A PROJECT REPORT SUBMITTED IN PARTIAL FULLFILMENT OF B.TECH.

IN MECHANICAL ENGINEERING FROM 28/5/2012 TO 2/7/2012

INDEX:
SR. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 NAME OF THE OBJECT Acknowledgement Introduction The Lathe Vertical Boring machine Alternator Clutch System Introduction about Workshop Safety and Body building guidelines Minor engine repair and engine servicing Basic requirement of engine service Engine service procedure Specification Maintenance schedule procedure Maintenance procedure Automobile shop equipments Reason for trouble in various parts of vehicle Factor affecting power output of an engine Recommendations lubricants, coolants and fuel Main components of an automobile engine (power plant) Operational requirement on an I.C. engine Organizational structure

ACKNOWLEDGEMENT
Industrial training for engineering students is a part of their studies. Though the laboratories and workshop are well equipped and sufficient advanced but the industrial improvement and practice cannot be submitted by lab and workshop. We can apply theoretical concepts into practical during the valuable training period.

I am thankful to KURUKSHETRA UNIVERSITY Kurukshetra who provide us a precious opportunity to learn and see practically, which are studied earlier. I would like to express my heart full thankful to Mr. Yash Paul Sharma W/M HRTC D/W Bilaspur.

I wish to thanks to our HOD Er. Jitender Katariya of our institute E-max Institute of Engineering & Technology Badhauli, Ambala. Under whose dynamic and able guidance we were able to complete the Industrial Training.

THANKING YOU

INTRODUCTION
As stated in our syllabus we have prepared our report on our industrial training. As being Mechanical Engineering student in present we need to be an acquainted with practical exposure about components of industrial field procedure and practical so as have an operation of size and scale of operation. To develop comprehensions regarding concepts, principals taught in the classrooms and their application involving field/industrial task problems. To have firsthand knowledge culture and to mentally prepared them before actually joining word of work services. So for this very purpose, I went to HRTC D/W, BILASPUR. On feedback we prepared following report. All data taken in this report such as specification various parts etc is about TATA LP/LPO 1512TC vehicle manufactured by TELCO where quality is the watchword.

Recommendations
Following are the recommendations to Mech. Department. We should be given exposure to practical aspects to automobile industry that we can improve our knowledge. We should have at least one industrial tour in every month.

Introduction about workshop

Workshop is a place where repair or change of the parts of vehicle is done or in other words it is place where theory or laws changes practically to original structure. In D/W BILASPUR there is about 50 staff members of which mechanics are about 30. The others are related to clerical staff or other officers such as D.M. and Dy. D.M. works manager, head mechanics. There are about 40 buses. About 10 buses remain present at every time. There is a big store in the workshop in which every part of buses or every equipment is available. Storekeeper keeps every part in its place, he use catalogue to give a part to the worker, Works Manager and Head Mechanic check the working of every worker and told workers how to make procedure, if any trouble comes to a worker.

Safety Guidelines
To avoid accident and to keep them from happening following safety guidelines should be allowed:

1. Provide your attention at most to the job quietly. 2. Keep the tool within your convenient reach under your control. 3. Arrange neatly without scattering them around and out of way. Always keep 4. 5. 6. 7. 8. 9.
jack handles pointing up to avoid tripping up to wheel creepers are not in use stand them against the wall to avoid stumbling over them. Be serious about your work never including in horseplay or other foolish activities to avoid injury to other. Never put sharp objects like screw driver in your pockets otherwise you will cut yourself or get stabbed. Always wear suitable clothes for the job otherwise serious injuries can be caused by sleeves or ties getting caught by the machine or full leathers shoes with non skid rubber heel should be worn. To provide good grip on tool or part always wipe excess oil and grease up hand tool as required. To avoid slipping and falling to the ground due to spilt oil or grease or any liquid clean up immediately the ground. Compressed air should never be used to blow dust from your clothes. Compressed air should never be pointed to any person because flying particles or chips may harm him.

THE LATHE
INTRODUCTION:
The lathe is one of the oldest machine tools and came into existence from the early tree lathe which was then a noble device for rotating and machining a piece of work held between two adjacent trees. This device continued to develop through centuries and in the year 1797 Henry Maudslay, an Englishman, designed the first screw cutting lathe which is the forerunner of the present day high speed, heavy duty production lathe, a machine tools which has practically given shape to our present day civilization by building machines and industries.

FUNCTION OF THE LATHE:

The main function of the lathe is to remove metal from a piece of work to give it the required shape and size. This is accomplished by holding the work securely and rigidly on the machine and then turning it against cutting tools which will remove metal from work in the form of chips. To cut the work piece, should be rigidly held on the machine and should be fed or progressed in a definite way relative to work.

THE LATHE USED:

The centre lathe: This lathe is the most important member of the lathe family and is the most widely used. The term engine is associated with the lathe owing to the fact that early lathes were driven by steam engines. Similar to the speed lathe, the engine lathe has got all the basic part e.g. bed, headstock, and tailstock. But the headstock of an engine lathe is much more robust in construction

and it contains additional mechanism for driving the lathe spindle at multiple speeds.

THE LATHE

BORING MACHINES
INTRODUCTION:
The boring machine is one of the most versatile machine tool used to bore holes in large and heavy parts such as engine frames, steam engine cylinders, machine housings etc. Which are practically impossible to hold and rotate in an engine lathe or a drilling machine. Boring machine has, therefore, been developed primarily to do this. In addition to its primary purpose of boring the range of speeds and feeds provided to the various traversing components allow drilling, milling and facing to be performed with equal facility. By the fitting of simple attachments, the use of the machine can be extended still further to include screw cutting, turning, planetary grinding, or gear cutting.

VERTICAL BORING MACHINE:

ALTERNATOR
DESCRIPTION:
This 3 HA 15 Alternator is 12 poles 3 phase machine of revolving field with stationary armature type. The machine which is ventilated design is cooled by means of a fan mounted on the rotor shaft at the drive end. The output from the stator winding is rectified by means of a full wave bridge assembly. Auxiliary diodes provide rectification of the field. The output current of the alternator is self limiting. A fuse is provided on the positive line to protect the diodes in the event of an inadvertent battery reversal. An electronic regulator is housed inside the alternator itself and provides voltage regulation.

TECHNICAL SPECIFICATIONS: ALTERNATOR:

Rated voltage System Maximum output Maximum operating speed Cut in speed Regulator setting speed (Nominal) Stator connection Direction of rotation Weight : : : Star Clock (viewed from pulley end) 5.3 kg. (With vacuum pump, without Pulley) : : : : : : 12 volts Negative earth 40 amps 11500 rpm 1000 rpm 14.2 14.6 volts

CLUTCH SYSTEM
GENERAL:
Clutch is the mechanism interposed between engine and the gear box which enables engine power as well as torque of the engine to be transmitted at WILL to the gear box through friction drive. When clutch pedal is depressed the clutch is disengaged and motion & power flow from engine to gear box and hence to road wheels is disconnected.

Important functions of clutch within the power train are as follows: 1. Moving the vehicle from rest:
Engine gives sufficient power required for moving the vehicle from rest only at high rpm. Therefore, it is necessary to run the engine on no load up to such rpm and then connect to the gear box. This is achieved by disengaging the clutch upon which engine is separated from gear box.

2. Shifting in to gears:
While changing gear it is necessary that the gears in the gear box should not be under the load of transmitted power. Therefore, during each up or down gear shift it is necessary to interrupt the power flow from engine to the gear box. This is achieved by disengaging clutch before shifting in to gears.

3. Protection within the power train:

Clutch is the only flexible link between the engine and the power train as the power transmission is only through the friction drive. There is no rigid connection between driving and driven members which provides safety within the power train against the abnormal load/power transmission.

DRY CLUTCH

Minor engine repair: or engine servicing

To keep the motor vehicle in a condition of safety, reliability, comfort, cleanliness performance and economy automobile service is very necessary in modern fast moving time. Type of Automobile can be broadly decided in like following two types:

1. Self-diagnosed services
In these services are include the lubrication, washing body and being repair of brakes tires, steering alignment etc these services are necessary for efficient running and maintenance of automobile.

2. Performance services
For correcting engine performance and electrical troubles, the performance services are carried out. Performance services are quite different from self-diagnosed services before carrying out and of performance services.

BASIC REQUIRMENT OF ENGINE SERVICES:

The basic requirement of engine services is to find out the following information: To 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 in it would provide new performance of the reconditioning it is due to fact that original setting limits 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 like lack of power, poor acceleration, hard

starting missing king pin poor idling rough running as well as heavy fuel consumption are the indication of loss in performance.

Engine services procedure

Before servicing an automobile engine it is 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 should produced by the engine and this sound of the engine emission the analysis of the symptoms of troubles and troubleshooting charts are very helpful for this purpose generally these are two types of engine troubles: 1. Internal troubles. 2. External troubles. The engine servicing procedure involves these following steps.

Engine disassembly: The dismantling and removing is done for finding the
cause of troubles in engine parts such as: a) b) c) d) e) f) g) h) Manifolds Cylinder head Cylinder block Piston and connecting rod Shaft Sump or oil chamber Turbo charger Sub assembly

Cylinder head and cylinder block

Fig. CRANK SHAFT

Fig. piston and connecting rod

Fig. exhaust manifold Cleaning of parts:

Parts disassemble and in repairable condition should be cleaned. These are in general two types of cleaning done on an engine: i) Degreasing ii) 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 a part. It should be checked.

Condition of engine parts:

Condition should be remembered and they should be in working. Some conditions are such as: a) b) c) d) e) f) g) h) i) Valve Valve train Camshaft Lifter Rocker arm Push rod Valve spring Valve retainer Rocker shaft

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

Servicing the piston:

a) Ring grooves 1) Compression ring 2) Oil ring b) Skirt c) Piston pin d) Cylinder wall e) Piston assembly

Shaft and bearing:

a) Crank shaft b) Cam shaft CAM SHAFT

c) d) e) f) g) h) i)

Bearing Cylinder block Cylinder wall Main bearing Oil pump Water pump Covers

SPECIFICATIONS
Engine:
Model Type CUMMINS 6BT 5 9 TC water cooled direct injection Turbo charged diesel engine Bore stroke No of cylinders Max. Engine output Max. Torque Capacity Compression ratio Firing order Weight of engine 102/120 mm 6 93.5 KW (125.3 HP) at 2500 rpm 410 Nm (41.8 m/kg) at 1400-1700 rpm 5883 cc 17:6:1 1-5-3-6-2-4 413 kg

Air filter:
Type dry type remote mounted

Fuel filter:
Type pre and fine filtration with water Separator.

A fuel filter is a filter in the fuel line that screens out dirt and rust particles from the fuel, normally made into cartridges containing a filter paper. They are found in most internal combustion engines.

Oil filter:
Type full flow spin on paper type

An oil filter is a filter designed to remove contaminants from engine oil, transmission oil, lubricating oil, or hydraulic oil. Oil filters are used in many different types of hydraulic machinery. A chief use of the oil filter is in internalcombustion engines in on- and off-road motor vehicles, light aircraft, and various naval vessels. Other vehicle hydraulic systems, such as those in automatic transmissions and power steering, are often equipped with an oil filter.

Fuel injection pump:

Type MICO A type inline

An Injection Pump is the device that pumps fuel into the cylinders of a diesel engine. Traditionally, the 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 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).

Mechanical pumps are gradually being phased out in order to comply with international emissions directives, and to increase performance and economy. Alternatives include common rail diesel systems and electronic unit direct injection systems. These allow for higher pressures to be developed, and for much finer control of injection volumes compared to mechanical systems.

Turbo charger:
Type HOLSET

Cooling system:
Capacity Coolant Radiator frontal area 24 liters (total) water and ethylene glycol ratio 1:1 pre mixed 2887 sq cm

Clutch:
Type single plate dry friction type

Outside diameter of clutch Lining Friction area

310 mm

1030 sq cm (approx)

Gear box:
Model No of gears Gear ratio 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

Rear axle:
Type single reduction, hypoid gears Fully floating axle shafts Ratio 5.2285:1(37/7) STD

5.857:1(41/7) optional

Front axle:
Type heavy duty forged beam reverse Elliot type

Steering:
Type Steering gear box Ratio manual steering standard recalculating ball type 34:2:1 for I.P 151 TC 59 wheelbase LPO 1512 TC

Brake:
Parking brake Type Engine exhaust brake hand operated spring actuated parking brake acting on rear wheels coupled with Service brake

Frame:
Type ladder type heavy duty frame with Riveted/bolted cross members Channel section Depth Width side members 223 mm (max) 60 mm

Suspension:
Type semi elliptical leaf spring at front and Rear

Spring span

front 1450 mm Rear 1600 mm

Leaf width

front 70 mm Rear 80 mm

Shock absorber

hydraulic double acting telescopic Type at front and rear

Wheels and tyres:

Tyres Wheel rims No of wheels 9.00 x 20 14 PR 7.00 x 20 front 2 Rear 4 spare 1

Fuel tank:
Capacity 160 liters 250 liters optional for 52, 59 wheel base

CAB/COWL:
Type all steel full forward control cowls

Electrical system:
System voltage Alternator capacity Battery 24 volts 45 amps 2 x 12 v 180 Ah

Performance:
Max geared speed in top Gear (with std. rear axle) 87Km/h std. 79Km/h for optional ratio of RA

Max. Climbing ability in

1st gear

16.2% standard
18% optional ratio of RA

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 10615 10325 3225 1950 1809 5860 4225 1950 1809 7380 5195 1950 1809 8975 5895 1950 1809 10025

Weight (KG):
For IPO 1512 TC Wheelbase in mm Bare chassis kern weight with Cowl (with spare wheel & tools) As per IS 9211 max permissible FAW Max permissible Ra AW Max permissible GVW 10160 14860 10160 14860 4700 4700 4190 4380 4725 5545

Filling capacity of aggregates:

Engine oil sump Max 14.3 liters Min 12.30 liters Gear box GBS-40 Rear axle Ra-108 RR Steering gear housing Hydraulic clutch actuation system Cooling system Front hub grease per hub Rear hub grease per hub Water pump grease 5.2 liters 7.5 liters 0.95 liters 0.21 liters 0.24 liters 450 gm 450 gm 80 gm

Maintenance schedule
Check: Daily
Engine oil level Fuel level Coolant level Fan Drive belt

weekly (after 1000 km)

clutch pedal free play oil level in gear box oil level in rear axle brakes fluid level for clutch power steering fluid level

after 9000 km
air intake system air cleaner steering system brake system shocks absorber

Water trap in Air tank

separator steering system house

clutch

Brakes Tyre pressure Leakage of Coolant Electrical system

battery brakes system wheel nuts fuel oil suspension bolts

After 18000km
Antifreeze concern.

after 36000km
Drive belt tension

after 72000km
vibration Damper

Transmission system Brake system Body mountings Rear axle Wheel alignment

tension bearing valve clearance fan hub crown wheel thrust pad brakes system Electrical system Wheel hub bearing play

battery

Lubrication required at:

Linkage bushes pins wheel hubs

Change:
Front hubcap grease Fuel filter Gear box oil Engine oil filter

Over haul:
Clutch system Power steering Brake system Suspension spring Butterfly valve exhaust Gear box

Maintenance procedure Daily

Engine oil level:
Before starting or at least 5 minutes after the engine is shutdown check the oil level and top up if necessary never particles engine with the oil level below mark or above the high mark.

Marking on dipstick:
Low mark to high marks capacity Grade Confirming to classification 2.1 liters SAE 15W-40 API CE/SG

Fuel level:
Check fuel in fuel tank. Top up if necessary and secure cap capacity 160 liters. Removing radiator pressure cap: Removing the pressure cap when the coolant is cold (below 50*C) 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 cracks. Proper mounting, replace fan if damaged.

Drive belt:
Visually inspect the belt, replace the belt if frayed or pieces of material missing or longitudinal.

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 (1) by operating drain valve.

Brakes:
Check for proper functioning of brakes.

Tyre pressure:
Check and inflate the tyre in cold condition Front tyre pressure Rear tyre pressure 5.3 bar (75 psi) 6.0 bar (85 psi)

Leaks:
Check for leaks of water, air, fuel and oil at gaskets hose connections flexible pipes and pipe connections. If there is any fault replace the part.

Electrical system:
Check the functioning of light, 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 10 mm

Adjusting free play:

If free play is less adjust by loosening check nut on push rod of master cylinder check and free play and lock the nut. Vary the free play at pedal again.

Gear box:
Open oil drain plug and check oil level play. Check level of gear box oil top up if necessary. Grade APIGLA-SAE 80

Rear axle:
1. Oil drain plug. 2. Oil level plug. Check level of rear axle oil top up if necessary Grade AIPGL5 SAE90 (up to 9*C) SAE75 (9 to 45*C)

Power steering fluid level:

Check oil level in the power steering tank with engine switched off just place the dipstick in position while checking. The oil level should be 1 to 2 cm above the mark on dipsticks for topping up use oil conforming ATF-type A.

Steering system hoses:

It 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 nuts and tight them. If necessary when the wheel on the rear axle care must be exercised to insure that between the drum and inner wheel rim spherical washers are placed in the wheel studs with flat surface towards the wheel. After lifting the inner and outer wheel spherical washers should be placed in such a way that the spherical surface is towards the wheel rim and the drum. Torque (nonspigot Ted: 45-55m/kg wheel rims are fitted the spherical washers and spherical spring washer is not required torque (spigotted wheel rim nuts 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 wenches or with a socket wrenches or with a socket and handle of at least 60 cm length torque (U bolt nut 35 mkg) torque (check nut 35 mkg).

Lubricate linkage bushes and pins:

Lubricate oilcan brake chamber fork and pinball joins 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 bush gear shifting linkage propeller shaft U joint sliding yoking pins tie rod ends drag link end front spring pins rear spring pins helper spring brackets rear grade purpose grease no 2.

Inspection after every 72000 km

Vibration damper:
Check the index line on the damper hub and the inertia member if the lines are more than 1.5 mm Out an alignment replace the damper.

Inspecting rubber member:

Inspect rubber member for deterioration if pieces of rubber are missing. If elastic member is more than 3.13 mm below the metal surface replace the damper. Also look for forward movement of the damper ring on the hub. Replace the damper if any movement is detected.

Schematic circuit of hydraulic clutch actuation:

1. 2. 3. 4. Clutch master cylinder. Clutch fluid screw. Bleeding screw. Clutch sleeve cylinder.

Clutch system:
Dismantle clean inspect and reassemble clutch sleeve cylinder and master cylinder. Replace damaged/worn out parts.

Bleeding clutch system:

Remove the dust cap from slave cylinder bleed screw and attach the bleed tube to bleed screw. Place the other end of the tube in clean glass for containing sufficient brake fluid to submerge the end of the tube. Pump the clutch pedal twice/thrice slowly throughout its spoke and by holding the pedal pressed loosed the bleed screw and watch then air bubbles in the glass jar. Retighten the bleed screw. Repeat the procedure until air bubbles cease to appear at the end of bleed tube. Replace the dust cap on the bleed screw total system. Capacity of clutch fluid Grade 210 cc SAEJ 1703 E/F

Steering oil and filter change:

Drain off hydraulic oil of power steering big loosing drain. Plug remove carrier and insert new filter cartridge with metal color in upward direction. Fill this oil into this oil tank crank the engine and add oil to mark up the oil level to the top mark of dipstick.

Recommended oil:
Confirming to System capacity ATF-type-A 3 liters

Bleeding power steering system:

Jack up the front only and run the engine at idle speed turn the steering wheel several times from lock to lock so that air escapes from the cylinder keep adding oil until oil level remains at upper mark at dipstick and air bubbles are no longer rising in the oil tank when steering wheel is turned shut the engine off and lower front axle. Check oil level and add if necessary. To bring the oil level 1 to 2 cm above the top mark of dipstick.

Brake system:
Front Rear Air brake chamber Mounting bracket to rear axle Camshaft bearing block 18 mugs 20 mugs 10-13 mugs 8 mugs 5 mugs

Spring:
Dismantle front and rear spring clean and apply graphite grease while reassembling grease spring pin with grease plan

Butterfly valve in exhaust:

Dismantle and clean bitterly valve. Do not lubricate.

Gear box:
Dismantle clean inspect and reassemble the gear box 1. Drain gear oil while still hot clean magnetic and rain plug. 2. Check and tighten left hand nut to specified torque if necessary dismantle drive shaft. Reassemble and replace left hand nut and tighten it to specified torque replace bearing if required. 3. Check bearing on main shaft counter shaft and needle roller bearing on main shaft for scoring/pitting mark replaces bearing needed roller bearing if necessary. 4. Adjust endplay of bearing on counter shaft main shaft and drive by selecting shims. 5. Check backlash on speed gears it should be within 0.25 mm. inspect gears replace worn/scored/pitted gears. 6. Refills the gearbox with recommended oil. 7. Test the gearbox for gear noise and smooth gear engagement.

Inspection after every 3,20,000 km

Cooling system replacement:
Wait until temperature falls below 50 *C before draining. Drain the cooling system by opening the drain valve on the radiator and removing the plug at the inlet to water pump used drain pen with capacity of 30 liters. Prolonged and repeated contact with used antifreeze can cause disorders or other body injury. Use 0.5 kg of sodium carbonate for every 23 liters of water to prepare flushing mixture. Fill this system slowly wait 2 or 3 minutes to allow air to be vented and add mixture to bring the level to top. Dont install the radiator cap operate the mixture temp. above 80*C. Shut to the engine off and drain cooling system fill the cooling system with clean water be sure to vent the engine for complete filling. Dont install the radiator cap operate the engine for five minutes with the flushing mixture above 80*C. shut the engine off and drain the cooling system. Fill the cooling system with clean water be sure to vent the engine for complete filling. Dont install the radiator cap. Again operate the engine for 5 minutes. With the water temperature above 80*C. shut the engine and drain the due cooling system. If the water drained is still dirty the system must be flushed again until the water is clean. Use the mixture of 50% Water and 50% Ethylene Glycol antifreeze to the cooling system. Total system capacity Engine capacity 24 liters 9 liters

Fill the system slowly to prevent air locks during filling air must be vented from the engine and coolant. Maximum filling rate 19 liters

Dont exceed this fill rate wait for 2-3 minutes to allow this air to be vented then add mixture to bring the level to the top install the pressure cap operate the line engine until it reaches a temperature of 80*C and check for coolant leaks wait until this coolant temperature and check coolant level again make sure this system is fill of coolant.

Final drive:
The function of final drive is to provide a permanent speed reduction and to turn the drive round through 90*. The reduction provided is about 4:1 in cars and 10 :1 in buses.

Differential:
When the car is taking turn the outer wheels will have to travel greater distance as compared to the inner wheels in the same time. If therefore, the car has a solid rear axle only and no other device; there will be tendency for the wheels to skid. Hence of the wheel skidding is to be avoided. Some mechanism must be incorporated in the rear axle, which should reduce the speed of inner wheels and increase the speed of all the wheels same when going straight ahead. Such a device, which serves the above function, is called differential. To understand the principle on which differential works consider figure. To the crown wheel of the final drive is attached a cage, which carries a cross pin and a spider. To sun gears mesh with the two or four planet pinions. Axle half-shafts are splinted to each of these sun gears. The crown wheel is free to rotate on the cross pin or the spider arm, they cannot apply different torque to the teeth on one side, therefore, they act as balance and divide the torque between the two wheels on axle, even when their speeds are different.

A) Input torque is applied to the ring gear (blue), which turns the entire carrier (blue), providing torque to both side gears (red and yellow), which in turn may drive the left and right wheels. If the resistance at both wheels is equal, the planet gear (green) does not rotate, and both wheels turn at the same rate.

B) If the left side gear (red) encounters resistance, the planet gear (green) rotates about the left side.

Brakes:
It goes without saying that brakes are one of the most important control components of the vehicle. They are required to stop the vehicle within the smallest possible distance and this is done by converting the kinetic energy of the wheels into the heat energy which is dissipated into the atmosphere.

Requirements:
1. The brakes must be strong enough to stop the vehicle within minimum distance in an emergency. 2. The brakes must have good anti fade characteristics.

Types:
1. 2. 3. 4. 5. Mechanical brakes Hydraulic brakes Vacuum brakes Electric brakes Air brakes

But here we have to study only three types of brakes which are discussed below:

1. MECHANICAL BRAKES:
These are absolute known as service brakes. However these are still used on rear wheels in many cars, as parking or emergency brakes.

LINKAGES:
When the pedal is pressed, the brakes are applied. This simple linkage system however has the advantage that it is very difficult to obtain. Equal effect at the wheels for which the compensators have to be used in heavier vehicles.This is done either in one or two stages for lesser reduction say up to 71 single reduction is used in two steps. The final drive in practice consists of a bevel pinion and crown wheel or alternatively worm and wheel arrangement. The bevel pinion is mounted on a shaft, which is connected to the propeller shaft generally through a universal joint. From the crown wheel the drive goes to the differential. Three types of gears are used for the final drive bearing.

2. Hydraulic brakes:
Most of cars today use hydraulic operated foot brakes on all the four wheels with an additional 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 fluid under pressure forces the piston apart there by applying the brakes.

3. Air brakes:
In this the compressor takes air from the atmosphere through the filter and the compressed air is sent to the reservoir through the unloaded valve which gets lifted at a predetermined 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

STRAIGHT BEVEL GEARS:

These contain the straight bevel gears at one instant only one pair of teeth of pinion and the crown wheel will be in contact. As a result and uneven transmission of motion will take place as the load is transferred from one pair of teeth to the next. Thus these gears are noised and suffer from high wear.

Hypoid gears:
The name Hypoid is driven from the revolution the basic surface on which the teeth are cut in their case are hyperboloid, which is a solid obtained by rotating a hyperbola about an offset axis. Such gears are employed to connect shafts at right angles to each other, but not lying in the same plane. In case of hypoid gears, the pinion shaft is placed below the axis of the crown wheel with hypoid gears, pitch diameter of the pinion for given size of the crown wheel for a given speed reduction is more on account of offset. This increases strength of the pinion by about 20% to 30%. It also provides a larger pitch overlap, resulting in real silent running.

Worm and wheel arrangement:

Instead of bevel pinion and the crown wheel, the crown frequently. Worms used are of multi star type. Such a worm would have a lead equal to number of starts times its pitch and would thus advance the wheel through a large distance compared to single star worm. This decreases the gear ratio.

Gear ratio of drive = no. of teeth on the wheel / No. of stars on the worm

Worm and wheel type of final drive is particularly useful in heavier vehicles where the final reduction is greater than about 6. This gives a quiet, efficient and very strong derive.

Automobile shop equipment

A good workshop must have equipped to undertake all types of fault finding and servicing jobs. The following is the list of tools and equipments, which should be in the workshop: 1. 2. 3. 4. 5. 6. 7. 8. 9. Screw driver Spanners, wrenches etc. Pliers Hammer Chisel Files Hacksaw Drilling Machine Bench vice

10. Grinder 11. Measuring Tools 12. Chain Pulley Block 13. Hydraulic Jack and Axle Stands 14. Creeper 15. Lubrication Equipments 16. Battery Testing and Charging 17. Electric Equipment 18. Hydraulic Lift 19. Tools for Tyres 20. Tyre Remover 21. Wheel Balancing Equipment 22. Brake Testing

ORGANISATIONAL STRUCTURE HRTC

MANAGING DIRECTOR
G.M. TECHNICAL G.M.OPERATIONAL G.M. ADMINISTRATION

D.M. TECHNICAL

D.M. OPERATIONAL

R.M.

W.M.

T.M.

FOREMAN

STORE ADMINISTRATOR

S.S.I.

STORE INCHARGE

H.M.

STORE KEEPER

MECHANIC

HELPER