GOVT.

POLYTECHNIC
AMBALA CITY

Industrial Training Report

on Haryana Roadways
Workshop
 Introduction Myself

Name: Rahul
Father Name : Karmbir
Roll No :240011700094
Branch : Mechanical
Engg.
Section : ‘B’
Semester : 3rd
Certificate
 PROJECT PROFILE

Project Name : Ashok buses maintenance

Project Scope : Student can work on
The Basic of project work
Project Duration : Four week
Team Strength : 1 Student
External Guide : Mr.Jagseer Kumar
Internal Guide : Mr. Sunil
Submitted TO : Govt. Polytechnic Ambala
 COMPANY PROFILE

Company Name : Haryana Roadways workshop

Company Address : Near by Main Busstand,
Hisar.
Founded by : Mr. Rahul Mittal
Work : To Repair Gearbox &
Clutchplate.
 Acknowledgement

I am fortunate to have my training at Haryana

Roadways Workshop , Hisar . The Environment of the
factory which gives the evidence of true work culture
where every worker attends his duty.

I would like to thank all faculty member of Haryana

Roadways for guidelines supporting me in the
completion of project from time to time.

I thankful to all the Lectures of Mechanical Engineering

Department for their valuable suggestion and timely
help.I have enhanced of my guides Mr Rakesh Dadhwal
Head of the Department of Mechanical
engineering .GOVERNMENT POLYTECHNIC AMBALA
CITY ,HARYANA.

At last , I would like to thank the management of my

college and university for introducing this training
report in our study curriculum.
ABOUT WORKSHOP

⮚ Gearbox shop
⮚ Radiator shop
⮚ Engine shop
⮚ Paint shop
⮚ Washing shop
⮚ Pump shop
⮚ Tyre repair shop
⮚ Electrical shop
⮚ Welding shop
⮚ Grinding shop
 Safety rules

1. Do not wear flowing clothing and

adornments such as wrist watch,
necklace, tie and loose sleeve, etc.
2. Do not play rough (horse play) in the
workshop
3. Machines and tools should be
maintained before and after use.
4. The workshop floor should not be
slippery
5. Machines must be switched off when
not in use.
6. Proper training must be given before
operating any machine and tool.
7. Keep your workspace clean.
8. Use right equipment.
9. Follow safety regulation.
10.Maintain machines and tools.
11. Proper training in essential.
 Service and maintenance of buses

When it comes to service and maintenance of

workshops in buses, it is important to prioritize
regular maintenance to ensure the safety and
reliability of the bus fleet. A routine bus
maintenance strategy will promote safety and
compliance with state or federal regulations 1.
Bus maintenance tasks and work orders
encompass a wide range of activities that are
designed to keep the bus in good working
condition, prevent breakdowns, and prolong the
life of the bus. These tasks include regular
inspections, cleaning, and repairs of the bus and
its components, as well as routine maintenance
such as oil changes and fluid level checks 1.
If you are responsible for a small fleet of school
buses or a large fleet of city buses, it is important
to follow best practices and stay up to date on
the latest techniques and technologies to
improve your maintenance crew’s efficiency and
allow your business to remain competitive
 Introduction of Gearbox
A gearbox is often called a transmission. A gearbox simply
refers to a set of gears and their casing, most commonly found
in automobiles. Since most automotive
efficiently and also help slow down and stop the machine
Gearboxes are used to transfer energy from one rotational
power source to another and are found in automobiles,
turbines, and heavy machinery. In this article, you will learn

about gearboxes and their types.

 Parts Of GearBox

1. Main Shaft: ( Components of

Gearbox )
Main shaft is the output shaft in a gearbox. This shaft is kept
parallel to the lay shaft and in front of the clutch shaft or engine
output shaft. The gears are changed using this shaft because it is
connected to the gear lever
2. Clutch Shaft: ( Components of
Gearbox )
This shaft is used to carry the output from the engine to the
gearbox. It helps to engage and disengage the engine output.

3. Lay Shaft: ( Components of

Gearbox )
The lay shaft is used to transfer the output of the engine to the
main shaft by the continuous meshing of a gear on the lay shaft
to the gear on the clutch shaft.
4. Gears: ( Components of Gearbox )
Gears are basically connecting circles with teeth on them. They
rotate and meshes with another gear on the different shaft so as
to transmit the circular motion between 2 different shafts. There
are different types of gear such as –spur gear, helical gear, bevel
gear and worm gear.
5. Synchromesh Shaft: ( Components
of Gearbox )
They are the special devices used in modern gearbox
(synchromesh gearbox) .They make the shifting of gears smooth
by maintaining same speed of main shaft, lay shaft and clutch-
shaft. They don’t have to slide over the shaft for the shifting of
the gear.
6. Gear lever: ( Components of
Gearbox )
This lever is operated by the driver to change or shift the gear.
The movement of the lever is designed in a specific manner.

Tools For open Gearbox

1. Gizmo circlip plier :- Circlip pliers are a particular type of
hand tool designed for installing and removing C-clips.

2. Plug Socket Key :- A plug socket key tool is a device that is

used to lock and unlock plug sockets. It is also known as
a plug key or a socket key

3. Spanner :- A spanner is a tool used to grip and turn nuts or

bolts. It has a shaped opening or jaws that can be
adjusted to fit different sizes of nuts or bolts

4. Ring spanner :- A ring spanner is a type of wrench that has a closed

loop at one or both ends. The closed loop is designed to fit over the head
of a bolt or nut, providing a secure grip and allowing the user to apply
torque to the fastener. Ring spanners are a
 5. Screw driver:- A screwdriver is a tool used for turning screws. It
consists of a handle and a shaft, ending in a tip that fits into the head of a
screw to turn it 1. Screwdrivers come in various sizes to accommodate
different screws 2
`

Classification of gear box

A gearbox is a mechanical device that transmits power from an

engine to the wheels of a vehicle. It is located between the
clutch and the propeller shaft 1. There are several types of
gearboxes, including sliding mesh type gearbox, constant-mesh
type gearbox, synchromesh gearbox, and epicyclic
1
gearbox . The main components of a gearbox include the main
shaft, clutch shaft, lay shaft, synchromesh shaft, gears, and
gear lever 1. Gears come in a variety of shapes and sizes,
including spur gear, helical gear, bevel gear, and worm gear 1.
● Concentric: the input and output shafts are aligned on
the same axis
● Parallel: the input and output shafts are parallel but not
on the same axis
● Right angle: the input and output shafts are
perpendicular to each other
● Shaft mount: the gearbox is mounted directly on the
driven shaft
● Helical: the gears have teeth that are cut at an angle to
the axis of rotation
● Coaxial helical inline: a type of helical gearbox where
the input and output shafts are concentric
● Bevel helical: the gears have teeth that are cut on a
conical surface
● Skew bevel helical: a type of bevel helical gearbox
where the gears are not mounted on intersecting shafts
● Worm reduction: the gears have a worm and a worm
wheel that reduce the speed and increase the torque
● Planetary: the gears have a sun gear, a ring gear, and
several planet gears that rotate around the sun gear
 Types of gear box

Following are the types of gearbox used in modern

vehicles:

1. Sliding mesh type gearbox

2. Constant-mesh type gearbox
3. Synchromesh gearbox
4. Epicyclic gearbox

1. Sliding mesh gearbox: This type of gearbox is the simplest

and oldest type of gearbox. It consists of a set of gears that slide
on the main shaft and mesh with the corresponding gears on the
layshaft. The gears are moved manually using a gear lever.

2. Constant mesh gearbox: This type of gearbox is similar to the

sliding mesh gearbox, but it has a constant mesh between the
gears on the main shaft and layshaft. The gears are always in
mesh, but only one gear on each shaft is free to rotate at any
given time.

3. Synchromesh gearbox: This type of gearbox is similar to the

constant mesh gearbox, but it has synchromesh devices that
help to match the speed of the gears before they are engaged.
This makes it easier to shift gears smoothly.

4. Epicyclic gearbox: This type of gearbox uses a planetary gear

system to achieve different gear ratios. It is also known as an
automatic transmission.
 sliding mesh gearbox
constant mesh gearbox

Purpose of gearbox
A gearbox is a mechanical device that is used to increase the output
torque or change the speed of a motor 1. It is often called a
transmission and consists of a set of gears and their casing, most
commonly found in automobiles 1. Since most automotive engines
have high operating and idle speeds, transmissions allow the machine
to run efficiently and also help slow down and stop the
machine 1. Gearboxes are used to transfer energy from one rotational
power source to another and are found in automobiles, turbines, and
heavy machinery 1. The most basic definition of a gearbox is that it is
a mechanical unit or component consisting of a gear train or set of
gears embedded in a housing 1. In fact, the name itself defines it as a
box containing gears 1. In the most basic sense, a gearbox works like a
gear system. Change torque and speed between a drive, such as a
motor, and a load. Gears in gearboxes can be one of several types,
from bevel and helical gears to worm gears and planetary gears 1.
 Manufacturing of gearbox

Gear manufacturing is a complex process that requires

precision and expertise. The process of manufacturing
gears varies depending on the type and application of
the gear. Gears are used in various industries, including
the automobile industry, aerospace sector, industrial
machinery, and more. The most common types of gears
are spur gears, helical gears, bevel gears, worm gears,
and rack and pinion. The manufacturing process for
gears involves several steps such as casting, forging,
extrusion, and more 1.
There are several companies in India that specialize in
gear manufacturing. Some of the leading companies
include PTB 2, Shanthi Gears Limited 3, and Transtech
Gears Pvt 4. These companies design and manufacture
gears, gearboxes, geared motors, and gear assemblies
using their contemporary integrated manufacturing
facilities.

Introduction of clutch plate

The clutch plate is a component of the clutch system in a
bus. It is the driving member of the clutch and is gripped
between the flywheel and the pressure plate 1. The clutch plate
slides on the splined hub and is tightly gripped between the
pressure plate and the flywheel. The friction between the
linings on the clutch plate, and the flywheel on one side and
the pressure plate on the other, cause the clutch plate and
hence, the driven shaft to rotate
 Parts of clutch plate
Rivets:- Rivets are used to hold together the rotating component and the
friction lining of the clutch 1. In a clutch assembly, the clutch plate is the
driving member of the clutch and is gripped between the flywheel and the
pressure plate. It is mounted on the clutch shaft through the
splines. When it is gripped, it rotates the clutch shaft and the power is
transmitted from the engine to the transmission through the clutch 2. The
rivets used to attach facings to clutch components in automotive
transmissions are called clutch facing rivets

Cushioning springs:- A cushioning spring, also

known as clutch disc facing spring, is a flat metal
spring located under the friction lining of the clutch
disc. It has a slight wave or curve, allowing the lining
to flex inward slightly during initial engagement,
which results in smooth engagement. The cushion spring is a thin wavy
steel disc placed between the clutch friction pads and is designed with
different radial stiffnesses in order to ensure the desired smoothness of
engagement. The springs mounted on the inner hub of the clutch plate
cushion the clutch engagement and work as a torsional vibration damper
to absorb fluctuations in the engine’s
power delivery

Torsional coil springs:- Torsional springs are mounted on the inner

hub of the clutch plate to cushion the clutch engagement and absorb
fluctuations in the engine’s power delivery. They work as dampers to
make the power delivery smoother and more linear than if there were no
springs. Torsional coil springs allow the clutch disc to rotate slightly in
relation to the pressure plate while they absorb the torque forces,
therefore reducing shock of re-engagement. Torsion springs are designed
to store and release rotational energy
 Types of
clutch plate
Clutch Plate | Types Before this, you know how
the clutch plate works, now we know how many
types of clutch plates are there, then for your
information, let us tell you that there are mainly
6 types of clutch plates which are as follows
Single plate clutch:- A single plate clutch is a type of friction
clutch that is used to connect and disconnect the engine from the transmission
system. It consists of a single clutch plate that is mounted on the splines cut off
the driving shaft, and the flywheel is mounted on the engine crankshaft and
rotates with it 1.

Multi-plate clutch:- A multi-plate clutch is a type of clutch that has

multiple clutch plates instead of only one clutch plate as in the case of a single-
plate clutch. The increased number of friction surfaces obviously increases the
capacity of the clutch to transmit torque 1. The construction or main parts of a
multi-plate clutch include flywheel, pressure plates, clutch hub or inner hub,
clutch pedal, steel plates or driven plates, friction plates or drive plates, and
clutch springs 1.

Centrifugal clutch plate:- A centrifugal clutch is a

mechanical device that transfers rotational power from an
engine to a transmission in a vehicle to facilitate gear
changes 1. The clutch plate is a circular, disc-shaped
component made of friction material that is located inside the
clutch basket and is in direct contact with the clutch
shoes 2. The clutch plate is designed to provide the necessary
friction to transmit power from the engine to the driven
equipment 2

Purpose of clutch plate

The clutch plate is a crucial component of the
clutch system in a vehicle. It is the driving
member of the clutch and is gripped between
the flywheel and the pressure plate 1. When it is
gripped, it rotates the clutch shaft and transmits
power from the engine to the transmission
through the clutch 1. The clutch plate is mounted
on the clutch shaft through splines and carries
friction materials on both of its surfaces 1. The
primary function of a clutch is to enable the
driver to disconnect the engine from the driving
wheels instantaneously and to engage drive from
the engine to the driving wheels gradually while
moving the vehicle from rest 1.
 Introduction of radiator
Radiators are used to convert thermal energy from one
mode to another for the purpose of cooling and heating.
Radiators function in automobiles, buildings as well as
in electronics. It acts as a source of heat to the
surrounding but might be the purpose of heating the
environment, it acts as a coolant source for automotive
engine cooling.
Radiators transfer most of their heat via convection
rather than thermal radiation. If there are large
temperature differences, it can cause distortion of the
engine components.
The radiator will do the cooling purposes because the
temperature of the burning gases in the engine cylinder
reaches up to 1500 to 2000°C.

If the heat is not dissipated there can be a failure of the

cylinder

material. Radiators can reduce the chances of piston

seizure and keep the temperature minimum.

Parts of radiator
Filler cap:- A filler cap is a small mechanical device that is
used to control the pressure of the hot coolant in the radiator 1.
It is also known as a radiator pressure cap.

Cooling fins:- Cooling fins are thin metal pieces that are
in contact with tubes carrying liquid pumped through the
radiator. They increase the surface area available for heat
exchange with the surroundings, allowing air or other exterior
fluid to carry off heat and cool off the fluid. Fins enhance heat
transfer from a surface by exposing a larger surface area to
convection and radiation.
Outlet to engine:- The outlet and inlet tank are
the parts of the radiator where the coolant flows in and out of
the radiator. They are located in the radiator head, which is
made of metal or plastic. The hot coolant flows through the
inlet portion to the radiator from the engine and from the outer
portion to the engine.

Core tubes:- Tubular Core Type is a type of radiator where

the upper and lower tanks are connected by a series of tubes
that pass water within the radiator. The tubes are surrounded
by fins that help in efficient heat transfer. The heat from the
coolant is absorbed by the fins and transferred to the
atmosphere through fans

Inlet from engine:- he inlet tank of a radiator is the part of

the radiator that receives hot coolant coming from the engine 1.

Defects in radiators

● High temperature gauge

readings
● Coolant leaks
● Coolant discoloration
● Cabin heater not working
● Blocked radiator fins
 ● Leaking coolant onto the floor
● Vehicle overheats
● Sludge in the radiator
● Low coolant

Trick to fix the

radiator
1.Bleeding the radiator valve to release
trapped air and improve heat distribution.
2.Replacing the steam radiator vent to
regulate the steam pressure and prevent
banging noises.
3.Applying epoxy putty to seal small leaks or
cracks in the radiator.
4.Flushing the radiator to remove dirt and
debris that can clog the system and reduce
efficiency.
5.Installing a new radiator valve to control
the flow of hot water and adjust the
temperature.

Introduction of engine
The engine is the power unit of a bus. It is
responsible for converting fuel into mechanical
energy that propels the vehicle. Bus engines are
typically internal combustion engines, which
means they burn fuel within the engine to create
energy. The first internal combustion engine
buses were used in 1895 1.
Bus engines come in different sizes and
configurations, depending on the size and
intended use of the bus.
In addition to size, bus engines can also be
classified based on their fuel type. Diesel engines
are the most common type of engine used in
buses, but there are also buses that run on
gasoline, propane, or natural gas 2.

Parts of bus engine

A bus engine is a complex machine that converts
fuel into mechanical energy to power the
vehicle. The engine is the main working
component of a bus 1. It is composed of several
parts, including the following:

1. Cylinder block: This is the main

structure of the engine and houses the
cylinders, pistons, and crankshaft.
2. Cylinder head: This covers the top
of the cylinder block and contains the
combustion chamber, valves, and spark
plugs.
3. Pistons: These are cylindrical
components that move up and down
inside the cylinders to convert fuel into
mechanical energy.
4. Connecting rods: These link the
pistons to the crankshaft and transfer
power from the pistons to the
crankshaft.
5. Crankshaft: This converts linear
motion into rotational motion and
transfers power from the connecting
rods to the transmission.
6. Camshaft: This controls the opening
and closing of valves in the cylinder
head.
7. Valves: These control the flow of fuel
and air into and out of the combustion
chamber.
8. Spark plugs: These ignite the fuel-
air mixture in the combustion chamber.
Common defects in bus
engine
I found a pre-trip inspection checklist for
buses that can help you identify mechanical
issues, defects, and damages in the bus
engine 1. The checklist is divided into
several sections such as exterior parts,
under the bus, interior condition, and engine
parts. It also includes a section to attach
photos of defects and add notes to describe
the issue. Here is a brief overview of the
checklist:
● Check the exterior parts such as tires,
mirror, windows, and windshield.
● Check under the bus if there are traces
of leaks.
● Check bus interior condition.
● Start the engine and inspect its parts,
brake systems, and lights.
● Attach photos of defects and add notes
to describe the issue.
● Add overall recommendations.
 ●

Maintenance of diesel
engine

⮚ Inspection
⮚ Check coolant level
⮚ Check oil level
⮚ Check air filter
⮚ Check diesel filter
⮚ Check radiator hoses
⮚ Clean cooling system
⮚ Check proper oiling in system
 Main tools to use repairing
engine

⮚Torque wrench
⮚Socket and Ratchet set
⮚Breaker bar
⮚Screwdrivers
⮚Wrench set
⮚Pliers
⮚Hammers
⮚Impact wrench
⮚Funnels
⮚Engine stand

Thank
you