HALDIA INSTITUTE OF TECHNOLOGY

(Haldia, Purba Medinpur, West Bengal)

A Project Report on Industrial Training

Carried out at
T M INTERNATIONAL LOGISTICS
LIMITED
(Haldia, Purba Medinpur, West Bengal)

Training Duration: 1st April, 2022 to 30th April, 2022

Academic Year: 2021-2022
Prepared by: -

Surajit Pramanik
Stream: - Mechanical Engineering
Year & Semester: - 3rd Year, 6th Semester
 Acknowledgement

The dissertation has been prepared based on Industrial Training undergone in

an esteemed organization, a pioneer in logistic sector (TM International Logistics
Limited).
I would like to express my heartfelt gratitude to authority of TM International
Logistics Limited for providing me such an opportunity to undergone in training in
Maintenance of Automobile Section.
I would also like to thank experienced engineers Mr Subhashis Biswas, Mr
Arup Karfa & Mr Moulik Kr Maity, without whom such type of concept building in
Automobile Engineering would not have been possible.
I have given my best effort to prepare and represent the report. I
hope my endeavor will be beneficial to the audience and urge to exonerate eye
for any mistake or error found in the report.
 Table of Content

Topic Topic Name Page no.

no.

1. About the company 1

2. Company’s all fleets and vehicles 2

3. Introduction 3

4. Basic engine components 3-7

5. Fuel system in diesel engine 7-9

6. Coolant system 10-11

7. Lubricant system 11-13

8. Differential system 13-14

9. Air condition system 14-15

10. Transmission system 15-17

11. Brakes system 17-20

12. Conclusion 21
 About the company
 This is a joint industrial organization one is Tata Steel Limited and another is IQ Martrade (Germany) to
from TM International Logistics Limited (TMILL).
 TMILL strives to build further on its capability of offering a single window end-to-end logistics solution for
Dry Bulk, Containerised and Project Cargo.
TMILL encompasses a wide range of logistics services including

Port Terminal Operation:

Turnkey Port Management & Cargo Handling services covering cargo

operation in or out of ship, to receipt or dispatch of cargo from port
premises.

Shipping:

Comprehensive shipping services, with focus on dry bulk and break bulk
cargo, reaching a wide spectrum of customer globally.

Railways:

One of the Largest Rail operators in India, operating Rakes under Special
Freight Train Operation (SFTO) policy of Indian Railways.

Freight Forwarding:

Freight Forwarding and logistics service offered through the Company’s offices
in India, China and Germany.

Maritime Logistics Services:

End-to-end barging solution, Mid-stream transshipment operations, Cargo

management, Ship Agency, Husbandry functions and Advisory management
services.

Warehousing:

State-of-the-art warehousing services as well as part of an integrated logistics solution

including last mile delivery.

Supply Chain Management:

Strategic partner of Tata Steel for integrated end-to-end supply chain

management services for ‘Pravesh’ products.

1
 Company’s all Fleets & Vehicles

 WHEEL LOADERS:-22 no’s  REACH STACKER:-2 no’s

(Volvo-10, SDLG-8, CAT-2, Liebherr-2) (45 ton capacity)(TIL)

 EXCAVATOR:-3 no’s  TRAILER:-10 no’s

(Volvo-2, TATA Hitachi-1) (TATA Make)

 FORKLIFT:-8 no’s  MOBILE HARBOUR CRANE:-2 no’s

(1no3ton, 1no12ton, 1no16ton, 3no25ton, 2no32ton) (100ton & 124ton)(Liebherr Make)

2
 Introduction:

In my training period my observation in Maintenance of Automobile section. This company have many vehicles
like Wheel loaders, Trailer, Forklift etc. that is show in the upper page. In this vehicle we observed many things.
As I am a Mechanical student so I briefly observed some main mechanical parts and their working principles in
an automobile. That’s I written below

My observation topics are:-

 Basic Engine Components

 Fuel, Coolant, Lubricating System
 Differential
 Air-condition System
 Transmission System
 Brake System

Even without these I know the working functions of Alternator, Self-starter, and Turbocharger etc.

Basic Engine Components

As I know most conventional heavy-duty vehicles use CI engines. It is a logistic company so here uses heavy-duty
vehicles. So all these vehicles are driven by CI (Compression-Ignition) engine. That’s why I discuss only this type of all
engine components. The essential parts of the engine:

1. Cylinder Block
2. Cylinder Head
3. Cylinder Head Gaskets
4. Crankcase
5. Oil Pan or Sump
6. Piston
7. Piston Ring
8. Piston Pin
9. Connecting Rod
10. Cylinder Liners
11. Crankshafts
12. Valves
13. Flywheel
14. Camshaft
15. Manifold

Cylinder Block:-

Cylinder Block, cylinder head and crankcase-these three parts from foundation and main stationary body of the
automobile engine. They serve as support and enclosure for moving parts. In modern engines, the cylinder
block and crankcase from a single casting, which gives a rigid structure. Ribs are cast in the crankcase to give it
extra strength and to support the main and in some cases, the cam shaft bearing.

A cylinder block consists of three parts:

1. The cylinder in which the pistons slide up and down.

2. The ports or opening for the valves.
3. The passages for the flow of cooling water.
3
The cylinder block usually made from grey cast iron, and some times, with
addition of nickel and chromium. Engine blocks are classified depending on the
configuration of the engine. These types are:

 V Engine
 Inline Engine
 Boxer Engine

The cylinder head is mounted on the cylinder block. Cylinder head and Cylinder
Block are provided with water jackets in the case of water cooling. The bottom
Fig:-Cylinder Block
portion of the cylinder block is called crankcase. The inner surface of the
cylinder block which is machined and finished accurately to cylinder shape is
called bore or face.

Cylinder Head:-

The top of the cylinder is covered by a separate cast piece known as the
cylinder head. The head is bolted to the top of the cylinder block. It
contains combustion chamber. Some valves (in I-and F-head) are
mounted in it. It incorporates passage for the flow of cooling water.
The cylinder head is usually made of grey iron or aluminium alloy.
Depending upon the valve layout, the cylinder head may carry the cam
shaft, rockers & valves. Water passages are provided adjacent to the
valve.
Fig:-Cylinder Head

Cylinder Head Gaskets:-

A gasket is placed between the cylinder head & cylinder block to retain
compression in the cylinder, to prevent leakage and to ensure metallic
tight fit joint. The gasket should be able to withstand not only high
pressure but also extreme temperature. Often the gaskets are coated
with a special varnish which melts and seals all the small inters ticks of
the block and when the engine warms up. Suitable holes are made in
the Gasket to pass the studs and for cylinder bore. Gaskets are also Fig:-Cylinder Head Gaskets
used to seal joints between others parts, such as between oil pan,
manifolds, or water pump and the block.

Crankcase:-
Crankcase is attached to the bottom face of the cylinder block. It acts as the base of the engine. It supports the
crankshaft and cam shaft in suitable bearings and provides the arms for supporting the engine on the frame. The
oil pan and the lower part of the cylinder block together are called the crankcase.

The cylinder block and upper half of the crankcase usually are cast as single integral unit. This casting is usually
made of a ferrous alloy or semi-steel to provide a stronger and harder casting. The use of stronger and tougher
material permits thinner casting walls, thus saving weight and improving cooling, although it is more difficult to
machine than grey iron. Aluminium alloy is also a potentially attractive material for crankcase. This is because of
its light weight, good thermal conductivity and good cooling effect.

Oil Pan or Sump:-

The
3 bottom half of the crankcase is called the oil pan or sump. It is bolted or screwed to the lower
flange of the main casting and usually is made of pressed steel or aluminium. The oil pan serves as
a reservoir for the storage, cooling and ventilation of engine lubricating oil. 4
The oil pump in the lubricating system draws oil pan and sends it to all working parts
in the engine. The oil drains off and runs down into the pan. Thus, there is a
constant circulation of oil between the pan and the working parts of the engine.
Fig:-Sump

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. The purpose of the piston is to provide a means of
conveying the expansion of the gases to the crankshaft, via the connecting rod,
without loss of gas from above or oil from below. Piston is essentially a cylindrical
plug that moves up and down in the cylinder. It is equipped with piston rings to
provide a good seal between the cylinder wall and piston. Although the piston
Fig:-Piston
appears to be a simple part, it is actually quite complex from the design stand point.
The top of the piston is called Head. Ring grooves are cut on the circumference of the upper portion of the
piston. The part below the ring grooves is called Skirt. The portions of the piston that separate the grooves are
called the Lands. Some pistons have a groove in the top land called a Heat Dam which heat transfer to the rings.
The piston bosses are the reinforced sections of the piston designed to hold the piston pin or wrist pin.

The material used for pistons is mainly aluminium alloy. Aluminium pistons can be either cast or forged. Cast
iron is also used for piston.

Piston Ring:-

Piston rings are fitted into the grooves of the piston to maintain good seal between
the piston and the cylinder wall. There are three functions of piston rings as
following:

1. To provide a pressure seal to prevent blow-by of burnt gas. Blow-by is the

name that describes the escape of burnt gases from the combustion
chamber, past the piston, and into the crankcase.
2. To from the main path for conduction of heat from the piston crown to the
cylinder walls. Fig:-Piston Ring
3. To control the flow of oil to the skirt and rings themselves in adequate
quantity while preventing an excessive amount reaching the combustion
chamber with consequent waste and carbonization.
There are two types of piston rings:

1. Compression Ring
2. Oil Control Ring
 Compression rings seal the combustion pressure as the mixture burns.
 Oil control rings scrape off excessive oil from the cylinder wall and return it to the oil pan.

Piston rings are usually made off fine-grained alloy cast iron.

Piston Pin:-
Piston pin or wrist pin or gudgeon pin connects the piston and small end of the
connecting rod. Piston pin is generally hollow and made from cast hardened steel
heat treated to produce a hard, wear resisting surface.

Piston pins may be selectively fitted and, if supplied with the piston, are not Fig:-Piston Pin 5
Interchangeable. In very heavy alternate loading of the piston pins of compression ignition engines, special care is
taken to avoid risk of fatigue cracks. The external bearing surface is finished to very high degree of accuracy to
ensure correct fit in the piston and connecting rod. Piston pin should be inspected for wear, cracking or pitting.

Connecting Rod:-

The connecting rod is the connection between the piston and crankshaft. It
joins the piston pin with the crankpin. Small end of the connecting rod is
connected to the piston pin and the big end to the crank pin. The function of
the connecting rod is to convert linear motion of the piston into rotary
motion of the crankshaft. The connecting rod usually has I-beam cross
section; and is made forged steel. They are carefully matched in sets of
uniform weight in order to maintain engine balance. The connecting rod
carries the power thrust from piston to the crankpin and hence it must be
very strong, rigid and also as light as possible. Fig:-Connecting Rod

Cylinder Liners:-

The problem of cylinder wear is considerable and this has been solved by the use of
cylinder liners. The cylinder liners are in the form of barrels made of special alloy iron
containing silicon, nickel and chromium. These liners are of the oil hardening typ3e and
offer considerably longer life of the engine. The cylinder liners are the two types: - Dry
Liners & Wet liners. Dry liner is not in direct contact with the cooling water. Wet liner is
in direct contact with the cooling water & wet liners are thicker than dry liner.

Fig:-Cylinder Liners

Crankshaft:-
Crankshaft is the first part in the power transmission system on to which the
reciprocating motion of the piston is converted into the rotating motion with the
help of connecting rod. A crankshaft consists of crankpins, webs balancing weights
and main journals. Big end of the connecting rod is connected to the crankpin of
the crankshaft. Centre to centre distance between the crankpin and crankshaft is
half of the piston displacement during a stroke. Thus, one complete revolution of Fig:-Crankshafts
the crankshaft makes two stroke of the piston. The parts of the crankshaft inside
the main bearings are called the main journals. The crankshaft is supported by the
main bearing on the main journals. Balancing weights are provided on the opposite
side of the crank arms for balancing.

Valves:-

Valve is a device to close and open a passage. Two valves are used for each cylinder – an
inlet or intake valve and an outlet or exhaust valves. Fuel is admitted to the cylinder by
the inlet valve, and the burned gases escape by the exhaust valve. When closed, the
valve must seal the combustion space tightly. The valves are usually made of austenitic
stainless steel which is corrosion and heat resisting material. Exhaust valve is usually
made of silchrome steel which is an alloy of silicon and chromium. Inlet valve being
subjected to less heat is usually made of nickel chromium alloy steel. Fig:-Valves

Flywheel:-
A flywheel is a fairly heavy steel wheel attached to the rear end of the crankshaft. The size of the flywheel
depends upon the number of cylinder and the general construction of the engine. The flow of power from
the engine cylinder is not smooth. Although the power impulses in a multi-cylinder engine overlap or follow
each 6
Other to provide a fairly even flow of power, however, additional levelling of power
impulses is required. This is done by a flywheel. To understand the function of a
flywheel in a better away, take the example of a four-stroke, single cylinder engine.
There are times when more power is being delivered than add other times. This tends
to make the crankshaft speed up and then slow down. The engine delivers power
during one stroke only – the power stroke; and it absorbs power during the other three Fig:-Flywheel
strokes- to push out the exhaust gases, to intake fresh charge in the cylinder and to
compress this charge.

Camshaft:-
A camshaft is simply a shaft on which cams are mounted. The cam shaft is
mounted in bearings in the lower part of the cylinder block in most in-line
engines. In a few engines it is located on the cylinder head. A cam shaft is a
device that changes rotary motion of the cam shaft into linear motion of the
follower or lifter. The cam has high spot or lobe. The follower riding on the
cams will move away from or toward the camshaft as the cam rotates. The Fig: - Camshaft
cam shaft is driven by the crankshaft either by a pair of meshing gears or by
means of a pair of timing sprockets connected by a chain.

Manifolds:-

In an engine has two types manifold one is Intake Manifold another is Exhaust
Manifold. Intake Manifold is a pipe which connects the intake system to the inlet
valve of an engine and through which air is drawn into the cylinder. Exhaust
Manifold is a pipe which connects the exhaust system to the exhaust valve of the
engine through which the products of combustion escape into the atmosphere.
Fig: - Manifold

Fuel System in a Diesel Engine

In my training period I see the many fuel system parts like fuel tank, fuel feed pump, and see how change the fuel
filter, injector pump etc. Then I know the process of fuel system in a diesel engine with the help of there senior
engineer. Below I write this briefly.

The power in a diesel engine is developed when fuel is injected into the compressed air in the cylinder. On the intake
stroke only air is pulled into the cylinder. When the engine is ready for a power stroke, a small quantity of fuel is
injected into the compressed air. The diesel engine fuel supply system serves two functions:

1. It provides the source of fuel. 7

2. It also provides the source of ignition.
 The fuel injection system developed for diesel engine is different from that used on a petrol engine. The fuel
injector on a petrol engine is mounted in the intake manifold whereas the diesel injector is mounted in a swirl
chamber directly in the combustion chamber. The basic fuel supply system in diesel engine consists of a fuel tank,
fuel filter and air cleaner, fuel feed pump, fuel injection pump, fuel injector & governor.

Fuel Tank:-

It is using the gravity fuel tank. In this arrangement, the fuel tank must be at least 30 cm above the fuel filters and
injection pump. When the fuel cock is opened, the fuel flows direct to a hand lever type of fuel priming pump, from
which it then passes out to the inlet side of the main fuel filter. The fuel after being filter proceeds to the inlet side
of the fuel injection pump. From the injection pump, heat flows under high pressure in the four fuel feed pipes
leading to the fuel injectors. Each injector have a leak-off fuel pipes to carry off any back leakage fuel from the
nozzle valve and guide members. This back leakage fuel is return to the fuel tank ,together with any back leakage
from the distributor injection pump unit.

Fuel Filter:-

Dirt carried in the fuel is recognized as prime source of trouble and inefficient in
diesel engine operation, as it is the cause of wear in the fuel injection pump and
nozzles. The fuel injection pump is a sturdy, well designed piece of equipment
that will give trouble- free service for many thousands of hours running,
provided the fuel is clean, but if dirt, especially fine dust, is allowed to pass into
the system in the fuel, then wear follows with it irregular running and loss of
power; maintenance costs will become heavy and engines will need frequent
attention. Where sedimentation in the supply tank can be efficiently carried out, this will greatly reduce the
amount of dirt carried in the fuel. Under working conditions, however, it absolutely essential that the fuel be
properly filtered before entering the injection pump.

Air Cleaner:-
In a diesel engine air is very important. Before go to the engine it is necessary to clean the air. These cleaning
processes happen in air cleaner. The air cleaner serves the following functions:

i. The filters dirt or dust particles out of the air that enters the engine.
ii. It acts as flame arrester in case the engine back fires through the air intake system.

Air cleaner are broadly classified in following types:- Heavy duty type air cleaner, Light duty type air cleaner &
Thermostatic air cleaner.
Fuel feed pump:-
There is two different working of the fuel feed pump diesel engine one is manual operation while removing
airlock and one is fuel supply operation while engine start.

 Manual operation while removing airlock: - when vehicle getting off because of the airlock in the fuel
supply system. Then the users have to bleed the air from the system. Now the users have to open the
manual priming by pulling and pushing this manual priming lever. Continues priming of the lever there
is suction is being creating and takes fuel from fuel tank and supply to the system.
 Fuel supply operation while engine start: - during engine starting the cam shaft of the engine is gives
drive to the fuel feed pump diesel engine. The plunger is start moving front & rear. While the plunger
is comes back then a suction take place inside the body. Because of this suction fuel flow from fuel
tank and filled into the pump body by opening the inlet check valve. While the plunger is goes front
then it makes pressure on the fuel and fuel flow to the system by opening the outlet check valve.
During fuel outlet some fuel goes behind the plunger through the continuity channel. While plunger
goes back again then fuel come see from fuel tank into the pump body but the fuel which is at the
behind of the plunger is flow to the system and make a continuity of fuel supply. 8
Fuel Injection Pump:-

It is a pump, which delivers metered quantity of fuel to each cylinder at appropriate time under high pressure.

Diesel fuel is injected in diesel engine through injectors with the help of fuel injection pump. The system
using injectors, fuel injection pump, fuel filter, and fuel lines is called fuel injection system. The main
functions of fuel injection system are:
1. To measure the correct amount of fuel required by engine speed and load,
2. To maintain correct timing for beginning and end of injection,
3. To inject the fuel into the combustion space against high compression pressure,
4. To atomise the fuel for quick ignition.
Process of fuel injection in diesel engine is of two types: (i) Air injection (ii) Solid injection.
Air injection: In this process, the engine uses compressed air to force the fuel into the cylinder. It is a
bulky system and hence it is not considered very suitable for vehicles and tractors. It is mostly used on
heavy-duty stationary engines.
Solid injection: A high-pressure pump is used for forcing the fuel into the combustion chamber.

Fuel Injector:-
The injector is operated by the fuel pressure. The pressure developed by the injection pump acts on the
exposed annular area of the needle valve. It is lifted from its seat as soon as the force acting on the annular
area exceeds the force of the pressure spring. The fuel is then injected through the nozzle orifices into the
combustion chamber. During injection, the fuel goes through the injection pump lines to the fuel inlet
passage to the injector housing, into the pressure chamber and through spray orifice into the combustion
chamber. Fuel leaking past the valve stem is returned to the fuel tank by the return line. After injection of the
fuel into the combustion chamber, the pressure spring forces the needle valve back on its seat. The injector
nozzle is then closed and ready for the next pressure stroke.

Governor:-

The main function of a governor is to regulate the supply of fuel through some mechanism so that the engine
speed remains within its range. On an increased load, the engine speed drops. The governor which is set for a
particular engine speed operates a mechanism such that more fuel is injected to increase the engine power.
When the load decrease, the engine speed increases. The governor in this case operates the mechanism to
reduce the supply of fuel in the engine. Without a governor, the engine speed increases at lighter loads and
dynamic stresses damage the engine parts. Therefore a governor is essential to keep the engine speed within
limits
9
 Coolant System in a Diesel Engine
There are many types coolant process but here I discuss only water cooling system because my observation on
water coolant engine. The water cooling system circulates water around hot engine parts to carry off the heat.
Coolant passages called water jackets surround each cylinder in the block. They are also placed in the cylinder
head very close to the valve area. Heat from the burning air-fuel mixture passes through the metal of the cylinder
head and cylinder wall and enters the water jackets. The heat then goes into the water circulating through the
water jackets.

Components of the Water Cooling method are - Radiator, Thermostat, Water pump, Fan, Water jackets.
Radiator:-
Radiator is a device for having a large amount of cooling surface to the large
amount of air so that the water circulating through it is cooled efficiently. It consists
of an upper tank and a lower tank and between them a core. The upper tank is
connected to the water outlet or outlets from the engine jacket by a hose pipe; and
the lower tank is connected to the jacket inlet through the water pump. The core is
radiating element which cools the water. There are 2-types of cores: (a) Tubular (b)
Cellular. Radiators are usually made of copper and brass because of their high heat
conductivity. The various sections of the radiator are almost completely joined Fig: - Radiator
together by soldering.

Thermostat:-
A thermostat valve is used in the water cooling system to regulate the circulation of water in
system to maintain the normal working temperature of the engine parts during the different
operating conditions. The thermostat valve automatically works in the cooling system. When
the engine is started from cold, the thermostat valve prevents the flow of the water from
engine to radiator so that the engine readily reaches to its normal working temperature, after
which it automatically comes into action. Generally, the thermostat valve does not permit the Fig: - Thermostat

water below70 degree Celsius.

Water pump:-

A pump is used in the water cooling system to

increase the velocity of the circulating water.
Impeller type pump is mounted at the front
end of the cylinder block between the block Water Cooling System using Thermostat Valve
and the radiator.
The pump consists of housing with inlet and outlet; and the impeller. The impeller is a flat
plate mounted on the pump shaft with a series of flat or curved blades or vanes. When the
impeller rotates, the water between the blades is thrown outwards by centrifugal force;
and is forced through the pump outlet and into the bottom of the radiator; and the water
from the radiator is drawn into the pump to replace the water forced through the outlet. Fig: -Water pump
10
The pump is driven by a belt to the drive pulley mounted on the front end of the engine crankshaft. The impeller
shaft is supported on one or more bearings. A seal prevents water from leaking out around the bearings.
Fan:-
The radiator is usually placed in the front of the automobile, right behind the grillwork. As
the vehicle is driven, air is directed through the grill and through the radiator core. As long
as the vehicle is moving fast enough. There is enough air flow for cooling. When the
engine running and automobile is not moving, however, there is not enough natural flow
of air through the radiator core. For this reason, a fan is placed between the radiator and
the engine. The fan is normally mounted to the same pulley that drives the coolant pump.
When the engine is running, a drive belt turns the fan. The fan pulls air through the Fig: -Fan
radiator core.
Water Jackets:-

Water jackets are cast into the cylinder block and heads.
Jackets are simply the passages through which water
circulates around the cylinders, valve ports and seats,
combustion chambers and any other hot parts that require
cooling. The heat combustion is conducted through the
metal walls to the water in the jackets which removes the
excess heat as it circulates through them.

Fig: -Water jackets

Lubricant system in a Diesel Engine

In my training time I see how to change the lubrication oil and see the oil pump, oil filters etc. Then I know how this system
working. The lubrication system circulates oil between moving parts to prevent the metal to metal contact which causes wear. Oil
between moving parts allows them to move easily, with less friction. The engine parts which are to be lubricated are as follows:

1. Main crank shaft bearings

2. Big end bearings
3. Small end bearings
4. Camshaft bearings
5. Piston rings & cylinder walls
6. Timing gears
7. Valve mechanism

Parts of lubricating system: Oil sump,

Oil pump, Oil filter, Oil cooler, Oil pressure

Gauge, Oil pressure indicating light, Oil

Level indicator

Oil sumps:-
The oil sump is the lowest part of the crank chamber. It provides a covering for the crankshaft and
contains oil in it. In wet sump lubricating system, the oil is taken out from the sump and after
lubricating different parts, it drops in the sump.

The oil sump is also known as the oil pan. It usually made of steel pressings. Sometimes it is
produced of aluminium or cast iron. It contains a drain plug at its lowest part to drain out the oil. In
some cases, it contains oil strainer a barrel for dipstick and a connection for oil line. In a dry-sump
lubricating system, the oil is contained in a separate oil tank.

Oil pumps:-
The oil pump is typically placed inside the crankcase below the oil level. The function of the oil pump is to
supply oil under pressure to the varies engine parts to be lubricated. The different types of oil pumps
11
used for engine lubrication are as follows,
 1. Gear pump
2. Rotor pump
3. Plunger pump
4. Vane pump
1. Gear Pump: It consists of two meshed spur gears and closed in housing. There is very little clearance
between the teeth and housing of the gear. A gear is attached to a shaft that is driven from the
engine camshaft or crankshaft through the appropriate gear.

2. Rotor Pump: It consists of an inner and outer rotor within the pump body in place of gears, that is, two
gears mesh internally. The external gear has the number of teeth one more than on the internal gear. The
oil is displaced from the inlet to the outlet side just like the gear pump.

3. Plunger Pump: It consists of the plunger which reciprocates in the pump body while moving up, the
plunger sucks oil from the inlet and while moving down it forces out the oil from the outlet. This type of
sump is used to deliver oil under low pressure to the troughs of splash systems.

4. Vane Pump: It contains the cylindrical casing with outlet and inlet and drum. The drum is mounted
eccentrically in the casing and contains two vanes with spring. With the drum rotates, the vanes wipe the oil
from the inlet to the outlet side.

Oil Filter:-
The oil filter is used in the engine lubricating system of most of the motor vehicles to filter out the dirt or grit
particle from the oil.

The oil filter systems are of the two types:

1. By-pass system
2. Full flow system
1. By-pass system

In the by-pass system, the whole of the oil does not pass through the filter at the same time, but some of
the oil without being filtered goes to the bearings. The remaining oil passes through the filter and then to
the bearing. When the engine is run continuously for a long period of time, the entire oil is filtered out.

2. Full flow system

In full flow system, the whole passes first through the filter and then goes to the bearing. If the filter is
stopped for some reason, the system completely fails and the bearings will starve.

Oil Strainer

Oil strainer is simply a wire mesh screen. It is attached to the inlet of the oil pump so that the oil going in
the oil pump is free from impurities. The strainer retains the dirt or grit of the oil. Usually, a floating strainer
installed which is hinged to the oil pump inlet.
Oil cooler:-
The purpose of oil cooler is to cool the lubricating oil in the heavy-duty engine where the oil
temperatures become quite high. Because the viscosity of the oil decreases with the temperature rise
and also the oil film may break at high temperatures, the oil must be kept cold in the lubricating
system.
Oil Pressure Indicating light:-
In many motor vehicles, the engine oil pressure is indicated by a warning light. The light comes when
the ignition switch is turned on and the oil pressure is low. The circuit user four-stage diaphragm
switch which operates a warning a lamp according to the oil pressure required for different engine
feeds.
12
 Oil Pressure gauge:-
An oil pressure gauge is mounted on the instrument panel of all cars equipped with a pressure
lubricating system to tell the driver what the oil pressure is in the engine. The oil pressure gauges are
of the following types:
Oil cooler:-

1. Pressure expansion type

2. Electric-type
1. Balancing coil type
2. Bimetal-thermostat type
Oil level indicator:-
The level of the oil in the crankcase is checked by a dipstick. It is a long stick with a handle at one
end for holding. It is graduated with marks full, half and empty. To check the oil level, the stick is
dipped into the crankcase, and taken out.
The oil sticks on the stick which shows the oil level in the crankcase. The oil should fall below a
critical mark. Before starting a vehicle particularly for a long journey. The oil level must be checked.

Differential system
All vehicles have differential system. In maintenance time I see all parts in a differential system and know the working function of
these parts.

A differential is defined as a gear train, which consists of three gears that feature the rotational speed of one shaft is the average
speed of the others, or a fixed multiple of that average.

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.

Parts of Differential:- Following are the parts of the differential system:

1. Differential side gear or sun gears

2. Pinion shaft or cross pin
3. Axle shafts or half shafts
4. Ring gear or crown wheel
5. Drive pinion or bevel pinion
6. Differential pinions or planet gears
7. Differential case or Housing
Differential side gear or sun gears: - The differential is consists of a small bevel gear called differential side gear or
sun gear. It is mounted on the inner ends of each axle. In this, two bevel gears are fixed together to combine both the
driving and driven shafts at 90° angles.
Pinion shaft or cross pin: - There are two pinion gears and their supporting shaft is called the pinion shaft. It is
fitted in the differential case.
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.
Ring gear or crown wheel:- The ring gear is also known as a crown wheel. They act as an equalizer in dividing the
torque between the two driving wheels while allowing one to turn faster than the other.
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Drive pinion or bevel pinion: - The drive pinion is also known as bevel pinion. It is assembled with a
differential housing called a differential case or carrier.
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.

Differential pinions or 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.
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.
How Differential Works?
The power from the engine is transferred to the ring gear through a pinion gear. The ring gear is connected
to a spider gear, which is at the heart of the differential system. The spider gear is free to rotate in two
different ways, one along with the ring gear and two on its own axis. The spider gear meshes with two side
gears, so power from the engine flows from the pinion to the left and right wheels. Let‟s consider some
cases.

The vehicle moves straight: In this case, spider gear rotates along with the ring gear but it does not
rotate on its own axis. Spider gear will push and make the side gears turn, and both will turn at the same
speed.

The vehicle is taking a turn: Spider gear plays an important role here. Along with the rotation of the ring
gear, it rotates on its own axis. So the spider gear is having a combined rotation.

When properly meshed side gear should have the same peripheral velocity as that of the spider gear.
When the spider gear is spinning as well as rotating, peripheral velocity as the left side of spider gear is the
sum of spinning and rotational velocities.
But on the right side, it is a difference between the two. Or left side gear will have higher speed compared
to the right side gear. This is how the differential manages to turn the left and right wheels at different
speeds.

Air Conditioning System

An air conditioning system consists of a compact version of the components of the normal air conditioner that has
an evaporator, compressor, condenser, expansion device, and a fan which are fitted in a car to provide air condition
inside the passenger’s compartment.

Components of Air Conditioning System: -

 Compressor
 Condenser
 Expansion Valve
 Evaporator
 Receiver/ Drier
 Refrigerant

1. Compressor – It is also known as the heart of the AC system, a compressor provide pressure rise to
the refrigerant to convert the vapour refrigerant into liquid refrigerant which in turn enables the further flow
of the refrigerant through condenser. The compressor of the car air conditioning system is driven by the
crankshaft of the engine through the belt drive.
2. Condenser – It is the device looks like a small radiator and is used after the compressor as it provides
condensing i.e. lowers the temperature, of the high pressure and high temperature liquid refrigerant sent
by compressor through forced convection provided either by radiator fan or by separated fan used with
condenser.
3. Expansion valve- It is a device used in car air conditioning system to expand the high pressure, low
temperature liquid refrigerant sent by the condenser in order to release pressure of the refrigerant before
sending it to evaporator for the further process.
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4. Evaporator – It is a device that looks like another heat exchanger and is place just behind the AC vent
over a dash board of a car, an evaporator takes heat from the passenger‟s compartment and convert the
liquid refrigerant sent by the expansion valve into vapour, which in turn provides cooling through the fan
inside a passenger‟s cabin.
Thermal expansion valve is used in vehicles that enable the passenger to change the temperature
according to the requirement, by just adjusting the knob provided over a dashboard in passenger‟s cabin.
5. Receiver-Dryer- It is a safety catch used in an automobile or car air conditioning system as there is a
chance that instead of vapours some liquid also flows towards the compressor which can damage the
compressor, so the receiver dryer is used in between evaporator and compressor to convert that
remaining liquid into vapours before sending it to compressor for compression.
6. Refrigerant – It is the heat sensitive fluid with very low boiling point that is used in AC as a medium of
heat exchanging.

Working Procedure: - The working of an automobile AC system is also almost same as the normal AC
but little difference is there-
1. The evaporator which is the another heat exchanger used in AC takes heat from the passenger‟s cabin
which in turn converts the liquid refrigerant flowing through the evaporator into vapours which in turn
provide cooling with the help of the blower fan.
2. This vapour having high temperature low pressure is then sent to compressor which in turn increases
the pressure over the vapour and converts the vapour refrigerant into liquid refrigerant.
Now the refrigerant is in high pressure and high temperature liquid state.
3. This high pressure high temperature liquid refrigerant is then sent to the condenser which lowers the
temperature of this refrigerant by forced convection provided by the radiator fan or by separated fan used.
Now the refrigerant is having low temperature but the pressure of the liquid is almost the same.
4. This high pressure and the low-temperature refrigerant is then sent to the expansion valve which in turn
releases the pressure from the refrigerant and converts it into its original state.
5. This refrigerant is then again sent to the evaporator for the further cycle.

Transmission system
The transmission system is the mechanism by which power created by the engine is transferred to the
driving wheels. This part of the vehicle is the most important in determining the power and functionality of
your engine systems.

Components of Transmission System

The transmission system consists of the following components:

1. Clutch. 2. Gearbox.

3. Propeller shaft. 4. Differential.

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5. Live Axle.
1. Clutch:

This component enables the engine to keep disconnected from road wheels. The rotary motion available at
the crankshaft is not transferred to road wheels. It allows the transfer of motion when desired by the driver
of the automobile. Clutch also allows the transfer of motion gradually so that the vehicle starts moving
gradually. It works on the principle of friction.

2. Gearbox:

It consists of some pairs of gear wheels. These transmit the motion available from the crankshaft, through
the clutch, at different speeds.
This provides required leverage between the engine and the road wheels. This leverage is variable to cope
up the different conditions encountered during the movement of the vehicle.

3. Propeller shaft:

The third component of the automobile transmission system, which transfers motion from the gearbox end
to the differential end. The distance between the two can be large, and therefore, it is a shaft which is thin
and long to connect the two.

4. Differential:

One of the requirements of the transmission system is to turn the motion through 90 degrees as the axis of
the propeller shaft and live axle are at a right angle to each other. This is performed by the differential
through wheel and pinion arrangement. Another function performed by the differential is the variation in the
speeds of inner and outer wheels when the vehicle is taking a turn.

5. Live axle:

The axle where motion from the crankshaft of the engine is transferred is known as a live axle. The other
axle takes up only the load of the vehicle and therefore is termed as dead axle or simply the axle. The
motion is generally transferred to the rear axle, but it can be transferred to the front axle or both the axles.
When the motion is transferred to both the axles, it is known as four-wheel drive. Finally, motion is
transferred to the road wheels at the two ends of the live axle. The wheels rotate, and friction between their
surface and road surface makes possible the movements of the vehicle on the road.

Working Procedure:- The internal combustion engine generates power which is transmitted to the road
wheels.
The output from the engine is available in the form of rotation of the crankshaft. This rotary motion is
transmitted to the road wheels.
The friction between the road and the surface of the wheel makes possible the movement of the
automobile. Transmission system performs this function.
The automobile transmission system consists of several components. These components work together to
transmit the rotary motion at the crankshaft smoothly and efficiently to the road wheels.
A sudden change of state, from rest to motion or vice versa is not desirable. It may be uncomfortable, or
even dangerous, to the occupants of the automobile.
Therefore, the rotary motion of crankshaft should be transmitted gradually and not suddenly. Another
aspect of transmission is that the motion from the crankshaft should not be transmitted as soon as the
engine starts.
It is not desirable that as soon as the engine starts, the vehicle begins moving. The motion is required to be
transmitted only „when desired.‟
The rotary motion of the crankshaft gives rise to torque and transmission of this torque to road wheels give
rise to a propulsive force or tractive effort causing the movement of wheels on the road.
When starting from rest, a great tractive effort is needed. The engine produces almost the same torque.
This torque has to be enhanced so that enough tractive effort is produced.

This necessitates the introduction of `leverage‟ between the engine and the road wheels. 16
A variation in the leverage is essential because if the same leverage is used for climbing as well as moving
on the level road, the maximum possible speed would be unduly low.
Large leverage implies a large reduction in speed between the engine and the wheels, and at a quite
moderate road, the engine speed would be very high but at high engine speeds, the engine torque falls off
so that tractive effort available would be less thereby reducing the road speed.
On properly maintained road comfortable cruising speed for a car can be approximately 50 kilometres per
hour, and with a wheel diameter of 30 cm, it will have a rotary speed of about 1060 rpm .Considering the
speed of the engine to be about 3500 rpm, the automobile transmission system will have to reduce 3500
rpm at the engine to about 1060 rpm at the wheel (ratio 3.3:1). This ratio may vary with the engine size and
engine specifications.
While the nature of transmission is not affected greatly by the changes in the form of „carriage unit,‟ so that
the transmission of a 4-wheel drive vehicle is similar to that of rear-wheel drive vehicle, the arrangement of
transmission will be different in both the cases.
The axis of the rear road wheels, where the motion is usually transmitted is perpendicular to the centre line
of the automobile. Therefore, drive between the engine and the road wheels are turned through 90
degrees. If the automobile moves on a circular path, the inner and outer wheels will traverse circles of
different radii. Thus, the inner and outer wheels travel different distances.
Because the automobile moves as a single unit, they have to travel different distances during the same
period. In the majority of automobiles, the engines are fitted in the front portion on the frame of the carriage
unit. Usually, the motion is transmitted to the road wheels on the rear side. The distance between the two is
quite considerable. The motion is required to be transmitted through this distance. Also, the rear axle is
attached to the frame through springs.
Due to the uneven surface of the road, the axle moves up and down, and the springs flex. The relative
positions of the engine and the axle changes and automobile transmission system should be capable of
taking it up.

Brake system
Company‟s most vehicles use Hydraulic braking system & Pneumatic braking system so, I only write these two topics.

Hydraulic Braking System: -A hydraulic braking system in automobiles is the brake operating system which
uses fluid for their operation. It is highly efficient braking system. The hydraulic braking system works on the principle
of Pascal‟s Law.

PASCAL‟S LAW: - The Pascal law states that “Pressure at any point in a static fluid is equal in all directions”. Hence
such Pascal‟s law is used in the hydraulic braking system to apply the brake.

A hydraulic braking system in Automobile consists of the following components:-

Pedal, Master Cylinder, Oil Reservoir, Cylinder 2, Brake Shoes
Pipeline
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1)PEDAL:- Brake pedal is pivoted and connected from middle to piston rod. When the driver presses the pedal,
the piston presses the fluid inside the master cylinder.

2) MASTER CYLINDER: - It consists of piston, oil & return spring. When the driver presses the pedal, the piston
presses the oil inside the master cylinder. The oil reservoir is connected to the master cylinder which maintains the
oil quantity inside the system. Return spring is used to maintain pressure on the piston therefore when the driver
releases the brake pedal; the piston comes to its original position.

3) OIL RESERVOIR: - It maintains the oil quantity inside the system.

4) CYLINDER 2:- It is located inside the wheel drum. It consists of the two-piston & Piston rods are connected to
the shoes. When oil comes from the master cylinder, oil enters into cylinder 2 hence both pistons expand.

5) BRAKE SHOES: - There are 2 brake shoes used in the brake drum. Both piston rods are connected to one end
of the shoes. Other ends of the shoes are hinged Brake shoes have friction lining on the outer surface. Hence when
the driver presses the pedal, the pistons of cylinder 2 expands therefore Resulting in brake shoes expands therefore
due to friction between shoes & brake drum, Wheel stops.

The shoes are connected with the return spring. Therefore when the driver releases the clutch pedal, Pressure on
oil releases hence shoes are coming to their original position due to spring.

6) PIPELINE: - It is used to flow oil from master cylinder to cylinder 2.

Working of hydraulic brakes: -

The hydraulic brake is a braking system structure where sufficient brake fluid has been used to shift
pressure from the control mechanism to the brake mechanism. On the same concept, hydraulic brakes in
automobiles also perform.

 The master piston shifts within the master cylinder when we apply a little force to the pedal with our
foot, and the pressure generated is transmitted via the brake oil to work on a larger-area piston.
 A large force acts on the piston and stretches the brake shoes against the brake lining and is pulled
back.
 A small force on the pedal generates a strong retarding force on the wheels in this manner.
 A significant benefit of the system is that all cylinders connected to the four wheels are transmitted
similarly to the pressure set by pressing a pedal, so that the braking effort on all wheels is
equivalent.

Pneumatic braking System: The pneumatic

braking system is one of the types of Automobile Braking
System. It is also known as the Air braking system. It is
invented by George Westinghouse in the 1860s. In this
Braking System, Compressed Air is used apply the Brake.
The Brake force produce by the Hydraulic Brake is not
sufficient to stop the heavy vehicles. Therefore Pneumatic
Brake is used in heavy vehicles.

The five Basic components of a Pneumatic or Air brake

system are Air Compressor, Storage Tank/Air Reservoir,
Brake Valve, Brake Chamber, and Brake Drum.

It consists of the following components:-

Air Compressor, Air Filter, Air Dryer, Storage Tank,

Safety Valve / Pressure Regulator Valve, Brake Valve,
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Brake Chamber, Brake Drum, Shoes
1) AIR COMPRESSOR: - Compressor works on the engine power. The compressor takes Air from the atmosphere and
compresses it and sends to the Storage tank.

2) AIR FILTER: - Air Filter is used Before the Compressor to remove the Dust Particles from the Air, before entering
into the Compressor.

3) AIR DRYER: - Air Dryer is used Before the Compressor to remove the Moisture from the Air, before entering into
the Compressor. Because Moisture damages the Compressor Blades.

4) STORAGE TANK: - It Stores the Compressed Air receives from the Compressor.

5) SAFETY VALVE / PRESSURE REGULATOR VALVE: - This Valve is used on the Storage Tank to maintain the pressure
in inside the tank & Removes the excessive air from the tank.

6) BRAKE VALVE: - It is used to regulate the Air flow from the Storage Tank to Brake Chamber.

It is control by the Brake Pedal. When Driver presses the brake pedal, Brake Valve Opens, Therefore Air flows from
the Storage Tank to Brake Chamber.

When Driver release the brake pedal, Brake Valve Closes, Therefore Air Stops to flows from the Storage Tank to
Brake Chamber.

7) BRAKE CHAMBER: - It is consists of the Diaphragm, Return spring.

The Diaphragm is connected to the push rod & Push Rod is connected to the Lever & Lever is connected to the cam.

When Driver release the brake pedal, Return spring is keeps the diaphragm in original position.

8) BRAKE DRUM: - It is consists of the Two Brake shoes, Cam, Return spring.

One end of the both shoes hinged & other ends are connected to the Cam. Hence when cam rotates, the brake
shoes expand inside the brake drum.

On the outer surface of the brake shoes has friction lining. Therefore when brake shoes expand, Due to friction
between shoes & brake drum, Wheel stops.

9) SHOES: -The shoes are connected with the return spring. Therefore when driver release the clutch pedal, Shoes
are comes to original position due to spring.

Pneumatic braking system working: -

When Brake applies:-

1) Compressor takes Air from the atmosphere and compresses it and sends to the Storage tank.

2) When Driver Press the Brake Pedal, Brake Valve opens, Therefore flows from the storage tank to the
Brake Chamber.

3) In the Brake Chamber, Air applies the Force on Diaphragm, hence Due to this through push rod and
adjustable lever, Cam Rotates inside the Brake Drum.

4) Therefore, when cam rotates, the brake shoes expand inside the brake drum & Due to friction between
shoes & brake drum, Wheel stops.

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When Brake release:-

1) When Driver Release the Brake Pedal, Brake Valve Closes.

2) Hence, Air Stops flowing from storage tank to Brake Chamber.

3) Diaphragm comes to original position & through push rod & Adjustable lever, Cam again Rotates in
opposite direction.

Due to Cam movement, Shoes comes to inside. Hence Wheel starts rotating.

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 Conclusion
Industrial training is very much important for instrumentation engineering point
of view. Here all units very much important and every unit have an important
object.

It was a great internship in TMILL full of knowledge. I really enjoyed the training
period. I have learnt about different services and the major and minor defects
generally seen in the car and how to solve them. Most of the times I see how
change the brake pads, tires, replacing the engine oil, coolant and many other
things. I also seen that how an organization work under extreme pressure and
how to handle it like when so many cars have to repair in the limited time it is
really a very big task. Overall it was a good experience and it increases my
interest in the Automobile Engineering, now I am planning to enhance my skills
in this field.

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