presention indusrtial report

1. HIMACHAL ROAD TRANSPORT
COPORATION TARADEVI
SHIMLA (H.P)
AKSHAY KUMAR SUMBIT TO – HOD OF AUTOMOBILE DEPTT.
SR.NO – 21
I/R NO – 358/19(L)
AUTOMOBILE 5TH SEMESTER

2. ACKNOWLEDGMENT
No Endeavour can be successful without the active cooperation of the people concemed with it,
Which was fourth in full during this study. It is extremely difficult to find words which can do justice
to this sort of cooperation.
I am deeply indebted to Mr. PAWAN KUMAR SHARMA (Regional Manager) H.R.T.C WORKSHOP
TARADEVI (SHIMLA) Who allowed me feel lucky to complete my training under the Table and
competent guildance of Workshop Manager.
I am extermely grateful faculty members for their whole hearted co-operation.
I extend my deepest gratitude to all those persons who supported me all through my training . My
interaction with all these people has left a long lasting impression in my mind that will influence
my project and my behavior for all times to come.
Akshay Kumar
5th Semester
Automobile engineering
190720602001

3. INDEX
S.No. CONTENT
1. Introduction
2. Basic information about
H.R.T.C
3. About H.R.T.C. workshop
Taradevi (Shimla)
4. Safety guidelines
5. Bus type
6. Engine
7. Main parts of engine
8. Gearbox
9. steering system
10. Conclusion
11. Bibliography

4. INTRODUCTION
This training is done at H.R.T.C. Workshop which comes under TARADEVI- SHIMLA (HP)
Division. This Workshop is undertaking the work of repair of H.R.T.C. Ordinary, Semi
Deluxe and Deluxe buses, Ultra Luxury Air Conditioned Buses (HIMSUTA) and Electrical buses (Him-
Trang). These divisional Workshops undertake the major repair work of buses of Units falling under the
respective division.
This industrial training is described under syllabus and required for experience and practical
knowledge. We had studied all kinds of the theoretical things about Clutches, Brakes,
Engine, Gear Box, Fuel Injection Pump and all the things related to our “Automobile Branch”.
In this workshop the Fabrication of Buses is done on Chassis which are brought from there
respective Motor Company. Here different departments were also made fort here pair and
maintenance purposes. Here during this training I have seen all things and done practically
which has helped to in rich my knowledge greatly. This project report is all what I have seen
in the H.R.T.C. workshop and done practically with my hands. I am really thankful to all
staff members of the H.R.T.C. and the workers with whose helpful nature and guidance
 I completed my Industrial training and Project Report.

5. ABOUT H.R.T.C. WORKSHOP TARADEVI
 Workshop is a place where repair a change of the parts of the vehicles is done or in other
 words it is place where theory or changes practically to the original structure. The
 corporate office at Shimla controls 4 divisional offices located at Shimla, Mandi, Hamirpur
 and Dharamshala. These 4 divisions control 23 regional offices under them. Shimla
 division has 11 regions in it. These regions are Nahan, solan, Rampur, Rohru, Taradevi, Shimla
Local, Shimla Rural, Recongpeo, karsog, Nerwa.
 Taradevi consist of 2 workshops, one is divisional workshop and other is regional
 workshop. In H.R.T.C. workshop Taradevi there are about 115 staff members. The others are
 related to the clerical staff or other officers such as R.M., D.M. and workshop manager.
 There are about 160 buses run under Taradevi division. Assemblies like engine, gearbox,
 steering box etc. are overhauled. There is big store in the workshop in which every part in
 it place use catalogue to give a part to the workshop manager and head mechanic check the
 working of every worker they told to the worker.

6. BASIC INFORMATION ABOUT
H.R.T.C.
 a) ORGANISATIONAL STRUCTURE
Himachal road Transport Corporation is held by the Board of Directors with Transport
Minister as the Chairman. Managing Director is the Chief Executive of the corporation.
Himachal Road Transport Corporation has three tier structures. The corporate office at
Shimla controls 4 Divisional offices located at Shimla, Mandi, Hamirpur and
Dharamshala. These four divisions control 23 Regional offices under them.
SHIMLA
NAHAN, SOLAN, RAMPUR,
ROHRU, TARADEVI, SHIMLA
LOCAL, SHIMLA RURAL,
RECONGPEO, KARSOG, NERWA

7. b) STATASTICS OF H.R.T.C.
PARTICULARS
STATUS ON
2.10.1974
STATUS ON
2021
Number of buses 733 3,880
Number of routes 379 2,573
Annual coverage 3.03 Lakhs
KMs
180.82 Lakhs
Number of divisions NILL 4

8. SAFETY GUIDELINES
To avoid accidents & to keep them from happening following safety
guidance should be allowed.
• Provide your attention at most to the job & work quietly.
• Keep the tools with in your convenient reach. Arrange neatly without scattering
them around.
• Always keep jack handles pointing up to avoid tripping up to. When creepers are
not in use stand than against the wall to avoid stumbling over then.
• Be serious about your never including in horseplay or other foolish activities to
avoid injury to other.
• Never put sharp objects like screwdriver in your pocket otherwise you will cut
yourself or get stabled or ruin the up hot slay of a vehicle.
• Always wear suitable clothes for the job serious injuries are liable be caused by
cleaning sleeve or lies getting caught the machining sandals or open to be worn full
eather with non skid rubber heel & shoe or steel to safety shoe should be worn.
• To provide good grip on tool or part always wipe excess oil and grease up fly our
hand tool.

9. BUSTYPES
 HRTC is operating four types of buses:-
 1. Ultra luxury AC Buses – HIMSUTA
 2. Luxury AC Buses - HIMGAURAV
 3. Semi Deluxe Buses
 4. Ordinary Buses
 5. Electric Buses - HIMTARANG

10. Ultra Luxury Air Conditioned Buses
(HIMSUTA)
 HRTC is operating Ultra Luxury AC Buses (Volvo &its equivalent)from
 Delhi to Shimla, Manali and Dharamsala vice versa. Theses buses are
equipped
 with latest and comfortable facilities to the passengers.

11. Luxury AC Buses (HIMGAURAV)
HRTC is operating Luxury AC Buses (2X2) to and fro Delhi
from Shimla, Manali,
Dharamshala and Palampur. These buses are equipped
with Luxury Push Back Seats.

12. Semi Deluxe Buses
 HRTC is operating non AC Deluxe Buses (2X2) to and
fro Delhi from Shimla,
 Manali, Dharamsala and Palampur. Theses buses are
equipped with Luxury Push
 Back Seats.

13. Ordinary Buses
 Ordinary Buses (2X3) are equipped with latest comfortable
hi-tech seats. These buses areplied on long and intra-state
routes on ordinary fare to provide the passengers economic
comfortable journey.

14. ELECTRIC BUSES (HIMTARANG)
 Himachal Pradesh Transport Corporation has done something
really unique in its initiative to save the nature in the state. It
runs a zero emission all-electric bus regularly at an altitude of
more than 13,000 feet. Christened as ‘Him Tarang’

15. ENGINE
 An engine is mechanical device which converts one form of energy into other
or It is a powerproducing device or machine which converts chemical energy
of fuel into heat energy and then into mechanical work.
A typical engine of Tata 1510 TC

16. The power system of an automobile is the engine.it is the heart of the automobile.
In the power system, an assembly of the large number of parts is used to do work
and make transfer of energy. This energy is stored in the flywheel connected to
the crankshaft. The flywheel connected to the crankshaft. The flywheel transmits
this energy to wheels through the transmission system.in this way the power i.e.
the engine sets the vehicle in motion.
Main parts of engine:-
1. Cylinder block
2. Cylinder head
3. Pistons
4. Turbo charger
5. Crankshaft
6. Camshaft
7. Rocker arm
8. Flywheel
9. Fuel injection pump
10. Injector nozzle
11. Thermostat
12. Radiator
13. Oil sump
14. Fuel filter

17. DETAILS OF PARTS AND THEIR FUNCTIONS:-
DETAILS OF PARTS AND THEIR FUNCTIONS:-
1. Cylinder block:-
Cylinder block of a diesel engine
The main body of the engine to which the piston cylinders are attached
and which contains the crankshaft and crankshaft bearing is called bearing
is called crankcase and cylinder block. This member also hold other parts in
alignment and resist the explosion and inertia force.it also protect the parts
from the dirt etc. and serves as part of lubrication system.

18. 2. Cylinder head:
A typical cylinder head of diesel engine
Attached or made integral part of crank case. The cylinder is either integral
part or linear inserted in which the piston reciprocates to develop power.it
withstand a very high pressure and temperature due to direct combustion.
For the water cooled engine water jackets i.e. Hollow spaces are provided for
the water circulation .it is made of cast iron.

19. 3. PISTON ASSEMBLY
Piston and connecting rod
assembly
Piston assembly consists of a piston, piston rings and piston pin known as gudgeon pin.
Functions of piston assembly are given below:
It transmits gas force generated during combustion to the connecting rod and crankshaft.
As piston is connected to small end of the connecting rod with the help of gudgeon pin. It
guides the connecting rod when gas force is transmitted. Air/fuel mixture is compressed
by piston. Piston rings restrict the flow of hot gases into the crankcase. This is also
referred as blow by control . Piston rings lubricate the cylinder wall. Piston rings restrict
the amount of oil from crankcase into the gap between piston and cylinder head. Heat is
transferred to the cylinder wall from piston by piston rings.

20. 4. Turbo charger:-
Basically it is an air compressor which is used to supply air to the inlet
manifold at higher content. By this complete combustion of the fuel in the
combustion chamber take place. Turbo charger is now used in vehicle.it is
attached to the exhaust gases are carried out by exhaust manifold. We
can use this exhaust gases and also minimize the exhaust gases and
used it for power supply. There are two turbines in turbo charger which
are connecting each other with the shaft. The exhaust gases went into
the turbine, rotate it and produced power.

21. 5. Crankshaft:-
The crank shaft is said to be backbone of the engine.it receives
oscillation motion from the connection rod and gives to the main shaft
a rotatory motion. It also drives the camshaft which in turn operates
the values of the engine.it is made up of forged steel.

22. 6. Cam shaft:-
A camshaft is a shaft with the cam for each intake and exhaust valve.
Each cam has high spot called cam bob which control the valve
opening. It rotates half of the camshaft. One four stroke cycle is
complete in two revolution of the crank shaft each cam must open and
close the inlet and exhaust valve once every two revolution of the
crankshaft.

23. 7. Flywheel:
A flywheel is an electromechanical device that couples a motor generator with a
rotating mass to store for short duration. Conventional flywheel are “charged”
and “discharged” via an integral motor/generator. The motor /generator draws
provided by the grid to spin the rotor of the flywheel. During the power outage,
voltage sag, or other disturbance t e motor/generator provides power. The kinetic
energy stored is transformed to dc electric energy by generator, and the energy
is delivered at constant frequency and voltage through an inverter and controls
system. Traditional flywheel rotors are usually constructed of steel and are
limited to a spin rate of few thousand revolutions per minute.

24. PROCUDRE FOR DISMANTLING OF
ENGINE:
Following is the procedure for the dismantling of the engine:
I. First of all caps are removed from the each valve with the help of
spanner.
II. After this all the valve springs are removed with the help of valve spring
remover and all the cotters are removed. These can also remove with the
help of striking hammer on the top of the valve springs.
III. The nozzles are removed from the cylinder head.
IV. The fuel injection pump is removed from the engine.
V. The oil cooler is removed by means of unscrewing the bolts and nuts.
VI. Cylinder head is removed from the engine with this all the rocker arms
are also removed.
VII. After this the pistons are removed by opening the bearing from the
crankshaft with the connecting rod and camshaft is removed.
VIII. At the end the crankshaft is removed from the cylinder block.
IX. After this all the parts of engine are washed with the help of diesel.

25. PROCEDURE FOR ASSEMBLY OF ENGINE:
Following is the procedure for the assembly of the engine.
I. First of all the engine cylinder is kept on the table.
II. The cylinder boxes are checked with the help of dial gauge according to the given specifications.
III. After this the crankshaft bearings are checked with the help of dial gauge.
IV. The crankshaft is fixed in the crankshaft bearing in the center of the main bearing the thrust washer is
fixed.
V. After this the pistons are inserted into the cylinders of the engine and the connecting rod is connected to
the piston with the help of piston pin and the crankshaft is connected to the Big end bearing of the
connecting rod.
VI. After this the water plate is connected to the engine.
VII. After this the flywheel is connected to the crankshaft and clutch plate is also adjusted in to the engine.
VIII. After this the camshaft is connected to the engine and the air compressed piston is connected with the
camshaft.
IX. Camshaft is closed from both end and the gears are connected with the crankshaft and camshaft and the
timing is adjusted.
X. At the other side the two pulley are there by means of belts.
XI. The cylinder head is kept over the cylinder block by inserting the nozzles and valves and rockers arms
into the cylinder head.
XII. The fuel injection pump is connected to the engine and the oil cooling plate is inserted into the engine.
XIII. The injectors from the fuel injection pump is connected to the each nozzles by mean of fuel pipe.
XIV. At the end the engine is tested in the engine testing machine.

26. DEFECTS:
I. Breakage in the crankshaft.
II. Breakage of gear teeth.
III. Worn in the piston.
IV. Breakage of piston Rings.
V. Corrosion in the cylinders.
VI. Breakage of the connecting rods end bearings.

27. INSPECTION OF VARIOUS PARTS OF
ENGINE:
1. Inspection of the cylinder boring honing of the cylinder bore gone oval in
shop inserting the cylinder liner or sleeve.
2. Inspection of the piston changing of piston if necessary.
3. Crankshaft grinding.
4. Camshaft grinding.
5. Inspection of water gasket sand oil, galleried.
6. Checking the valve mechanism.
7. Gasket and lubricating oil are changed after over hauling.
8. Inspection and replacing of the bearing.
9. Rings are settled with the help of piston ring compressor.
10. Piston rings expands in used for removing ring form pistons.

28. GEARBOX
A gearbox is used to alternate the rotational speed and torque that the engine
delivers to the drive wheels of a vehicle. It uses different gear ratios to achieve it.
The synchronizer’s job is to bring the next gear ratio (up shift or down shift) up to
speed so that out put shaft and the gears are at the same speed to allow for a
smooth gear change. Earlier, when ”synchronizers" were not used one had to
double-clutch for allowing gear shift on the go. At every gear shift one had to press
and release the clutch twice, hence the name "double clutching." It was an art to
avoid gear clashing. Modern automobile Blocker Ring Synchronizers in order to
avoid the need for double clutching.

29. The Gear Box are of two types:-
 Constant mesh Gear box
 Synchromesh Gear Box
Constant mesh gear box is not used in the present vehicles only
the synchromesh gear box is used. This is used in every vehicle,
because of the following:
 Easy to operate
 There is no wear and tear in the gear box or gears.
 Because of the synchromesh the gear shifting is easy.
After this they told us about the complete parts of the gear box
when they are working over there we also done the dismantling and
assembly of the gear box.

30. Function of Gear Box:
An automobile is able to provide varying speed and torque
through its gear box. Various functions of a gear box are listed
below:
(a) To provide high torque at the time of starting, vehicle
acceleration, climbing up a hill.
(b) To provide more than forward speeds by providing more than
one gear ratios. In modern cars, five forward gears and reverse
gear is provided. For given engine speed, higher speed can be
obtained by running in higher (4th and 5th) gears.
(c) Gear box provides a reverse gear for driving the vehicle in
reverse direction.

31. Component of Synchromesh gear
box:
1. Gear Box housing: This is the body in which all the component of
gear box are assembled. It consist of two plug, one is for OIL LEVEL PLUG
and second is for OIL DRAIN PLUG.
2. Main Shaft: Shaft on which all gear are mounted. Gear shifting sleeve are
also mounted on it. Small groove are present on main shaft.
3. Lay Shaft: Lay shaft consist of gear which are always in mesh with the
gears which is on main shaft.
4. Gears: Different gear are present on shaft which having different number
of teeth. Constant gear take power from clutch and transmit to lay shaft.
5. Gear Shifting sleeve: These are mounted on main shaft. It one for two
gears. It has teeth on inner side.

32. 6. Gear Shifting Fork: These are attached on gear box and fork are
assemble on sleeve.
7. Covering finger: It is used to change gear.
8. Synchronizer: It has teeth on outer side which come in contact with
inner teeth of sleeve. And also it has friction material which initially come in
contact with gear so that it can gain speed before assemble with it. It also
eliminate the problem of double declutching.

33. FOR DISMANTLING OF THE GEAR
BOX FOLLOWING TOOLS ARE USED:-
 Hammer
 Chisel
 Tommy bar
 Open end spanner
 Extension rod
 Iron stick
 Socket set
 Ring Spanner
 Nose pliers
 Speed handle
All of the above tools are used for the dismantling and assembly of the gear box.

34. SYNCHROMESH GEAR BOX PARTS:-
1. Gear Box Housing
2. Counter Shaft or lay shaft Assembly
 Constant mesh Gear (38 teethes)
It always attached with primary shaft.
 4th on countershaft
It is of two types.
28 teeth +4th on main shaft (20 teethes)
29 teeth +4th on main shaft (19 teethes)
3. Twin Gear:
It is of two types
 Groove type
 Without grove
4. 2nd Gear on counter shaft (32 teethes)
5. 1st Gear + Ideal gear
6. Reverse Gear:-
 Anti-clockwise rotation
 Backward

35. BEARINGS:-
The number of bearing that are used in the gear box assembly Therefore, total
seven bearing are used in the gear box assembly.
The bearing are used to bear the gear load and to abstract the play between the
gears and the components.
COLLAR BUSH:-Collar bush is only inserted between first and third gear.
OIL RETAINER:-In oil retainer an oil seal is fixed to overcome the leakage
problem in the gear box. It prevents the Lubricating oil from leakage.
HUB: Hub is placed in the second and fourth gear.
SYNCHRONIZING CONE:-Synchronizing cone is used to meshing the speed of the
different gears at different instant. It is made of the brass material. The numbers of
synchronizing cone used are five

36. SLEEVE:-
Sleeve is the part used over the synchronizing cone. It is used for shifting the gear. Over the
sleeve fork is used, when the gear lever is operated the fork changes its position to the required
stage and sleeve lock the gear, which is used to drive the vehicle. Sleeves are used in the gear
box assembly are there. These are one for every two gears.
e.g. For 1st and reverse For 2nd and reverse 3rd for 4TH and 5TH
BUTT RING:-
Buttering is used to lock the main shaft. It is also used to check the play between the gears.
CARRIERS:
Carriers are used to lock the gear in the main shaft. These are different in structure. In these
the springs are inserted with the pins two types are used.
Round shaped for revers
Square shaped for 1st, 2nd, 3rd, 4th. These are used for the adjusting the sleeves.
FORK & FORK HANDLE:-
Forks is used to change the gears at the different instant with the help of gear lever.
These are of four types.
1st gear fork 2nd and 3rd gear box 4th and 5th gear box
Reverse gear fork

37. 1. Axial flow of drive shaft between four points’ bass bearing and front housing cover.
2. Axial play of main shaft four point’s ball bearing and rear housing cover.
3. Axial play of countershaft measured on rear housing cover.
4. Play between snap ring and clay roller bearing grove.
5. Distance from face of countershaft gear to housing front face.
6. Axial play on gears in assembled conditions on main shaft.
DISASSEMBLY OF GEAR BOX:-
(A) Gear box housing
(B) Coupling plunger
(C) Shifting fork
(D) Shaft
(E) Shifting sleeve
o Primary shaft
o Main shaft
o Counter shaft
Counter shaft has one fixed gear, if the counter shaft has small gear than main shaft in its
opposite mashes its big gear. Arrangement of counter shaft and main shaft there is a lock nut
between the counter shaft and main shaft first of all we can remove it and opens the shaft. o
Idle or reverse shaft
G.B.S. 40 INSPECTION SHEET

38. DISASSEMBLY OF A GEAR BOX IN
BRIEF:-
1. First of all gear box cover is removed with the help of socket and tommy rod.
2. After that oil retainer is removed with the help of spanner.
3. Now with the help of Iron stick lock is matched on the main shaft and then light
blow of hammer is strike and on the main shaft and gear is removed before this butt
ring is removed with the help of chisel and hammer.
4. When gear box cover is removed then fork is removed.
5. After that counter shaft is removed with the help of rod and hammer.
6. Then idle gear pin is removed with the help of hammer.
ASSEMBLY OF GEAR BOX:-
After dismantling the gear box first the gear box is washed with
the help of diesel and other component are also wash with it.
Then with the help of pressured water all the component and
gear box is washed for complete cleaning Jan is fixed in the gear
box cover and great is also used to prevent the leakage of oil.
Five liter of lubricating oil is pour in the gear box.

39. DEFAULTS
1. Gears teeth broken
2. Play between gear components
3. Bearing is not smooth running
4. The teeth of fork is broken
5. Components of gear shift mechanism may be worn or
damaged.
6. Counter shaft gear may be worn out.
7. Miss Alignment of counter shat and main shaft gears.
8. The main shaft gears may be tight or splines.
9. The darn plug may be loose or damaged.
10. Damaged or even missing gasket.

40. STEERING
Steering is a system of components, linkages, etc. which allows any
vehicle to follow the desired course. An exception is the case of rail
transport by which rail tracks combined together with railroad
switches provide the steering function
STEERING MECHANISM
The steering mechanism allows the driver to control the direction of
vehicle travel. This is made possible by linkage that connects the
steering wheel to the steerable wheels and tires. The steering
system may be either manual or power. The only energy source for
the steering system is the force the driver applies to the steering
wheel, the vehicle has manual steering. Power steering uses a
hydraulic pump or electric motor to assist the driver`s effort.

41. Power steering
Power steering meaning: The steering system of a vehicle is one of its key
components. In a hydraulic power steering system, the effort required to turn
the wheel of a vehicle by the rotation of the steering wheel is reduced with the
help of hydraulic assistance
TYPES OF POWER STEERING
1. Hrauydlic Power Steering
2. Electric Power Steering
3. Hybrid Power Steering

42. Hydraulic Power Steering
hydraulic power steering system, the effort required to turn the wheel of a
vehicle by the rotation of the steering wheel is reduced with the help of
hydraulic assistance. When the steering wheel is turned, a hydraulic pump,
which draws power from the vehicle’s engine, starts to pump hydraulic
fluid through the system’s lines. This high-pressure hydraulic fluid then
enters a cylinder and exerts force on the cylinder piston. This piston then
pushes the hydraulic fluid ahead of it through the system’s lines, which in
turn exerts pressure on the rack and pinion, coupling arrangement,
multiplying the input force several times and resulting in the rotation of
the vehicle’s front wheels.

43. Steering Pump
you can find the steering pump attached to the car engine, usually right next to the car
alternator and A/C compressor. We connect the steering pump to the engine through a
belt-pulley mechanisms using an engine belt. When the your car’s engine is running,
the engine belt turns in a loop and that also turns the steering pump. With that, the
pump pulls the steering fluid from the steering fluid reservoir and pressurizes them.
How exactly do they do that? Well, I don’t want to overwhelm you with all the tiny
details, but if you are interested in knowing more, we have an article on the steering
pump coming up very soon. For now, think of the steering pump as a black box. We put
low pressure steering fluid in, and high pressure steering fluid comes out of the other
end. Steering pump for hydraulic power steering system. Steering pump for hydraulic
power steering system. These high pressure steering fluid then leaves the steering
pump, through the steering hoses and into the steering rack, specifically into the rotary
valve.

44. CONCLUSION
Industrial training is the way for us to get the practical knowledge of the
entire theoretical concept studied in college session. In college workshop
we are not able to give proper time for practical work as in industrial
training. So as a Automobile Engineering student I think this training is
very useful for us and we learn enough things in the training period and
our knowledge level will be increased.
We enjoy the training and maintain discipline in workshop and the entire
mechanics are impressed with our attitude and sense of learning and they
give us best wishes for our future and say that you must be hard work as
an engineering student to make your future bright. So, at last I would like
to thanks once again to all workshop members, work manager of “H.R.T.C
D/W WORKSHOP TARADEVI SHIMLA – 10” and HOD
of Automobile Engineering of “GP SUNDERNAGAR”

45. BIBLIOGRAPHY
1. www.google.co.in
2. www.himachal.nic.in/hrtc
3. AUTOMOBILE ENGINEERING (VOL – 1,2) BY KIRPAL SINGH
Under the Guidance of:-
1. RAVI SHAKYAN (Class In-charge)
2. Workshop Manager Vanita verma
3. Mr. Raj Kumar(Head Mechanic)
4. Mr. Moti Sharma (Supervisor)

46. THANK – YOU !