summar training report hrtc training report

8/13/2019 Summar Training Report HRTC TRAINING REPORT

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A PROJECT REPORT SUBMITTED IN PARTIAL

FULLFILMENT OF B.TECH. IN MECHANICAL

ENGINEERING FROM 28/5/2012 TO 2/7/2012INDEX:

SR.

NO.

NAME OF THE OBJECT

1 Acknowledgement

2 Introduction

3 The Lathe

4 Vertical Boring machine

5 Alternator

6 Clutch System

7 Introduction about Workshop

8 Safety and Body building guidelines

9 Minor engine repair and engine servicing

10 Basic requirement of engine service

11 Engine service procedure

12 Specification

13 Maintenance schedule procedure

14 Maintenance procedure

15 Automobile shop equipments

16 Reason for trouble in various parts of vehicle

17 Factor affecting power output of an engine

18 Recommendations lubricants, coolants and fuel

19 Main components of an automobile engine

(power plant)

20 Operational requirement on an I.C. engine21 Organizational structure


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INTRODUCTIONAs 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 applicationinvolving 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 asspecification various parts etc is about TATA LP/LPO 1512TC vehicle

manufactured by TELCO where quality is the watchword.


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RecommendationsFollowing 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 workshopWorkshop 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 originalstructure. In D/W BILASPUR there is about 50staff 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 40buses.

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 keepsevery 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.


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Safety GuidelinesTo 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

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.

4.Be serious about your work never including in horseplay or other foolishactivities to avoid injury to other.

5.Never put sharp objects like screw driver in your pockets otherwise you willcut yourself or get stabbed.

6.Always wear suitable clothes for the job otherwise serious injuries can becaused by sleeves or ties getting caught by the machine or full leathers shoes

with non skid rubber heel should be worn.

7.To provide good grip on tool or part always wipe excess oil and grease uphand tool as required.

8.To avoid slipping and falling to the ground due to spilt oil or grease or anyliquid clean up immediately the ground.

9.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.


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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 machininga piece of work held between two adjacent trees.

This device continued to develop through centuries and in the year 1797 HenryMaudslay, an Englishman, designed the first screw cutting lathe which is the

forerunner of the present day high speed, heavy duty production lathe, a machinetools 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 ofwork to give it the required shape and size. This is accomplished by holding thework 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 lathefamily 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 thespeed 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


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

speeds.

THE LATHE


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BORING MACHINES

INTRODUCTION:

The boring machine is one of the most versatile machine tool used to boreholes 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 ofspeeds and feeds provided to the various traversing components allow drilling,

milling and facing to be performed with equal facility. By the fitting of simpleattachments, the use of the machine can be extended still further to include screw

cutting, turning, planetary grinding, or gear cutting.

VERTICAL BORING MACHINE:


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ALTERNATOR

DESCRIPTION:

This 3 HA 15 Alternator is 12 poles 3 phase machine of revolvingfield 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 thediodes 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 : 12 volts

System : Negative earth

Maximum output : 40 amps

Maximum operating speed : 11500 rpm

Cut in speed : 1000 rpm

Regulator setting speed : 14.214.6 volts

(Nominal)

Stator connection : Star

Direction of rotation : Clock (viewed from pulley end)

Weight : 5.3 kg. (With vacuum pump, without

Pulley)


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DRY CLUTCH


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Minor engine repair: or engine servicingTo 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 servicesIn these services are include the lubrication, washing body and beingrepair of brakes tires, steering alignment etc these services are

necessary for efficient running and maintenance of automobile.

2.Performance servicesFor 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 causeof trouble experienced as well as the repair and parts required to replace. Inmodern engine, which are complicated and critical to restore normal

performance fully and accurately some extra operation in addition topersonal 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 wouldprovide 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


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starting missing king pin poor idling rough running as well as heavy fuel

consumption are the indication of loss in performance.

Engine services procedureBefore 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 byand 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 purposegenerally 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 thecause of troubles in engine parts such as:

a Manifoldsb Cylinder headc Cylinder blockd Piston and connecting rode Shaftf Sump or oil chamberg Turbo chargerh Sub assembly


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Fig. CRANK SHAFT

Cylinder head and cylinder block


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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 Degreasingii) De carbonizing


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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 anyaddition 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 Valveb Valve trainc Camshaftd Liftere Rocker armf Push rodg Valve springh Valve retaineri Rocker shaft

Piston:

A vertical wear on the thrust surface and slight looseness of the top ring ingroove is common wear visible and piston with the type of wear can be

reconditioned usually.


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Servicing the piston:

a) Ring grooves1 Compression ring2 Oil ringb)Skirtc) Piston pind)Cylinder walle) Piston assembly

Shaft and bearing:

a) Crank shaftb)Cam shaft CAM SHAFT

c) Bearingd)Cylinder blocke) Cylinder wallf) Main bearingg) Oil pumph)Water pumpi) Covers


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SPECIFICATIONS

Engine:

Model CUMMINS 6BT 5 9 TC

Type water cooled direct injection

Turbo charged diesel engine

Bore stroke 102/120 mm

No of cylinders 6

Max. Engine output 93.5 KW (125.3 HP) at 2500 rpm

Max. Torque 410 Nm (41.8 m/kg) at 1400-1700 rpm

Capacity 5883 cc

Compression ratio 17:6:1

Firing order 1-5-3-6-2-4

Weight of engine 413 kg

Air filter:

Type dry type remote mounted


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Fuel filter:

Type pre and fine filtration with water

Separator.

A fuel filteris afilter in the fuel line that screens out dirt andrustparticles from

the fuel, normally made into cartridges containing afilter paper.They are found inmostinternal combustion engines.
http://en.wikipedia.org/wiki/Filter_(chemistry)http://en.wikipedia.org/wiki/Rusthttp://en.wikipedia.org/wiki/Filter_paperhttp://en.wikipedia.org/wiki/Internal_combustion_enginehttp://en.wikipedia.org/wiki/Internal_combustion_enginehttp://en.wikipedia.org/wiki/Filter_paperhttp://en.wikipedia.org/wiki/Rusthttp://en.wikipedia.org/wiki/Filter_(chemistry)


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Oil filter:

Type full flow spin on paper type

An oil filteris afilter designed to remove contaminants fromengine

oil,transmission oil,lubricating oil,orhydraulic oil.Oil filters are used in manydifferent types ofhydraulic machinery.A chief use of the oil filter is ininternal-

combustion engines in on- and off-roadmotor vehicles,lightaircraft,and

variousnaval vessels. Other vehicle hydraulic systems, such as those inautomatictransmissions andpower steering,are often equipped with an oil filter.
http://en.wikipedia.org/wiki/Filtrationhttp://en.wikipedia.org/wiki/Engine_oilhttp://en.wikipedia.org/wiki/Engine_oilhttp://en.wikipedia.org/wiki/Automatic_transmission_fluidhttp://en.wikipedia.org/wiki/Lubricant#Mineral_oilhttp://en.wikipedia.org/wiki/Hydraulic_fluidhttp://en.wikipedia.org/wiki/Hydraulic_machineryhttp://en.wikipedia.org/wiki/Internal-combustion_enginehttp://en.wikipedia.org/wiki/Internal-combustion_enginehttp://en.wikipedia.org/wiki/Automobilehttp://en.wikipedia.org/wiki/Aircrafthttp://en.wikipedia.org/wiki/Navalhttp://en.wikipedia.org/wiki/Automatic_transmissionhttp://en.wikipedia.org/wiki/Automatic_transmissionhttp://en.wikipedia.org/wiki/Power_steeringhttp://en.wikipedia.org/wiki/Power_steeringhttp://en.wikipedia.org/wiki/Automatic_transmissionhttp://en.wikipedia.org/wiki/Automatic_transmissionhttp://en.wikipedia.org/wiki/Navalhttp://en.wikipedia.org/wiki/Aircrafthttp://en.wikipedia.org/wiki/Automobilehttp://en.wikipedia.org/wiki/Internal-combustion_enginehttp://en.wikipedia.org/wiki/Internal-combustion_enginehttp://en.wikipedia.org/wiki/Hydraulic_machineryhttp://en.wikipedia.org/wiki/Hydraulic_fluidhttp://en.wikipedia.org/wiki/Lubricant#Mineral_oilhttp://en.wikipedia.org/wiki/Automatic_transmission_fluidhttp://en.wikipedia.org/wiki/Engine_oilhttp://en.wikipedia.org/wiki/Engine_oilhttp://en.wikipedia.org/wiki/Filtration


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Fuel injection pump:

Type MICO A type inline

An Injection Pumpis the device that pumps fuel into the cylinders of adieselengine.Traditionally, the pump is driven indirectly from thecrankshaftby gears,

chains or a toothed belt (often thetiming belt) that also drives thecamshaft.It

rotates at half crankshaft speed in a conventionalfour-stroke engine.Its timing is

such that the fuel is injected only very slightly beforetop dead centre of thatcylinder's compression stroke. It is also common for the pump belt on gasoline

engines to be driven directly from the camshaft. In some systems injectionpressures 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 includecommon rail diesel systems and electronicunit direct

injection systems. These allow for higher pressures to be developed, and for muchfiner control of injection volumes compared to mechanical systems.
http://en.wikipedia.org/wiki/Diesel_enginehttp://en.wikipedia.org/wiki/Diesel_enginehttp://en.wikipedia.org/wiki/Crankshafthttp://en.wikipedia.org/wiki/Timing_belthttp://en.wikipedia.org/wiki/Camshafthttp://en.wikipedia.org/wiki/Four-stroke_enginehttp://en.wikipedia.org/wiki/Top_dead_centrehttp://en.wikipedia.org/wiki/Common_rail_dieselhttp://en.wikipedia.org/wiki/Unit_Injectorhttp://en.wikipedia.org/wiki/Unit_Injectorhttp://en.wikipedia.org/wiki/Unit_Injectorhttp://en.wikipedia.org/wiki/Unit_Injectorhttp://en.wikipedia.org/wiki/Common_rail_dieselhttp://en.wikipedia.org/wiki/Top_dead_centrehttp://en.wikipedia.org/wiki/Four-stroke_enginehttp://en.wikipedia.org/wiki/Camshafthttp://en.wikipedia.org/wiki/Timing_belthttp://en.wikipedia.org/wiki/Crankshafthttp://en.wikipedia.org/wiki/Diesel_enginehttp://en.wikipedia.org/wiki/Diesel_engine


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Turbo charger:

Type HOLSET

Cooling system:

Capacity 24 liters (total)

Coolant water and ethylene glycol ratio 1:1 premixed

Radiator frontal area 2887 sq cm


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Clutch:

Type single plate dry friction type

Outside diameter of clutch 310 mm

Lining

Friction area 1030 sq cm (approx)

Gear box:

Model GBS-40 synchromesh

No of gears 5 forward, 1 reverse

Gear ratio 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


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5.857:1(41/7) optional

Front axle:

Type heavy duty forged beam reverse Elliot

type

Steering:

Type manual steering standard

Steering gear box recalculating ball type

Ratio 34:2:1 for I.P 151

TC 59 wheelbase LPO 1512 TC

Brake:

Parking brake hand operated

Type spring actuated parking brake

Engine exhaust brake acting on rear wheels coupled with

Service brake

Frame:

Type ladder type heavy duty frame with

Riveted/bolted cross members

Channel section side members

Depth 223 mm (max)

Width 60 mm

Suspension:

Type semi elliptical leaf spring at front and

Rear


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Spring span front1450 mm

Rear1600 mm

Leaf width front70 mm

Rear80 mm

Shock absorber hydraulic double acting telescopic

Type at front and rear

Wheels and tyres:

Tyres 9.00 x 2014 PR

Wheel rims 7.00 x 20

No of wheels 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 24 volts

Alternator capacity 45 amps

Battery 2 x 12 v 180 Ah

Performance:

Max geared speed in top 87Km/h std.

Gear (with std. rear axle) 79Km/h for optional ratio of RA


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Max. Climbing ability in 16.2% standard

1stgear 18% optional ratio of RA

Main chassis dimension as per IS 9435 in mm:

Wheel base 3225 4225 5195 5895

Track front 1950 1950 1950 1950

Track rear 1809 1809 1809 1809

Overall length 5860 7380


(For 50% ROH)

Overall length 10325

(For 55% ROH)


(For 60% ROH)

Max width 2434 2434 2434 2434

Front overhang 1185 1185 1185 1185

Weight (KG):

For IPO 1512 TC 4725 5545

Wheelbase in mm

Bare chassis kern weight with 4190 4380

Cowl (with spare wheel & tools)

As per IS 9211 max permissible 4700 4700

FAW

Max permissible Ra AW 10160 10160

Max permissible GVW 14860 14860


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Filling capacity of aggregates:

Engine oil sump Max 14.3 liters

Min 12.30 liters

Gear box GBS-40 5.2 liters

Rear axle Ra-108 RR 7.5 liters

Steering gear housing 0.95 liters

Hydraulic clutch actuation system 0.21 liters

Cooling system 0.24 liters

Front hub grease per hub 450 gm

Rear hub grease per hub 450 gm

Water pump grease 80 gm

Maintenance schedule

Check:

Daily weekly (after 1000 km) after 9000 km

Engine oil level clutch pedal free play air intakesystem

Fuel level oil level in gear box air cleaner

Coolant level oil level in rear axle steering system

Fan brakes fluid level for clutch brake system

Drive belt power steering fluid level shocks absorber

Water trap in separator steering system clutch

Air tank house


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Brakes battery

Tyre pressure brakes system

Leakage of wheel nuts

Coolant fuel oil

Electrical system suspension bolts

After 18000km after 36000km after 72000km

Antifreeze concern. Drive belt tension vibration

Damper

Transmission system tension bearing battery

Brake system valve clearance

Body mountings fan hub

Rear axle crown wheel thrust pad

Wheel alignment brakes system

Electrical system

Wheel hub bearing play

Lubrication required at:

Linkage bushes pins wheel hubs

Change:

Front hubcap grease

Fuel filter

Gear box oil

Engine oil filter


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Over haul:

Clutch system

Power steering

Brake system

Suspension spring

Butterfly valve exhaust

Gear box

Maintenance procedure

DailyEngine oil level:

Before starting or at least 5 minutes after the engine is shutdown check the oil leveland 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 2.1 liters

Grade SAE 15W-40

Confirming to classification 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.


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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 orlongitudinal.

Water separator:

Lift the spring load valve as shown above and drain the water until clear fuel isvisible.

Caution:

Excessive draining will introduce and into the system causing the engine to be hardto start.

Draining condensed water:

Drain off condensed water from air tank (1) by operating drain valve.

Brakes:

Check for proper functioning of brakes.


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Tyre pressure:

Check and inflate the tyre in cold condition

Front tyre pressure 5.3 bar (75 psi)

Rear tyre pressure 6.0 bar (85 psi)

Leaks:

Check for leaks of water, air, fuel and oil at gaskets hose connections flexible pipesand 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 cylindercheck 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)


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Power steering fluid level:

Check oil level in the power steering tank with engine switched off just place thedipstick 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 caremust 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. Afterlifting 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 (non-

spigot 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 35mkg).

Lubricate linkage bushes and pins:

Lubricate oilcan brake chamber fork and pinball joins of exhaust brake linkage

clutch linkages pivots linkage of foot brake.


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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 aremore 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 thedamper. 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. Clutch master cylinder.2. Clutch fluid screw.3. Bleeding screw.4. Clutch sleeve cylinder.

Clutch system:

Dismantle clean inspect and reassemble clutch sleeve cylinder and master cylinder.

Replace damaged/worn out parts.


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Bleeding clutch system:

Remove the dust cap from slave cylinder bleed screw and attach the bleed tube tobleed 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 bleedscrew 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 210 cc

Grade SAEJ 1703 E/F

Steering oil and filter change:

Drain off hydraulic oil of power steering big loosing drain. Plug remove carrierand 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 ofdipstick.

Recommended oil:

Confirming to ATF-type-A

System capacity 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 addingoil 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.


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Brake system:

Front 18 mugs

Rear 20 mugs

Air brake chamber 10-13 mugs

Mounting bracket to rear axle 8 mugs

Camshaft bearing block 5 mugs

Spring:

Dismantle front and rear spring clean and apply graphite grease while reassemblinggrease 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 dismantledrive shaft. Reassemble and replace left hand nut and tighten it to specifiedtorque replace bearing if required.3 Check bearing on main shaft counter shaft and needle roller bearing on mainshaft for scoring/pitting mark replaces bearing needed roller bearing if

necessary.4 Adjust endplay of bearing on counter shaft main shaft and drive by selectingshims.5 Check backlash on speed gears it should be within 0.25 mm. inspect gearsreplace worn/scored/pitted gears.6 Refills the gearbox with recommended oil.

7 Test the gearbox for gear noise and smooth gear engagement.


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Inspection after every 3,20,000 km

Cooling system replacement:

Wait until temperature falls below 50 *C before draining. Drain the coolingsystem by opening the drain valve on the radiator and removing the plug at theinlet 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 prepareflushing 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 minuteswith the flushing mixture above 80*C. shut the engine off and drain the coolingsystem.

Fill the cooling system with clean water be sure to vent the engine forcomplete 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 duecooling 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 thecooling system.

Total system capacity 24 liters

Engine capacity 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 thenadd mixture to bring the level to the top install the pressure cap operate the lineengine 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 fillof coolant.


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Final drive:

The function of final drive is to provide a permanent speed reduction and to turnthe 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 hasa 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 beincorporated 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 adevice, which serves the above function, is called differential. To understand the

principle on which differential works consider figure. To the crown wheel of thefinal 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 toeach 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.
http://en.wikipedia.org/wiki/File:Differential_free.pnghttp://en.wikipedia.org/wiki/File:Differential_locked-2.pnghttp://en.wikipedia.org/wiki/File:Differential_free.pnghttp://en.wikipedia.org/wiki/File:Transmission_diagram.JPGhttp://en.wikipedia.org/wiki/File:Differential_free.pnghttp://en.wikipedia.org/wiki/File:Differential_locked-2.pnghttp://en.wikipedia.org/wiki/File:Differential_free.pnghttp://en.wikipedia.org/wiki/File:Transmission_diagram.JPGhttp://en.wikipedia.org/wiki/File:Differential_free.pnghttp://en.wikipedia.org/wiki/File:Differential_locked-2.pnghttp://en.wikipedia.org/wiki/File:Differential_free.pnghttp://en.wikipedia.org/wiki/File:Transmission_diagram.JPGhttp://en.wikipedia.org/wiki/File:Differential_free.pnghttp://en.wikipedia.org/wiki/File:Differential_locked-2.pnghttp://en.wikipedia.org/wiki/File:Differential_free.pnghttp://en.wikipedia.org/wiki/File:Transmission_diagram.JPG


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A)Input torque is applied to the ring gear (blue), which turns the entirecarrier (blue), providing torque to both side gears (red and yellow), whichin 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 thewheels into the heat energy which is dissipated into the atmosphere.

Requirements:

1. The brakes must be strong enough to stop the vehicle within minimumdistance in an emergency.

2. The brakes must have good anti fade characteristics.Types:

1. Mechanical brakes2. Hydraulic brakes3. Vacuum brakes4. Electric brakes5. 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 rearwheels in many cars, as parking or emergency brakes.
http://en.wikipedia.org/wiki/File:Differential_locked-2.png


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LINKAGES:

When the pedal is pressed, the brakes are applied. This simple linkage systemhowever 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 isused in two steps. The final drive in practice consists of a bevel pinion and crownwheel or alternatively worm and wheel arrangement. The bevel pinion is mounted

on a shaft, which is connected to the propeller shaft generally through a universaljoint. 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 canbe 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 brakechambers 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. Unloaded valve2. Brake valve3. Hand control valve4. Brake chamber5. Chamber air brake


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STRAIGHT BEVEL GEARS:

These contain the straight bevel gears at one instant only one pair of teeth of pinionand 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 theteeth 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 rightangles 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, pitchdiameter 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 byabout 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 startstimes 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 andvery strong derive.


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Automobile shop equipmentA 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. Screw driver2. Spanners, wrenches etc.3. Pliers4. Hammer5. Chisel6. Files7. Hacksaw8. Drilling Machine9. 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


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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

summar training report hrtc training report

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