2. ACKNOWLEDGMENT
No Endeavour can be successful without the active cooperation of the people
concerned 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 guidance of Workshop
Manager.
I am extremely 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
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 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
theworking of every worker they told to the worker.
6. BASIC INFORMATION ABOUT H.R.T.C.
1) 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.
2)STATASTICS OF H.R.T.C
7. SAFETY GUIDELINES
To avoid accidents & to keep them from happening following safety guidance
should be allowed.
1. Provide your attention at most to the job & work quietly.
2. Keep the tools with in your convenient reach. Arrange neatly without
scattering them around.
3. 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.
4. Be serious about your never including in horseplay or other foolish activities
to avoid injury to other.
5. 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.
6. 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 either with nonskid rubber heel & shoe or steel to safety shoe
should be worn.
7. To provide good grip on tool or part always wipe excess oil and grease up fly
our hand tool.
8. To avoid one sleeping and falling to the ground due to split of oil grease or
any liquid clean up immediately Compressed air should, never be used to
below dust from your clothes. Compressed a hose should never be pointed to
any person because fling particles may harm him.
8. 9. Wheel welding and grinding always water out for flying speak which can set
your clothes on fire.
10. To hold the bus safety & work under it safety always us bus stand and jack
it up properly
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 – HIM-TARANG
➢ Ultra-Luxury Air Conditioned Buses (HIMSUTA)
HRTC is operating Ultra Luxury AC Buses (Volvo & its equivalent) from Delhi
to Shimla, Manali and Dharamshala vice versa. Theses buses are equipped with
latest and comfortable facilities to the passengers.
10. ➢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.
➢Semi Deluxe Buses
HRTC is operating non AC Deluxe Buses (2X3) to and from Kangra from
Shimla, Manali, Dharamsala and Palampur. Theses buses are equipped with
Non Luxury Push Back Seats.
11. ➢Ordinary Buses
Ordinary Buses (2X3) are equipped with latest comfortable hi-tech seats.
These buses are aplied on long and intra-state routes on ordinary fare to
provide the passengers economic comfortable journey.
➢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”.
12. An engine is mechanical device which converts one form of energy into other or
It is a power producing device or machine which converts chemical energy of
fuel into heat energy and then into mechanical work
A Typical engine of Tata 1510 TC
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
13. 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
15. Dampers
16. Manifolds (inlet and outlet)
17. Valves (inlet valve and outlet valve)
18. Connecting rod
19. Timing housing plate
14. ➢ 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.
15. 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.
16. 3. PISTON – CONNECTING ROD 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.
17. 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.
18. 5.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.
6.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 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.
19. ➢ 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
20. ➢ 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.
21. ➢ 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.
✓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. Camshaft grinding.
4. Inspection of water gasket sand oil, galleried.
5. Checking the valve mechanism.
6. Gasket and lubricating oil are changed after over hauling.
7. Inspection and replacing of the bearing. Rings are settled with the help of
piston ring compressor.
8. Piston rings expands in used for removing ring form pistons.
22. ❖ 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 output 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.
➢The Gear Box are of two types:-
➢ Constant mesh Gear box
➢ Synchromesh Gear Box
23. 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.
✓ 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:
1) 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.
2) Gear box provides a reverse gear for driving the vehicle in reverse direction
24. ❖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.
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.
25. ❖ FOR DISMANTLING OF THE GEAR BOX
FOLLOWING TOOLS ARE USED:-
1) Hammer
2) Chisel
3) Tommy bar
4) Open end spanner
5) Extension rod
6) Iron stick
7) Socket set
8) Ring Spanner
9) Nose pliers
10) Speed handle
All of the above tools are used for the dismantling and assembly of the gear box.
26. ✓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
27. ➢ 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
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
28. 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
29. ✓ G.B.S. 40 INSPECTION SHEET
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
➢ Primary shaft
➢ Main shaft
➢ 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. Idle or reverse shaft.
30. ➢ 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.
31. ❖ 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.
32. ➢ 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.
33. ❖ 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) Hydraulic Power Steering
2) Electric Power Steering
3) Hybrid Power Steering
• 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.
34. ✓ 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.
35. ✓ 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”
36. ✓ BIBLIOGRAPHY
❖ REFERENCES
➢www.google.co.in
➢ www.himachal.nic.in/hrtc
AUTOMOBILE ENGINEERING (VOL – 1,2) BY KIRPAL SINGH
Under the Guidance of:-
• RAVI SHAKYAN (Class In-charge)
• Vanita verma (Workshop Manager)
• Mr. Raj Kumar(Head Mechanic)
• Mr. Moti Sharma (Supervisor)
