SUMMER TRAINING AT

UTTARAKHAND TRANSPORT
CORPORATION (TANAKPUR)

Course –
TIP491A

SUBMITTED BY : Akash Bahadur

I.D. NO. : 46863
WORKS-MAINTENANCE OF
BUSES
• Buses made by TATA
• Buses made by Ashok Leyland
WORK STATIONS(SECTIONS)
• Front Axel Section
• Rear Axel Section
• Brake Drum Section
• Leaf Spring(Kamani) Section
• Alternator & Self Starter,Electric Section
• Gear Box Section
• Tires Section
• F.I.P. Section
• Engine Section
• Field Workshop & Welding Section
LAYOUT OF BUS
• Radiator.
• Fan.
• Cylinders.
• Oil Sump.
• Flywheel Hub.
• Fly wheel.
• Pressure Plate.
• Main Shaft.
• Gear Box.
• Differential.
 EGR((EXHAUST GAS RECIRCULATION))
• It’s function is to reduce the amount of NOX formation by
controlling combustion chamber temperature.in this system the
fresh air in the intake manifold which reduces the max.
combustion chamber temp. & thereby reducing NOX content.

• Air filter MAF sensor turbo charger intercooler engine

FRONT
AXLE
• PARTS OF FRONT AXLE
1. Front I-Beam.
2. struct axle.
1. king pin (L&R)
2.king pin bush(2L&2R)
3.washer
3. Right side-Roller Bearing.
4. Left side-Brash & steel bearing.
5. Break cam shaft(L&R)
Diaphram bracket.
6. Tie rod.
Tie rod ends contains bearings used & work for
taking turns(L&R).
REAR
AXLE
• Part of Rear Axle

1. Differential unit
1. Pair of sun gears.
2. Pair of planet gears.
2. Diaphram
AIR-BRAKE TRANSMISSION
SYSTEM
 SELF STARTER

Self starter work is

to start a vehicle . It
contains a solenoid
inside it.
 ALTERNATOR

 It is used to charge the battery it generates 3-phase AC

current
• voltage generation=14.2—14.8v
• (ideal)o/p during slow running—14.2v
• at 2000rpm –14.8v
• It’s parts
• Rotor-it is a magnet
• Stator-it generates AC
.
• Rectifier plate-it converts ac—dc
• REGULATOR-it controls the o/p voltage
FUEL INJECTION PUMP(F.I.PUMP):-
In Diesel Engine F.I. Pump is used for
delievering the FUEL in correct amount ,
time, to the fuel inejctor.
WORKING PRINCIPLE
The Fuel suck by Fuel Pump from the tank at a
low pressure with the help of a filter and than
after reaching a certain pressure it is delivered to
fuel injector with the help of it’s rail and the rest
fuel is returned through the Relief valve

 Injection Pressure- different an per engine.

 CAM Sequence- 1-5-3-6-2-4.
 Direction of Rotation- Clock Wise.
 ((1)) ((2))

1 Flywheel
2Cylinder Head
3-Turbo Charger

((3))
FUEL
TRANSMISSION:
-

1-Fuel Tank
2-Feed Pump
3-Paper Filter
4-cloth Filter
5-F.I.Pump
6,7-Automizers
8,9-Nozzles
10.11-Cylinders
GEAR
BOX :- in different loads & in different types of roads. With the help of
Gear box is fixed with Clutch Plate Housing behind Clutch. Gear box is used to
drive vehicles
gears the speed of vehicles is used as required.

TYPES OF GEAR BOX:-

 Sliding mesh gear box.
 Constant mesh gear box.
 Synchromesh gear box.
 Planetarty gear box.( Epicyclic gear box).
PARTS OF GEAR BOX

1 Main Shaft. 10 Spring Washer

2 Counter Shaft. 11 Oil Seal.
3 Shifting Rod. 12 Front Cover.

4 Gear Box
Housing. 5-Cover 13 Hub and Bush.

Plate. 14 Synchronizing.

6 Bearing and Sleeve.

15-Drive Shaft.
7 Fork.
8 Cylindrical pin.
9 Gear Box Cover Rear.
 ((1)) ((2)) ((3))

1)—Piston 2)—
Compression Ring 3)-
Oil Ring
LUBRICATION
80 W 90 Lubricating oil is used for theOF THE
Lubrication of Gear GEAR
Box. Splash lubrication

BOX
method is used for the Lubrication.
QUANTITY:-3.5 to 4 ltr.
Precaution and Safety features-:
 Lubrication of all Gear box is necessary.
 Gear selection should happen according to the nature of Load and Road.
 Gear shifting should happen according to the speed of vehicle and engine.
 Gear shifting should happen softly.
LEAF
SPRING :- to prevent these shock the LEAF
Because of the up’s and down’s the vehicle get’s so
many shock’s,
SPRING’S are used. They are Semi-Elliptical in
shape.

 The total number of the leaf Spring in a vehicle is 4,.

 One spring contains 15 leafs
 In Front axle the length of Spring is 74 Inch and decreases 4
inch to downwards,
 In Rear Axle the length of Spring is 78 Inch and simultaneously
decreases as front axle.
ENGINE:-

125HP(TATA)
135HP(ASHOK LEYLAND)
PARTS OF ENGINE:-
1-Cylindrical Head. 2-Oil Pump.
3-Cylinder Block. 4-Piston.
5-Crank Shaft. 6-Cam Shaft.
7-Cooling Fan. 8-Radiator.
9-Valve Mechanism. 10-Self Starter.
11-Fly Wheel. 12- Cooling Plate.
13-Damper Pulley. 14-Vibration Damper Pulley.
15-Water Pump. 16-Timing Plate Housing.
17-Push Rod. 18-Diesel Filter.
19-Tappet. 20-Gudgeon Pin.
21-Alternator. 22-Turbo Charger.
((1))

1-CYLINDER BLOCK
2-CYLINDER GASKET

((2))
 CRANKSHAFT

CYLINDER HEAD
FUEL FILTER OIL FILTER
GEAR BOX
DIFFERENTIAL
WATER PUMP
CLUTCH
 RADIATOR FAN
COOLANT &
DIFFUSER FAN
SPECIFICATIONS OF
ENGINE:-
 MODEL – T.C. 1512 (TATA).

 NUMBER OF CYLINDER – 6.

 BORE SIZE – 102 mm.

 FUEL USED- DIESEL.

 FIRING ORDER- 1, 5, 3, 6, 2, 4

 INJECTION PRESSURE- 175-180.

 AVERAGE – 5-6 km/litre.

PRECAUTION & SAFETY FEATURES:-

Tappet clearance should be clean.

a) When inlet is hot >> 0.10 inch
b) When outlet is hot >> 0.20 inch
Rocker Arm & Lubrication of Rocker Arm
should be checked.
Tappet cover should always fix.
Lubrication oil should be replaced in
regular intervals.
SUMMER TRAINING
AFTER 6 SEMESTER
TH

AT S.G. ENTERPRISES
(SULTANPUR)
 COMPANY PROFILE
S.G. Enterprises is a fast growing and
recognized company in the field of High
quality of Heat Exchangers, Water
pump. Electric Fans, Condensers, Boilers,
Process Equipments, Coils, etc. From
various materials of construction such as
stainless steel, carbon steel, Alloy Steel,
Nickle, Monel, Copper, etc. They extend
their hands with many associations and
are life members of SIDCUL,
UTTARAKHAND and Federation of small
scale Industries(FSSI).
They are also Manufacturer and
exporter of water pumps, ceiling
pumps, voltage stabilizers, electric
geysers, electric stand fans, gas
geysers, cooler fans, exhaust fans,
heavy duty fans and ceiling fans.
 PRODUCT
INFORMATION
• Heat Exchanger
•Electric Fans
• Condensers
• Boilers
•Immersion Rod
• Electric Iron
• Electric Geysers
HEAT EXCHANGER
A heat exchanger is a device designed to efficiently transfer or
"exchange" heat from one matter to another. When a fluid is used
to transfer heat, the fluid could be a liquid, such as water or oil,
or could be moving air. The most well known type of heat
exchanger is a car radiator.
ELECTRIC FAN
A fan is a powered machine used to create flow within a fluid,
typically a gas such as air. A fan consists of a rotating
arrangement of vanes or blades which act on the air.
CONDENSER
In systems involving heat transfer, a condenser is a device or
unit used to condense a substance from its gaseous to
its liquid state, by cooling it. In so doing, the latent heat is given
up by the substance and transferred to the surrounding
environment.
BOILER
A boiler is a closed vessel in which fluid (generally water) is heated.
The fluid does not necessarily boil. The heated or vaporized fluid
exits the boiler for use in various processes or heating applications
IMMERSION RODS
Immersion rods are used to heat many liquid substances like
water, oil, chemicals and even to stabilize gas within their tanks.
They are used in many industries within different liquid storing
tanks, during the processing of pipes and in pressurizing the
storing containers.
ELECTRIC IRON

An iron is a device that, when heated, is used to press clothes to

remove creases. It is named for the metal of which the device was
historically commonly made, and the use of it is generally
called ironing. Ironing works by loosening the ties between the long
chains of molecules that exist in polymer fiber materials. With the
heat and the weight of the ironing plate, the fibers are stretched and
the fabric maintains its new shape when cool.
SOME IMAGES OF
PLANT
POWDER COATING
TESTING MACHINE
FAN TESTING MACHINE
THANK YOU