INTERNSHIP PROJECT

UTTRAKHAND TRANSPORT CORPORATION

DEHRADUN

Submitted by

SIDDHARTHA KUMAR SINGH

(ROLL NO: 160106004)

in partial fulfillment for the award of the degree

of

B.TECH.(FULL TIME)
in

MECHANICAL ENGINEERING

DEPARTMENT OF MECHCNAIL ENGINEERING

DEHRADUN INSTITUTE OF TECHNOLOGY
DEHRADUN
 ACKNOWLEDGEMENT

I feel much honored in presenting this dissertation report in such an authenticable form
of sheer endurance and continual efforts of inspiring excellence from various coordinating
factor of cooperation and sincere efforts drawn from all sources of knowledge.

I express my sincere gratitude to mentors for their constant support, guidance and
mentoring. Whatever I have learnt, I owe it to my mentors at Uttarakhand Transport
Corporation, Dehradun.

I thank the Mechanical Department and DIT University for this opportunity.
I extend my thanks to all classmates who have given their full cooperation and valuable
suggestion for my dissertation report work.

Place: DEHRADUN (SIDDHARTHA KUMAR )

 PREFACE

I am very grateful to our honorable H.O.D Dr. Manoj Kumar that he gave me a golden
chance in the working process, management, machines and advanced technologies used
in industries by this field exposure.
It was a 30 days training period in which I joined Roadways Regional Workshop
DEHRADUN (Uttarakhand), which is a major workshop of U.K Transport
Corporation. There I learned about the parts and working process of buses as well as
repairing and assembling of parts. I wish I had the chance to assemble the parts. I wish
I had some more time to develop my technical knowledge by this training process.

Thank You DATE-09/09/2019

SIDDHARTHA KUMAR SINGH
Mechanical Engineering
6th semester
TABLE OF CONTENT

● ACKNOWLEDGEMENT

● PREFACE

● NAME AND ADDRESS

● DATE OF JOINING AND LEAVING

● NATURE OF INDUSTRY

● SECTION OF THE UNIT VISIT AND ACTIVITIES THERE IN

● DETAIL OF MACHINE/TOOL AND INSTRUMENTS USED IN THE

SECTION OF THE UNIT VISITED

● WORK PROCEDURE IN THE SECTION

● USE OF COMPUTERS

● SAFETY MANON WORK PLACE AND WORKING CONDITIONS

● SPECIFICATION OF THE PRODUCT AND MATERIAL USED

● WORK OF REPAIR AND MAINTAINANCE

 UTTARAKHAND TRANSPORT CORPORATION,
ROADWAYS WORKSHOP (REGIONAL)

ADDRESS: DEHRADUN (U.K.)

DATE OF JOINING:

25/05/2019

DATE OF LEAVING:

21/06/2019

U.T.C REGIONAL WORKSHOP, DEHRADUN

OVERVIEW-:

WORK OVERVIEW
Service center for Uttarakhand roadways buses is situated in Dehradun and also
known as UTTRAKHAND MANDALIYA KARYALAYA. In the workshop, the
repairing of damaged parts of buses is carried out by the workers. Also
repaired/new bus parts are assembled. The servicing of buses is also carried out
in the workshop. For these operations the workshop is divided into different
sections. Most of job of maintenance like replacement, assembling, inspection etc
is done manually and is based on past experience.
WORKING HOURS -:
In Roadways Workshop Dehradun the work scheduleis as follows:
Working Time : 8:00 AM TO 10:00 AM.
Tea Time : 10:00 AM TO 10:30 AM.
Working Time : 10:30 AM TO 12:00 PM.
Lunch Time : 12:00 PM TO 01:00 PM.
Working Time : 01:00 PM TO 05:00 PM.

SECTIONS:
The Roadways Workshop Dehradun has the following sections-:

1) Engine Section.

2) Gear Box and Clutch Section.

3) Spring Section.

4) Fuel Injection Pump Section.

5) Axel Section.

6) Electric Section.
1. Engine Section:-

In this section tuning and testing of engines of is carried out. The engine is repaired and
damaged engine parts are replaced. All the engine parts are then assembled and engine
is then tested to check if it is functioning properly. Any functional errors encountered
are removed before approving the engine for installation on buses.
All the engines are turbocharged.
Engines of the following buses are repaired in the workshop
1. TATA- 1312
2. TATA- 1520
3. TATA- 1210
4. LEYLAND

PARTS OF ENGINE:-
There are following parts of an Engine-:
1. Cylindrical Head.
2. Oil Pump.
3. Cylinder Block.
4. Piston.
5. Crank Shaft.
 6. Cam Shaft.
7. Cooling Fan.
8. Radiator.
9. Valve Mechanism.
10. Self-Starter.
11. Fly Wheel.
12. Cooling Plate.
13. Dumper Pulley.
14. Vibration Dumper Pulley.
15. Water Pump.
16. Timing Plate Housing.
17. Push Rod.
18. Diesel Filter.
19. Tappet.
20. Gudgeon Pin.
21. Alternator.
22. Turbo Charger.

SPECIFICATIONS OF ENGINE-:
1. MODEL – T.C. 1312 (TATA).

2. NUMBER OF CYLINDER – 6.

3. BORE SIZE – 102 mm.

4. FUEL USED- DIESEL.

5. FIRING ORDER- 1, 5, 3, 6, 2, 4

6. INJECTION PRESSURE- 175-180.

7. AVERAGE – 5-6 km/lt.

ASSEMBLY OF T.C.1312 (TATA)-:
First of all Engine Block is used in assembling of Engine. Then bush bearing is fixed in
Engine Block. Then Crank shaft is fixed; now Crank Shaft is clamped by Crank Shaft
Head. Then Crank Shaft is connected with Piston by Connecting Rod and Gudgeon Pin.
Then Oil Ring and Compressor Ring are attached with Piston.
Now by the Connecting Rod Head the Piston is clamped to Crank Shaft.
Now the Timing Plate Housing is clamped in the front part of Engine Block and Rear
oil Seal is fixed in back side, which prevents leakage of oil.
Now Oil pump is fixed in front of Timing Plate. Oil Pump contains two gears, small
size gear is attached with Crank Shaft and big size gear is attached with small size gear.
Than we clamp Cam Shaft whose gears mesh with Crank Shaft. Than we use a Timing
Pin in between Oil Pump and Cam Shaft to control the fuel supply. Than Side Plate is
clamped, after that Push Rod is inserted than Injectors are clamped over the Inlet and
Outlet Valve then Tappet Covers are fixed.

WORKING PRINCIPLE-:
In Roadways Buses Four Stroke Diesel Engines is used.
The strokes are -:
1. Suction Stroke.
2. Compression Stroke.
3. Combustion/Power Stroke.
4. Exhaust Stroke.
When the engine starts crank shaft rotates. And this rotates the cam shaft
because they both are fixed together by a soft Timing Pin.
Cam rotates because it is a part of cam shaft, rotating of cam uplifts the tappet.
Tappet uplifts the push rod by which some action goes to Rocker Arm, the
timbre end of Rocker Arm goes down, and this applies pressure on valve stem.
Valve Phase comes down from valve seat and ports open. Through the ports
fuel enters into the engine cylinder.
LUBRICATION OF DIESEL ENGINE: -
Different engine parts are lubricated using pressure to deliver lubricating oil. Through
Oil Pump or Oil Sump, oil is sucked under pressure (200 to 400 KPa). It passes through
gallery. After reaching to main gallery some amount of oil reaches to big end bearing
then through cross holes it passes through main bearing to reach the piston and gudgeon
pin.
The oil used for lubrication of engine is 15W40.

PRECAUTION & SAFETY FEATURES: -

1. Tappet clearance should be clean.

a. When inlet is hot >> 0.10 inch

b. When outlet is hot >> 0.20 inch

2. Rocker Arm & Lubrication of Rocker Arm should be checked.

3. Tappet cover should always fix.

4. Lubrication oil should be replaced in regular intervals.

2. GEAR BOX SECTION:-

Manual transmissions often feature a driver- operated clutch and a movable gear
stick. Most automobile manual transmissions allow the driver to select any
forward gear ratio ("gear") at any time, but some, such as those commonly
mounted on motorcycles and some types of racing cars, only allow the driver to
select the next-higher or next-lower gear. This type of transmission is sometimes
called a sequential manual transmission. The way a manual transmission works is
that the flywheel is attached to the engine, clutch disk is in between the
pressure plate and the flywheel. When running, the clutch disk is spinning with
the flywheel and when pressure is applied to the clutch pedal the throw out
bearing is pushed in and it makes the pressure plate stop applying pressure to
the clutch disk and making it stop receiving power from the engine so the gear
can be shifted without any problems and when pressure stops being applied to the
clutch pedal the clutch disk is allowed to start receiving power from the engine.

Manual transmissions are characterized by gear ratios that are selectable by

locking selected gear pairs to the output shaft inside the transmission.
Conversely, most automatic transmissions feature epicyclic (planetary) gearing
controlled by brake bands and/or clutch packs to select gear ratio. Automatic
transmissions that allow the driver to manually select the current gear are called
Manumatics. A manual-style transmission operated by computer is often called
an automated transmission rather than an automatic.

Contemporary automobile manual transmissions typically use four to six forward

gears and one reverse gear, although automobile manual transmissions have been
built with as few as two and as many as eight gears. Transmission for heavy
trucks and other heavy equipment usually have at least 9 gears so the
transmission can offer both a wide range of gears and close gear ratios to keep
the engine running in the power band. Some heavy vehicle transmissions have
dozens of gears, but many are duplicates, introduced as an accident of
combining gear sets , or introduced to simplify shifting. Some manuals are
referred to by the number of forward gears they offer (e.g., 5-speed) as a way
of distinguishing between automatic or other available manual transmissions.
Similarly, a 5-speed automatic transmission is referred to as a "5-speed
automatic."

Gear box is fixed with Clutch Plate Housing behind Clutch. Gear box is used to
drive vehicles in different load conditions. With the help of gears the speed of
vehicles is varied as required.

In this section the assembly and repairing of gearbox is done. In this section following
type of Gear Box are assembled-:
 1. GBS-40--------- T.C(TATA)
2. GBS-30--------- T.C(TATA)

PARTS OF GEAR BOX-:

1. Main Shaft 10.Spring Washer
2. Counter Shaft 11.Oil Seal
3. Shifting Rod 12.Front Cover
4. Gear Box Housing 13.Butt Rings
5. Cover Plate 14.Hub and Bush
6. Bearing and Sleeve 15.Synchronizer
7. Fork 16.Carrier and Compressor Pin
8. Cylindrical Bin 17.Drive Shaft
9. Mug Drain Pin 18.Gear Box Cover Rear

ASSEMBLY-:
Counter Shaft adjusts in Gear Box which is made up of Cast Iron by Casting. There
are Five Gears in counter shaft. Main shaft acts as a base purpose shaft. The main
shaft is assembled in which there are 6 helical gears. There are 5 forward and 1
reverse gear. In these sleeve fork fits after the shifting rod.

Number of Teeth in each Gear-:

A. In Main Shaft-:
1. First Gear - 39
1. Second Gear – 32
2. Third Gear – 25 or 26
3. Fourth Gear – 19 or 20
4. Fifth Gear – 17
B. In Counter Shaft-:
1. First Gear – 11
2. Second Gear – 17
3. Third Gear – 23 or 24
4. Fourth Gear – 29
5. Fifth Gear – 36

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

Working-:

1) Neutral Position-: The power of Engine reaches to Counter Shaft. But because
of no Pinion meeting of Main and Counter Shaft, power doesn’t go forward and the
Vehicle remains unmoved.

2) First Gear-: With the help of Gear Lever Shaft the First Gear of Main
Shaft meshes with the First Gear of Counter shaft. The power of Engine comes to
Counter Shaft than goes to Main Shaft. Main Shaft Rotates clockwise and gives
movements to Propeller Shaft and the vehicle start to move.

3) Second Gear-: By taking Gear Lever to downwards the Second Gear of Main
and Counter Shaft mesh together, movements has already send to the Propeller Shaft,
by the Second Gear the speed of vehicle increased, because the pinion of the Main and
Counter Shaft decreases & increases respectively.

4) Third, Fourth and Fifth Gear-: There working is just like the Second Gear,
but in Fourth Gear Main Shaft starts taking power directly from Clutch Shaft.

5) Reverse Gear-: When Gear Lever takes Gear to the Reverse Gear position the
small tooth’s of Reverse Gear mesh with the First Gear of Main Shaft and big tooth’s
mesh with the Reverse Gear of Counter Shaft, Main Shaft rotates anti-clockwise and
the vehicle comes backward.

Lubrication of the Gear Box-:

80W90 lubricating oil is used for the lubrication of gear box. Splash lubrication
method is used.
Precaution and Safety features-:

1. Lubrication of the all Gear box is necessary.

2. Gear selection should happen according to the nature of load.

3. Gear shifting should be done according to the speed of vehicle and engine.

4. Gear shifting should be done softly.

3. Fuel Injection Pump Suction-:

In Diesel Engine F.I. Pump is used for carrying the in correct amount time, high
pressure and reaches it to injector in it the injection pressure is 7 to 30 M Pa.
Parts of F.I. Pump-:
1. Delivery Valve. 10. Air Nipple.
2. Delivery valve spring. 11. Hand Primer.
3. Plunger. 12. Cotton Glassy.
4. Pump housing. 13. Paper Glassy.
5. Control pack. 14. Idling.
6. Plunger Return spring. 15. Lever Washer
7. Control sleeve. 16. Control Rod
8. Cam Shaft. 17. Sluing Lever
9. Feed Pump. 18. Fly Weight

SPECIFICATION OF F.I. PUMP-:

Model -Bosh Type F.I. Pump
Injection Pressure - 7 to 30 M Pa.
CAM Sequence - 1-5-3-6-2-4.
Direction of Rotation -Clock Wise.

WORKING PRINCIPLE-:
Fuel by suck fuel pump from the tank at low pressure with the help of filter. Fuel is
supplied to unit injector where its pressure is increased. And the high pressure fuel is
then supplied to the engine cylinders at appropriate time. Any extra fuel goes again to
tank through relief valve.
FLOW DIAGRAM FOR F.I PUMP-:
Hand Primer
|
Fuel Supply
|
Feed Pump
|
Glassy
|
Strainer
|
Diesel Filter
|
Pump
|
Air Nipple
|
Self-Start

Precaution & Safety Features-:

1. Pump should remain clean always.
2. Mountings should be tight.
3. Do not clamp retainers very tight.

4. Spring Section-:
Because of the up’s and down’s encountered in the road, the vehicle experiences many
shocks. To prevent damage to the vehicle due to these shocks leaf springs are employed.
They are semi-elliptical in shape.
The length of these springs is different for both Axles. In front axle the length of spring
is 74 Inch and decreases 4 inch downwards, and in Rear Axle the length of spring is 78
Inch decreases as in the front axle. The width of Leafs is 3 inch. The total number of
the Road Spring in a vehicle is 4, and one spring contains 15 leafs.
Krampe Hydraulic Machine is used for the bending of road springs. The machine’s
type is HKTG. In the vehicle these Road Springs are hanged in a Chassis Hanger
Bracket, and then with a U Bolt.
Working-:
When a vehicle experiences a shock, the shock is transmitted to the springs through
the axel, and spring tend to get to straight position, Shekel helps them to do this. So
the maximum part of the shock is absorbed by the spring and little by the body.

Precautions And Safety Features -:

1. There is no breakage in the Leaf.
2. Mounting should be tight.
3. Weekly Lubrication is required for the Shekel pin.
4. Too much play in shekel is not permissible.

In Roadways Workshop Dehradun the following tools are used for repair and
assembly-:
1. Spanner.
2. Hammer.
3. Chisel.
4. Pliers.
5. Screw Drivers.
6. Anvil.
7. F.I Pump Testing Machine.
8. Hydraulic Krampe Machine.
9. Micrometer.
10. Lathe machine.

In Roadways Workshop Dehradun mainly assembly and repairing is done. It is done

follows-:

1. At first the damage parts of automobile from various Depots send to Roadways
Workshop Dehradun. Here they are classified and send to suitable Workshop
Section.
2. In every section the automobile parts are dissemble.
3. Dissembled parts washed by Dermal.
 4. The washed part replaces the damaged part.
5. Now the assembly is done.
6. The washed parts checked carefully from where it damaged.
7. In this way after repairing new assembled part supply to the depot.

In the Roadways Workshop Dehradun there is a limited use of computers.

The use of computers is as follows-:

1. The data related to Purchase and Selling of parts is stored.
2. To prepare the list of automobile parts and their costs and from which company
they have been purchased.
3. In the Registration of Roadways Buses.
4. Details of spare parts stored in the depot.

The following step should be taken for safety on the work place-

1. The workshop should be clean and there will be security apparatus must be
given to the workers.
2. The Workshop System of air must be managed.
3. Do not smoke and peep away of the fire substance from working place.
4. Use Apron, Shoes, and Glassware during work.
5. The wiring of the Workshop should be done properly.

In This Roadways Workshop there is no production work is done. Only the assembling
work is done in the respect of production.

The damage part of the bus is changed by new part and the assembling is done. In the
assembling there are various sections in the Workshop and the assembling of various
parts in the respective section is done.
For example: In the Engine Section, assembling for its part like Crank Shaft , Cam Shaft
etc., is done and the new assembled Engine is prepared by various parts of various
companies.
5. AXLE SECTION-:

REAR AXLE-: Power from the engine is delivered to the rear axle through propeller shaft. In
the rear axle a differential is mounted which distributes the power from the engine in between
the two tires as per the requirement.

The differential has three jobs:

 To aim the engine power at the wheels

 To act as the final gear reduction in the vehicle, slowing the rotational speed
of the transmission one final time before it hits the wheels
 To transmit the power to the wheels while allowing them to rotate at different
speeds

Torque is supplied from the engine, via the transmission, to a drive shaft (British term:
'propeller shaft', commonly and informally abbreviated to 'prop-shaft'), which runs to the
final drive unit that contains the differential. A spiral bevel pinion gear takes its drive
from the end of the propeller shaft, and is encased within the housing of the final
drive unit. This meshes with the large spiral bevel ring gear, known as the crown
wheel. The crown wheel and pinion may mesh in hypoid orientation , not shown. The
crown wheel gear is attached to the differential cage, which contains the 'sun' and
'planet' wheels or gears, which are a cluster of four opposed bevel gears in
perpendicular plane, so each bevel gear meshes with two neighbours, and rotates
counter to the third, that it faces and does not mesh with. The two sun wheel gears are
aligned on the same axis as the crown wheel gear, and drive the axle half shafts
connected to the vehicle's driven wheels. The other two planet gears are aligned on a
perpendicular axis which changes orientation with the ring gear's rotation. In the two
figures shown above, only one planet gear (green) is illustrated, however, most
automotive applications contain two opposing planet gears. Other differential designs
employ different numbers of planet gears, depending on durability requirements. As
the differential carrier rotates, the changing axis orientation of the planet gears imparts
the motion of the ring gear to the motion of the sun gears by pushing on them rather
than turning against them (that is, the same teeth stay in the same mesh or contact
position), but because the planet gears are not restricted from turning against each
other, within that motion, the sun gears can counter-rotate relative to the ring gear and
to each other under the same force (in which case the same teeth do not stay in
contact).

Thus, for example, if the car is making a turn to the right, the main crown wheel may
make 10 full rotations. During that time, the left wheel will make more rotations
because it has further to travel, and the right wheel will make fewer rotations as it has
less distance to travel. The sun gears (which drive the axle half-shafts) will rotate in
opposite directions relative to the ring gear by, say, 2 full turns each (4 full turns
relative to each other), resulting in the left wheel making 12 rotations, and the right
wheel making 8 rotations.
The rotation of the crown wheel gear is always the average of the rotations of the side
sun gears. This is why, if the driven roadwheels are lifted clear of the ground with the
engine off, and the drive shaft is held (say leaving the transmission 'in gear',
preventing the ring gear from turning inside the differential), manually rotating one
driven roadwheel causes the opposite roadwheel to rotate in the opposite direction by
the same amount.

When the vehicle is traveling in a straight line, there will be no differential movement
of the planetary system of gears other than the minute movements necessary to
compensate for slight differences in wheel diameter, undulations in the road (which
make for a longer or shorter wheel path), etc.

FRONT AXLE-: Power to the front axle comes from the rear axle. The Front Axle
and suspension consists of I- Section beam, to which the stub Axle is connected at
each end.

MAIN PARTS OF AXLE-:

1) I- Beam 9) King Pin
2) Crown 10) King Pin Sims
3) Sun & Star gears 11) Staff Axle
4) Pinion 12) Cutter Pin
5) Bearing Cone 13) Split Nut
6) Distance Piece washer 14) Second Arm
7) Thrust Washer 15) Third Arm
 8) Chuck Washer 16) Oil seal ring

Assembly of Axle-:
I-Beam
|
Staff Axle
|
King Pin
|
King pin Sims
|
Roller Bearing
|
Cutter Pin
|
Inner Bearing
|
Break Richet
I
Break-Shoe
|
Lining
|
Break Cam shaft
|
Plastic Slip
|
Hub

SPECIFICATION OF AXLE-:
1. I-beam- 34801UZ164142.

2. Roller bearing- 19 Balls.

3. Inner Bearing- 1888400-565/562 no.

4. Outer Bearing- 32308no.

Precaution and Safety features-:

1. Lubricates King Pins every week.
2. Always use the specified Lubricant.
3. Always wipe the nipples clean before filling grease.
4. Grease has to be pumped in through top/bottom grease nipples.

6. Electric Section-:
Electric Section consists of:
1. SELF STARTER
2. ALTERNATOR

1. SELF STARTER – Self-starter’s only work is to start vehicle. By pressing self

the operator starts the vehicle

Main parts of Self Starter-:

1. Main field.
2. Auxiliary Field.
3. Clutch.
4. Armature.
5. Pinion.
6. Solenoid Switch.
7. DE and CE Switch.
8. D Plate.
9. Trip Plate.
WORKING-:

When the Self Start is pressed, current comes to auxiliary field; auxiliary field presses
armature forward, the trip plate of armature presses the lever of solenoid switch by
which the current comes in main field, then current goes to Commutator.

2. ALTERNATOR -:
It is used to charge the battery for various purposes.

MAIN PARTS-:
1. Pulley.
2. Straighter.
3. Regulator.
4. Rectifier.
5. Slip Ring.

WORKING-:

Dynamo sends D.C Current to the straighter and the rectifier fixed in straighter
changes the current to A.C and imparts movement to the Rotor. This generates the
electricity.
The electricity generated travels to the regulator. The regulator sends current to the
battery. Thus battery is charged by the alternator.
When battery has sufficient Charge the regulator cuts the power supply between
alternator and battery.

Precautions and safety features-:

1. Connections should be tight and clean.
2. Saves the wires from Grease and Oil.
3. Do not let the wires hanging.
4. The insulation should be correct.