PROJECT REPORTON

INDUSTRIAL TRAININGAT

PATEL-L&T CONSORTIUM

Submitted by :- NITISH KUMARCLASS ROLL NO.:- 7104013BOARD ROLL NO.:-10051100225Auto Engg.(5th sem.)

Submitted To:- ER. VIVEK GUPTA H.O.D (AE)

ACKNOWLEDGEMENT

Creating something new requires inspirations and these inspirations and this

inspiration has some hidden forces which motivate to achieve the objective. Completion of any

project requires combined efforts of many people. We would like to express our sincere thanks to

all those, whose unending support helped us to perform our CONSTRUCTION SKILLS,

REPARING & MAINTENANCE OF CONSTRUCTION EQUIPMENT named “PARBATI

HEP PROJECT SAINJ KULLU”.

We would like to place our deepest our sense of gratitude to Er. VIVEK GUPTA

(H.O.D AUTOMOBILE) for providing necessary Infrastructure and Environment. We would

specially like to mention Er. BRIJ BHUSHAN for his unending help and taking pain to provide

answers to our queries. We would like to thankful to our teacher who gives extra time in the lab

for the completion of the objective, they provide us necessary and helpful material related to our

project.

We are greatly indebted to all the officials of the AUTOMOBILE Department for their

cooperation and timely help in one or the other way. At the last but least we would like to say

thanks to all our friends for their co-operations and help they provided in accomplishment of the

undertaken project.

INDEX

Basic requirement of engine services

Engine service procedure

Specification

Maintenance schedule

Engine section

Gearing and gear box

Power steering section

Fuel injection pump

Self starter

Brakes

Automobile shop equipment

Maintenance procedures

SAFETY GUIDELINES

To avoid at to keep then happening following safety guidelines be allowed.

1. Provide your attention at most to the job and work quietly.

2. Keep the tool with in your convenient reach under your control arrange neatly without

scattering then around and out of the way.

3. Always keep jack handles pointing up to avoid tripping up to when creepers are not in

use stand then against the wall to avoid stumbling over them.

4. Be serious about your work never including in horseplay or other foolish activities to

avoid injury to other.

5. Never put sharp objects like screw driver in your pocket otherwise you will cut yourself

of get stabled.

6. Always wear suitable clothes for he job serious injuries are liable be caused by cleaning

sleeve.

7. To provide good grip on tool or part always wipe excess oil- and grease up fly our hand

tool.

8. To avoid one slipping and falling to the ground due to split oil or grease or any liquid

clean up immediately.

9. Compressed air should never be used to below dust from your clothes compressed a hose

should never be pointed to any poison because living panicles or chips may harm him.

10. While welding and grinding always water out for living speak when con set your clothes

on fire.

BASIC REQUIREMENT OF ENGINE SERVICES

The basic requirement of engine services is to find our the following information-

To determine what is wrong in the engine

To find exactly as to what type of services is required for correcting the fault and restoring the

normal performance economy.

A full and proper test of engine is necessary for establishing the exact cause of trouble

experienced as well as the repair and parts required to replace. In modern engine, which are

complicated and critical to restore normal performance fully and accurately some extra operation

in addition to personal skill and experience is required for testing the engine with in economic

limits of time and corrective service required.

It will be seen that when the motor vehicle has been properly run it would new

performance of the reconditioning it is due to fact that original setting limit 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 likes of power,

poor acceleration, hard starting, missing pin king poor idling, rough running as well as heavy

fuel consumption are the indication of loss in performance.

SEGINE SERVICE PROCEDURE

Before servicing an automobile engine its necessary to determine the cause of the trouble in the

engine. This is done by observing the symptoms produced by and indicated in the instrumental

check visual examination sound produced by the engine and this sound of the engine emission

the analysis of the symptoms of troubles and trouble shooting charts are very helpful for this

purpose generally these are two types-

1. Internal troubles.

2. External troubles.

The engine servicing procedure involves these following steps:-

Engine disassembly: - the dismantling and removing is done for finding the cause of

troubles in engine parts such as:-

i. Manifolds.

ii. Cylinder head.

iii. Cylinder block.

iv. Piston and connecting rod.

v. Shaft.

vi. Sump or oil chamber.

vii. Turbo charger.

viii. Sub assembly.

Cleaning of parts: - part disassembles and in repair condition should be cleaned these are

in general two types of cleaning done on engine-

i. Digressing.

ii. De carbonizing.

Inspection of parts:-inspection of parts is very necessary for fine working of an engine. Inspection of parts should be done carefully in common there are two types of inspection mentioned as below:-

a) Visual inspection: - from visual inspection we mean that inspection of any crack or any addition to part. if part is faulty another one should replace it.

b) Dimensional inspection:- it is meant for the inspection of dimension of a part. It should be checked.

4. Conditon of engine parts:- condition should be remembered and thy should be in working . some conditions are such as:

A. valve

B. valve train

Camshaft

Lifters

Rocker arm

Push rod

Valve spring

Valve retainer and locks

Rocker shaft

5. Piston:- a vertical wear on the thrust surface and slight looseness of the top ring in groove is common wear visible andPiston with this type of wear can be reconditioned usually.

Piston6. Servicing the piston :-

1. Ring grooves

a. Compression Ringb. Oil Ring.

2. Skirt.

3. Piston Pin.

4. Cylinder Wall.

5. Piston Assembly.

Piston ring

7. Shaft and bearing :-

A. Crankshaft.

B. Camshaft.

C. Bearing

D. Cylinder block.

Shaft Bearing

Specification

1. Engine :- Cummins 6BT 5.9 TC

Model water cooled direct injection

Type turbo charges diesel engine

Bore stroke 102/120mm

No of cylinder 6

Max engine output 93.5kw (125.3hp) at 2500 rpm

Max torque 410 nm (41.8mkg) at 1400-1700rpm

Capacity 5883cc

Compression ratio 17:6:1

Firing order 1-5-3-6-2-4Weight of engine 413kg

Engine

2. AIR FILTER:-

Type dry type remote mounted

AIR FILTER

3. FUEL FILTER

Type per end fine filtration with water separator.

FUEL FILTER

4. OIL FILTER

Type full flow spin on paper type

Oil Filters 5. FUEL INJECTION

Type MICO (A) Type

Fuel injectors

6. TURBO CHARGER

Type HOLSET

Turbo Charger

7. COOLING SYSTEM

Capacity 24 liters (totals)

Radiator frontal area 2887 sq cum

Cooling system

8. CLUTCH:-

Type single plate type

Outside diameter of clutch lining 310 mm

Friction area 1030 sq cm (approx)

Clutch / Drive train / Flywheel

9. GEARBOX:-

Model GBS-40 SynchromeshNo of gears 5 forward

1 reverse

1st -7.51

2nd -3.99

3rd -2.30

4th -1.39

5th -1.00

Rev.-6.93

Synchromesh gearbox

10. REAR AXLE:-

Type single reduction, hyped

Gears.

5.285:1(37/7) STD5.857:1(41/7) OPTIONAL.

Rear axle

11. FRONT AXLE:-

Type heavy duty forged 1 be Am reverse Elliot type.

Front axle

12. STEERING:-

Type manual steering stand.

Steering gear box recalculating ball

Ratio 34.2:2:1 for 1.p 151

TC 59 Wheelbases

LPO 1512 TC

Parking brake hand operated

Type spring actuated

Parking brake

Acting on rear wheels

Engine exhaust brake coupled with service

Brake

STEERING

13. Frame:-

Type ladder type heavy

Duty frame with

Riveted / bolted cross

Member.

Ankai Bus Frame

Channel section side members

Depth 223 mm (max)

Width 60 mm

14. Suspension:-

Type semi elliptical leaf

Spring at front

And rear

Spring span front – 14500 mm

Rears -1600 mm

Leaf width front- 70 mmRear-80 mm

Shock absorber hydraulic double acting

Telescopic

Suspension

15. Wheel and Tyres:-

Tyres 9.00 X 20-14 PR

Wheel rim 7.00 X 20

No. of wheel front -2

Rear – 4

Spare -1

Wheel and tyres

16. Fuel Tank:-

Capacity 160 liters

250 lit optional for 52,59

Wheel base.

Fuel tank

17. cab/cowl:-

Type all steel full forward

Control cowl

18. Electrical system:-

System voltage 24 volts

Alternator capacity 45 amps

Battery 2*12v. 180 ah

Electrical system

19. Performance:-

Max geared speed in top 87 km/h standard

Gear (with std. rear axle) 79 km/h optional

Ratio of Ra

20. 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 ……. ……

Overall length …… …… 8975 10025

(For 50%roh)

Overall length ……. ……. ……… 100325

(for 55%roh)

Overall length ……. ……. 9485 1615

(for 60%roh)

Max width 2434 2434 2434 2434

Front overhang 1185 1185 1185 1185

21. Weight (kg):-

For IPO 1512 TC

Wheel base m mm 4725 5545

Bare chassis kern weight with 4190 4380

Cowl (with spare wheel and tools)

As per IS 9211

Max permissible FAW 4700 4700

Max permissible RAW 10160 10160

22. Filling capacity of aggregates:-

Engine oil sump ……………………………………………………. max. 14.3 letters min. 12.3 liter

Gear box GBS-40…………………………………………………… 5.2 liters

Tear axle RA -108 RR……………………………………………….. 7.5 liter

Steering gear housing ………………………………………………… 0.95 liter

Hydraulic clutch actuation system ……………………………………. 0.21 liters

Cooling system ………………………………………………………. 24 liter

Front hub grease per hub ……………………………………………… 450 germs

Rear hub grease per hub ………………………………………………. 450 germs

Water pump grease …………………………………………………….. 80 germs

Maintenance scheduleCheck:-Daily weekly (after 1000kms) after 9000 kms

Engine oil level clutch pedal free play air system

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 air tank separator steering system clutchBrakes battery

Axle pressure brakes system

Brakes of coolant fuel oil wheel nuts

Electrical system suspension bolts

After 1800(Kms)

Antifreeze concentration

Transmission system

Body mounting

Break system

Rear axle

Wheel alignment

o Lubricate

Linkage

o Change

Front hubcap grease

Fuel filter

Gearbox oil

Engine oil filter

Lubricate: wheel hubs

Overhaul:

Clutch

System

MAINTENANCE PROCEDURE

DAILY:-

Engine oil level:-Before starling or at least 5minutes after the engine IS shutdown check the

oil level and top up if necessary never particles with the oil level below mark or above the high

mark

Marking on dipstick:-

Low mark to high 2 Liters

Marks capacity

Grade SAE 15 W-40

Conforming to classification APICE/SG

Fuel level:-

Check fuel level in fuel tank. Top up if necessary cap capacity 160 liters.

Removing radiator pressure cap:-

Removing the pressure cap when the coolant is cold(below50C) failure to do so can result

personal injury

Coolant level:-

Check coolant level

Fill the cooling system to bottom of the radiator if necessary.

Coolant mixture- 50 % water

50% Ethylene glycol (antifreeze)

Fan:- Rotate the crankshaft and Visually inspect the fan for creaks

Proper mounting.

Replace fan if damaged.

Drive Belt:-

Visually inspect the belt, replace the belt if frayed 01pieces of material missing or

longitudinal.

Cracks intersect with transverse cracks.

Water separator:-

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

Caution:-

Excessive draining will introduce and into the system causing the engine to be hard to

start.

Draining condensed water:-

Drain off condensed water from air tank (I) by operating till type drain value.

Brakers:-

Check for proper functioning of brakes.

Tye pressure:-

Check and inflate the Tyre in cold condition

Front tyre Pressure 5.3 bar (75Psi)

Return tyre pressure 6.0 bar (85Psi)

Laks:-

Check for laks of water an fuel and oil at all gaskets hose connect torn flexible pipes and pipe

connection. If there is an/ fault replace that fault.

Electrical system:-

Check functioning of light horn, 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 10mm

Adjusting free play:-

If free play is less adjusts loosening check nut push rod of master cylinder check and free play

and lock the nut. Very the free play at pedal again.

Gearbox:-

Open oil drain plug and checik oil levelplay. Check level of gearbox 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 :- APLGL 5 AE 90(UP TO9c) SAE 75 (0 TO 40C)

Power steering fluid level:-

Check oil level is the power steering tank with engine switched off place the dipstick in position

while checking . the oil level should be 102 Cm above the mark on dispsticks for topping up use

oil conforming ATF-Type-A.

Steering system hoses:-

If 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 and tighter, if necessary when changing the wheel on the rear axle caremust be

exercised to ensure that between the drum and inner wheel rim spherical washers are placed

in the wheel studs with flat surface toward the wheel . after lifting the inner and outer wheel

spherical washers should be placed in such a way that the spherical surface is toward the

wheel nut failure to do so will cause damage to the wheel rim and the drum.

Torque (non-apigot Ted.45-55-Kgwheel rims are fitted the spherical washers and spherical

spring wadher is not required torque (spigot Ted wheelmmnuts (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 watches or with a socket wrench and handle of at least 60 cm length torque (U bolt

nut 35 mkg) tor1que (check nut 35 mkg)

Lubricate linkage bushes and pins:-

Lubricate oilcan brake chamber fork and pinball joints of exhaust brake linkage clutch

linkages pivots linkage of foot brake.

Grease with grease gun:-

Brake pedal bush brake double level block adjuster and camshaft bushes (AAL) clutch

Pedal bushing accelerator linkages support brush gear shifting linkage propeller shaft U

Joint sliding yoking pins tie rod ends drag link end front spring pms rear spring pins helper

spring brackets rear grade purpose Grease NO.2

INSPECTION AFTER EVERY 9000 KM:-

Air intake system:-

Inspect the intake piping for damage cracked hoses loose clamps etc. Replace damages

hoses and tighter loose clamps.

Service indicator check:-

The air cleaner service indicator reset the end flag if it is in the raised position operates the

engine at max rpm load of check if the red flag rises. AGAIN in window , which indicates intake

restriction.

Air filter change:-

Change the primary filter element when the red indicator flag rises again in the window because

of intake resistance.

Note:- the secondary filter is to be changed after replacement of primary filter for three times.

After the air cleaner has been serviced push the button to reset the service indicator and check by

operation the engine once again.

Steering system:-

Check and tighten if necessary. Pitman arm drag link tie rod steering gear box mounting bolts.

Break system –

1. Tighten brake torque plate mounting belts 10 to 11 mkg.

2. Check for travel of brake chambers push the brakes have to be adjusted

before it reaches 45 cm check brake lining wear and electric with the drum 0.5 to 1 mm

adjust brake if necessary..

3. Exhaust brake linkage.

a) A few- drop of oil should be applied to the ball pin of outer linkage and friction

surface

b) Material, should not be lubricated since the tube oil would cause seizure of the

valve in the exhaust manifold.

c) Check for proper fun timing of exhaust brake free movement of plunger of seizing

of butterfly valve in the exhaust brake value – mounting bolt for looseness and

slackness in linkages.

d) With brake pedal fully released these should be no exhaust brake application of it

is on readjust exhaust break value suitably exhaust brake application can be made

out form the distinct change in engine noise.

Adjustment of service Brakes and slacks adjusters:-

Excessive travel of brakes chamber push rod indicator, the need of the brake

adjustments if the angle between the brake chamber push rod and the centerline of

slack adjusts less than 90 in the brake applied condition the brakes should be

adjusted.

All normal should be made only be mean of the slack adjust brake adjustment is to be

done when drum are cold and not when they are hot.

Procedure:-

1. Jack up wheel clear of the ground release the hand brake it is on the

condition

2. Position a box spanner or ring spanner over the adjust a hexagon by

depressing the

Licking sleeve turn the adjuster screw anticlockwise until the wheel rotate freely./ release

locking.

Note:- ensure that the licking sleeve engages with the hexagon head of adjuster screw if it is

possible to check. The clearance between the drum and lining by using the filter gauge through

the inspection hole alter removing the rubber grommet recommended clearance.

Adjustment of the brake pedal foreplay:-

A certain amount of play is kept between the dual brake valve spindle and double lever pin. This

is to ensure that accidentally brakes don’t get operated thee will be slight haul feeling at brake

pedal while depressing when play zero can be defined as “ brake pedal “ free play” adjust brake

pedal free play below.

1. ensure brake are in released condition.

2. loosen check nut in pull rod length such that brake pedal free travel is

approx 10 mm.

3. move dual brake value spindle by hand and make sure that this is play

between spindle and double lever pin.

4. lock checks nuts of full rods with out disturbing adjusted length operate

brake pedal a

few times to ensure desired brake pedal free play.

Adjustment of exhaust brake valve:-

If brake paddle is adjusted for any reason simultaneously exhausts brake valve should also be

suitable adjusted as per the procedure given below.

1. Complete all adjustment of brake pedal before ay adjustment of exhaust

brake valve.

2. in released condition of brake pedal adjust brake valve spindle length

sure that valve is full pressed (-3mm) and 1 has tighten lock nut brake pedal free play

should not be disturbed while adjusting exhaust brake valve.

3. Apply brake pedal a few times to make sure that exhaust brake is

operation properly.

Adjustment of stop light switch:-

a mechanical stop light switch is mounted below brake control level mounting box whenever

brake pedal is depressed for applying brakes stop light switch comes into operation and light

s are tear tail lamps glow.

1. Ensure that brakes are in release condition.

2. Adjust dimension between stoplight switch and double level(6mm) As shown in sketch

tighten nuts

3. Operate brakes a few times to make sure that a stoplight indication comes properly.

Hand Bake Adjustment

1. No separate adjustment is required to the same service brake adjustment hold good for

hand brake also.

2. Check travel of brake chamber’ S push.

3. Check service brake lining wear and clearance with drum .

4. Adjust service brake if necessary , in proper brake adjustment can cause brake grabbing

more air consumption or tower brake efficiency

Clutch:-

Check if necessary tighten mounting of shock absorber check condition shock absorber

rubber bushes and replace necessary .

INSPECTION AFTER EVERY 1800 KMS.

Engine oil and filter change:-

Warm up the engine remove the drain plug and allow the oil to drain . a rain pan with a

capacity of 20 loiter will be adequate removal oil filter. Clean around the filter head remove

the oil filter and clean the gasket

Pre installation

Fill the anew filter with clean lubrication oil apply a light film of lubrication oil to the gasket-

sealing surface before installation the filter install the filter and tighten it half turn after its seal

contact the seal head.

Caution:-

Mechanical over tightening may distort the threads or damages the filter element real.

Oil drum Plug:-

Install he oil drain plug and tighten 8 mkg. Filling the engine with the clean oil to the proper

level sump capacity 143 liters. Total system capacity 164 liters.

Recommended oil:-

For ambient temperature 1 DC and above use SAE-40 40 oil conforming to (APISE SG

classification )

Inspection:-

Operate the engine at idle and inspect for leaks at filter and drain plug.

Filter wrench:-

For removal and installation of engine oil filter/ fuel filters use filter wrench par no 2318901805

N

Anti concentration:-

Check the antifreeze concentration and ensure that 1:1 antifreeze and water mixture is used.

Transmission system:-

Check and if necessary tighten gearbox mounting belt propeller shaft coupling flange bolts and

propeller shaft centre bearing support bracket bolts.

Body Mounting:-

Check and if necessary tighten all body mounting sand spare wheel carriers.

Brake System:-

Check for hose damage and replace if necessary check condition of gaiter in different brake

valve, exhaust flap in dual brake valve Nylon breaths tube and slips of spring brake mounting

and tank mounting airline clams and tighten if necessary.

Wheel alignment:-

Check the wheel alignment and adjust if necessary toe-in 0 to 3 min.

Front hub:-

Remove front hubcap fill with ¾ the full wheel bearing grease and refill.

Replacing fuel filter:-

Remove two filters from the dual filter adapter clean the gasket surface fo the filter head replace

the “O” rings. Fill the new filter with clean fuel lubricant the “O” ring seal with clean lubrication

oil. Install the filter and tighten ½ turn after the real contact the filter head.

Caution:-

Mechanical over tightening may distort threads or damage the filter element real.

Bleeding fuel system:-

Controlled venting is provided at the injection pump through the fuel drain manifold small

amounts of air introduced by changing the filter or injection pump supply line will be vented

automatically. If the fuel filter is changed in accordance with the instruction no manual bleeding

of fuel lines is required.

Note:-

1. Manual bleeding is required:-

2. If the fuel filters not filled prior to installation.

3. Injection pump is replaced.

4. High pressure fuel line connection is loosened or lines replaced.

5. Initial engine start up to or start up after an extended period of no engine operation.

6. Vehicle fuel tank had run empty.

Bleeding fuel system manually:-

Open two bleed screws.

Operate the hand lever until the fuel flowing from the fitting as.

Free of air tighten the bleed screw toru-1 mkg

Air can be vented from the pump through tile fuel drain manifold lines.

Loosen the drain line outlet from the pump. Operate the hand lever until the fuel flowing the fee

of air.

Tighten the vent screw:-

Loosen one of the fittings at the injector crank the engine to allow entrapped an to bleed from the

line don’t crank for more than30 seconds at a time wait 2 minutes between cranking tighten the

line fitting torque 3 mkg start the engine and vent one I line ate tine until engine run smoothly.

Gearbox:-

Oil drain plug.

Oil level plug

Drain while hot

Fill gearbox with new oil

Capacity 5.2 liters.

Recommended oil: - Grade APIG 1-SAE 80

Rear axle:-

Position in diagram:-

1. oil drain plug

2. oil level plug

Drain while hot

Fill gearbox with new oil

Capacity 7.5 liters.

Recommended oil:-

1) grade-APIGLS

2) SAE-90 (UPTO-9C)

3) SAE-7 (9C TO 40C)

Power steering

Breaker system

Suspension spring

Butterfly valve in exhaust

Gear box

ENGINE SECTION

In this section major overhauling f engine is carried out under different operations.

ENGINE OVERHAUL

In order to provide internal cleaning, replacement of worn parts and adjustment of other parts,

over hauling of engine is carried out. Although an engine will continue to operate efficiently if it

is given good maintenance parts and servicing as well as due care and attention yet its, internal

parts wear and carbon is formed in the cylinder during its normal operation after a long period of

running, loss of power & bad running or rattling is caused and noticed due to wear and or carbon

should be cleaned periodically parts checked for wear and the repairs and or adjustments should

be carried out if necessary.

Turbo- charged engine

In this section overhauling is carried out big inspection, cleaning and by replacing warn part after dismantling the engine.

The main parts of the engine assembly are:-

1. engine block

2. Crank shaft: heads balance weights.

3. Cam shaft.

4. Connection rods.

5. main line oil supply

6. oil casing

7. Fly wheel dumper.

This overhauling includes:

DISMANTLING

All nuts screws and small parts, should be removed carefully and to present their lose and

facilitate their cleaning put then in container.

REMOVAL OF CYLINDER HEAD:

All components and parts fitted cylinder heed as well as spark plugs and valve operating gear

should be removed carefully.

REMOVAL OF ENGINE BLOCK:

Engine block should be dismantled and removed from engine carefully.

Removal of pistons and connecting rods:

Drain the oil from the engine sump. While removing the sump care should be taken not to lose

the nuts, washer as well as avoid its falling to safeguard

Against any cracking distribution, disconnect the connection rods from the crankshaft to remove

pistons.

REMOVAL OF CRANK AND CAM SHAFT:

After removing the connection and crank shaft and cam shaft are removed from crank case.

REMOVAL OF OTHER ACCESSORIES

After removing the main parts other accessories like compressors, oil pups. Piston rings, fly

wheel etc.

Cylinder head gasket

QUALITIES:-

Wear the pressure of water, gas and temperature.

Does not corrode.

After tightening head no change should be in impression ratio.

MATERIAL:

Copper asbestos, steel asbestos copper.

FAULTS AND REMEDIES:

FAULTS REMEDY

1. Un smoothed cylinder head and block face . Do replacing,

2. Cylinder head is not tightened on complete

torque.

Tight at proper torque.

3. Depots of carbon. Remove carbon.

4. Overheating. Change gasket.

REMOVAL OF CARBON FROM DISMANTLED PARTS:-

Carbon is removed by washing the parts with diesel and soft cloth. After that they are washed

with pressure and dried by air pressure. PARTS: CYLINDER HEAD

This is top most part of engine.

MATERIAL:

Gray cast iron, aluminum alloy.

QUALITIES:

Cylinder head is very important part of an engine. All inlet and exhaust values and nozzle mechanism is fitted in this part of the engine. It covers the cylinder block and giving room for combustion of mixture stops the maximum pressure leakage from combustion chamber. PARTS:

Combustion chamber Valve guide Spark plug injector hole.Water jacket’s Intake and exhaust parts.

FAULT:

Water and oil leakage resulting reduction in oil pressure, and leakage from combustion chamber, carbon deposits, bending of valves etc.

REMEDY:-

Carbon deposit are washed, wide valves are changed valves are also changed and proper grinding of holes with aeropause is done with the help of girding stock.

CYLINDER HEAD GASKET

Usually cylinder block and cylinder head are detachable. Infect, head and block have their faces very smooth but with besides that after tightening by nut and stud, water and gases leaks, so gaskets inserted between them which prohibit leakage of water, gas and wear high temperature.

CYLINDER BLOCK OR CRANK CASE

MATERIAL: gray cast iron. Aluminum alloy.

QUALITIES:

1. Gives space for cylinder

2. Gives rooms for crank and cam shaft.

3. Expands less due to heat.

4. Proper place for cooling and lubrication of cylinder.

PARTS:

Face, stud, or stud hole, water jacket, lubricating oil hole, valve tapped chamber, cam shaft hole,

crank main hole cap, crank case chamber flange, fly wheel hushing flange, cylinder hoe,

cylinder.

Cylinder block

FAULT IN CYLINDER BLOCK:

Expansion and contraction in cylinders, breaking of studs, distortion in face irregularities in face.

REMEDIES:

In case of irregularities in new sleeves are bore into the block by power press which further

bored by cylinder boring machine and finished by hydraulic honing machine. In case of breaking

of suds. Studs are changed.

FAULTS IN CRANK CASE:

Expansion and contraction inteh crank case and cam case

REMEDIES:

In case of contraction in cam and crank case being is done to crank case chambers. Flange and

cam flange by line boring machine.

PISTON

It is an part of r compression and power pressure scale

QUALITIES:

1. Expands less

2. Give places for rings.

3. Give pace for gage pin.

4. Do not expand or contract.

MATERIAL:

Gray cast iron, aluminum ally, cast iron.

PARTS:

Head, compression ring grove. Land, rib represent, oil ring grove, piston pin basis, tea slat,

piston skirt, PISTN

Faults and effect on engine:

1. Deep striking sound from engine:- valve stroking on piston head replica head skirt engine

over cooling.

2. More oil consumption by piston (i) less clearance- change the piston.

3. over heating of engine:- (i) less clearance –do cylinder honing,

4. piston lease: due to less clearances

CONNECTING ROD

it is used to match crank pin & piston .

MATERIAL:

Forged steel, aluminum alloy, nickel steel, nickel crane.

PARTS:

Small end hole, eye beam, eye slot, C.R.bolt oil spray hole hut bush oil dipper.

FAULT AND REMEDIES:

1. Loosening of big ed bearing.

RESULT: this will increase the clearance and ultimately engine parts will wear.

REMEDY: tight the bearing cap or change bearings seal.

2. Wear o f small end bush.

RESULT: piston knocking will occur

REMEDY: change the bush.

3. Cylinder one side wearing.Result: non-uniform of piston and rings.Remedy:-change connection rod or straighten it by power press.

Calibration of connecting rod

Assembling

After doing the repair of each and every part of the engine, they are assembled together of form

engine assembly with proper lubrication and curl, nut, bolts, and ports are checked and tarring is

done valve $ give proper clearance for expansion . After assembling the with gear junction it is

dispatched to testing section.

ENGINE TESTING

In order to correct faults and to improve the performance of engine, the testing is the major work

operator performed for its production, repair and adjustment . It can be done by fitting the

engine to a vecile and trying but it is quite difficult and expensive. Therefore for convenience

and cheapness, engine control loading unit is used. In order to check their performance and

behavior. The engine speed load, fuel consumption, temperature of engine oil and working parts.

Heat given of by the cooling system, exhaust temperature, nature of the exhaust gases etc are

checked recorded. For testing and recording , different type of devices used are indicators,

dynamometer for measurement .purposed of an engine testing;

1. To obtain information which can not be determined by calculations

2. To verify the validity of data used the design

3. To satisfy the customer recording its rates power in comparison to guarantee fuel

consumption.

ENGINE VOLVE TIMINGS AND FIRING ORDER

Inlet valve opens 25 o before TDC and suction stroke continues for240o.

Inlet valve closed 35 o after BDC, compression stroke continue for next 145 o

Expansion stroke for next 145o At this moment i.e. 35 o before BDC , exhaust valve

opens.

Exhaust stroke continues for next 135o. exhaust valve closes 20o after TDC

Overlapping provided is for 45 o

There are six cylinders in the TAT A-1312 engine. These are employed for the purposed of

regularizing torque. They fire in the order.1-5-2-4-3-6.

\

GEARING AND GEAR- BOXES

NECESSITY:

An internal combustion engine produces little power at low rpm and maximum power at given

sped depending on particular engine. With direct coupling asset of or fixed road speed is

provided to the engine by this. But this would be suitable on level ground, because when

climbing the vehicle has to bi lifted as well as propelled at slight gradient. The accelerator could

help to overcome this on levee ground but on steep gradient even at full throttle the engine speed

on all condition of load and vehicle speed of the engine up while sacrificing same road speed. In

order to multiply the tongues. A gear box is used PRINCIPLE.

Gear wheels of different sized is provided in a gear box for engaging or disengaging them for

transmission of motion and power. No mechanical advantage is provided when two gear wheels

of same six are meshed together. A large gear meshed with a small gear will drive the small

wheel at increased speed and vice versa.

PARTS:-Gear box in order to house the gears, a casing or box usually made of aluminum alloy or

malleable cast iron is used.

Primary shaft it is driving shaft of the gear box fitted into the hub of the clutch plate. Lay shaft it

is the shaft which drives through the constant mesh gear wheels as well as carries two or three

different sized gears.

POWER STEERING SECTION

The control of an automobile is done by means of a steering system the provides directional

changes to the moving automobile.

PARTS OF GEAR BOX

GEAR BOX

For a power shaft steering a booster arrangement is provide for turning the steering wheel shift.

By setting the booster in operation, most of the work of steering is taken over by it. Pore steering

employs compressed air, electrical mechanism and hydraulic pressure for Turing the steering

wheel shaft . in most of vehicles, hydraulic pressure operated power steering ,mechanism is used.

PARTS:-

1. Rotary valve it provides responsive steering control.

2. DU Bushing or roller bearings, allows the steering gear to operate with high efficiency and

reversibility.

3. Unloading valves furnish pert steering pump protection and reduce pressure to unload

steering linkage at ends of steering gear travel.

4. recalculating balls combines high mechanical affiance with smoothes operations

5. Dirt and water seals lip type seal on both input and out put shafts.

6. torsion bar provides positive valve centering with definite “feel of the road”

7. Relief valves furnish pump protection by limiting maximum pressure.

WORKING when the driver turns the steering wheel, he transmits force from the wheel to the

steering gear input shaft. A torsion bar pinned at its one end to the inputs and at its other end to

the worm shot and exerts a rotational force on the worm shaft. In response to this rotational

force the form shat, action through the.

4. Main or sliding shaft in order to rapport the rear end of there primary shaft a spigot is

pored. For forming the spigot, the front end of a shaft is in line with the primary shaft is

machined.

The number of gears and the type of gears on the main shaft and the counter shaft ARE:

GEAR MAIN SHAFT COUNTER SHAFT TYPE OF GEARS

1 39 11 SPUR

2 32 17 HELICAL

3 26 22 HELICAL

4 19 29 HELICAL

5 17 36 HELICAL

REVERSE 36(IDLER-20) 11 SPUR

REVERSE GEAR:

The shaft used to reverse the direction of the drive by bringing into mesh the largest gear

wheel on the main shaft with the lay shaft is known as the reverse gear shaft. Gear box

TROUBLES:

TROUBLE REMEDY

1. oil leakage

i. immense oil in gear box Level the oil.

ii. Spoiling of the oil seal. Change oil seal.

iii. Wear of the clutch bearing. Change bearing.

Iv leakage by oil packing. Change packing

v. crack in housing. Do welding.

2. noise in gear box

i. braking of gear teeth. Change gear.

ii. Wear of main or clutch shaft. Change bearing.

iii. Lessen of lay shaft. Repair lay shaft.

3. gears slip while vehicles is running

i. wear of the gear. Change gear.

ii. Braking of forks. Replace new unit.

ii. Pilot bearing’s loosen. Change pilot bearing.

4. Gear locks.

i. each part of bearings loosen. Check each part of change worn out part.

ii. Wrong alignment. Put right alignment.

Recalculation ball mechanism, tries to move the rack piston axially throw the gear housing

cylinder assemble.

The rack piston’s axial movement is resisted by its engagement to the sector shaft, which is

connected by linkage to the steered wheels, now, because of this resistance the torsion bar is

twisted by the input haft, thereby actuating the control valve. Pressurized fluid. Directed by

the control valve, assists in moving the rack piston there turns the sector shat to steer the

vehicle. The system resulting the opening of a vale. It directs liquid to the appropriate side of

the cylinder for steering wheel effort has exceeded a pre- determined valve. In order to

prevent the tendency of the wheels to defect when the wheels the fluid is directed by the

valve to the cylinder. Although the vehicle is safely controlled in case of any emergency

FAULTS. CUSSED AND REMEDIES OF STEERING

1. WANDERING VEHICLE.

Cause __________________________________remedy

Looseness of chassis of the steering boxes. Tight the bolts.

Wheel of steering gear. Change the gear

.

Les pressure in tyros. Correct the pressure.

2. vehicle pulls to one side:

I. v bolt of rod spring loose bolt tighten the U bolt

.

Ii. Braking of spring. Change the spring.

iii. bending of shock absorber. Change the shock.

FUEL INJECTION PUMP

PART

1. body (housing)2. Cam shaft.3. Intermediate bearing.4. Bearing end plate.5. Cam shaft oil seal.6. Mounting plate.7. Timber gear.8. Governor weight.9. plunger spring quadrant teeth10. element (looking plate)11. delivery valves,12. Copper washer.13. Delivery holder.

Fuel injection pump

WORKING

This is widely used to supply fuel under high pressure in diesel engines. In this pump the

plunger stroke remains constant but the effective stroke is reduced b changing the position of

the helix on the plunger with respect o fuel inlet port.

The fuel pump has a cylindrical plunger which is closely fitted into the barrel by lapin the

plunger has a constant stoke and reciprocating motion of the plunger is given by the cam.

The vertical hole expends from the top of the plunger into another helical groove. When the

inlet and spill port or the by pass ports are closed by the.

Upper edge of the plunger during its ascending motion, the oil above the plunger gets

compressed and the delivery valve gets lifted off its seat due to tee high pressure developed.

Then the fuel is forced through the r pipe to the injector. The supply of fuel to the injector is

continued until the helical groove reaches the inlet port. The pump space in this position to

the plunger communicates with the spill port though the spiral slot and the vertical groove is

thus connected to her atmosphere. The pressure on the spring side is release the delivery

valve falls back to its seat and there supply of fuel to the atomizer is stopped. At this time,

the fuel I the barrel escapes from the spill port or the by pass port. During the downward

streak of the plunger, the section is seated and the fie; as drawn mote the barer; through

supply port.

The quantity of fuel being supplied to the injector depends upon the position of the helical

groove. The plunger can be rotated by means of the tooth rack. By turning the plunger to the

right, the effective pumping stroke can be increased the instant at which the space

communication with the spill port can be delayed and so, more fuel can be supplied to the

engine at higher loads. The rack is iterated by there governor.

CALIBRATION OF THE F.I PUMP

Test specification

Combination number:9400030708-E04400594

Injection pump: PES 6A 100D 320/3 R53506

Governor: RQU 400 1250 AB 1323 R

Customer: Tata Cummins Pvt. Ltd.

Engine model: 6BT

Engine code: 75006

Application: Vehicular.

Calibration of the F.I Pump

Test bench requirements:

Test oil inlet temperature: 40-45 degree C.

Overflow valve: 9451037430

Inlet pressure in bar: 2.0

Test injector: 0681 943009

Opening pressure in bar: 170-172

Higher -* pressure pipe (ODXIDX length) :- 6X2X600

SELFSTARTER

Self-starter is the device used to start the engine, as piston engine are not self starting. They

are incapable of running below a certain minimum speed. Therefore, it is necessary to

provide certain system in the engine circuit to overcome the stand will resistance and crank it

to speed at which it is self supporting and self starting. For this purpose a starting system or

circuit, which consists of a series would motor which manually operated switch, is provided.

It is mounted on the side of engine. The started derive are mainly concerned with the method

of linking the starting motor to the engine flywheel for cranking the engine until it starts

running. It requires about 150 to500A wheel starting engine.

PRINCIPAL:

As current flows from the battery, a magnetic field produced moves the plunger to close the

switch connecting the battery and the starter motor.

PARTS:

Switch, Plunger nut, Armature windings ,Spring Shied,Slot,Strip let plate.

FAULT REMEDY

1.Starter motor does not resolve

2.aulty or discharge battery Change the battery

3. Short circuit. Correct the short

2.Starter resolves but does not crank.

1Shift mechanism pinion does not reach

mechanism to fly wheel.

Adjust shift

2.Looseness of bolts Correct the alignment from the ring gear.

3. Starter gear does not disengage

1. Oxidation of generator voltage regular Do filling

2 obstruction in plunger running Wash with petrol

BRAKES

It goes without saving that brakes are one of the most important control components of vehicle.

They are required to stop the vehicle within the smallest possible distance and this is done by

converting the kinetic energy if the wheel into the heat energy which is dissipated into the

atmosphere.

Requirements-

1. The brakes must be strong enough to stop the vehicle within minimum

distance in

an emergency,

2. The brake must have good ant fade characteristics.

Types:-

1. Mechanical brakes.

2. Hydraulic brakes.

3. Air brakes.

4. Vacuum brakes.

5. Electric brakes.

 Hydraulic Brakes

But here we have studied only first three types of brakes, which are discussed below –

1. Mechanical brakes-

These are absolute now as service brakes. However these are still used on tear wheels in many

cars, as parking or emergency brakes.

LINKERS:- When the pedal is passed , the brakes at what arc applied. This simple linkage

system however , has the advantages that it is very difficult to obtain.

Equal effect at the wheels for which the compensation have to be used.

Hydraulic brake:-

Most of cars today use hydraulic operated foot brakes on all the four wheels with an additional

have brake mechanically operated on the rear wheels.

Master cylinder is the main component of the hydraulic locking system. This can be rightly name

as heart of the hydraulic linking system wheel

Cylinder is the 2nd main component of this system. Its construction is very simple. The brake

fluid under pressure forces the piston apart, there by applying the brakes.

Air Brakes:-

In this the compressor takes air from the atmosphere through the filter and

The compressed air is sent to the reservoir pressure and also to the brake chambers also called

diaphragm units at each wheel through the brake valve.

Valve is with the driver who can control the intensity of braking according to the requirements.

Main components of air brakes are:-

1. Unloaded valve

2. Brake valve

3. Hand control valve

4. Brake chamber

5. Chamber air brake

Automobile shop equipment

As good workshop must have equipped undertake all types of fault finding and Servicing jobs.

The following is a list of tools and equipment which are must in the workshop:-

1. Screw drivers.

2. Spanners, Wrenches etc.

3. Pliers.

4. Hammer

5. Chisel

6. Files

7. Hack saw

8. Drilling machine

9. Bench vice

10. Grinder

11. Measuring tools

12. Chain pulley block

13. Hydraulic jack and axle stands

14. Creeper

15. lubrication equipment

16. Battery testing and charging.

17. Electric equipment.

18. hydraulic lilt

19. Tools for treys .

20. Tyre remover

21. wheel balancing equipment

22. brake testing

23. high pressure washing equipment

24. Engine analyzer.

25. Air compressor and pressure gauge.

26. workshop manuals for popular vehicle

27. Hydraulic press.

28. Piston ring compressor.

29. Ring remover.

30. ring fitting tool

31. Piston grooves cleaner.

32. Cylinder boring machine.

33. cylinder boring machine

34. Valve facing machine.

35. Valve seat grinding equipment.

36. Chassis alignment equipment.

37. Spark plug testing and cleaning machine.

38. Steering geometry and alignment machine .

39. Connecting rod alignment machine.

40. Nozzle testing and cleaning equipment.

41. Fuel injector tester.

42. Centre lathe.

43. Fire extinguisher.

44. Electric welding set.

Screw drivers

Spanners, Wrenches

Pliers, Hammer, Chisel

Files

Drilling machine

Hydraulic press

Centre lathe

Cylinder boring machine

Ring fitting tool

Tools for tires

ELECTRONIC TORQUE WRENCH

Bench Grinder

CONCLUSION

I got a lot of practical knowledge of various systems of the service center, also

understood how the actual work is carried out on the shop floor related to the theory. I also

gained the knowledge how to work efficiently with less effort and proper care to avoid accidents

and how to keep good relations among the workers.

The various qualities added and knowledge gained in me after

completion of vocational training are:-

How to maintain good relation with the subordinates.

Knowledge about time management and its effect of efficiently

of work.

Precautions taken during the work and also the safety

mindness.

Practical knowledge about various process flows on the shop

floor.

How to work in an organization while maintaining good relation and co-operation with

colleagues and with seniors.