A REPORT ON CO-OP TRAINING PROGRAM AT “UTTAR

PRADESH STATE ROAD TRANSPORT CORPORATION”

IN REGIONAL WORKSHOP AGRA

Under the guidance of

MR. ANURAG YADAV (SERVICE MANAGER) & MR.YASVIR SINGH

RANA (FLOUR INCHARGE)

SUBMITTED TO-
MR. SAURAV SIKARWAR

DEPT. OF AUTOMOBILE ENGINEERING

FACULTY OF ENGINEERING

(DEEMED UNIVERSITY)

SUBMITTED BY-

RISHABH ARYA

B.VOC AUTOMOBILE 3RD YEAR

ROLL NO. - 2002619

1
 ACKNOWLEDGEMENT
I express to my sincere to all officers at "UPSRTC, AGRA" who has assisted me during my
training period. I should be particularly thanks to "Mr. ANURAG YADAV (SERVER
MANAGER) and Mr. YASHVIR SINGH RANA (FLOUR INCHARGE). Who helped in
joining and completing the training.

I extended special thanks to him for their guidance & co-operation throughout my training for
completion of this project report. Their guidance has helped me a lot understanding other process
of service in workshop.

I also thank to all instructors for their kind that they have paid to me. That project is result of co-
operation of all the members and staff of " UPSRTC, AGRA ".

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 PREFACE
I worked with " UPSRTC, AGRA " as training from a completion of B.VOC in
"AUTOMOBILE ENGG." I complete three month training under supervision. During my
training period I have learn many things such as, what happen in different types of services.

In my training period I come to know that the specification of any vehicle can be done by the
following things Dimension, Weight, Engine, Capacity, Specification, Servicing and
Maintenance etc.

During my training, it has been put my knowledge that which part are covered under warranty. I
also to know the importance of servicing and maintenance. I am including all those things, which
I have learnt during period in this project report.

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 LIST OF CONTENTS

CHAPTER 1 OVERVIEW ………………………………………..8-10

A. INTRODUCTION
B. HISTORY OF UPSRTC
C. INFRASTRUCTURE OF UPSRTC
D. LOGO OF UPSRTC
E. BUSED USED IN UPSRTC

CHAPTER 2 GARAGE TOOLS AND EQUIPMENT…………11-13

CHAPTER 3 ALTERNATOR SECTION………………………14-16

A. ALTERNATOR
B. MAIN PARTS OF ALTERNATOR
a. C.E BRACKET
b. STATOR
c. ROTOR
d. D.E BRACKET

CHAPTER 4 SELF STARTER SECTION………………….......17-19

A. SELF STARTER
B. MAIN PARTS OF SELF STARTER
a. BRUSH GEAR
b. DRIVE PINION
c. ARMATURE
d. BODY

CHAPTER 5 ENGINE SECTION……………………………….20-26

A. DIESEL ENGINE
B. MAIN PARTS OF DIESEL ENGINE
a. CYLINDR HEAD
b. CYLINDER BLOCK
c. CYLINDER LINER
d. PISTON
e. CONNECTING ROD
f. CRANKSHAFT

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 g. FLYWHEEL
h. VALVES
i. CAMSHAFT
j. OIL PUMP
k. OIL PAN OR SUMP
l. CYLINDER HEAD GASKET
m. PISTON RINGS

CHAPTER 6 TYRE SECTION………………………………….27-35

A. HISTOYR OF TYRE
B. FUNCTION OF TYRES
C. BASIS OF CONSTRUCTION
1. CROSS PLY TYRE CONSTRUCTION
2. RADIAL PLY TYRE CONSTRUCTION
D. TYRE RETREADING
E. MAIN PARTS OF TYRE RETREADING
a. CURING BAG
b. FLAP
c. RIM SUPPORTER
d. RUBBER SOLUTION
F. MASHINE USED OF TYRE SECTION
a. RUBBER PRESS MACHINE
b. BUFFING MACHINE
c. COLD CARING CHAMBER
d. COMMON RAIL MACHINE
G. PROCEDURE

CHAPTRT 7 TRANSMISSION SYSTEM………………………….36

A. TRANSMISSION SYSTEM OR RUNNING SYSTEN
B. MAIN PARTS OF TRANSMISSION SYSTEM
a. GEAR BOX
b. CLUTCH
c. PROPELLER SHAFT
d. UVIVERSAL JOINT
e. DIFFERENTIAL
f. HALF SHAFT
g. REAR WHEEL

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CHAPTER 8 CLUTCH SECTION……………………………37-38
A. CLUTCH
B. MAIN PARTS OF CLUTCH
a. CLUTCH COVER
b. PRESSURE PLATE
c. FRICTION PLATE
d. RELEASING SPRING
e. RELEASE LEVERS
f. PRESSURE SPRING

CHAPTRT 9 GEARBOX SECTION………………………….39-43

A. TYPES OF GEARBOX
a. SLIDING MESH GEARBOX
b. CONSTANT MESH GEARBOX
c. SYNCHROMWSH GEARBOX
B. MAIN PARTS OF ASHOK LEYLAND GEARBOX
a. MAIN SHAFT
b. COUNTER SHAFT
c. SELECTING TOWER
d. SELECTING FORK
e. IDLE GEAR
f. FORK PADS
g. SHIFTER SLEEVE DOWEL PIN

CHAPTER 10 DIFFERENTIAL SECTION……………………44-45

A. DIFFERENTIAL
B. MAIN FUNCTION OF DIFFERENTIAL
C. MAIN PARTS OF DIFFERENTIAL
a. RING GEAR
b. CASE
c. PLANET GEAR
d. SUN GEAR
e. BEVEL PINION
f. HALF SHAFT

CHAPTER 11 SUSPENSION SECTION……………………….46-47

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 A. SUSPENSION SYSTEM
B. FUNCTION OF SUSPENSION SYSTEM
C. REQUIREMENTS OF A SUSPENSION SYSTEM
D. LEAF SPRINF TYPE SUSPENSION
E. BUS LEAF SPRING DETAILS
F. MATERIAL

CONCLUSION……………………………………………………….48

INTERNSHIP CERTIFICATE……………………………………...48

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CHAPTER 1 OVERVIER

A. INTRODUCTION
The Uttar Pradesh State Road Transport Corporation (UPSRTC) is a public sector passenger
road transport corporation which services Uttar Pradesh, India, and adjoining states of North
India. It operates as a stare and interstate bus service and has the largest fleet of buses in North
India. The corporation are located in Lucknow.

B. HISTORY OF UPSRTC
Passenger road transport services in the state of U.P. started on 15th May, 1947 with the
operation of bus service on the Lucknow - Barabanki route by the erstwhile U.P. Government
Roadways.

At the time of establishment of the Corporation it had a fleet of 4253 buses which were operating
on 1123 routes. The corporation's earned kilometers operated at that time were 228.8 million
kilometers. While the total number of passengers carried by its buses totalled 251.3 million.

By the end of the decade the fleet of the corporation had attained a strength of 5679 buses, the
operations had increased to 1782 routes. As a result of this increase in operations, the earned
kilometers totaled about 395.3 million kilometers, while the total numbers of passengers carried
totalled over 449.1 million.

During the 4th Five-Year Plan, the erstwhile UP Government Roadways was rechristened as
Uttar Pradesh State Road Transport Corporation (UPSRTC) on 1 June 1972 under the provisions
of the Road Transport Act, 1950.

The end of the 6th five-year plan saw a further increase in the corporation's operational
parameters. With the increase in fleet strength of 6,198 buses, the earned kilometers of the
corporation rose to 425.7 million kilometers.

During the 7th five-year plan, emphasis was placed on strengthening the fleet of the corporation.
Thus, by the end of this plan period, the fleet had risen to 8,161 buses from the initial strength of
6,198.

By 1989-90, the corporation operates 2,525 routes covering 648.6 million kilometers and carried
471.2 million passengers.

During the 8th five-year plan, 2,722 buses were replaced with new buses.

However, 3142 buses were auctioned, and fleet at the end of 1996-97 became 7,463 buses.

During the 9th five-year plan, 2,427 buses were replaced and 3,785 buses were auctioned at the
end of 2001-02, the corporation had 6,105 buses.

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In the 10th five-year plan 5,274 buses were inducted and 4818 buses were removed from fleet.
At the end of 2006-07 the Corporation had 6,561 buses apart from 784 hired buses operated
under its control.

In the 11th five-year plan 4,518 buses were inducted and 4,189 buses were removed from fleet.
At the end of 2011-12 the Corporation had 6,890 buses apart from 1,763 hired buses operated
under its control.

In the 12th five-year plan 4,866 buses were inducted and 2,659 buses were removed from fleet.
At the end of 2016-17 the Corporation had 9,277 buses apart from 2,400 hired buses operated
under its control.

C. INFRASTRUCTURE OF UPSRTC
The corporation has been divided into 20 regions for efficient functioning of which 1 region
operates urban and suburban services. Each region has a regional workshop, where major repair
and maintenance, as well as assembly and reconditioning is performed. Each region has been
further divided into operational units called depots, of which there are 115, including car section.
Each depots as a workshop attached to it to provide supportive maintenance facilities.

D. LOGO OF UPSRTC

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 E. BUSES USED IN UPSRTC
 Buses primarily uses by Ashok Leyland, TATA and Volvo.
a. ASHOK LEYLAND

FIG 1.1 ASHOK LEYLAND BUD

b. TATA

FIG 1.2 TATA BUS

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CHAPTER 2 GARAGE TOOLS AND EQUIPMENT

1. HAMMERS:- Hammer is a striking tools which is used to strike on object.

FIG 2.1 HAMMER

2. PLIERS:- Plier are used to bend wires and grip small parts.

FIG 2.2 PLIER

3. SCREWDRIVER:- The screwdriver is used to install and remove screws.

FIG 2.3 SCREWDRIVER

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4. ADJUSTABLE WRENCH:- In addition to adjustable wrench has an adjustable
jaw which can be moved with an adjusting screw to vary the jaw width.

FIG 2.4 ADJUSTABLE WRENCH

5. DOUBLE END OPEN SPANNER:- Double ended wrenches that have “Two
Jaws” with parallel sides that fit snugly on nuts and bolts.

FIG 2.5 DOUBLE END OPEN SPANNER

6. RATCHET & SOCKETS:- A socket wrench is a type of wrench or spanner that

has a socket attached at one end, usually used to turn fast most prevalent form is a
ratching socket wrench often informly called a ratchet.

FIG 2.6 RATCHET & SOCKETS

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7. TORQUE WRENCH:- A torque wrench is a tool used to apply a specific torque to
a fastener such as a nut, bolt, or lag screw.

FIG 2.7 TORQUE WRENCH

8. FEELER GAUGE:- A feeler gauge is a tool used to measure gap widths. Feeler
gauges are mostly used in engineering to measure the clearance between two parts

.
FIG 2.8 FEELER GAUGE
9. LIFTING JACK:- Lifting jacks are used for leveling or positioning heavy
equipment, lifting automobiles and for supporting structures.

FIG 2.9 LIFTING JACK

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CHAPTER 3 ALTERNATOR SECTION
A. ALTERNATOR:- Alternator is a device which convert the mechanical energy into
electric energy.
B. MAIN PARTS OF ALTERNATOR:- D.E Bracket, Bearing, C.E. Bracket,
Freewheel pulley, Fan, Rotor, Stator, Rectifier, Regulator, Through bolt, Plastic cover,
Retainer plate

FIG. 3.1 ALTERNATOR

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a. STATOR:-
 A stator is the stationary part of a machine in the form of a hallow cylinder inside which
the rotor will be placed with a narrow air gap between them.

FIG. 3.2 STATOR

b. ROTOR:-
 The rotor is also known as the rotating magnetic core, or flywheel, of an alternator.
Rotors are the moving part in an alternator that have permanent magnets that move
around the stator‟s iron plates to generate an alternating current (AC).

FIG. 3.3 ROTOR

15
c. Rectifier:-
 The rectifier is used to convert alternating current (AC) produce to direct current (DC)
during the charging process.

FIG. 3.4 Rectifier

d. Regulator:-
 The voltage regulator is a part that controls the amount of power supply from the
alternator to the battery.

 FUNCTION:-
 Charging the battery.
 Automatic cut the current and ampere.
 The primary function of an alternator is to charge a car battery so that other electrical
components in the car can be powered.
 Alternator is convert the mechanical energy into electrical. energy. (24 volt, 55amp.)
 The R.P.M of alternator is 11000 to 14000.
 When the car is running, alternator generate energy to feed the electrical system and the
battery.

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CHAPTER 4 SELF STARTER SECTION

A. SELF STARTER:-Self starter is a device which is drive the engine flywheel by the
help of battery.
B. MAIN PARTS OF SELF STARTER:- Solenoid Switch, Solenoid Caps, Field
Coils, Brush Gears, Plunger & Contacts, Brush Sets, Armature, Bushes, Drive Pinion,
Pole Shoe, Etc.

FIG. 4.1 SELF STARTER

FIG. 4.2 SELF STARTER

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a. DRIVE PINION:-
 A pinion is a small mechanism containing gear and springs. It engages immediately the
engine starter, by extending the gear to the flywheel teeth. The flywheel is the source of
engine rotation.

FIG. 4.3 DRIVE PINION

b. ARMATURE:-
 An armature is an electromagnet component that is mounted on the driveshaft or bearing
for a guide. It is made of a laminated soft iron core which is wrapped with numerous
conductor loops or winding.

FIG. 4.4 ARMATURE

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c. COMMUTATOR:-
 On DC motors that purpose of the commutator is to insure that the current flowing
through the armature windings is always in the same direction.

FIG. 4.5 COMMUTATOR

d. SOLENOID SWITCH:-
 The solenoid features two coils of wire that are wrapped around the core. This solenoid
serves as a switch that connects and close the electrical connection between the starter
motor and the vehicle‟s battery.

FIG. 4.6 SOLENOID SWITCH

 FUNCTION:-
e. It is crank the engine.
f. It is crank in miner timing.
g. It is convert the electrical energy into mechanical energy.
h. The R.P.M of self starter is 11000 to 14000.

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CHAPTER 5 ENGINE SECTION
A. DIESEL ENGINE:- An internal combustion engine in which air is compressed to a
temperature sufficiently high to ignite fuel injected into the cylinder where the
combustion and expansion actuate a piston. Its called diesel engine.
B. MAIN PARTS OF DIESEL ENGINE:- cylinder block, cylinder head, piston,
connecting rod, compression ring, oil ring, camshaft, Rocker Arm, valves, valve spring,
valve stems, flywheel, crankshaft, cylinder liner, C.R Bearing, sump etc.

FIG. 5.1 DIESEL ENGINE

a. CYLINDER HEAD :-
 The cylinder head is bolted to the top of cylinder block.
 It contains combustion chamber.
 Injector and sometimes valves are mounted in it.
 The cylinder head usually made of gray cast iron or aluminum alloy.
 Aluminum has the advantages of lightness in weight and high heat conductivity.

FIG. 5.2 CYLINDER HEAD

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b. CYLINDER BLOCK:-
 Cylinder block serve as support and enclosure for moving parts. Cylinder block are
normally made of cast iron or aluminum alloy.
 A cylinder block consists of three parts:
1. The cylinders in which the pistons slide up and down.
2. The openings for the valves.
3. The passages for the flow of cooling water.
 The composition of a cast iron cylinder is as follows:
1. Carbon 2.2%
2. Silicon 1.2%
3. Manganese 0.63%
4. Sulphur 0.12%
5. Phosphorus 0.85%
6. Iron 95%
 A typical aluminum alloy composition for cylinder and piston consists of:
1. Aluminum 91%
2. Tin 2%
3. Copper 7%

FIG. 5.3 CYLINDER BLOCK

c. CYLINDER LINER:-
 Cylinder liner or sleeve is used to protect the cylinder wall. Cylinder liner is inserted into
the bore of cylinder block. Cylinder liners are mainly made of aluminum alloy and cast
iron.
 Chromium plating is done on the cylinder liner to make it wear resistant.

21
 FIG. 5.4 CYLINDER LINER

d. PISTON
 Piston is considered to be one of the most important parts in a reciprocating engine in
which it helps to convert the chemical energy obtained by the combustion of fuel into
useful mechanical power. Pistons are made of aluminum alloy.
 The piston performs the following function:
1. To receive the thrust generated by the explosion of the gas in the cylinder and transmit it
to the connecting rod
2. To reciprocate in the cylinder as a gas tight plug causing suction, compression,
expansion, and exhaust strokes.

FIG. 5.5 PISTON

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e. CONNECTING ROD:-
 The connecting rod is the connection between piston and crankshaft. Small end of the
connecting rod is connected to the piston pin and big end is connected to the crank pin
with inside main journal bearing. The main function of connecting rod is to convert the
liner or reciprocating motion of the piston to rotary motion of crankshaft.
 Aluminum alloy is also used for connecting rod.

FIG. 5.6 CONNECTING ROD

f. CRANK SHAFT:-
 It is the converted the reciprocating motion of piston into rotary motion with the help of
connecting rod. The part of the crankshaft inside the main bearings are called the main
journals.
 Crankshaft must have strong and rigid. It is made of forged steel or cast iron.

FIG. 5.7 CRANK SHAFT

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g. FLYWHEEL:-
 Flywheel is a heavy steel wheel attached to the rear end of the crankshaft. The size of
flywheel is depends upon the number of cylinder and general construction of the engine.
The engine delivers power during one stroke only the power stroke and it absorbs power
during the other stroke.
 Flywheel used in engines are made of cast or nodular iron, steel or aluminum.
 It also has teethes on its periphery to mesh with electric cranking motor drive pinion
when engine is being cranked to start it.

FIG. 5.8 FLYWHEEL

h. VALVES:-
 Valve is a device to close and open a passage. In motor vehicle engines two valves are
used for each cylinder- an inlet valve and an exhaust valve. Exhaust valve is usually
made of silchrome steel which is an alloy of silicon and chromium with unusual
resistance to heat . Inlet valve is being subject to less heat usually made of nickel
chromium alloy steel.

FIG. 5.9 VALVE

24
i. CAMSHAFT:-
 A camshaft is simply a shaft on which cams are mounted. The camshaft is mounted in
lower part of the cylinder block in most in-line engines. In a few engines it is located on
the cylinder head.
 A camshaft has a numbers of cams along the length, two cams for each cylinder one to
operate inlet valve and other to exhaust valve. In addition, camshaft has an eccentric to
operate the fuel pump and gear to drive the ignition distributers and oil pump.
 The camshaft is drive by crankshaft by a pair of timing gears.

FIG. 5.10 CAMSHAFT

j. OIL PUMP:-
 It is generally located inside the crankcase below the oil level. The function of oil pump
is to supply oil under pressure to the various engine parts are lubricated.

k. OIL PAN OR SUMP:-

 The oil sump contains the engine oil required for lubrication. The oil is extracted from it
by an oil pump and conveyed into the engine block oil ducts via the oil filter. The oil then
floes back into the oil sump from the lubrication points.

FIG. 5.11 OIL SUMP

25
l. CYLINDER HEAD GASKET
 A gasket is placed between the cylinder head and cylinder block to retain compression in
the cylinder to prevent leakage and to ensure metallic tight fit joint. The gasket should
able to withstand not only high pressure but also extreme temperature.
 Following important gaskets are used in automobile engine:
1. Copper-asbestos Gasket
2. Steel- asbestos Gasket
3. Steel- asbestos -Copper Gasket
4. Single steel rigid or Corrugate Gasket
5. Stainless steel gasket

FIG. 5.12 CYLINDER HEAD GASKET

m. PISTON RINGS:-
 Piston rings are fitted into the grooves of the piston to maintain good seal between the
piston and cylinder wall.
 TYPES OF RINGS:-
1. COMPRESSION RINGS: Compression rings seal in the air-fuel mixture as it is
compressed and also the combustion pressure as the mixture burns.
2. OIL CONTROL RINGS: oil control rings scrape off excessive oil from the
cylinder wall and return it to the sump.

FIG. 5.13 PISTION RINGS

26
CHAPTER 6 TYRE SECTION
A. HISTORY OF TYRE:
 A tire (American English) or tyre (British English) is a ring-shaped component that
surrounds a wheel's rim to transfer a vehicle's load from the axle through the wheel to the
ground and to provide traction on the surface over which the wheel travels.

B. FUNCTIONS OF TYRES:
 It supports the load on vehicles.
 It absorbs shock during motion.
 It enables to take turn to left or right.
 It helps to get best acceleration and braking.

C. Basis of Construction:
1. CROSS PLY TYRE CONSTRUCTION

FIG. 6.1 CROSS PLT TYRE

 ADVANTAGES OF CROSS PLY TYRE:

 These tyres provide high vehicle stability.
 They also provide good resistance against sidewall damages.
 These tyres are economical as their production is cheaper.

 DISADVANTAGES OF CROSS PLY TYRE:

 Due to the rolling resistance these tyres heat up quickly.
 Cross ply tyres bring rigid, prove to be less comfortable.
 Due to high resistance of the tyre, the fuel consumption is high.

27
2. RADIAL PLY TYRE CONSTRUCTION

FIG. 6.2 RADIAL PLY TYRE

 ADVANTAGES OF RADIAL PLY TIRE:

 These tyre have a lower rolling resistance loss which leads to less fuel consumption.
 They have a longer tread life as less heat generated.
 They provide better braking efficiency.

 DISADVANTAGES OF RADIAL PLY TIRE:

 These tyres have a steel belt due to which it does not fare well against minor bumps in the
load.
 Their soft sidewalls are vulnerable.
 Due to harder tread they make huge noise.

28
FIG. 6.3 TYRE CONSTRUCTION

29
EXAMPLE:- P-175/70 R14 84T, LT-175/70 R14 84T

 P=Passenger car
 LT= Light truck
D. TYRE RETREADING: Retreading allows tyre to perform same as a new tyre
adding extra mile to your tyre life.

FIG. 6.4 TYRE RETREADING

E. MAIN PARTS OF TYRE RETREADING:- Curing Bag, Flap, Rim Supporter,

Rim Plate Cushion, Rubber Solution

a. RIM SUPPORTER:-
 The rim plate is placed on top of the rim supporter.

FIG. 6.5 RIM SUPPORTER

30
b. CURING BAG:-
 Curing bag is used to fill air in tyres during tyre retreading process.

FIG. 6.6 CURING BAG

c. FLAP:-
 The flap is used to support the curing bag so that it does not come out during tyre
inflation.

FIG. 6.7 FLAP

31
d. RIM PLATE:-
 The tyre is locked with a rim plate before being sent to the cold caring chamber.

FIG. 6.8 RIM PLATE

 Nylon tyre life better than radial tyre.

FIG. 6.9 RADIAL TYRE

32
 FIG. 6.10 NYLON TYRE

 Bus Tyre Size:- 9.00R20

F. Machine Used Of Tyre Section: Rubber Press Machine, Buffing Machine, Cold
Caring Chamber, Common Rail Machine

a. COMMON RAIL MACHINE:-

 Common rail machine is a hydraulic pressure driven machine. In this, the tyre is tied and
sent to the cold caring chamber through the rail.

FIG. 6.11 COMMON RAIL MACHINE

33
b. RUBBER PRESS MACHINE:-
 The rubber press machine is used to pasting the rubber of the tyre and it is operated by
hydradulic pressure.

FIG. 6.12 RUBBER PRESS MACHINE

c. COLD CARING MACHINE:-

 The curing process sees the „built‟ tyre placed into a hot, segmented radial matrix within
a curing press. The tyre is heated for up to 95 minutes at 155°C.

FIG. 6.13 COLD CARING CHAMBER

34
d. BUFFING MACHINE:-
 The buffing process removes the remaining tread and sidewall rubber from the casing to
the exact specified dimensions by means of high-speed revolving rasps and brushes.

FIG. 6.14 BUFFING MACHINE

G. PROCEDURE:-

1) Initial Inspection:- The first part of the retreading process is to inspect the tyre to see
whether it meets with our stringent quality specifications.

2) Buffing:- The buffing process removes the remaining tread and sidewall rubber from
the casing to the exact specified dimensions by means of high-speed revolving rasps and
brushes.

3) Building:- During the Building process, new tread material is applied, or stitched, to
the casing using a patented computer-controlled process. A continuous strip of premium
rubber compound is wrapped around the tyre whilst it revolves on an inflatable chuck.

4) Curing:- The curing process sees the „built‟ tyre placed into a hot, segmented radial
matrix within a curing press. The tyre is heated for up to 95 minutes at 155°C.

5) Final Inspection:- Once the cured tyres have been deflated, removed, cooled and
trimmed, they are ready for the Final Inspection process.

35
CHAPTER 7 TRANSMISSION SYSTEM

A. TRANSMISSION SYSTEM OR RUNNING SYSTEM:- The transmission

system takes engine power and transmit the wheel in a smooth way according to the
requirement is called transmission system.

 ENGINE – CRANKSHAFT – FLYWHEEL – CLUTCH – TRANSMISSION BOX TO

DIFFERENTIAL – FINAL DRIVES – HALF AXLE – DRIVE WHEEL.

B. MAIN PARTS OF TRANSMISSION SYSTEM:- Gear Box, Clutch, Propeller

Shaft, Universal Joint, Differential, Half Shaft, Rear Wheel Etc.

FIG. 7.1 TRANSMISSION SYSTEM

36
CHAPTER 8 CLUTCH SECTION
A. CLUTCH:- Clutch is a device used in the transmission system of a motor vehicle to
engage and disengage the engine to the transmission. Thus, the clutch is located between
the engine and the transmission.

FIG. 8.1 CLUTCH

B. Main Parts Of Clutch:- Clutch cover, Pressure plate, Friction plate, Releasing
spring, Release levers, Pressure spring

a. FRICTION PLATE:-
 A friction clutch plate is used in vehicles to allow the transmission input shaft and engine
to run at the same speed when rotating.

FIG. 8.2 FRICTION PLATE

37
b. CLUTCH COVER:-
 The clutch cover is an essential component of the clutch system presenting a separable
connection between the engine and the drive train, and furthermore serves the
transmission of power.

FIG. 8.3 CLUTCH COVER

c. PRESSURE SPRING:-
 The function of these short coil spring is to continuously hold the friction and driven
plates together through spring tension, preventing slippage except when the clutch lever
is engaged.

FIG. 8.4 PRESSURE SPRING

38
CHAPTER 9 GEARBOX SECTION
A. TYPES OF GEARBOX:- Four types gearbox used in automobile.

• Sliding mesh gearbox

• Constant mesh gearbox

• Synchromesh gearbox

 Synchromesh Gearbox:-The modern cars/buses use helical gears and synchromesh

devices in the gear boxes that synchronize the rotation of gears the are about to be
meshed. The gears on the lay shaft are fixed and the main shaft gears are free to rotate.
 Advantages:
 Gear changing is very much simplified.
 Reduction in gear we occurs.
 It allows the usage of helical gears that run quietly.
 Disadvantages:
 The design is very much complex.
 Initial cost is high

B. Main Parts Of Ashok Leyland Gearbox:- Main shaft, Counter shaft,

synchronizer device, selecting tower, selecting fork, idle gear, fork pads, Shifter sleeve,
Dowel pinetc.

FIG. 9.1 ASHOK LEYLAND GEAR BOX

39
 FIG. 9.2 SELECTING TOWER

 Main Parts Of Leyland Gear Box Main Shaft:-2nd Gear N.R.B, 2nd Gear, 2nd
Synchronizer Cone Or Synchronizer Ring, 1st Or 2nd No. Gear Hub, Shifter Sleeve (Dog
Clutch), Fixed Dog Clutch, Reverse Gear, Sleeve, 3rd Gear N.R.B, 3rd Gear, 3rdOr 4th No.
Hub, 4th No. Gear Synchronizer Ring Or Synchronizer Cone, 4th Gear, 4th Gear N.R.B Or
4th Gear Sleeve, 5th Gear, 5th Gear N.R.B, 5th Or 6th No. Gear Synchronizer Kit, lock or
circlip, Etc.

a. MAIN SHAFT:-
 It is the shaft that runs at the vehicle speed. It carries power from the counter shaft by use
of gears and according to the gear ratio.

FIG. 9.3 MAIN SHAFT

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b. LAY SHAFT:-
 A lay shaft is a shaft that connects with the clutch shaft directly. It contains the gear
which connects it to the clutch shaft as well as the main shaft.

FIG. 9.4 LAY SHAFT

c. CLUTCH SHAFT:-
 A clutch shaft or driving shaft is a shaft that takes power from the engine to further
supply to other shaft. The clutch shaft has only one gear fixed on it and it rotates at the
same speed as the engine crankshaft.

FIG. 9.5 CLUTCH SHAFT

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d. IDLER GEAR:-
 The idler gear is used to reverse the vehicle.

FIG. 9.6 IDLER GEAR

FIG. 9.7 ALL COMPONENTS OF MAIN SHAFT

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1. Clutch Shaft :-
 It is the input shaft to gearbox
 Its outer end is connected to the clutch disc.

2. Lay Shaft :
 The lay shaft is freely suspended in bearing mounted on the transmission case.
 It has gears rigidly mounted/machined on it.

3. Main Shaft :-
 It is output shaft of the gearbox.
 its outer end is connected to the propeller of the shaft through universal joint.

4. Bearings :
 Generally, taper roller bearings are used.
 These bearings are required to take radial and thrust load during gear engagement.

5. Reverse Idler Shaft :

 It is a short shaft that supports the reverse idler gears.

6. Transmission Gears :
 These gears can be grouped into
Gears on clutch shaft - rigidly attached/machined
Gears on lay shaft - rigidly attached/machined
Gears on main shaft - free to rotate on main shaft

7. Selector mechanism :
 The selector mechanism employed is similar to that used on sliding mesh gearbox.

8. Transmission case :
 It provides support for bearing and shafts.
 It also provides and enclosure for lubricating oil.
 Generally it is made up of aluminum to reduce weight.

9. Working:-
 In the synchromesh gearbox, gear shifting is the done with the help of a shift fork.
 The gear lever is connected to the shift fork and the shift fork is connected to the sliding
sleeve. Hence when the driver shifts the gears, the shift fork moves the sleeve in the hub.
 When the sleeve moves on the hub it presses the synchronizer ring or the cone and then
sleeve internally locks the cone and hub by internally meshing.
 The synchronizer ring pressed on the cone the output shaft starts to rotate at the speed or
gears. Hence synchronizer ring helps in bring the speed of all shafts to the same.
 A sliding sleeve helps in the engagement of gears by internally locks the cone and hub by
internally meshing.

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CHAPTER 10 DIFFERENTIAL SECTION
A. Differential: The differential is a set of gears, that transfers engine torque to the
wheels. It takes power from the engine and delivers it, allowing each wheel to rotate at a
different speed on turns.In1827, the first conventional automobile differential was
invented by a French watchmaker OnésiphorePecqueur. It was used in steam-powered
vehicles.

B. Main Function Of The Differential Are As Follows:-

• It allow the inner rear wheel to revolves slowly and the outer wheels revolves faster when
the vehicle is at turn.

• It converts the drive to an angle of 90 degree.

• Power transmit at 90 angle.

• In turning condition rpm transfer at outer wheel.

• Uneven rod surface rpm transferring.

C. MAIN PARTS OF DIFFERENTIAL: Half Shaft, Ring Gear (Crown Gear),

Cage, Planet Gear, Sun Gear, Bevel Pinion, Bolts Etc.

a. Side Gear Or Sun Gear:- The differential consists of a two sun gear. It is mounted
on the inner ends of each axle. In this two sun gears are fixed together to combine both
the driving and driven shaft at 90 degree angle.

FIG. 10.1 DIFFERENTIAL

b. Axle Shafts Or Half Shafts:- An axle shaft is a solid shaft that is located between
the differential and gear set of an axle housing. It transfers rotational force from
the transmission system to the wheels attached to the axles.

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c. Ring Gear Or Crown Gear:- They act an equalizer in dividing the torque between
the two driving wheels while allowing one to turn faster than the other.

d. Drive Pinion Or Bevel Pinion:- The driver shaft is connected to the drive pinion
by a universal joint and it engages with a ring gear. Therefore, when the driver rotates the
shaft the drive pinion rotates, and thus, the ring gear rotates.

e. Planet Gears:- Planetary gears are used in the differential. Since the axles of the
planetary gears rotate around the common axis of the sun and ring gear that coincides and
rolls in the middle of the differential system.

f. Differential Case Or Housing:- A differential case is attached with two-wheel

axles and differential side gears. It is consists of bearings that rotate two axle shafts.

FIG. 10.2 REAR DIFFERENTIAL DETAILS

FIG. 10.3 REAR DIFFERENTIAL DETAILS

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CHAPTER 11 SUSPENSION SECTION

A. DEFINITION OF SUSPENSION SYSTEM:-

 The function of the suspension system is to absorb vibration due to the up and down
motion of wheels, caused by the irregularities in the road surface.
 The suspension system is two types:-

1. Rigid System:-In the rigid system the road spring are attached to a rigid beam axle. It
is mostly used in the front axle of commercial vehicles and in the rear axle of all types of
vehicles.

2. Independent System:-The independent system is mostly used in small cars.

B. Function Of Suspension System:-

1. To prevent the road shocks from being transmitted to the vehicle frame.
2. To prevent the stability of the vehicle in pitching or rolling, while in motion.
3. To safeguard the occupants from road shocks.
4. To provide good road holding while driving, cornering and braking.
5. To maintain proper steering geometry.

C. Requirements Of A Suspension System:-

1. Minimum deflection consistent with required stability.
2. Comparability with other vehicle components – tyre, frame, wheel base, steering
linkage.
3. Minimum wheel hop.
4. Low maintenance and operating costs.
5. Low initial cost.
6. Minimum weight.
7. Minimum tyre wear.

D. Leaf Spring Type Suspension:-Leaf spring consists of a number of leaves, made of

steel plates, of increasing lengths from the center. All the leaves are clamped by a center
bolt at the center and side clamps at the sides so that the leave are in position. Main leaf is
the longest one having bent ends, called the spring eyes. The spring eyes is connected to
the frame by shackle. The center portion of the spring is connected to the front axle by U-
bolt.

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 FIG. 11.1 LEAF SPRING

E. Bus Lead Spring Details:-

No. of front leaf spring use – 12, No. of rear leaf spring use – 15 or requirement of load

F. Material:- Medium carbon steel (carbon 0.9-1.2% gram)

FIG. 11.2 LEAF SPRING

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 CONCLUSION

During my three months of internship period,As my training comes to end here in UPSRTC
AGRA. I would like to share my experience with you. I learned to repair the damage components
of the bus. It was the result of training only that to see the object in real. Practical use which I
had only read about and seen as 2d objects in the book. I wholeheartedly thank all the support
staff of UPSRTC for providing me the opportunity to training.

According to me summer training help me in the following ways-

 It helps in developing skills for a particular field.

 It gives us a chance to come across the industrial culture.
 It tells us the combination between the theoretical and practical knowledge.
 It creates a knowledge environment around us to improve our skills and get the
specialization.

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THANK YOU

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