Summar Training Report HRTC TRAINING REPORT
Summar Training Report HRTC TRAINING REPORT
Summar Training Report HRTC TRAINING REPORT
INDEX:
SR. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 NAME OF THE OBJECT Acknowledgement Introduction The Lathe Vertical Boring machine Alternator Clutch System Introduction about Workshop Safety and Body building guidelines Minor engine repair and engine servicing Basic requirement of engine service Engine service procedure Specification Maintenance schedule procedure Maintenance procedure Automobile shop equipments Reason for trouble in various parts of vehicle Factor affecting power output of an engine Recommendations lubricants, coolants and fuel Main components of an automobile engine (power plant) Operational requirement on an I.C. engine Organizational structure
ACKNOWLEDGEMENT
Industrial training for engineering students is a part of their studies. Though the laboratories and workshop are well equipped and sufficient advanced but the industrial improvement and practice cannot be submitted by lab and workshop. We can apply theoretical concepts into practical during the valuable training period.
I am thankful to KURUKSHETRA UNIVERSITY Kurukshetra who provide us a precious opportunity to learn and see practically, which are studied earlier. I would like to express my heart full thankful to Mr. Yash Paul Sharma W/M HRTC D/W Bilaspur.
I wish to thanks to our HOD Er. Jitender Katariya of our institute E-max Institute of Engineering & Technology Badhauli, Ambala. Under whose dynamic and able guidance we were able to complete the Industrial Training.
THANKING YOU
INTRODUCTION
As stated in our syllabus we have prepared our report on our industrial training. As being Mechanical Engineering student in present we need to be an acquainted with practical exposure about components of industrial field procedure and practical so as have an operation of size and scale of operation. To develop comprehensions regarding concepts, principals taught in the classrooms and their application involving field/industrial task problems. To have firsthand knowledge culture and to mentally prepared them before actually joining word of work services. So for this very purpose, I went to HRTC D/W, BILASPUR. On feedback we prepared following report. All data taken in this report such as specification various parts etc is about TATA LP/LPO 1512TC vehicle manufactured by TELCO where quality is the watchword.
Recommendations
Following are the recommendations to Mech. Department. We should be given exposure to practical aspects to automobile industry that we can improve our knowledge. We should have at least one industrial tour in every month.
Safety Guidelines
To avoid accident and to keep them from happening following safety guidelines should be allowed:
1. Provide your attention at most to the job quietly. 2. Keep the tool within your convenient reach under your control. 3. Arrange neatly without scattering them around and out of way. Always keep 4. 5. 6. 7. 8. 9.
jack handles pointing up to avoid tripping up to wheel creepers are not in use stand them against the wall to avoid stumbling over them. Be serious about your work never including in horseplay or other foolish activities to avoid injury to other. Never put sharp objects like screw driver in your pockets otherwise you will cut yourself or get stabbed. Always wear suitable clothes for the job otherwise serious injuries can be caused by sleeves or ties getting caught by the machine or full leathers shoes with non skid rubber heel should be worn. To provide good grip on tool or part always wipe excess oil and grease up hand tool as required. To avoid slipping and falling to the ground due to spilt oil or grease or any liquid clean up immediately the ground. Compressed air should never be used to blow dust from your clothes. Compressed air should never be pointed to any person because flying particles or chips may harm him.
THE LATHE
INTRODUCTION:
The lathe is one of the oldest machine tools and came into existence from the early tree lathe which was then a noble device for rotating and machining a piece of work held between two adjacent trees. This device continued to develop through centuries and in the year 1797 Henry Maudslay, an Englishman, designed the first screw cutting lathe which is the forerunner of the present day high speed, heavy duty production lathe, a machine tools which has practically given shape to our present day civilization by building machines and industries.
and it contains additional mechanism for driving the lathe spindle at multiple speeds.
THE LATHE
BORING MACHINES
INTRODUCTION:
The boring machine is one of the most versatile machine tool used to bore holes in large and heavy parts such as engine frames, steam engine cylinders, machine housings etc. Which are practically impossible to hold and rotate in an engine lathe or a drilling machine. Boring machine has, therefore, been developed primarily to do this. In addition to its primary purpose of boring the range of speeds and feeds provided to the various traversing components allow drilling, milling and facing to be performed with equal facility. By the fitting of simple attachments, the use of the machine can be extended still further to include screw cutting, turning, planetary grinding, or gear cutting.
ALTERNATOR
DESCRIPTION:
This 3 HA 15 Alternator is 12 poles 3 phase machine of revolving field with stationary armature type. The machine which is ventilated design is cooled by means of a fan mounted on the rotor shaft at the drive end. The output from the stator winding is rectified by means of a full wave bridge assembly. Auxiliary diodes provide rectification of the field. The output current of the alternator is self limiting. A fuse is provided on the positive line to protect the diodes in the event of an inadvertent battery reversal. An electronic regulator is housed inside the alternator itself and provides voltage regulation.
CLUTCH SYSTEM
GENERAL:
Clutch is the mechanism interposed between engine and the gear box which enables engine power as well as torque of the engine to be transmitted at WILL to the gear box through friction drive. When clutch pedal is depressed the clutch is disengaged and motion & power flow from engine to gear box and hence to road wheels is disconnected.
Important functions of clutch within the power train are as follows: 1. Moving the vehicle from rest:
Engine gives sufficient power required for moving the vehicle from rest only at high rpm. Therefore, it is necessary to run the engine on no load up to such rpm and then connect to the gear box. This is achieved by disengaging the clutch upon which engine is separated from gear box.
2. Shifting in to gears:
While changing gear it is necessary that the gears in the gear box should not be under the load of transmitted power. Therefore, during each up or down gear shift it is necessary to interrupt the power flow from engine to the gear box. This is achieved by disengaging clutch before shifting in to gears.
DRY CLUTCH
1. Self-diagnosed services
In these services are include the lubrication, washing body and being repair of brakes tires, steering alignment etc these services are necessary for efficient running and maintenance of automobile.
2. Performance services
For correcting engine performance and electrical troubles, the performance services are carried out. Performance services are quite different from self-diagnosed services before carrying out and of performance services.
starting missing king pin poor idling rough running as well as heavy fuel consumption are the indication of loss in performance.
Engine disassembly: The dismantling and removing is done for finding the
cause of troubles in engine parts such as: a) b) c) d) e) f) g) h) Manifolds Cylinder head Cylinder block Piston and connecting rod Shaft Sump or oil chamber Turbo charger Sub assembly
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.
Piston:
A vertical wear on the thrust surface and slight looseness of the top ring in groove is common wear visible and piston with the type of wear can be reconditioned usually.
c) d) e) f) g) h) i)
Bearing Cylinder block Cylinder wall Main bearing Oil pump Water pump Covers
SPECIFICATIONS
Engine:
Model Type CUMMINS 6BT 5 9 TC water cooled direct injection Turbo charged diesel engine Bore stroke No of cylinders Max. Engine output Max. Torque Capacity Compression ratio Firing order Weight of engine 102/120 mm 6 93.5 KW (125.3 HP) at 2500 rpm 410 Nm (41.8 m/kg) at 1400-1700 rpm 5883 cc 17:6:1 1-5-3-6-2-4 413 kg
Air filter:
Type dry type remote mounted
Fuel filter:
Type pre and fine filtration with water Separator.
A fuel filter is a filter in the fuel line that screens out dirt and rust particles from the fuel, normally made into cartridges containing a filter paper. They are found in most internal combustion engines.
Oil filter:
Type full flow spin on paper type
An oil filter is a filter designed to remove contaminants from engine oil, transmission oil, lubricating oil, or hydraulic oil. Oil filters are used in many different types of hydraulic machinery. A chief use of the oil filter is in internalcombustion engines in on- and off-road motor vehicles, light aircraft, and various naval vessels. Other vehicle hydraulic systems, such as those in automatic transmissions and power steering, are often equipped with an oil filter.
An Injection Pump is the device that pumps fuel into the cylinders of a diesel engine. Traditionally, the pump is driven indirectly from the crankshaft by gears, chains or a toothed belt (often the timing belt) that also drives the camshaft. It rotates at half crankshaft speed in a conventional four-stroke engine. Its timing is such that the fuel is injected only very slightly before top dead centre of that cylinder's compression stroke. It is also common for the pump belt on gasoline engines to be driven directly from the camshaft. In some systems injection pressures can be as high as 200 MPa (30,000 PSI).
Mechanical pumps are gradually being phased out in order to comply with international emissions directives, and to increase performance and economy. Alternatives include common rail diesel systems and electronic unit direct injection systems. These allow for higher pressures to be developed, and for much finer control of injection volumes compared to mechanical systems.
Turbo charger:
Type HOLSET
Cooling system:
Capacity Coolant Radiator frontal area 24 liters (total) water and ethylene glycol ratio 1:1 pre mixed 2887 sq cm
Clutch:
Type single plate dry friction type
310 mm
1030 sq cm (approx)
Gear box:
Model No of gears Gear ratio GBS-40 synchromesh 5 forward, 1 reverse 1st-7.51 2nd -3.99 3rd -2.30 4th -1.39 5th -1.00 Rev -6.93
Rear axle:
Type single reduction, hypoid gears Fully floating axle shafts Ratio 5.2285:1(37/7) STD
5.857:1(41/7) optional
Front axle:
Type heavy duty forged beam reverse Elliot type
Steering:
Type Steering gear box Ratio manual steering standard recalculating ball type 34:2:1 for I.P 151 TC 59 wheelbase LPO 1512 TC
Brake:
Parking brake Type Engine exhaust brake hand operated spring actuated parking brake acting on rear wheels coupled with Service brake
Frame:
Type ladder type heavy duty frame with Riveted/bolted cross members Channel section Depth Width side members 223 mm (max) 60 mm
Suspension:
Type semi elliptical leaf spring at front and Rear
Spring span
Leaf width
front 70 mm Rear 80 mm
Shock absorber
Fuel tank:
Capacity 160 liters 250 liters optional for 52, 59 wheel base
CAB/COWL:
Type all steel full forward control cowls
Electrical system:
System voltage Alternator capacity Battery 24 volts 45 amps 2 x 12 v 180 Ah
Performance:
Max geared speed in top Gear (with std. rear axle) 87Km/h std. 79Km/h for optional ratio of RA
16.2% standard
18% optional ratio of RA
Weight (KG):
For IPO 1512 TC Wheelbase in mm Bare chassis kern weight with Cowl (with spare wheel & tools) As per IS 9211 max permissible FAW Max permissible Ra AW Max permissible GVW 10160 14860 10160 14860 4700 4700 4190 4380 4725 5545
Maintenance schedule
Check: Daily
Engine oil level Fuel level Coolant level Fan Drive belt
after 9000 km
air intake system air cleaner steering system brake system shocks absorber
clutch
After 18000km
Antifreeze concern.
after 36000km
Drive belt tension
after 72000km
vibration Damper
Transmission system Brake system Body mountings Rear axle Wheel alignment
tension bearing valve clearance fan hub crown wheel thrust pad brakes system Electrical system Wheel hub bearing play
battery
Change:
Front hubcap grease Fuel filter Gear box oil Engine oil filter
Over haul:
Clutch system Power steering Brake system Suspension spring Butterfly valve exhaust Gear box
Marking on dipstick:
Low mark to high marks capacity Grade Confirming to classification 2.1 liters SAE 15W-40 API CE/SG
Fuel level:
Check fuel in fuel tank. Top up if necessary and secure cap capacity 160 liters. Removing radiator pressure cap: Removing the pressure cap when the coolant is cold (below 50*C) Failure to do so can result personal injury.
Coolant level:
Check coolant level Fill the cooling system to bottom of the radiator if necessary.
Coolant mixture:
50% water 50% ethylene glycol (antifreeze)
Fan:
Rotate the crankshaft and visually inspect the fan for cracks. Proper mounting, replace fan if damaged.
Drive belt:
Visually inspect the belt, replace the belt if frayed or pieces of material missing or longitudinal.
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.
Brakes:
Check for proper functioning of brakes.
Tyre pressure:
Check and inflate the tyre in cold condition Front tyre pressure Rear tyre pressure 5.3 bar (75 psi) 6.0 bar (85 psi)
Leaks:
Check for leaks of water, air, fuel and oil at gaskets hose connections flexible pipes and pipe connections. If there is any fault replace the part.
Electrical system:
Check the functioning of light, horn, wiper blinker, switches and gauges.
Gear box:
Open oil drain plug and check oil level play. Check level of gear box oil top up if necessary. Grade APIGLA-SAE 80
Rear axle:
1. Oil drain plug. 2. Oil level plug. Check level of rear axle oil top up if necessary Grade AIPGL5 SAE90 (up to 9*C) SAE75 (9 to 45*C)
Battery check:
Check electrolyte level it should be between 10 to 22 mm above the top of the battery plates. Battery mounting clamps and starter motor terminals must be kept clear and firm. Apply Vaseline/petroleum jelly on battery terminals.
Wheel nuts:
Check wheel nuts and tight them. If necessary when the wheel on the rear axle care must be exercised to insure that between the drum and inner wheel rim spherical washers are placed in the wheel studs with flat surface towards the wheel. After lifting the inner and outer wheel spherical washers should be placed in such a way that the spherical surface is towards the wheel rim and the drum. Torque (nonspigot Ted: 45-55m/kg wheel rims are fitted the spherical washers and spherical spring washer is not required torque (spigotted wheel rim nuts 50-60 mugs)
Brake system:
1. Check free movement of spindle in dual brake valve. 2. Check brake system for leaks and rectify if necessary.
Clutch system:
Dismantle clean inspect and reassemble clutch sleeve cylinder and master cylinder. Replace damaged/worn out parts.
Recommended oil:
Confirming to System capacity ATF-type-A 3 liters
Brake system:
Front Rear Air brake chamber Mounting bracket to rear axle Camshaft bearing block 18 mugs 20 mugs 10-13 mugs 8 mugs 5 mugs
Spring:
Dismantle front and rear spring clean and apply graphite grease while reassembling grease spring pin with grease plan
Gear box:
Dismantle clean inspect and reassemble the gear box 1. Drain gear oil while still hot clean magnetic and rain plug. 2. Check and tighten left hand nut to specified torque if necessary dismantle drive shaft. Reassemble and replace left hand nut and tighten it to specified torque replace bearing if required. 3. Check bearing on main shaft counter shaft and needle roller bearing on main shaft for scoring/pitting mark replaces bearing needed roller bearing if necessary. 4. Adjust endplay of bearing on counter shaft main shaft and drive by selecting shims. 5. Check backlash on speed gears it should be within 0.25 mm. inspect gears replace worn/scored/pitted gears. 6. Refills the gearbox with recommended oil. 7. Test the gearbox for gear noise and smooth gear engagement.
Fill the system slowly to prevent air locks during filling air must be vented from the engine and coolant. Maximum filling rate 19 liters
Dont exceed this fill rate wait for 2-3 minutes to allow this air to be vented then add mixture to bring the level to the top install the pressure cap operate the line engine until it reaches a temperature of 80*C and check for coolant leaks wait until this coolant temperature and check coolant level again make sure this system is fill of coolant.
Final drive:
The function of final drive is to provide a permanent speed reduction and to turn the drive round through 90*. The reduction provided is about 4:1 in cars and 10 :1 in buses.
Differential:
When the car is taking turn the outer wheels will have to travel greater distance as compared to the inner wheels in the same time. If therefore, the car has a solid rear axle only and no other device; there will be tendency for the wheels to skid. Hence of the wheel skidding is to be avoided. Some mechanism must be incorporated in the rear axle, which should reduce the speed of inner wheels and increase the speed of all the wheels same when going straight ahead. Such a device, which serves the above function, is called differential. To understand the principle on which differential works consider figure. To the crown wheel of the final drive is attached a cage, which carries a cross pin and a spider. To sun gears mesh with the two or four planet pinions. Axle half-shafts are splinted to each of these sun gears. The crown wheel is free to rotate on the cross pin or the spider arm, they cannot apply different torque to the teeth on one side, therefore, they act as balance and divide the torque between the two wheels on axle, even when their speeds are different.
A) Input torque is applied to the ring gear (blue), which turns the entire carrier (blue), providing torque to both side gears (red and yellow), which in turn may drive the left and right wheels. If the resistance at both wheels is equal, the planet gear (green) does not rotate, and both wheels turn at the same rate.
B) If the left side gear (red) encounters resistance, the planet gear (green) rotates about the left side.
Brakes:
It goes without saying that brakes are one of the most important control components of the vehicle. They are required to stop the vehicle within the smallest possible distance and this is done by converting the kinetic energy of the wheels 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 brakes must have good anti fade characteristics.
Types:
1. 2. 3. 4. 5. Mechanical brakes Hydraulic brakes Vacuum brakes Electric brakes Air brakes
But here we have to study only three types of brakes which are discussed below:
1. MECHANICAL BRAKES:
These are absolute known as service brakes. However these are still used on rear wheels in many cars, as parking or emergency brakes.
LINKAGES:
When the pedal is pressed, the brakes are applied. This simple linkage system however has the advantage that it is very difficult to obtain. Equal effect at the wheels for which the compensators have to be used in heavier vehicles.This is done either in one or two stages for lesser reduction say up to 71 single reduction is used in two steps. The final drive in practice consists of a bevel pinion and crown wheel or alternatively worm and wheel arrangement. The bevel pinion is mounted on a shaft, which is connected to the propeller shaft generally through a universal joint. From the crown wheel the drive goes to the differential. Three types of gears are used for the final drive bearing.
2. Hydraulic brakes:
Most of cars today use hydraulic operated foot brakes on all the four wheels with an additional brake mechanically operated on the rear wheels. Master cylinder is the main component of the hydraulic locking system. This can be rightly name as heart of the hydraulic linking system wheel cylinder is the 2nd fluid under pressure forces the piston apart there by applying the brakes.
3. Air brakes:
In this the compressor takes air from the atmosphere through the filter and the compressed air is sent to the reservoir through the unloaded valve which gets lifted at a predetermined reservoir pressure and also to the 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.
Hypoid gears:
The name Hypoid is driven from the revolution the basic surface on which the teeth are cut in their case are hyperboloid, which is a solid obtained by rotating a hyperbola about an offset axis. Such gears are employed to connect shafts at right angles to each other, but not lying in the same plane. In case of hypoid gears, the pinion shaft is placed below the axis of the crown wheel with hypoid gears, pitch diameter of the pinion for given size of the crown wheel for a given speed reduction is more on account of offset. This increases strength of the pinion by about 20% to 30%. It also provides a larger pitch overlap, resulting in real silent running.
Gear ratio of drive = no. of teeth on the wheel / No. of stars on the worm
Worm and wheel type of final drive is particularly useful in heavier vehicles where the final reduction is greater than about 6. This gives a quiet, efficient and very strong derive.
10. Grinder 11. Measuring Tools 12. Chain Pulley Block 13. Hydraulic Jack and Axle Stands 14. Creeper 15. Lubrication Equipments 16. Battery Testing and Charging 17. Electric Equipment 18. Hydraulic Lift 19. Tools for Tyres 20. Tyre Remover 21. Wheel Balancing Equipment 22. Brake Testing
D.M. TECHNICAL
D.M. OPERATIONAL
R.M.
W.M.
T.M.
FOREMAN
STORE ADMINISTRATOR
S.S.I.
STORE INCHARGE
H.M.
STORE KEEPER
MECHANIC
HELPER