INPLANT TRAINING IN METROPOLITAN

TRANSPORT CORPORATION(CHENNAI) LIMITED,

BY
GOPINATH K

DEPARTMENT OF MECHANICAL ENGINEERING

SCHOOL OF MECHANICAL

SATHYABAMA INSTITUTE OF SCIENCE AND

TECHNOLOGY JEPPIAAR NAGAR, RAJIV GANDHI SALAI,

CHENNAI – 600119. TAMILNADU.

INPLANT TRAINING DETAILS
Name of the Student :GOPINATH K
Registration Number :3615085

:METROPOLITAN TRANSPORT
Title of the Inplant training CORPORATION (CHENNAI) LTD.,

Name of the Company / : PATULLOS ROAD WORK SHOP(PRD),

Industry address CHENNAI.
Inplant Training Durationwith : 10/12/2018-19/12.2018
date
CONTENTS:

1.ENGINE SECTION,
2.FUEL SECTION,
3.FRONT AXLE SECTION,
4.BREAK SECTION,
5.GEAR SECTION,
6.JOINT SECTION.
 1.ENGINE SECTION

Engine Type : BS III

ENGINE SPECIFICATION
Engine Model : HA6DTI3N

Fuel : DIESEL

Compression Ratio : 1.77:1

Firing Order : 153624

Displacement Volume: 5.566 liters (5566 cc)

Compression pressure: 29/32 kg/square cm at 280 rpm

Direction of rotation: counter clockwise from the fly wheel

Lubrication system: pressure feed lubrication system

1.1Introduction:
The function and construction of every part are going to study here

The essential parts of the engine are as follows

1. Cylinder block
2. Cylinder head
3. Crank case
4. Piston
5. Piston ring
6. Piston pin
7. Connecting rod
8. Crank shaft
9. Flywheel
10. Rocker arm
11. Turbo charger
12. Alternator
13. Air Compressor
FIG.1. CRANK CASE

FIG .2.TURBO CHARGER

 FIG.3.FAN

1.2 Cylinder block:

Cylinder block, cylinder head and crankcase these three parts are the foundation of
engine. In these cylinder block is usually made up of cast iron also nickel and chromium. The
bottom of the block supports the crank shaft and oil pan. In this block consist of intake and
exhaust valve and manifold. The inlet coolant is supplied here to maintain the engine
temperature

1.3 Cylinder head:

Top of the cylinder is covered by a separate cast piece called cylinder head. The cylinder head is
bolted to the top of the cylinder block.it contains chamber, injector are mounted. It incorporated
passage for the flow of coolant. It contains metal sandwich gasket.
1.4 Crank case:
Crank case is attached to the face of the cylinder block. It acts as a base of theengine. It provides the arms
for supporting the engine on the frame. The problem of cylinder
wear is considerable and this has been solved by cylinder liner.
1.5 Piston:

Piston is consider to be one of the most important parts in a reciprocating engine in

which it helps to convert the chemical energy obtained by themechanical energy without leaving
any air fuel mixture or residual gasses.

1.6 Piston rings and pin:

In generally the piston contains three rings two for compression ring that seals the escape of
exhaust gases from the cylinder to the crankcase then the third one is oil ring which holds the oil
for reduce the wear of engine cylinder and pistion.to connect the connecting rod and the piston
the hollow pin is used which is called as gudgeon pin also rotates and converts the reciprocating
motion to the rotary motion.

1.7 Connecting rod:

Connecting rod is the connection between the piston and the crankshaftthis connects to the piston
by gudgeon pin and connects to the crank shaft by big end. The function of the connecting rod is
to convert the reciprocating motion to the rotary motion to the crank shaft.

1.8 Crank case:

Crank shaft is the first transmission system to converting the motion. It contains crank pin,web
(balancing extra weight)and main journals.one rotation of the crank shaft is done by the two
stroke of the piston.

1.9 Flywheel:

It is the heaviest component in the vehicle it is attached to the one end of the crankshaft. The
power obtained from the each stroke is not equal to equalize the power the flywheel is used.
Flywheel is the energy storing device which stores the power during power stroke and supplies
the power during the other three stokes to continue the cycle.

1.10 Turbo charger:

It is the advanced technology of supercharger which gets power
from the residual gas and supplies the required air to the combustion process in normal suction of
the air is insufficient during 2400 rpm this problem is solved by the turbo charger.
1.11 Rocker and Arm:
It is the part of the engine placed in the cylinder head and controls the inlet and outlet valve to
supply and throw out the residual gasses from the cylinder for this camshaft is placed in the near
to the crankshaft transmits the motion by the push rod.

1.12 Air compressor:

It is the top most part of the engine place to get the power from the engine and compresses the air
for breaking system supplies to the DD unit.

1.13 Alternator:
It is the power source for theelectrical system when the coil is rotates in
the field coil the minimum power is required to make it magnetize when the rotor is rotate the
emf is produced in the stator coil that is taken out and given to the battery and some other wiring
works

2.FUEL INJECTION SECTION:

2.1 Introduction:
Fuel injection system is the system which is used to pump the fuel to the respective cylinder and
gives the homogeneous mixture for complete combustion by an injector.

2.2 Requirements of good fuel injection system:

The amount of fuel supplied should be equal to pre-determined level
The fuel should inject at the correct time to the correct cylinder.
The fuel system should pressurize the fuel to open the nozzle.
 1. Inline pump
2. Rotating pump
3. Common rail injection system
4. Individual pump injector system

2.4 MPFI (rotating type):

Rotating pump is also called as rotating distribution pump system this system is driven by the
timer unit by the crank shaft. The driven shaft is connected to the piston

which is rotates also reciprocates by this reciprocation process piston compresses the fuel and
rotating controls the timing (injection order )by rotating the plunger the responsible for
distribute the fuel to respective cylinder.

2.5 Components:
 Relief valve: It is the responsible for sent out the excess fuel from injector
to the tank.

 Solenoid switch: This is act as a normal switch when the ignition switch
gets on the solenoidal gets magnetized by current induced controlled by the
ECU(electronic control unit ) then the valve gets open then the injection
starts.

 Timing sensor: This act as a normal sensor is connected to the fuel

injection system to sense the timing of injection and giving this data to the
 Governor/Positioner: This unit used to control the timing and speed
of the ECU
enginewhich is placed below
by controlling the fuelthe fuel pump.
amount this positioner is connected the
ECU.
 Six center holes: this is the holes that sent the fuel from the plunger to

 Footthe holder.it is the also act as a sensor gives the volts with respect to is
pedal:
push by the driver.
FIG.4. OVER VIEW OF AIR BRAKING SYSTEM

FIG.5.TIMING SENSOR
 FIG.6.SOLENOID SWITCH

FIG.7. CALIBURATION MACHINE

 3. FRONT AXLE:
3.1 Introduction:
The front axle is used to carry the weight of the part of the vehicle as well as to facilitate steering
and absorb shocks due to road surface variation. In the buses wildly we are using dead axle. This
beam contains I section in the center and in two ends having circular or elliptical beam.

3.2 Function of front axle:

It should sustain these loads self-weight, side thrust, driving
thrust, torque of the wheel.

This has the steering system and breaking system in it.

3.3 Main components:

I section beam, I bold ,stub axle, king pin, king pin bush, cotter ,air
chamber, tapper bearing, yoke, slap adjuster, S cam, hub, brake
drum, brake shoe.

Hear the major problem comes from the king pin, bush,and bearing.

3.4 Description:
In this system the grease should supplied continually to king pin and bush.
When we push the brake pedal the pressurized air sent to the air chamber by the linkages
the brake drum gets expended then the vehicle gets stop.

In the steering system drop arm from the steering box is connected to the P&P rod (push
and pull rod) further it transmit the power to the stub axle at stream 1.

In parallel to the axle beam tie rod is installed to transmit the steering motion connected
to the stream 2 and stream 3on the stub axle.

Load from the chassis drawn to the leaf spring end is connected I beam and fitted by I
bolt in two side. Hub is the intermediate component between stub axle and brake drum. This hub is
 FIG.8. OVER VIEW OF FRONT AXLE

4. BRAKE SYSTEM:
4.1 Introduction:
Stoppingof the vehicle is as necessary its starting. Once the vehicle is started, it must stop
somewhere. Brakes are applied on the wheels to stop the vehicle.Before

Applying the brakes, the acceleration is released to stop the fuel supply, thus the engine
develops no more power to run the vehicle and then the brakes are applied which stop the
rolling of the wheel on the road and hence the vehicle is stopped.

4.2 Function of the brakes:

To stop or slow down the vehicle in the shortest possible distance in
4.3 Hand brake:
It is also called as parking brake or secondary brake;these operate independent of the foot
pedal. It operated by the hand leaver in normally the brakes are pushed by the high tension spring
towards push rod piston when the engine gets started the from the air compressor. Then air
compressor pushes the air to the secondary cylinder and push out the diaphragm inside. Thus
the brake realized further the brake is controlled by the foot pedal.

4.4 Components:
Air compressor
DD unit
Reservoir
Foot pedal
Brake chambers
Slack adjuster

FIG.9. BACK RELIFE VALVE

FIG.10.BACK AIR CHAMBER

FIG.11.AIR RESERVIOR
FIG.12. DD Unit

4.5 Description:
Brake system is gets the power from the engine the required air is supplied to the DD unit
by the help of air compressor.

The compressed air is send to the DD unit which is responsible to separate the moisture
from the air and hold on the reservoirs one for front wheel and second one for rear wheel.

When driver pushes the foot pedal air is push piston towards the outside by the yoke
connected to the slap adjuster twisted the S cam having teethed.

On the other end a shaft like S shape when it tilled and brake shoe expands hits the brake
drum then the wheel gets stop.
5. GEAR BOX:
5.1 Introduction:
Next to the clutch is the transmission in the transmission system of a motor vehicle. The word
“transmission” is used for a device that is located between the clutch and propeller shaft. It may
be a gear box, a torque convertor, fluid drive. The modern cars use helical gears and
synchromesh devices in the gear boxes, that synchronize the rotation of gears that are about to be
meshed. This eliminates clashing of gears and make gear shifting easies. The synchromesh gear
box is similar to the constant mesh gear box, but the synchromesh gear box is provided with a
synchromesh device by which two gears to be engaged are first brought into frictional contact
which equalizes their speed after which they are fitted only on the top gears.

5.2 Function of the transmission system:

To give the initial torque for move the engine
It should give the high speed during the normal speed.
To Control the engine speed.

 This synchronous gear box contains three shaftsthey are clutch shaft from the engine
where power to be controlled.
Counter shaft (lay shaft) gets the power from the clutch shaft and provide this to the
different no of teeth gear and main shaft contains rings, cone, gear with different size.

 Here the dog clutch is holds having the crown connected to the main shaft by inner
teethed. While changing the gear dog clutch moves to the respective gear and connect
 By this the gears are changed with respect to the requirement of driver.
that gear’s ring to the main shaft ring.
 For the reverse gear an additional spur gear is attached to change the direction.
5.3 GEAR RATIO: 1 - 7.21:1
2 - 4.22:1
3 - 2.44:1
4 - 1.52:1
5 - 1:1
6 - 8.05:1
6.1 Introduction:
6.JOINT SECTION:
 Next to the gear box in the transmission system is the propeller shaft. It is connected
between the gear box and the differential with universal joint at each end.
  Propeller shaft is a driving shaft that connected the transmission to the differential. The
output shaft called main shaft from the transmission and pinion shaft is extended up to
differential unit connected to the propeller shaft and universal joint. A sliding joint also
used to the suspension system.

6.2 Main function:

To transmit the power from engine to differential.
To transmit power with inclination.

6.3 Universal joint:

A universal joint is used where two shaft are connected at an angle to transmit torque. In the
transmission system of a motor vehicle, the transmission main shaft, propeller shaft and the
differential pinion shaft are not in one line and hence the connected between them are done by
universal joint. One universal joint is enough to connect the two propeller shaft. In busses there
are three propeller shafts are available so two for shaft and two for connect the transmission and
differential.

Commonly we are using cross type or spider and two yoke type.

FIG.13.UNIVERSAL JOINTS
 THANK
OU!