CHAPTER I

INTRODUCTION

1.1 History and Background

The trend of automobile growth is increasing very rapidly in our country. So for fulfilling
these demand and services many automobile related company where established in our
country among them Autoways Engineering Pvt. Ltd is one of them which is continuously
providing service form 2059/06/10 till and then.
Autoways Engineering Pvt. Ltd. is one of the leading Eicher’s and Toyota’s vehicle in the
locality. Autoways Engineering Pvt. Ltd was established in 2059/06/10.Autoways Pvt.
Ltd., Pokhara is the sole distributor for Volvo Eicher heavy vehicles and Toyota luxurious
and passengers’ cars. “Autoways Engineering Pvt Ltd, Pokhara is the authorised service
centre for both Toyota motors and the Eicher vehicles. With the slogan "Transforming
your motorslook" Autoways Engineering Pvt Ltd, Nayabazar- Pokhara
Two types of vehicle that autoways deals are:
a) Eicher Vehicle
b) Toyota Vehicle

A. Eicher Vehicle
The common vehicles models that it deals with are as:
 HD vehicle model: 20.15, 20.16, 30.25, 35.31
It generally includes heavy load carrying vehicle.
 Bus model: 10.75, 10.90, Starline, Skyline, Pro 3000
 LMD vehicle model: Pro 1055, Pro 1059,Pro1080, Pro 1080XP, Pro 1095XP, Pro
1112XP, Pro 1114

B. Toyota
The vehicles that is dealt under Toyota are:
 SUV (Sport Utility Vehicle): For Sporty looks and speed. Example, Land Cruiser
Prado, Hilux.
 Commercial vehicle: Hiace, For commercial purposes

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1.2 Organization Structure
The organization structure in autoways follows functional type. The service manager has
staff in the different field who can handle the workers of other field too. Each staff just under
service manager has knowledge in specialized field. All the staffs have coordination in all
the field for the progress of organization. The flow chart of organization structure is shown
in figure 1.1.

Fig.1.1: Organization Structure

1.3 Company Details

Organization Name : Autoways Engineering Pvt. Ltd (Autoland)
Address:Showroom : Nayabazar, Pokhara
Workshop : Pokhara Industrial Estate, Chauthe
Established year : 2059/06/10
Area : 18 Ropani
Current staffs : 32 (including all level)
The logos of Eicher and Toyota is shown in figure 1.2 and 1.3 respectively.

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 Fig.1.2: Logos of Toyota and Eicher respectively

1.4 Company Layout

The layout of Autoways is as shown below:

Fig 1.3: Company Layout

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1.5 Process Layout
1.5.1 Process layout for a new vehicle

Quality
Receive
Test

Vehicle
Inspection

VIP
Delivery

1.5.2 Process layout for a servicing vehicle

Servicing Gate
Queue Job
VIS and Testing Billing
Card Card Pass
Maintenance

A. Vehicle Inspection
It is the process of examining vehicle in order to ensure that the vehicle is in good
condition. There are three types of inspection. They are:
i. Quality Receive Test (QRT)
ii. Pre Delivery Inspection (PDI)
iii. General Vehicle Inspection (VI)

I. Quality Receive Test

It is the inspection, carried out before the vehicle enters the dealer from manufacturer. The
main particulars, that are checked during QRT are:
 Model name
 Chassis number
 Engine number
 Battery make
 Battery number
 Manual
 Jack
 Tyre name
 Tyre number

II. Pre Delivery Inspection

It is the inspection that is done before delivering vehicle to the customer. It is generally
done to provide defect less vehicle to customers. In other words, it is a complete and

4
thorough examination of every aspects which includes exterior and interior inspection,
fluid level inspection.

Fig.1.4: PDI Sheet

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III. General Vehicle Inspection
It is the procedure to ensure vehicle is healthy in relation to safety, emissions or both.
General Vehicle Inspection is done to every vehicle that enters the workshop either to
claim warranty or for paid service. Emissions is especially checked by starting the vehicle.
Emission may be :
i. Black smoke: Occurs due to richer mixture of F/A.
ii. White smoke: Occurs when complete combustion does not occur due to low engine
temperature. This occurs mostly during winter season while cold starting.
iii. Blue smoke: Occurs when lubricating oil enters the combustion chamber and mixes
with fuel.
For proper maintenance of vehicles life, vehicle inspection should be done time and often.

Fig.1.5: Vehicle Inspection Sheet

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B. VIP Delivery
It is the process of handing over the vehicle to the customer in a special way, which
includes:
 Decoration of the vehicle
 Handing over the manual and keys
 A memorable photo session
VIP Delivery is one of the best ways to earn customers’ good will.

Fig.1.6(a): Decoration of vehicle

Fig.1.6(b): Handing over manual and keys

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C. Job Card
It is the sheet to be filled for a vehicle, arriving to get service. It includes:
• Engine number
• Chassis number
• Vehicle registration number
• Date of sale
• Customer order\ job details
• Technician allocation
• Estimated time for service

Fig.1.7: Job Card Sheet

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 CHAPTER II
DIFFERENT SYSTEMS IN AUTOMOBILE

Different systems involved in automobile are:

a) Cooling System
b) Lubrication System
c) Transmission System
d) Braking System

2.1 COOLING SYSTEM

2.1.1 Introduction
The cooling system forms an intrinsic part of an automobile engine. It performs multitude
of functions such as removing excess heat from the engine, maintaining efficient
temperature and allowing engine to perform its task within a short span of time. The heat
should be prevented from being transferred to the cylinder walls as it causes pre-ignition
of charge. Further, the lubricant might also burn because of excessive heat. Ideally,
automobile cooling system keeps the engine running at an optimum temperature whatever
the operating conditions are. Automobile cooling system consists of components or
equipment installed in vehicles for removing heat from all the moving parts so that they
can work suitably without melting, seizing and overheating. More specifically, automotive
cooling system makes use of coolant, lubricating oil and fan to maintain and regulate the
temperature of other parts of an engine. The burning of the lubricant, in turn, might lead
seizure of the piston. While the engine is running, heat should be continuously removed
from the engine. For this purpose, various methods of cooling the engine are utilized.

2.1.2 Types of cooling system

Mainly there are two types of cooling system
a) Water cooling
b) Air cooling
Among these, water cooling system is used widely.
Water Cooling System
In water cooling system, the cooling medium used is water. In this, engine cylinders are
surrounded by water jackets through which cooling water flows. Heat flows from the
cylinder walls into water which goes to the radiator where it loses its heat to the air. Usually
some antifreeze is added to the cooling water, due to which it is often referred to as coolant.
There are two types of water cooling system:
i. Thermo-syphon
ii. Forced circulation
These types are described below:
Thermo-syphon: In this system, the circulation of water is due to difference in
temperature (i.e. difference in densities) of water. So in this system pump is not required

9
but water is circulated because of density difference only. In this system, the circulating
water gets heat from the engine cylinder, there by cooling the same. The same heat in the
water is then dissipated into the atmosphere, through the radiator, by mainly conduction
and convection. In this system there is a fan which is rotated by the movement of the
crankshaft while the engine is running. The fan draws cold air from outside through the
radiator. When the outer surface of the radiator pipes come into contact with cold air, the
hot water passing through the radiator is cooled. Thus the engine is also cooled.

Fig.2.1:Thermo-syphon

Forced circulation: It is a simple centrifugal pump driven by a belt connected to the

crankshaft of the engine. The pump circulates fluid whenever the engine is running. The
water pump uses centrifugal force to send fluid to the outside while it spins, causing fluid
to be drawn from the center continuously. The inlet to the pump is located near the center
so that fluid returning from the radiator hits the pump vanes. The pump vanes fling the
fluid to the outside of the pump, where it can enter the engine. The fluid leaving the pump
flows first through the engine block and cylinder head, then into the radiator and finally
back to the pump.

Fig.2.2: Forced Circulation Process

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2.1.3 Components of Water Cooling System
The various components of water cooling system are:
(a) Radiator,
(b) Thermostat valve,
(c) Water pump,
(d) Fan,
(e) Water Jackets, and
(f) Antifreeze mixtures.
(g) Pressure cap

Radiator: A radiator is a type of heat exchanger. It is designed to transfer heat from the
hot coolant that flows through it to the air blown through it by the fan. The upper tank is
connected to the water outlets from the engines jackets by a hose pipe and the lover tank
is connect to the jacket inlet through water pump by means of hose pipes. In operation,
water is pumped from the engine to the top (receiving) tank, where it spreads over the tops
of the tubes. As the water passes down through the tubes, it loses its heat to the airstream
which passes around the outside of the tubes. To help spread the heated water over the top
of all the tubes, a baffle plate is often placed in the upper tank, directly under the inlet hose
from the engine. It is to be noted that radiators are generally made out of copper and brass
and their joints are made by soldering. Most modern cars use aluminum radiators.

Fig.2.3: Radiator
Thermostat Valve: It is a valve which prevents flow of water from the engine to radiator,
so that engine readily reaches to its maximum efficient operating temperature. After
attaining maximum efficient operating temperature, it automatically begins functioning.
Generally, it prevents the water below 80°C.Once the temperature of the coolant rises to
between 82 to 910C, the thermostat starts to open, allowing fluid to flow through the
radiator. By the time the coolant reaches 93 to 1030C, the thermostat is open all the way.

Fig.2.4: Thermostat Valve

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Water Pump: The water pump is a simple centrifugal pump driven by a belt connected to
the crankshaft of the engine. The pump circulates fluid whenever the engine is running.
The water pump uses centrifugal force to send fluid to the outside while it spins, causing
fluid to be drawn from the center continuously. The inlet to the pump is located near the
center so that fluid returning from the radiator hits the pump vanes. The pump vanes fling
the fluid to the outside of the pump, where it can enter the engine. The fluid leaving the
pump flows first through the engine block and cylinder head, then into the radiator and
finally back to the pump.

Fan: Like the thermostat, the cooling fan has to be controlled so that it allows the engine
to maintain a constant temperature. Front-wheel drive cars have electric fans because the
engine is usually mounted transversely, meaning the output of the engine points toward
the side of the car. The fans are controlled either with a thermostatic switch or by the
engine computer, and they turn on when the temperature of the coolant goes above a set
point. They turn back off when the temperature drops below that point.

Water Jackets: Cooling water jackets are provided around the cylinder, cylinder head,
valve seats and any hot parts which are to be cooled. Heat generated in the engine cylinder,
conducted through the cylinder walls to the jackets. The water flowing through the jackets
absorbs this heat and gets hot. This hot water will then be cooled in the radiator.

Antifreeze mixture: In western countries if the water used in the radiator freezes because
of cold climates, then ice formed has more volume and produces cracks in the cylinder
blocks, pipes, and radiator. So, to prevent freezing antifreeze mixtures or solutions are
added in the cooling water (a mixture of water and ethylene glycol (C2H6O2) is known as
antifreeze) example: methanol, ethanol, isopropyl alcohol, propylene glycol.

Pressure Cap: The radiator or pressure cap actually increases the boiling point of coolant
by about 45 F (25 0C). The same way a pressure cooker increases the boiling temperature
of water. The cap is actually a pressure release valve, and on cars it is usually set to 15 psi.
The boiling point of water increases when the water is placed under pressure. When the
fluid in the cooling system heats up, it expands, causing the pressure to build up. The cap
is the only place where this pressure can escape, so the setting of the spring on the cap
determines the maximum pressure in the cooling system. When the pressure reaches 15
psi, the pressure pushes the valve open, allowing coolant to escape from the cooling
system. This coolant flows through the overflow tube into the bottom of the overflow tank.
This arrangement keeps air out of the system. When the radiator cools back down, a
vacuum is created in the cooling system that pulls open another spring loaded valve,
sucking water back in from the bottom of the overflow tank to replace the water that was
expelled.

Air cooling system

Air cooling system is generally used in small engines say up to 15-20 kw and in aeroplane
engines, bikes etc. In this system fins or extended surfaces are provided on the cylinder
walls, cylinder head, etc. Heat generated due to combustion in the engine cylinder will be
conducted to the fins and when the air flows over the fins, heat will be dissipated to air.

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 2.2 LUBRICATION SYSTEM
I.C. Engine is made of many moving parts. Due to continuous movement of two
metallic surfaces over each other, there is wearing moving parts, generation of heat and
loss of power in the engine lubrication of moving parts is essential to prevent all these
harmful effects.
2.2.1 Purpose of Lubrication
 Reducing frictional effect:
The primary purpose of the lubrication is to reduce friction and wear between two
rubbing surfaces. Two rubbing surfaces always produce friction. The continuous
friction produce heat which causes wearing of parts and loss of power. In order to
avoid friction, the contact of two sliding surfaces must be reduced as far a possible.
This can be done by proper lubrication only. Lubrication forms an oil film between
two moving surfaces. Lubrication also reduces noise produced by the movement
of two metal surfaces over each other.
 Cooling effect:
The heat, generated by piston, cylinder, and bearings is removed by lubrication to
a great extent. Lubrication creates cooling effect on the engine parts.
 Sealing effect:
The lubricant enters into the gap between the cylinder liner, piston and piston
rings. Thus, it prevents leakage of gases from the engine cylinder.
 Cleaning effect:
Lubrication keeps the engine clean by removing dirt or carbon from inside of the
engine along with the oil.

2.2.2 Parts Requiring Lubrication

The following parts require lubrication:
a) Cylinder walls and piston
b) Piston pin
c) Crankshaft and connecting rod bearings
d) Camshaft bearings
e) Valve operating mechanism
f) Cooling fan
g) Water pump and
h) Ignition mechanism

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2.3TRANSMISSION SYSTEM
2.3.1 Introduction
A transmission system is a critical component in a vehicle's power train. It transfers the
power generated by the engine to the wheels of the vehicle and optimizes the power flow
through the required gear ratios. It ensures the vehicle has sufficient torque to move
forward from rest and sufficient speed while cruising. This optimization is carried out
through gears in the transmission system which vary the gear ratio between the engine
and wheels and optimize the transfer of engine power. The mechanism that transmits the
power developed by the engine of automobile to the engine to the driving wheels is called
transmission system (power train).

2.3.2 Parts of Transmission System

a) Clutch
b) The gear box
c) Propeller shaft
d) Universal joint
e) Differential gear
f) Rear axle
g) Wheel
h) Tyres
Clutch: A clutch is a mechanism which enables the rotary motion of one shaft to be
transmitted to second shaft, whose axis is coincident with that of first. Clutch is located
between engine and gear box. When the clutch is engaged, the power flows from the
engine to the rear wheels through the transmission system and the vehicle moves, when
the clutch is disengaged, the power is not transmitted to the rear wheels and the vehicle
stops, while the engine is still running.
Clutch is engaged only when the vehicle is to move and is kept engaged when the
vehicle is moving. Clutch is disengaged when
a) Starting the engine,
b) Shifting the gears,
c) Idling the engine.

Fig.2.5: Clutch Disc

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Gear Box: A gear box, also called gear case or gear head, is a gear system responsible for
transmitting mechanical power from a prime mover (an engine or electric motor) into some
form of useful work. A gear box is a set of gears for transmitting power from one rotating
shaft to another. They are used in wide range of industrial, automotive and home
machinery applications. The functions of a gear box are
 A gear box is precisely bored to control gear and shaft alignment.
 It is a metal casing for protecting gears and lubricant from water, dust and other
contaminations.

Fig.2.6: Gear Box

Propeller Shaft: A propeller shaft or drive shaft is a mechanical component for

transmitting torque and rotation, usually used to connect other components of drive train
that cannot be connected directly because of distance or the need to allow for relative
movement between them.

Fig.2.7: Propeller Shaft

Universal Joint: A universal joint is a joint or coupling in a rigid rod that allows the rod
to 'bend' in any direction, and is commonly used in shafts that transmit rotary motion. It
consists of a pair of hinges located close together, oriented at 90° to each other, connected
by a cross shaft.

Fig.2.8: Universal Joint

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Differential Gear: A differential is a gear train with three shafts that has the property that
the angular velocity of one shaft is the average of the angular velocities of the others, or a
fixed multiple of that average. In automobiles and other wheeled vehicles, the differential
allows the outer drive wheel to rotate faster than the inner drive wheel during a turn. This
is necessary when the vehicle turns, making the wheel that is traveling around the outside
of the turning curve roll farther and faster than the other. An increase in the speed of one
wheel is balanced by a decrease in the speed of the other.

Fig.2.9: Differential Gear

Rear Axle: An axle is a central shaft for a rotating wheel. On wheeled vehicles, the axle
may be fixed to the wheels or rotating with them, or fixed to the vehicle, with the wheels
rotating around the axle. A straight axle is a single rigid shaft connecting a wheel on the
left side of the vehicle to a wheel on the right side. The axis of rotation fixed by the axle
is common to both wheels. Such a design can keep the wheel positions steady under heavy
stress, and can therefore support heavy loads.

Fig.2.10: Rear Axles

Wheels and Tyres: A tire is a ring-shaped vehicle component that covers the wheel’s
rim to protect it and enable better vehicle performance. Most tires, such as those for
automobiles and bicycles, provide traction between the vehicle and the road while
providing a flexible cushion that absorbs shock. Tires are mounted onto wheels that most
often have integral rims on their outer edges to hold the tire. Automotive wheels are
typically made from pressed and welded steel, or a composite of lightweight metal alloys
such as aluminum or magnesium. These alloy wheels may be either cast or forged. The
mounted tire and wheel assembly is then bolted to the vehicle's hub.

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2.4 BRAKING SYSTEM
2.4.1 Introduction
Braking System is one of the important control components of vehicle, which helps to
slow down and eventually stop the running vehicle. The brakes must be strong enough to
stop the vehicle within a minimum distance in an emergency.

2.4.2 Types of Braking System

Brakes may be classified according to the construction as:
a) Disc brake
b) Drum brake

Drum Brake: In this type of brake, a brake drum is attached concentric to the axle hub
whereas the axle casing is mounted on a black plate. The black plate helps to increase
rigidity and to provide support for anchor and brake shoes. It also protects the drum and
shoe assembly from mud and dust. One or two reactor springs are used which serve to
keep the brakes shoes away from the drum when the brakes are not applied. The brake
shoes are anchored at one end, whereas on the other end, force is applied by means of some
brake actuating mechanism, which forces the brake shoe against the revolving drum,
thereby applying the brakes.

Fig.2.11: Drum Brake System

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Disc Brake: Type of brake that uses calipers to squeeze pairs of pads against a disc in
order to create friction that retards the rotation of a shaft, such as a vehicle axle, either to
reduce its rotational speed or to hold it stationary. The energy of motion is converted into
waste heat energy.
.

Fig.2.12(a): Disc Brake System Fig.2.12(b): Parts of Disc Brake System

When the brakes are applied, the pistons are hydraulically operated. They move the friction
pads into contact with the disc, thus applying equal and opposite forces on both sides of
the disc. When the brakes are released, the rubber sealing rings act as return springs, they
retract the pistons and the friction pads away from the disc.

Fig.2.12(c): Operation of Disc Brakes

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 CHAPTER III
MATERIALS AND METHOD

3.1 Tool Box:

It is the box containing all sorts of necessary tools.

Fig.3.1: Tool Box

3.1.1 Wrenches
Wrenches are the tools used to provide grip and mechanical advantage in applying torque
to turn objects. The most common shapes are called open-ended spanner and ring spanner.

Fig.3.1(a): Wrenches
19
3.1.2 Sockets
Socket wrenches come in sets for a wide variety of size, depending on requirements.
Socket extenders are indispensable items that help to reach those almost-unreachable
nuts and bolts.

Fig.3.1(b): Sockets
3.1.3 Screwdrivers
A screwdriver is a tool, manual or powered, for turning (driving or removing) screws. A
typical simple screwdriver has a handle and a shaft, and a tip that the user inserts into the
screw head to turn it. The shaft is usually made of tough steel.

Fig.3.1(c): Screwdriver
3.1.4 Ratchets
A ratchet is a hand tool in which a metal handle is attached to a ratcheting mechanism,
which attaches to a socket, which in turn fits onto a type of bolt or nut.

Fig.3.1(d): Ratchets
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3.1.5 Pliers
Pliers are a hand tool used to hold objects firmly, possibly developed from tongs used to
handle hot metal. They are also useful for bending and compressing a wide range of
materials.

Fig.3.1(e): Pliers
3.1.6 Hammer
A hammer is a tool or device that delivers a blow (a sudden impact) to an object.
Most hammers are hand tools used to drive nails, fit parts, forge metal, and break apart
objects. Hammers vary in shape, size, and structure, depending on their purposes.

Fig.3.1(f): Hammer
3.1.7 Extension Bar
There are many bolts that are out of easy reach. Whenever a mechanic is taking off a part
deep in the engine bay, or tearing out a transmission, a variety of extensions will
certainly make work easier.

Fig.3.1(g): Extension Bars

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3.2 HYDRAULIC JACK AND LIFT
A jack is a mechanical device used as a lifting device to lift heavy loads or to apply great
forces. A mechanical jack employs a screw thread for lifting heavy equipment.
A hydraulic jack uses hydraulic power.

Fig.3.2: Hydraulic Jack Fig.3.3: Hydraulic Lift

Working of Hydraulic jacks: It depend on force generated by pressure. Essentially, if
two cylinders (a large and a small one) are connected and force is applied to one cylinder,
equal pressure is generated in both cylinders. However, because one cylinder has a larger
area, the force the larger cylinder produces will be higher, although the pressure in the two
cylinders will remain the same. Hydraulic jacks depend on this basic principle to lift heavy
loads: they use pump plungers to move oil through two cylinders. The plunger is first
drawn back, which opens the suction valve ball within and draws oil into the pump
chamber. As the plunger is pushed forward, the oil moves through an external discharge
check valve into the cylinder chamber, and the suction valve closes, which results in
pressure building within the cylinder.

Working of Hydraulic lift: The pistons and the tubes are filled completely with an
incompressible fluid like water or oil. If the pistons have the same diameter, then the force
applied on one piston to push it down by a certain distance is the same as the force that
lifts the second piston up by the same distance. The relationship between force and the
surface area of the piston is defined by the equation Force = Pressure x surface area. The
pressure is constant due to the incompressible nature of the fluid. If one of the pistons is
built to have a larger surface area than the other piston, then the effect of the force can be
multiplied by the same factor as the increase in area of the piston. For example, if a
hydraulic system is built where one of the pistons is ten times larger than the other, then
moving the smaller piston over 10 meters with a certain amount of force will allow the
bigger piston to move by one meter for the same force. Despite the trade off in the distance
moved, the force can be used to lift bigger objects.

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3.3 AIR COMPRESSOR
Air compression is essentially a twofold process in which the pressure of air rises while
the volume drops. In most cases, compression is accomplished with reciprocating piston
technology, which makes up the vast majority of compressors on the market. Every
compressor with a reciprocating piston has the following parts:
 crankshaft
 connecting rod
 cylinder
 piston
 valve head

Fig.3.4: Air Compressor

3.4 HYDRAULIC PRESS
A hydraulic press consists of basic components used in a hydraulic system that includes
the cylinder, pistons, the hydraulic pipes; etc. The working of this press is very simple.
The system comprises of two cylinders, the fluid (usually oil) is poured in the cylinder
having a small diameter. This cylinder is known as the slave cylinder. The piston in this
cylinder is pushed so that it compresses the fluid in it that flows through a pipe into the
larger cylinder. The larger cylinder is known as the master cylinder. The pressure is
exerted on the larger cylinder and the piston in the master cylinder pushes the fluid back
to the original cylinder.
Since the hydraulic press works on the basis of
Pascal's Law. The force applied on the fluids by the
smaller cylinder results in a larger force when pushed
in the master cylinder. The hydraulic press is mostly
used for industrial purposes where a large pressure is
required for compressing metals into thin sheets.

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 Fig.3.5: Hydraulic Press
(Maximum capacity of 40 tonnes)

3.5 LATHE MACHINE

The lathe is a machine tool which holds the work piece between two rigid and strong
supports called centers or in a chuck or face plate which revolves. The cutting tool is
rigidly held and supported in a tool post which is fed against the revolving work. The
normal cutting operations are performed with the cutting tool fed either parallel or at
right angles to the axis of the work. The chuck or the face plate is mounted on the
projected end of the machine spindle. The cutting tool is rigidly held and supported in a
tool post and is fed against the revolving work. While the work revolves about its own
axis the tool is made to move either parallel to or at an inclination with this axis to cut
the desired material. In doing so it produces a cylindrical surface, if it is fed parallel to
the axis or will produced a Tapered surface if it is fed at an inclination.

Fig.3.6: Lathe Machine

24
3.6 GRINDING MACHINE
Grinding is a material removal and surface generation process used to shape and finish
components made of metals and other materials. The precision and surface finish obtained
through grinding can be up to ten times better than with either turning or milling. Grinding
employs an abrasive product, usually a rotating wheel brought into controlled contact with
a work surface. The grinding wheel is composed of abrasive grains held together in a
binder. These abrasive grains act as cutting tools, removing tiny chips of material from the
work. As these abrasive grains wear and become dull, the added resistance leads to fracture
of the grains or weakening of their bond. The dull pieces break away, revealing sharp new
grains that continue cutting.

Fig.3.7: Grinding Machine

3.7 PNEUMATIC TOOLS
A pneumatic tool or air-powered tool is a type of power tool, driven by compressed air,
supplied by an air compressor. Pneumatic tools are safer to run and maintain than their
electric power tool equivalents, and have a higher power-to-weight ratio. In general,
pneumatic tools are cheaper than the equivalent electric-powered tools. It is important to
know some general specification technical terms used in pneumatic tools while it is also
related to how to choose a good air compressor so that the tool can meet requirement.
Depending on different type of pneumatic tools, there are different specification values
Free Speed (rpm), Air Pressure (psi/bar), Air consumption (cfm/scfm or m3/min), Horse
Power (hp), spindle size,etc.

Fig.3.8(a): Pneumatic Gun Fig.3.8(b): Pneumatic Drill

25
 CHAPTER IV
CASE STUDIES

CASE 1: Problem in tail pinion

Vehicles Chassis No. : MC223CRC4E1285731
Vehicles Engine No. : E483CDEA632818
Vehicles model : 10.75 Tipper
Registration No. : Ga 1 Kha 5257
Report Date : 2016-07-17
Driver’s Description : Noise from differential, low pick-up, reduction in speed
Problems Encountered: Tail pinion teeth was broken, wear in crown gear and Shaft of
planet gear
Action Taken : Tail pinion and Crown gear were replaced.

Fig.4.1(a): Broken part of tail pinion Fig.4.1(b): Replaced tail pinion

Fig 4.1(c): Shaft of planet gear Fig.4.1(d): Crown gear

26
CASE 2: Problem in radiator
Vehicles Chassis No : FC963JGT8D1743740
Vehicles Engine No : E763CHFB863633
Registration No : Ga 1 kha 437
Report Date : 2073/07/28
Driver description : High water consumption and overheating in engine
Conditions analysed :
 Faulty operation of fan
 Radiator cap
 Level of coolant
 Types of coolant
 Radiator
Problem Encountered : Damaged spring of radiator cap and leakage in radiator hoses
Actions taken : Radiator cap was changed and hose was sealed

Fig.4.2(a): Rusted part of radiator due to leakage

Fig.4.2(b): Repaired radiator

27
CASE 3: Problem in brake drum
Vehicle Chassis No. : MC22BHRFOCDGO34185
Vehicle Engine No. : E683CDDG527186
Vehicles model : 20.15 Bus
Registration No : Ga 1 kha 5214
Driver’s Description : Amazing sound from brake and he guessed hub drum
was damaged and rear brake heated up.
Findings : Right hand side Hub drum was broken.
Action Taken : Hub drum was changed.

Fig.4.3(a): Broken drum

Fig.4.3(b): Replaced drum

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CASE 4: Problem in clutch plate
Vehicles Chassis No. : MC2F6GRC6FC099467
Vehicles Engine No. : E413CDE1010128
Vehicles model : 11.12XP Truck
Registration No. : Ga 1 kha 5404
Report Date : 2016/07/19
Drivers Description : Vehicle was in good condition, suddenly gear got hard to change
even after pressing clutch.
Findings : We found spring of clutch plate came out and it entered into
pressure plate and it damaged pressure plate too. Also we
found crank oil seal damaged.
Action Taken : Clutch plate, pressure plate and crank oil seal replaced.

Fig.4.4(a): Clutch plate spring broken out

Fig.4.4(b): Pressure Plate

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CASE 5: Problem in Air Compressor

Vehicles Chassis No : MC223ERF8D1267740

Vehicles Engine No : E483CDDB603633
Vehicles model : 10.75 E Bus
Registration No : Ga 1 kha 4463
Report Date :2016/07/22
Drivers Description : Driver found Engine oil leakage from engine.
Findings : Case of back compression. We found some scratches on
cylinder lining, we found piston ring broken, engine
cylinder head found burned.
Action Taken : Piston rings, liner, gasket set were replaced

Fig.4.5(a): Broken Liner Fig.4.5(b): Broken Rings

CASE 6: Problem in Gear

Vehicles Chassis No : MC262HRC0CK074764
Vehicles Engine No : E483CDCK590952
Vehicles model : 11.14 H
Registration No : Ga 1 kha 4302
Report Date :2016/7/24
Drivers Description : While shifting gear no.4, severe noise came from gear box
Findings : While shifting gear no.4 noise came from gear Box. Dissembling
the gear box, teeth of gear no. 4 was found worn out.
Action Taken : 4th gear was replaced, 4th and 5th gear synchronizer ring were
changed.

Fig.4.6(a): 4th gear broken Fig.4.6(b): Synchronizer rings broken

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CASE 7: Problem in Exhaust Manifold
Vehicles Chassis No : MC262HRC0DA077265
Vehicles Engine No : E483CDCM596651
Vehicles model : Eicher 11.14
Registration No : Ga 1 ka 2237
Report Date :2015/12/3
Drivers Description : While driving the vehicle, smoke came from engine head.
Findings : While moving the vehicle smoke came out from engine
head, on further inspection exhaust manifold found
cracked.
Action Taken : Exhaust manifold replaced.

Fig.4.7: Broken Exhaust Manifold

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 CHAPTER V
LESSON LEARNT

We learned through experience how to interact and communicate with people. We knew
that people have different characteristics and attitudes. From the interaction with
mechanics and workers we learned how and what types of tool are to be used according to
the type of cases and how to handle and tackle different issues. Although we worked and
interact with them for a short period of time, we learned a lot from them; the skills and
techniques that they shared with us that cannot be found on the books. We learned about
the management system of a company. We learned warranty policies of different parts of
automobile, for example the warranty of an engine is 3 years. We learned about what is
PDI, VI, how it is done and the factors to be considered during PDI and VI. OJT helped
us to know about different parts of automobile and the position as well as function of these
parts. Yes, it is a big deal to buy a vehicle, but the performance of vehicle should be
maintained in optimum condition. To maintain the optimum performance, the vehicle
should serviced periodically. The following things are to be checked before running the
vehicle
 Different oil levels should be checked.
 Before turning on the key, the gear should be in neutral.
 Air filter should be cleaned regularly and should be replaced after cleaning three
times.
 While cleaning air filter, the low pressure air is blown from inner to outer through
vertical movement.
 Before placing air filter engine should not be started.
 Leakage from exhaust manifold should be checked for proper efficiency of turbo
charger.
 The engine should be raced after placing engine in ideal for one to two minutes.
 Until the temperature of engine drop to air temperature the pressure cap of radiator
should not be opened.
 The coolant should be mixed with antifreeze as prescribed by the company.
 The antifreeze and water mixture should be in 30:70 ratio.
 The pressure of tyre should be checked always and is as prescribed by the company.

After running vehicle for 10,000 km the following things should be done:
 King pin, steering shaft, steering linkage, propeller shaft, front and rare spring pin
should be lubricated.
 Front and rear suspension U bolt should be tightened.
 Whether the brake oil has leakage or not should be checked.
 In every six month, brake oil should be changed.

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 CHAPTER VI
CONCLUSION, LIMITATIONS AND
RECOMMENDATION

CONCLUSION:
Nothing beats experience as the perfect learning tool. This training gave an inspiration to
be more serious and focused in studying.Despite the short period of training, it was still a
very meaningful one.It inspired to be more determined competitive in everything that is
done in student life. It really gave a taste of the real world - a glimpse of what lies ahead
after our completion of course study. One month OJT is very fruitful for both technical
students and the company. The practical knowledged experience in Autoways Engineering
Pvt. Ltd is very advantageous for the further study in the automobile sector .

LIMITATIONS:
Every companies have some limitations but they are not aware of that. Some of the
limitations of this company are below which should be solved for effective development
of company.
 Non availability of modern electrically, hydraulic and pneumatic operated maintenance
tools.
 Management field is not so good.
 There is no proper motivation and training for workers.
 The completion time of work committed by company during services is not done.

RECOMMENDATIONS:
According to sales trend of the Autoways Company, sales of Eicher and Toyota vehicles
are increasing day by day and it’s challenge for the company to reduce its limitations. On
one month internship we learn and know about this company and like to recommend some
suggestions for effective development of company.
 The modern equipment like pneumatic guns, hand grease gun, Bearing remover etc
Should be provided to mechanics for easy and fast work.
 Proper work division of work should be done to human resource. According to the field
of work of mechanics work should be assign. This could be done by collective effort of
management.
 Some mechanics don’t know how to use modern maintenance tools, the training should
be provided.
 There should not be direct link of the costumers and mechanics to whom work is
assigned
Because mechanics work on the vehicles whom they know for tips.This may result for
unsatisfactory service for costumers.This could be solve by new policy and management
of the company.

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 BIBLIOGRAPHY

Singh, Kripal, Automobile Engineering, Volume 1, 9th edition, Standard Publishers

Distributors, Delhi 2004.
Singh, Kripal, Automobile Engineering, Volume 2, 9th edition, Standard Publishers
Distributors, Delhi 2004.
Crouse, William H, and Donald L, Anglin, Automotive Mechanics, 10th edition, TATA
McGraw- Hill Publication, New Delhi 2007.

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