3320501:- INDUSTRIAL TRAINING REPORT

INDUSTRIAL TRAINING
A PROJECT REPORT
Submitted by

DOMADIYA RAVI JAYANTIBHAI (146470302014)

In fulfilment for the award of the degree

Of
DIPLOMA ENGINEERING
In
Automobile Engineering Department

SHREE TAPI BRAHMCHARYASHRAM SABHA COLLEGE

OF DIPLOMA ENGINEERING, SURAT.

GUJARAT TECHNOLOGICAL UNIVERSITY, AHMEDABAD

S. T. B. S. COLLEGE OF DIPLOMA ENGINEERING, SURAT.

DEPARTMENT OF AUTOMOBILE ENGINEERING

OCTOBER 2016

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CERTIFICATE

Date: 21/10/2016

This is to certify that the dissertation entitled “INDUSTRIAL

TRAINING” has been carried out by DOMADIYA RAVI
JAYANTIBHAI under my guidance in fulfillment of the Diploma
of Engineering in automobile (5th Semester) of Gujarat
Technological University, Ahmedabad during the academic year
2016 .

Guided by: Head of Department

Mr. V.R. SABHAYA Mr. V.R. SABHAYA

SING OF EXTERNAL EXAMINER

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CERTIFICATE OF WORKSHOP

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ACKONWLEDGMENT

First and foremost, I wish to express my heartfelt thanks to our

Institute guide Mr. Vijay R. Sabhaya, Lecturer in Automobile

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Department and Company advisors, Mr. Shyam Patel & Mr. Salim
Masalawala, Floor supervisers of “Empire Cars Private Limited”
for their invaluable guidance, continued & moral support,
encouragement and patience throughout the training period. Without
them the completion of this training would have been impossible.

I would also like to express my heartfelt thanks to all technicians for

the kind help & support during training.

I express my special thanks to Mr. Vijay R. Sabhaya, I/C Head of

Automobile Department & Prof. Y. S. Choupare, Principal of
College for extending their support in providing permission letter for
selection of training.

At last but not least, I am highly thankful to almighty God for

showering me with his kind blessings and love.

- Ravi J. Domadiya

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ABSTRACT
Now days, we have to know that the automobile is the famous word in
the world. Automobile is a self propelled vehicle who transport to
move goods & passenger one place to another place.

Last some years, we have to see very critical growth of automobile

industry. So many automobile industries are working in the world.
Customers are buying that company product that need to satisfy
customer of their company vehicle services. Customer satisfaction is
more important to automobile companies and for this, it is very
essential for technicians, supervisors and all the staff working in
workshop that they must have sufficient knowledge about vehicle
service. This knowledge is gained only by training. All the future
automobile engineers have been taking training about how vehicle has
been serviced.

I was visited so many workshop in surat, Gujarat. Viz. Hyundai

(Navjivan Motors), Nissan (Silicon Motors), Tata Motors (Shriji
Motors), Maruti Suzuki (Spectra Motors), Chevrolet (Empire Cars),
Honda (Landmark Cars).

I have chosen Chevrolet Workshop (Empire Cars Private Limited),

Piplod, Surat. They work for customer satisfaction & Methods of
technician to carry out work is quite impressive. So I have chosen
Empire cars workshop for my training.

Mainly two types of vehicle maintenance are carried out in the

workshop. First is Preventive Maintenance, is also known as General
Maintenance or Periodic Maintenance. Second is Breakdown
Maintenance. I had completed this two maintenance based training in
workshop and this report is all about this training and my personnel
experience on this training.

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LIST OF TABLES

Table Table of description Page No.

description
1) 1.2 (1) Profile of Chevrolet Division Of 2
General Motor Company
2) 1.2 (2) Profile Of Empire Cars(GM) 3
3) 1.4.1 Current Model Of Chevrolet Cars 5
4) 1.4.2 Discontinued models 5
5) 5.4 Trouble shooting of gear box 33
6) 5.5 Diagnosis and troubleshooting of 34
steering, suspension wheel and tires

7) 5.6 Trouble shooting of brake 38

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LIST OF FIGURES
FIGURE NO. FIGURE DESCRIPTION PAGE NO.

2.1 LAYOUT OF WORKSHOP 7

3.1 ORGANIZATION CHART 8
4.1.1 ALLEN KEY SET 11
4.1.2 STAR BIT KEY SET 11
4.1.3 ADJUSTABLE WRENCH 12
4.1.4 T SPANNERS 12
4.1.5 (1) NOSE PILERS 13
(2) LOCKING PILERS 13
4.1.6 SREW DRIVER 14
4.2.1 RING SPENNERS 14
4.2.2 FIX SPENNERS 15
4.2.3 COMBI SPENNERS 15
4.2.4 HAMMER 16
4.2.5 EXTENTION AND UNIVERSAL JOINT 16
4.2.6 SOCKET SPENNERS AND SMALL SOCKET 17
SPENNERS KIT
4.2.7 CHISEL AND CUTTER 17
4.3.1 ELECTRIC LIFT 18
4.3.2 WHEEL BALANCING 18
4.3.3 WHEEL ALIGNMENT 19
4.3.4 REFRIGENT RECOVERY RECYCLING 20
MACHINE
4.3.5 AUTOMATIC NITROGEN INFLOATER TIRE 20
SYSTEM
4.3.6 SPOT GUN 21
4.3.7 OXY ACETYYLENE TORCH 21
4.3.8 BATTERY TASTER 22
4.3.9 SELF LOCKING JACK STAND 22
4.3.10 HYDRAULIC JACK 22
4.3.11 PNEUMETIC GUN 23
4.3.12 COIL SPRING COMPRESOR 23
4.3.13 TORQUE WRENCH 23
4.3.14 OIL FILTER WRENCH 24

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4.4.1 MULTI METER 24

4.4.2 VERNIER CALIPER 25
4.4.3 MICRO METER 25
4.4.4 JUMPER CABLE 26
4.4.5 BATTERY CHARGER 26
4.4.6 PISTON RING COMPRESSOR 27
4.4.7 INJECTOR TESTING MACHINE 27
5.1 ENGINE DIAGNOSIS 29
6.4.1 ENGINE OIL AND OIL FILTER REPLACE 44
6.4.2 FUEL FILTER REPLACE 44
6.4.3 AIR FILTER REPLACE 44
6.4.4 BRAKE PAD REPLACE 45
6.4.5 CALIPER GREASING 45
6.4.6 TRANSMISSION OIL CHANGE 45
6.4.7 DIFFRENTIAL OIL CHANGE 46
6.4.8 AC FILTER REPLACE 46
6.5 ENGINE TUNE UP (ENGINE OIL) 46
6.6 BATTREY MAINTENANCE 48
6.7 HORN 49
6.8 GEAR BOX 49
6.8.1 CHANGE RELEASE BEARING 50
6.8.2 CHANGE SYNCHRONISOR RING 50
6.9 IAC VALVE 51
6.10 TURBOCHARGER 51
6.11 CLUTCH 52
6.12 TAPPET SETTING 53
6.13 WATER PUMP 54
6.14 THERMOSTATE VALVE 55
6.15 EGR VALVE 56
6.16 INTER COOLER 56
6.17.1 COLOR CUPBOARD 57
6.17.2 COMPAD 57
6.17.3 DRY GUID COAT 57
6.17.4 DRY SANDER MACHINE 57
6.17.5 FASTCUT 57
6.17.6 GREEN ISCOTCH PAD 57

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6.17.7 POLISH MACHINE 58

6.17.8 RED ISCOTCH PAD 58
6.17.9 LIQUID WAX 58
6.17.10 KOMBI FILLER 58
6.17.11 LIGHT WIGHT FILLER & HARDNER(PUTTY) 58
6.17.12 MASK 58
6.17.13 MASKING TAPE 58
6.17.14 MASKING ROLL 58
6.17.15 PRIMER GUN 58
6.17.16 RAPID HARDNER 59
6.17.17 RAPID LIGHT GRAY 59
6.17.18 POLYKIT PRO & POLYKIT PRO HARDNER 59
6.17.19 BLOCK PAPER P-180 59
6.17.20 POLISH PAPER P-1500 59
6.17.21 POLISH PAPER P-800 59
6.17.22 SANDER PAPER P-80 59
6.17.23 BLOCK PAPER P-120 59
6.17.24 BLOCK PAPER P-180 59
6.17.25 SANDER PAPER P-500 60
6.17.26 PAINT GUN 60
6.17.27 SANDER PAPER P-320 60
6.18.1 SAFETY MASK 60
6.18.2 PROTECTIVE EYEWEAR 61
6.18.3 EAR PLUG 61
6.20 BRAKE PAD 54
6.21 CLUTCH DISC 65
6.22 GEAR BOX 67

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INDEX
SR.NO. CONTENT PAGE NO.
1 Acknowledgment IV
2 Abstract V
3 List of table VI
4 List of figure VII
5 Index x
Ch-1 Introduction 1
1.1 Introduction of workshop 2
1.2 Company profile 2
1.3 History of company 3
1.4 Car models of chevrolet company 5
Ch-2 Layout of workshop 6
Ch-3 Organization chart 8
Ch-4 Tools and equipments 10
4.1 Minor tools 11
4.2 Major equipments 14
4.3 Special equipments 18
Ch-5 Diagnosis and troubleshooting 28
5.1 Engine diagnosis 29
5.2 Transmission troubleshooting 30
5.3 Proppelar shaft troubleshooting 32
5.4 Troubleshooting of gear box 33
5.5 Diagnosis and troubleshooting of 34
steering, suspension, wheel & tyre
5.6 Diagnosis and troubleshooting of 38

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brake
Ch-6 Industrial work 41
6.1 What is preventive maintenance ? 42
6.2 preventive maintenance 42
6.3 Types of service 42
6.4 Part including in service 44
6.5 Engine tune up 46
6.6 Battery maintenance 48
6.7 Horn 49
6.8 Gear box 49
6.9 Poor pick up 50
6.10 Turbocharger 51
6.11 Clutch 52
6.12 Tappet setting 53
6.13 Water pump 54
6.14 Thermostat valve 55
6,15 EGR valve 56
6.16 Inter cooler 56
6.17 Painting process 57
6.18 About safety of painting 60
6.19 Main process of painting 62
6.20 Wearing of brake disc 63
6.21 Hard gear shifting 65
6.22 Grinding noise in natural condition 67
when vehicle is running

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Ch-7 My liking and disliking on work place 69

7.1 My liking 70
7.2 My disliking 70
Ch-8 Conclusion 71
Ch-9 Bibliography 73

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