brake lining wear and electric with the drum 0.5 to 1 mm adjust brake if necessary.. 3. Exhaust brake linkage. a) A few- drop of oil should be applied to the ball pin of outer linkage and friction surface b) Material, should not be lubricated since the tube oil would cause seizure of the valve in the exhaust manifold. c) Check for proper fun timing of exhaust brake free movement of plunger of seizing of butterfly valve in the exhaust brake value mounting bolt for looseness and slackness in linkages. d) With brake pedal fully released these should be no exhaust brake application of it is on readjust exhaust break value suitably exhaust brake application can be made out form the distinct change in engine noise.

Adjustment of service Brakes and slacks adjusters:Excessive travel of brakes chamber push rod indicator, the need of the brake adjustments if the angle between the brake chamber push rod and the centerline of slack adjusts less than 90 in the brake applied condition the brakes should be adjusted. All normal should be made only be mean of the slack adjust brake adjustment is to be done when drum are cold and not when they are hot.

Procedure:1. condition 2. Position a box spanner or ring spanner over the adjust a hexagon by depressing the Licking sleeve turn the adjuster screw anticlockwise until the wheel rotate freely./ release locking. Note:- ensure that the licking sleeve engages with the hexagon head of adjuster screw if it is possible to check. The clearance between the drum and lining by using the filter gauge through the inspection hole alter removing the rubber grommet recommended clearance. Jack up wheel clear of the ground release the hand brake it is on the

Adjustment of the brake pedal foreplay:A certain amount of play is kept between the dual brake valve spindle and double lever pin. This is to ensure that accidentally brakes dont get operated thee will be slight haul feeling at brake pedal while depressing when play zero can be defined as brake pedal free play adjust brake pedal free play below. 1. 2. 3. 4. brake pedal a few times to ensure desired brake pedal free play. ensure brake are in released condition. loosen check nut in pull rod length such that brake pedal free travel is approx 10 mm. move dual brake value spindle by hand and make sure that this is play between spindle and double lever pin. lock checks nuts of full rods with out disturbing adjusted length operate

Adjustment of exhaust brake valve:If brake paddle is adjusted for any reason simultaneously exhausts brake valve should also be suitable adjusted as per the procedure given below. 1. brake valve. 2. in released condition of brake pedal adjust brake valve spindle length sure that valve is full pressed (-3mm) and 1 has tighten lock nut brake pedal free play should not be disturbed while adjusting exhaust brake valve. 3. Apply brake pedal a few times to make sure that exhaust brake is operation properly. Complete all adjustment of brake pedal before ay adjustment of exhaust

Adjustment of stop light switch:a mechanical stop light switch is mounted below brake control level mounting box whenever brake pedal is depressed for applying brakes stop light switch comes into operation and light s are tear tail lamps glow.

1. Ensure that brakes are in release condition. 2. Adjust dimension between stoplight switch and double level(6mm) As shown in sketch tighten nuts 3. Operate brakes a few times to make sure that a stoplight indication comes properly.

Hand Bake Adjustment

1. No separate adjustment is required to the same service brake adjustment hold good for hand brake also. 2. Check travel of brake chamber S push. 3. Check service brake lining wear and clearance with drum . 4. Adjust service brake if necessary , in proper brake adjustment can cause brake grabbing more air consumption or tower brake efficiency

Clutch:Check if necessary tighten mounting of shock absorber check condition shock absorber rubber bushes and replace necessary .

INSPECTION AFTER EVERY 1800 KMS.

Engine oil and filter change:Warm up the engine remove the drain plug and allow the oil to drain . a rain pan with a capacity of 20 loiter will be adequate removal oil filter. Clean around the filter head remove the oil filter and clean the gasket

Pre installation
Fill the anew filter with clean lubrication oil apply a light film of lubrication oil to the gasketsealing surface before installation the filter install the filter and tighten it half turn after its seal contact the seal head.

Caution:Mechanical over tightening may distort the threads or damages the filter element real.

Oil drum Plug:Install he oil drain plug and tighten 8 mkg. Filling the engine with the clean oil to the proper level sump capacity 143 liters. Total system capacity 164 liters.

Recommended oil:For ambient temperature 1 DC and above use SAE-40 40 oil conforming to (APISE SG classification )

Inspection:Operate the engine at idle and inspect for leaks at filter and drain plug.

Filter wrench:-

For removal and installation of engine oil filter/ fuel filters use filter wrench par no 2318901805 N

Anti concentration:Check the antifreeze concentration and ensure that 1:1 antifreeze and water mixture is used.

Transmission system:Check and if necessary tighten gearbox mounting belt propeller shaft coupling flange bolts and propeller shaft centre bearing support bracket bolts.

Body Mounting:Check and if necessary tighten all body mounting sand spare wheel carriers.

Brake System:Check for hose damage and replace if necessary check condition of gaiter in different brake valve, exhaust flap in dual brake valve Nylon breaths tube and slips of spring brake mounting and tank mounting airline clams and tighten if necessary.

Wheel alignment:Check the wheel alignment and adjust if necessary toe-in 0 to 3 min.

Front hub:Remove front hubcap fill with the full wheel bearing grease and refill. Replacing fuel filter:Remove two filters from the dual filter adapter clean the gasket surface fo the filter head replace the O rings. Fill the new filter with clean fuel lubricant the O ring seal with clean lubrication oil. Install the filter and tighten turn after the real contact the filter head.

Caution:Mechanical over tightening may distort threads or damage the filter element real.

Bleeding fuel system:Controlled venting is provided at the injection pump through the fuel drain manifold small amounts of air introduced by changing the filter or injection pump supply line will be vented automatically. If the fuel filter is changed in accordance with the instruction no manual bleeding of fuel lines is required.

Note:1. Manual bleeding is required:2. If the fuel filters not filled prior to installation. 3. Injection pump is replaced. 4. High pressure fuel line connection is loosened or lines replaced. 5. Initial engine start up to or start up after an extended period of no engine operation. 6. Vehicle fuel tank had run empty.

Bleeding fuel system manually: Open two bleed screws. Operate the hand lever until the fuel flowing from the fitting as. Free of air tighten the bleed screw toru-1 mkg

Air can be vented from the pump through tile fuel drain manifold lines. Loosen the drain line outlet from the pump. Operate the hand lever until the fuel flowing the fee of air.

Tighten the vent screw:Loosen one of the fittings at the injector crank the engine to allow entrapped an to bleed from the line dont crank for more than30 seconds at a time wait 2 minutes between cranking tighten the line fitting torque 3 mkg start the engine and vent one I line ate tine until engine run smoothly.

Gearbox:Oil drain plug. Oil level plug Drain while hot Fill gearbox with new oil Capacity 5.2 liters.

Recommended oil: - Grade APIG 1-SAE 80 Rear axle:Position in diagram:1. oil drain plug 2. oil level plug Drain while hot Fill gearbox with new oil Capacity Recommended oil:1) 2) 3) grade-APIGLS SAE-90 (UPTO-9C) SAE-7 (9C TO 40C) 7.5 liters.

Power steering Breaker system Suspension spring

Butterfly valve in exhaust Gear box

ENGINE SECTION In this section major overhauling f engine is carried out under different operations. ENGINE OVERHAUL In order to provide internal cleaning, replacement of worn parts and adjustment of other parts, over hauling of engine is carried out. Although an engine will continue to operate efficiently if it is given good maintenance parts and servicing as well as due care and attention yet its, internal parts wear and carbon is formed in the cylinder during its normal operation after a long period of running, loss of power & bad running or rattling is caused and noticed due to wear and or carbon should be cleaned periodically parts checked for wear and the repairs and or adjustments should be carried out if necessary.

Turbo- charged engine

In this section overhauling is carried out big inspection, cleaning and by replacing warn part after dismantling the engine. The main parts of the engine assembly are:1. engine block 2. Crank shaft: heads balance weights. 3. Cam shaft. 4. Connection rods. 5. main line oil supply 6. oil casing 7. Fly wheel dumper. This overhauling includes:

DISMANTLING
All nuts screws and small parts, should be removed carefully and to present their lose and facilitate their cleaning put then in container.

REMOVAL OF CYLINDER HEAD:

All components and parts fitted cylinder heed as well as spark plugs and valve operating gear should be removed carefully.

REMOVAL OF ENGINE BLOCK:

Engine block should be dismantled and removed from engine carefully. Removal of pistons and connecting rods: Drain the oil from the engine sump. While removing the sump care should be taken not to lose the nuts, washer as well as avoid its falling to safeguard Against any cracking distribution, disconnect the connection rods from the crankshaft to remove pistons.

REMOVAL OF CRANK AND CAM SHAFT:

After removing the connection and crank shaft and cam shaft are removed from crank case.

REMOVAL OF OTHER ACCESSORIES

After removing the main parts other accessories like compressors, oil pups. Piston rings, fly wheel etc.

Cylinder head gasket

QUALITIES:Wear the pressure of water, gas and temperature. Does not corrode. After tightening head no change should be in impression ratio. MATERIAL: Copper asbestos, steel asbestos copper. FAULTS AND REMEDIES: FAULTS REMEDY 1. Un smoothed cylinder head and block face . Do replacing, 2. Cylinder head is not tightened on complete Tight at proper torque. torque.

3. Depots of carbon. 4. Overheating.

Remove carbon. Change gasket.

REMOVAL OF CARBON FROM DISMANTLED PARTS:Carbon is removed by washing the parts with diesel and soft cloth. After that they are washed with pressure and dried by air pressure. PARTS: CYLINDER HEAD This is top most part of engine.

MATERIAL:
Gray cast iron, aluminum alloy.

QUALITIES:
Cylinder head is very important part of an engine. All inlet and exhaust values and nozzle mechanism is fitted in this part of the engine. It covers the cylinder block and giving room for combustion of mixture stops the maximum pressure leakage from combustion chamber.

PARTS:
Combustion chamber Valve guide Spark plug injector hole. Water jackets Intake and exhaust parts.

FAULT:
Water and oil leakage resulting reduction in oil pressure, and leakage from combustion chamber, carbon deposits, bending of valves etc.

REMEDY:Carbon deposit are washed, wide valves are changed valves are also changed and proper grinding of holes with aeropause is done with the help of girding stock.

CYLINDER HEAD GASKET

Usually cylinder block and cylinder head are detachable. Infect, head and block have their faces very smooth but with besides that after tightening by nut and stud, water and gases leaks, so gaskets inserted between them which prohibit leakage of water, gas and wear high temperature.

CYLINDER BLOCK OR CRANK CASE MATERIAL: gray cast iron. Aluminum alloy.

QUALITIES:
1. 2. 3. 4. Gives space for cylinder Gives rooms for crank and cam shaft. Expands less due to heat. Proper place for cooling and lubrication of cylinder.

PARTS:
Face, stud, or stud hole, water jacket, lubricating oil hole, valve tapped chamber, cam shaft hole, crank main hole cap, crank case chamber flange, fly wheel hushing flange, cylinder hoe, cylinder.

Cylinder block
FAULT IN CYLINDER BLOCK:
Expansion and contraction in cylinders, breaking of studs, distortion in face irregularities in face.

REMEDIES:
In case of irregularities in new sleeves are bore into the block by power press which further bored by cylinder boring machine and finished by hydraulic honing machine. In case of breaking of suds. Studs are changed.

FAULTS IN CRANK CASE:

Expansion and contraction inteh crank case and cam case

REMEDIES:
In case of contraction in cam and crank case being is done to crank case chambers. Flange and cam flange by line boring machine. PISTON It is an part of r compression and power pressure scale QUALITIES: 1. 2. 3. 4. MATERIAL: Gray cast iron, aluminum ally, cast iron. PARTS: Head, compression ring grove. Land, rib represent, oil ring grove, piston pin basis, tea slat, piston skirt, PISTN Faults and effect on engine: 1. Deep striking sound from engine:- valve stroking on piston head replica head skirt engine over cooling. 2. More oil consumption by piston (i) less clearance- change the piston. 3. over heating of engine:- (i) less clearance do cylinder honing, 4. piston lease: due to less clearances CONNECTING ROD it is used to match crank pin & piston . MATERIAL: Forged steel, aluminum alloy, nickel steel, nickel crane. PARTS: Small end hole, eye beam, eye slot, C.R.bolt oil spray hole hut bush oil dipper. FAULT AND REMEDIES: Expands less Give places for rings. Give pace for gage pin. Do not expand or contract.

1. Loosening of big ed bearing. RESULT: this will increase the clearance and ultimately engine parts will wear. REMEDY: tight the bearing cap or change bearings seal. 2. Wear o f small end bush. RESULT: piston knocking will occur REMEDY: change the bush. 3. Cylinder one side wearing. Result: non-uniform of piston and rings. Remedy:-change connection rod or straighten it by power press.

Calibration of connecting rod Assembling

After doing the repair of each and every part of the engine, they are assembled together of form engine assembly with proper lubrication and curl, nut, bolts, and ports are checked and tarring is done valve $ give proper clearance for expansion . After assembling the with gear junction it is dispatched to testing section.

ENGINE TESTING
In order to correct faults and to improve the performance of engine, the testing is the major work operator performed for its production, repair and adjustment . It can be done by fitting the engine to a vecile and trying but it is quite difficult and expensive. Therefore for convenience and cheapness, engine control loading unit is used. In order to check their performance and behavior. The engine speed load, fuel consumption, temperature of engine oil and working parts. Heat given of by the cooling system, exhaust temperature, nature of the exhaust gases etc are checked recorded. For testing and recording , different type of devices used are indicators, dynamometer for measurement .purposed of an engine testing;

1. To obtain information which can not be determined by calculations 2. To verify the validity of data used the design 3. To satisfy the customer recording its rates power in comparison to guarantee fuel consumption. ENGINE VOLVE TIMINGS AND FIRING ORDER Inlet valve opens 25 o before TDC and suction stroke continues for240o. Inlet valve closed 35 o after BDC, compression stroke continue for next 145 o Expansion stroke for next 145o At this moment i.e. 35 o before BDC , exhaust valve opens. Exhaust stroke continues for next 135o. exhaust valve closes 20o after TDC Overlapping provided is for 45 o

There are six cylinders in the TAT A-1312 engine. These are employed for the purposed of regularizing torque. They fire in the order.1-5-2-4-3-6.

\ GEARING AND GEAR- BOXES NECESSITY: An internal combustion engine produces little power at low rpm and maximum power at given sped depending on particular engine. With direct coupling asset of or fixed road speed is provided to the engine by this. But this would be suitable on level ground, because when climbing the vehicle has to bi lifted as well as propelled at slight gradient. The accelerator could help to overcome this on levee ground but on steep gradient even at full throttle the engine speed on all condition of load and vehicle speed of the engine up while sacrificing same road speed. In order to multiply the tongues. A gear box is used PRINCIPLE. Gear wheels of different sized is provided in a gear box for engaging or disengaging them for transmission of motion and power. No mechanical advantage is provided when two gear wheels of same six are meshed together. A large gear meshed with a small gear will drive the small wheel at increased speed and vice versa.

PARTS OF GEAR BOX

GEAR BOX PARTS:Gear box in order to house the gears, a casing or box usually made of aluminum alloy or malleable cast iron is used. Primary shaft it is driving shaft of the gear box fitted into the hub of the clutch plate. Lay shaft it is the shaft which drives through the constant mesh gear wheels as well as carries two or three different sized gears.

POWER STEERING SECTION

The control of an automobile is done by means of a steering system the provides directional changes to the moving automobile. For a power shaft steering a booster arrangement is provide for turning the steering wheel shift. By setting the booster in operation, most of the work of steering is taken over by it. Pore steering employs compressed air, electrical mechanism and hydraulic pressure for Turing the steering wheel shaft . in most of vehicles, hydraulic pressure operated power steering ,mechanism is used.

PARTS:1. Rotary valve it provides responsive steering control. 2. DU Bushing or roller bearings, allows the steering gear to operate with high efficiency and reversibility. 3. Unloading valves furnish pert steering pump protection and reduce pressure to unload steering linkage at ends of steering gear travel. 4. recalculating balls combines high mechanical affiance with smoothes operations 5. Dirt and water seals lip type seal on both input and out put shafts. 6. torsion bar provides positive valve centering with definite feel of the road

7. Relief valves furnish pump protection by limiting maximum pressure. WORKING when the driver turns the steering wheel, he transmits force from the wheel to the steering gear input shaft. A torsion bar pinned at its one end to the inputs and at its other end to the worm shot and exerts a rotational force on the worm shaft. In response to this rotational force the form shat, action through the. 4. Main or sliding shaft in order to rapport the rear end of there primary shaft a spigot is pored. For forming the spigot, the front end of a shaft is in line with the primary shaft is machined. The number of gears and the type of gears on the main shaft and the counter shaft ARE: GEAR 1 2 3 4 5 REVERSE MAIN SHAFT 39 32 26 19 17 36(IDLER-20) COUNTER SHAFT 11 17 22 29 36 11 TYPE OF GEARS SPUR HELICAL HELICAL HELICAL HELICAL SPUR

REVERSE GEAR: The shaft used to reverse the direction of the drive by bringing into mesh the largest gear wheel on the main shaft with the lay shaft is known as the reverse gear shaft. Gear box TROUBLES: TROUBLE REMEDY 1. oil leakage i. immense oil in gear box Level the oil. ii. Spoiling of the oil seal. Change oil seal. iii. Wear of the clutch bearing. Change bearing. Iv leakage by oil packing. Change packing v. crack in housing. Do welding. 2. noise in gear box i. braking of gear teeth. Change gear. ii. Wear of main or clutch shaft. Change bearing. iii. Lessen of lay shaft. Repair lay shaft. 3. gears slip while vehicles is running i. wear of the gear. Change gear. ii. Braking of forks. Replace new unit. ii. Pilot bearings loosen. Change pilot bearing. 4. Gear locks. i. each part of bearings loosen. Check each part of change worn out part. ii. Wrong alignment. Put right alignment. Recalculation ball mechanism, tries to move the rack piston axially throw the gear housing cylinder assemble. The rack pistons axial movement is resisted by its engagement to the sector shaft, which is connected by linkage to the steered wheels, now, because of this resistance the torsion bar is twisted by the input haft, thereby actuating the control valve. Pressurized fluid. Directed by the control valve, assists in moving the rack piston there turns the sector shat to steer the vehicle. The system resulting the opening of a vale. It directs liquid to the appropriate side of the cylinder for steering wheel effort has exceeded a pre- determined valve. In order to prevent the tendency of the wheels to defect when the wheels the fluid is directed by the valve to the cylinder. Although the vehicle is safely controlled in case of any emergency FAULTS. CUSSED AND REMEDIES OF STEERING 1. WANDERING VEHICLE. Cause __________________________________remedy

Looseness of chassis of the steering boxes. Wheel of steering gear. . Les pressure in tyros.

Tight the bolts. Change the gear Correct the pressure.

2. vehicle pulls to one side: I. v bolt of rod spring loose bolt . Ii. Braking of spring. iii. bending of shock absorber. Change the spring. Change the shock. tighten the U bolt

FUEL INJECTION PUMP

PART 1. 2. 3. 4. 5. body (housing) Cam shaft. Intermediate bearing. Bearing end plate. Cam shaft oil seal.

6. Mounting plate. 7. Timber gear. 8. Governor weight. 9. plunger spring quadrant teeth 10. element (looking plate) 11. delivery valves, 12. Copper washer. 13. Delivery holder.

Fuel injection pump

WORKING This is widely used to supply fuel under high pressure in diesel engines. In this pump the plunger stroke remains constant but the effective stroke is reduced b changing the position of the helix on the plunger with respect o fuel inlet port. The fuel pump has a cylindrical plunger which is closely fitted into the barrel by lapin the plunger has a constant stoke and reciprocating motion of the plunger is given by the cam. The vertical hole expends from the top of the plunger into another helical groove. When the inlet and spill port or the by pass ports are closed by the.

Upper edge of the plunger during its ascending motion, the oil above the plunger gets compressed and the delivery valve gets lifted off its seat due to tee high pressure developed. Then the fuel is forced through the r pipe to the injector. The supply of fuel to the injector is continued until the helical groove reaches the inlet port. The pump space in this position to the plunger communicates with the spill port though the spiral slot and the vertical groove is thus connected to her atmosphere. The pressure on the spring side is release the delivery valve falls back to its seat and there supply of fuel to the atomizer is stopped. At this time, the

fuel I the barrel escapes from the spill port or the by pass port. During the downward streak of the plunger, the section is seated and the fie; as drawn mote the barer; through supply port. The quantity of fuel being supplied to the injector depends upon the position of the helical groove. The plunger can be rotated by means of the tooth rack. By turning the plunger to the right, the effective pumping stroke can be increased the instant at which the space communication with the spill port can be delayed and so, more fuel can be supplied to the engine at higher loads. The rack is iterated by there governor.

CALIBRATION OF THE F.I PUMP Test specification Combination number:9400030708-E04400594 Injection pump: PES 6A 100D 320/3 R53506 Governor: RQU 400 1250 AB 1323 R Customer: Tata Cummins Pvt. Ltd. Engine model: 6BT Engine code: 75006 Application: Vehicular.

Calibration of the F.I Pump

Test bench requirements: Test oil inlet temperature: 40-45 degree C. Overflow valve: 9451037430 Inlet pressure in bar: 2.0 Test injector: 0681 943009

 Opening pressure in bar: 170-172 Higher -* pressure pipe (ODXIDX length) :- 6X2X600

SELFSTARTER
Self-starter is the device used to start the engine, as piston engine are not self starting. They are incapable of running below a certain minimum speed. Therefore, it is necessary to provide certain system in the engine circuit to overcome the stand will resistance and crank it to speed at which it is self supporting and self starting. For this purpose a starting system or circuit, which consists of a series would motor which manually operated switch, is provided. It is mounted on the side of engine. The started derive are mainly concerned with the method of

linking the starting motor to the engine flywheel for cranking the engine until it starts running. It requires about 150 to500A wheel starting engine. PRINCIPAL: As current flows from the battery, a magnetic field produced moves the plunger to close the switch connecting the battery and the starter motor. PARTS: Switch, Plunger nut, Armature windings ,Spring Shied,Slot,Strip let plate. FAULT REMEDY

1.Starter motor does not resolve 2.aulty or discharge battery Change the battery 3. Short circuit. Correct the short 2.Starter resolves but does not crank. 1Shift mechanism pinion does not reach Adjust shift mechanism to fly wheel. 2.Looseness of bolts 3. Starter gear does not disengage 1. Oxidation of generator voltage regular 2 obstruction in plunger running Correct the alignment from the ring gear. Do filling Wash with petrol

BRAKES
It goes without saving that brakes are one of the most important control components of vehicle. They are required to stop the vehicle within the smallest possible distance and this is done by converting the kinetic energy if the wheel into the heat energy which is dissipated into the atmosphere. Requirements1. distance in an emergency, 2. The brake must have good ant fade characteristics. The brakes must be strong enough to stop the vehicle within minimum

Types:Mechanical brakes. Hydraulic brakes. Air brakes. Vacuum brakes. Electric brakes.

Hydraulic Brakes
But here we have studied only first three types of brakes, which are discussed below 1. Mechanical brakesThese are absolute now as service brakes. However these are still used on tear wheels in many cars, as parking or emergency brakes.

LINKERS:- When the pedal is passed , the brakes at what arc applied. This simple linkage
system however , has the advantages that it is very difficult to obtain. Equal effect at the wheels for which the compensation have to be used.

Hydraulic brake:-

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

Air Brakes:In this the compressor takes air from the atmosphere through the filter and The compressed air is sent to the reservoir pressure and also to the brake chambers also called diaphragm units at each wheel through the brake valve. Valve is with the driver who can control the intensity of braking according to the requirements.

Main components of air brakes are:1. 2. 3. 4. 5. Unloaded valve Brake valve Hand control valve Brake chamber Chamber air brake

Automobile shop equipment

As good workshop must have equipped undertake all types of fault finding and Servicing jobs. The following is a list of tools and equipment which are must in the workshop:1. Screw drivers. 2. Spanners, Wrenches etc. 3. Pliers. 4. Hammer 5. 6. Chisel Files

7.

Hack saw

8. Drilling machine 9. Bench vice 10. Grinder 11. Measuring tools 12. Chain pulley block 13. Hydraulic jack and axle stands 14. Creeper 15. lubrication equipment 16. Battery testing and charging. 17. Electric equipment. 18. hydraulic lilt 19. Tools for treys . 20. Tyre remover 21. wheel balancing equipment 22. brake testing 23. high pressure washing equipment 24. Engine analyzer. 25. Air compressor and pressure gauge. 26. workshop manuals for popular vehicle 27. Hydraulic press. 28. Piston ring compressor. 29. Ring remover. 30. ring fitting tool 31. Piston grooves cleaner. 32. Cylinder boring machine. 33. cylinder boring machine 34. Valve facing machine. 35. Valve seat grinding equipment. 36. Chassis alignment equipment. 37. Spark plug testing and cleaning machine.

38. Steering geometry and alignment machine . 39. Connecting rod alignment machine. 40. Nozzle testing and cleaning equipment. 41. Fuel injector tester. 42. Centre lathe. 43. Fire extinguisher. 44. Electric welding set.

Screw drivers

Spanners, Wrenches

Pliers, Hammer, Chisel

Files

Drilling machine

Hydraulic press

Centre lathe

Cylinder boring machine

Ring fitting tool

Tools for tires

ELECTRONIC TORQUE WRENCH

Bench Grinder

CONCLUSION
I got a lot of practical knowledge of various systems of the service center, also understood how the actual work is carried out on the shop floor related to the theory. I also gained the knowledge how to work efficiently with less effort and proper care to avoid accidents and how to keep good relations among the workers. The various qualities added and knowledge gained in me after completion of vocational training are: How to maintain good relation with the subordinates. Knowledge about time management and its effect of efficiently of work. Precautions taken during the work and also the safety mindness. Practical knowledge about various process flows on the shop floor. How to work in an organization while maintaining good relation and co-operation with colleagues and with seniors.