TRIBHUWAN UNIVERSITY

INSTITUTE OF ENGINEERING
PASHCHIMANCHAL CAMPUS
POKHARA-16, LAMACHAUR

A REPORT ON
INDUSTRIAL ATTACHMENT
ON ASHOK LT ENGINEERING SERVICES PVT. LTD.
POKHARA-14, CHAUTHE

Submitted By:
KAPIL BARAL (PAS075BAME019)
PRABIN ACHARYA (PAS075BAME030)
RAMESH BHATTARAI (PAS075BAME033)
SABIN BANIYA (PAS075BAME036)
YAM BAHADUR POUDEL CHHETRI (PAS075BAM048)

Submitted to:
DEPARTMENT OF AUTOMOBILE AND MECHANICAL ENGINEERING

MAY 2022
 INTERNSHIP EVALUATION

Internship at Ashok LT Engineering Services Pvt. Ltd.

Pokhara-14, Chauthe

By

Kapil Baral, Prabin Acharya, Ramesh Bhattarai, Sabin Baniya, and Yam Bahadur
Poudel Chhetri

This report has been examined thoroughly and has been found that it is complete and
satisfactory in all respects. Any and all revisions required for the report examination
have been made.

SUPERVISED BY: APPROVED BY:

……………………. .....................................

Jr. Er. Ramesh Shahu Er. Kiran Poon

Service Engineer Workshop Incharge

May 2022
 ABSTRACT

The report entitled ‘A REPORT ON INDUSTRIAL ATTACHMENT AT ASHOK LT

ENGINEERING SERVICES PRIVATE LIMITED.’ was completed as a requirement of
course Industrial Attachment (AM 704). The industrial training at IME Motors Pvt. Ltd.
was done from 02 May 2022 to 20 May 2022. It is an internship report based on our
experience in Ime Automotives Pvt. Ltd. In the report, we have covered the basic
introduction to the service station, its management structure, plant analysis, workflow in
the station, machines used, inventory control, personnel management, and the various
works we were involved in during the internship period. During our internship, we
learnt mostly about the overall management system, various automotive technical
section, and the inventory control. This internship opportunity allowed us to link our
theoretical knowledge with the practical one, broadening our knowledge in the
automotive sector. Similarly, we were exposed to the corporate culture enabling us to
know how industries work in Nepal. Similarly, during this period, we also developed
various soft skills, which will be helpful throughout life. The report also emphasizes the
overview of Ashok Leyland and Escorts Construction Equipment. Moreover, this report
includes four case studies with different problems that frequently arise while running a
vehicle. The reason of the problems, their remedies, the duration of solutions and
conclusion about the findings are major concern of our internship. From all the way we
see our internship program as a positive point in our career.

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 ACKNOWLEDGEMENT

We would like to express our gratitude to ASHOK LT ENGINEERING SERVICES

PRIVATE LIMITED, Pokhara-14, Chauthe for providing us an internship opportunity
from 02 May 2022 to 20 May 2022.

We would like to thank Mr. Suman Sapkota (Branch Manager), Er. Kiran Poon
(Workshop In charge), Er. Ramesh Shahu (Service Advisor) and Mr. Nabaraj Sharma
(Accountant) for their consistent support, co-operation, and guidance throughout the
internship period. We must express our gratitude to Mr. Krishna Gurung (Head
Mechanic), Mr. Suman Tamang (Mechanic), Mr. Bishal Dhami (Mechanic)
all other technicians for sharing their valuable knowledge in the automotive sector and
guiding us perform several tasks in the centre.

We must acknowledge our deep sense of gratitude to Department of Mechanical and

Automobile Engineering, Pashchimanchal Campus and Society of Innovative
Mechanical Engineering Students (SIMES) for addressing several factors, allowing us
to utilize the internship opportunity to the fullest.

Lastly, we would like to extend our sincere thanks to all the staffs of Ime Automotives
Pvt. Ltd, Pokhara for providing a friendly environment throughout the internship period.

Thank you all.

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 TABLE OF CONTENTS

ABSTRACT..................................................................................................i
ACKNOWLEDGEMENT.........................................................................ii
TABLE OF CONTENTS..........................................................................iii
LIST OF FIGURES...................................................................................vi
CHAPTER ONE: INTRODUCTION.......................................................1
1.1 Introduction........................................................................................................................1
1.2 Vision...................................................................................................................................3
1.3 Mission................................................................................................................................4
1.4 Core Value..........................................................................................................................4
1.5 Products and Core service.................................................................................................4
1.5.1 Products and Core service:............................................................................................5
CHAPTER TWO: MANAGEMENT SYSTEM......................................7
2.1 Organizational Structure:.................................................................................................7
2.2 Job Allocation Process.......................................................................................................7
2.3 Production chart..............................................................................................................10
2.4 Plant Layout.....................................................................................................................11
2.5 Maintenance Management..............................................................................................11
2.6 Inventory Management...................................................................................................12
2.7 Quality Management.......................................................................................................12
CHAPTER THREE: EQUIPMENT AND SYSTEM............................13
3.1 Equipment:.......................................................................................................................13
3.1.1 Toolbox.......................................................................................................................13
3.1.2 Hydraulic Jack and Lift...............................................................................................16
3.1.3 Air Compressor...........................................................................................................17
3.1.4 Grinding Machine.......................................................................................................17
3.1.5 Pneumatic Tools..........................................................................................................17
3.1.6 Gear oil pump..............................................................................................................18
3.1.7 Engine Lifter...............................................................................................................18
3.1.8 Piston ring assembler..................................................................................................19
3.1.9 Torque wrench............................................................................................................20
3.1.10 Engine Lifter.............................................................................................................20
CHAPTER FOUR: ENGINE AND ITS PARTS...................................21
4.1 Introduction......................................................................................................................21
4.2 Components......................................................................................................................22
4.2.1 Cylinder block.............................................................................................................22
4.2.2 Piston...........................................................................................................................22

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 4.2.3 Inlet Manifold.............................................................................................................23
4.2.4 Exhaust Manifold........................................................................................................23
4.2.5 Connecting Rod...........................................................................................................24
4.2.6 Crankshaft...................................................................................................................24
4.2.7 Piston Rings................................................................................................................25
4.2.8 Gudgeon Pin................................................................................................................25
4.2.9 Camshaft.....................................................................................................................25
CHAPTER FIVE: DIFFERENT SYSTEM IN AUTOMOBILE.........27
5.1 Cooling System.................................................................................................................27
5.1.1. Introduction................................................................................................................27
5.1.2 Types of cooling system.............................................................................................27
5.2 Lubrication System..........................................................................................................33
5.2.1 Purpose of Lubrication.........................................................................................33
5.2.2 Parts Requiring Lubrication........................................................................................33
5.3 Transmission System.......................................................................................................34
5.3.1. Introduction................................................................................................................34
5.3.2 Parts of Transmission System.....................................................................................34
5.3 Braking System................................................................................................................44
5.3.1 Introduction.................................................................................................................44
5.3.2 Types of Braking System............................................................................................44
CHAPTER SIX: FIELD WORK AND ASSIGNMENT.......................47
6.1 Training Methods.............................................................................................................47
6.1.1 Consultant with supervisor..........................................................................................47
6.1.2 Taking the topic for observation and inspection.........................................................47
6.1.3 Literature review.........................................................................................................48
6.1.4 Observing the system and its components..................................................................48
6.1.5 Asks with technical supervisor...................................................................................48
6.1.6 Asks with technicians..................................................................................................48
6.1.7 Compare parts and components realizing theoretical and practical aspects:..............48
6.1.8 Case study on specific problem:.................................................................................49
6.1.9 Drawing conclusion:...................................................................................................49
6.1.10 Work done.................................................................................................................49
6.2 Managerial and Supervising Works...............................................................................49
6.3 Mechanic Work................................................................................................................50
6.3.1 General servicing........................................................................................................50
6.3.2 General Check-up.......................................................................................................50
6.3.3 Clutches and brake:.....................................................................................................51
6.3.4 Engines........................................................................................................................51
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 6.3.5 Gear box......................................................................................................................51
6.4 Case studies.......................................................................................................................51
CHAPTER SEVEN: LESSON LEARNT AND SKILLS GAINED.....57
CHAPTER EIGHT: CONCLUSION.....................................................59
CHAPTER 9: RECOMMENDATION...................................................60
REFRENCES............................................................................................61

LIST OF FIGURES
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Figure 1: IME MOTORS Pvt. Ltd.....................................................................................1
Figure 2: Parking...............................................................................................................2
Figure 3: Maintenance Bay...............................................................................................2
Figure 4: Maintenance Bay...............................................................................................3
Figure 5: Organization structure........................................................................................7
Figure 6 : Job Card............................................................................................................9
Figure 7: Production Chart..............................................................................................10
Figure 8: Plant Layout.....................................................................................................11
Figure 9: Toolbox............................................................................................................13
Figure 10: Wrenches........................................................................................................14
Figure 11: Sockets...........................................................................................................14
Figure 12: Screwdriver....................................................................................................14
Figure 13: Pliers..............................................................................................................15
Figure 14:Hamer(simple)................................................................................................15
Figure 15: Extension Rods..............................................................................................16
Figure 16: Hydraulic Jack...............................................................................................16
Figure 17: Air Compressor..............................................................................................17
Figure 18: Pneumatic Gun...............................................................................................18
Figure 19: Gear Oil Pump...............................................................................................18
Figure 20: Engine Lifter..................................................................................................19
Figure 21: Piston Ring Assembler...................................................................................19
Figure 22:Torque Wrench...............................................................................................20
Figure 23: Engine Lifter..................................................................................................20
Figure 24: Engines...........................................................................................................21
Figure 25: Cylinder Block...............................................................................................22
Figure 26: Piston.............................................................................................................23
Figure 27: Inlet Manifold................................................................................................23
Figure 28: Exhaust Manifold...........................................................................................24
Figure 29: Connecting Rod.............................................................................................24
Figure 30: Crankshaft......................................................................................................25
Figure 31:Engine Parts....................................................................................................25
Figure 32: Rocker Shaft...................................................................................................26
Figure 33: Thermo Syphon..............................................................................................28
Figure 34: Forced Circulation.........................................................................................29
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Figure 35: Radiator..........................................................................................................30
Figure 36: Thermostat Valve...........................................................................................31
Figure 37: Fan..................................................................................................................31
Figure 38: Clutch Disc.....................................................................................................35
Figure 39: Gear Shifting Fork.........................................................................................36
Figure 40: Gear Box........................................................................................................37
Figure 41: Input Shaft......................................................................................................38
Figure 42: Lay Shaft........................................................................................................38
Figure 43: Output Shaft...................................................................................................39
Figure 44: Forward Gears................................................................................................39
Figure 45: Reverse Gear..................................................................................................40
Figure 46: Synchronizer Ring Assembly........................................................................41
Figure 47: Propeller Shaft...............................................................................................42
Figure 48: Universal Joint...............................................................................................42
Figure 49: Differential Gears...........................................................................................43
Figure 50: Rear Axle.......................................................................................................44
Figure 51: Drum Brake System.......................................................................................45
Figure 52: Disc Brake System.........................................................................................45
Figure 53: Operation of Disc Brake................................................................................46
Figure 54: Training Process.............................................................................................47

vii
 CHAPTER ONE: INTRODUCTION

1.1 Introduction
Ashok LT Engineering Services Pvt. Ltd., located at Chauthe, Pokhara, is an
authorized service center for IME Motors & IME Automotives Pvt. Ltd. aimed to
repair, maintain, diagnose, service, inspect the vehicles of Ashok Leyland & Escorts
Heavy Equipment with the help of skilled and semi-skilled personnel such as
engineers, mechanics, helpers etc.

IME Motors Pvt. Ltd. Is the authorized sole distributor of Hinduja Group’s
commercial vehicle manufacturer Ashok Leyland Limited for Nepal. With the influx of
a new breed of young, highly qualified, and energetic managing partners who keep a tab
in their respective fields of automobile agency business, IME Motors Pvt. Ltd. is well
on course to becoming one of the most prolific automobile agencies in Nepal in
foreseeable future (IME Motors Pvt. Ltd., 2022).

IME Automotives Pvt. Ltd. has the national distributorship of “Escorts Heavy
Equipment” – Escorts Group India (IME Group, 2017).

Figure 1: IME MOTORS Pvt. Ltd

1
 Figure 2: Parking

Figure 3: Maintenance Bay

2
 Figure 4: Maintenance Bay

1.2 Vision
The main Visions of the Organization are as follows:

a. To become one of the foremost corporations by introducing innovation in all the

business concerns and creating shared values to their stakeholders.
b. To deliver superior value products and services to empower customers,
stakeholders and to society as a whole by creating synergy between the business
interests.
c. To provide the reliable service, repair and after sale support to all the Ashok
Leyland and Escorts vehicles.

3
1.3 Mission
To captivate the attention of customers with best product and after sales service.

IME MOTORS Pvt. Ltd. has following missions:

a. Create values in new ideas, hard work and commitment.

b. Provide best of services and care for the customers.
c. Comply with all the legal bindings.
d. Change the lives of the people with better services and care.
e. Provide growth opportunity and training to all employees.
f. Help the nation grow economically.

1.4 Core Value

a. Integrity

b. Accountability

c. Diligence

d. Perseverance

e. Discipline

IME MOTORS Pvt. Ltd has a vision of providing the supreme consumer experience by
its mission statement of captivating the attention of customers with best products and
after sales service on the customer behalf concerning the organization profit.

1.5 Products and Core service

Different products of Ashok Leyland and Escorts has been providing by IME MOTORS
Pvt. Ltd., and IME AUTOMOTIVES Pvt. Ltd. respectively. The core services they
provide are:

a. Their workshop services ensure us to get the highest-quality advice,

maintenance and parts when we need them. So, their flexible solutions help us
maximizing our uptime and our business.

4
 b. The moment we enter on their workshops, we understand why their technicians
are very special people. Their experts solve any problem we throw at them – and
suggest improvements we had not thought about, or knew were even possible.
c. Their comprehensive range of repair and service contracts will have every part
of our vehicle covered – so we can avoid problems.
d. Our team is always there to help us – we can call them any time of the day or
night. They can arrange for a service vehicle to be sent out, with the right parts
and tools.
e. Their lifecycle efficiency approach ensures cost efficiency and smooth
operations, environmental efficiency and performance optimization.

1.5.1 Products and Core service:

Different products of Ashok Leyland are provided by IME MOTORS Pvt. Ltd. The
different products names sold and repaired are listed below:

ASHOK LEYLAND (IME Motors, 2022):

A. BUSES
a. LYNX SMART
b. LYNX
c. VIKING
d. CHEETAH

B. TRUCKS
a. 6-WHEELER
 ECOMET 1012 STRONG
 ECOMET 1212 STRONG
 ECOMET 1214 BS III
 1616 IL COWL CHASIS
b. 8-WHEELER
 2516 IL
 2516 XL
 3118 IL LA
 3718 IL

5
 c. 10-WHEELER
 3718 IL

C. TRUCK TAILOR
 U-3518 TT
 U-4019 TT
 U-4923

D. TIPPER

a. 6-WHEELER
 ECOMET 1012
 ECOMET 1212
 1616 CARGO CAB
b. 10-WHEELER
 U-2518 T
c. 12-WHEELER
 U-3123 T

E. LIGHT VEHICLES

 DOST FSD
 DOST HS
 DOST CONTAINER

F. DEFENSE VEHICLES

 STALLION 4×4
 STALLION 6×6
 SUPER STALLION 6×6
 SUPER STALLION 8×8
 SUPER STALLION 10×10

6
 CHAPTER TWO: MANAGEMENT SYSTEM

2.1 Organizational Structure:

The Ashok LT Engineering Services Pvt. Ltd., has sale department and service
department situated at Chauthe, Pokhara. The service department consists of various
departments which are directly related with dealing for procurement, maintenance of
automobiles along with its spare parts and lubrications and accounting section of a
whole organization. The organizational structure of this branch is shown by the
following flowchart:

Branch Manager

Workshop Incharge Sales & Marketing Account & Finance

Service Engineer

Technical Advisor

Head Mechanic

Mechanic Mechanic Mechanic(Escorts)

(Ashok Leyland) (Ashok Leyland)

Figure 5: Organization structure

2.2 Job Allocation Process
The job allocation process starts with entry of vehicles and end with billing as illustrated
below:
a) Entry from gate
b) Enquiry with service advisor
c) Making of job cards
d) Allocation of job to technicians
7
 e) Trial verification
f) Billing
g) Closing the job

a. Entry from gate: This process starts when the vehicle enters to the gate verifying the
confirmation of maintenance or scheduled maintenance. Security guard provides
number card to every entered vehicle.

b. Enquiry with technical engineer: Customer describes the problem to technical

engineer. Then job card is prepared accordingly. Breakdown maintenance includes
inspection by supervisor and head technicians and describes the problem to customer
and service advisor. Simply scheduled maintenance requires no any trial inspection.

c. Making of job card: Whether it is scheduled maintenance or breakdown

maintenance each customer should make job card in which job is described in detail. In
job card vehicle number, vehicle model, customer name with contact number and name
of technician are included. The total expenses for the maintenance, delivery date and
time are written in job card.

d. Allocation of job to technicians: The supervisor asks the technicians to do the jobs.
Each job is done by specific number of technicians. The job is totally completed by
technicians under the supervision of supervisor. During maintenance if any part is
damaged, then technicians request supervisor and supervisor requests with service
advisor. Technical advisor writes the parts name in job card and customer receives parts
from spare parts department. If any additional works done, then they are also listed
asking with technicians.

e. Trial verification: Vehicles are taken to trial for the inspection either the complaint
is solved or not. This is done by expert driver or technicians who can detect the
problem.

f. Billing: After detecting if the problem is solved, the advice supervisor calculates all
the expenses in the job card and send it to the accounting section. Then customer pays
the total expenses of the maintenance. Gate pass is given to the customer after clearing
bill to go out from gate.

g. Closing the job: After billing, service advisor brings back the job card and closes the
job card entering all details of the job card including details of vehicle, its problem and
total expenses for maintenance in computer.
8
Figure 6 : Job Card

9
2.3 Production chart

Figure 7: Production Chart

10
2.4 Plant Layout

Figure 8: Plant Layout

2.5 Maintenance Management
Maintenance management describe the efficient and productive output of the
organization. In IME MOTORS Pvt. Ltd. ,number of bays are separated for specific
work. For servicing purposes two bays are separated for Ashok Leyland vehicles and
for Escorts single bay are used. Maintenance is all basis on the experience of technician.
Maintenance work is started with the costumer complain in their vehicle to service
advisor. He finds out problem and prepare job card accordingly. Then costumer handed
job card to supervisor who ordered specific technician with respect to difficulty of the
work. So, maintenance works are divided according to technician level. Each technician
has their own tool box so that it is easier to handle and save time because of their
habitual action with their own tool box. For difficult and heavy maintenance work a
group of technicians is separated. Inventories are maintained by two separate
departments spare viz. Lubricants and spare parts.

11
2.6 Inventory Management
It is one of the most important parts in the company. In this case company should have
all idea about their storage of the part. In IME MOTORS Pvt. Ltd. basically inventories
are divided into lubricants and spare parts. In the Lubrication section all lubricants such
as engine oil, transmission oil, differential oil & brake oil are maintained and on the
other hand spare part contains all parts required in the vehicle such as brake pads, gears,
air and diesel filter, bushes, bearing, etc.

In this service center, Microsoft Dynamic NAV software plays vital role in inventories
management. Every part is registered and this software with each part has unique part
number. So, advisor has brief information about the all-registered parts as he can inform
the customers about the availability of the parts. If new part that is unavailable is needed
then order of that part takes place immediately and arrive within a week.

Computers of inventories department and advisor’s computers are linked so that all
used part during the maintenance work is subtracted from the inventory department
computer.

2.7 Quality Management

Quality of the product and the maintenance work is one of main objective of the IME
MOTORS Pvt. Ltd.

To maintain the quality of the product, they use genuine parts from Ashok Leyland and
Escorts.

From the customer complaints and test drive, advisor and supervisor find out the
problems and then give order to technician based on the level of work needed. For
simple servicing and oil change they order junior technicians and for exceedingly
difficult work senior technicians are consulted.

Before replacing the spare parts, supervisor and technician observe the condition of the
part. Then based on the customer decision and condition of the part replacement is done.
Warranty is given to the replaced part for the customer satisfaction.

After completion of the work, trial takes place with the senior technician or with
customer. If everything is right then billing and payment is done.

12
 CHAPTER THREE: EQUIPMENT AND SYSTEM

3.1 Equipment:
For the repair and maintenance of the vehicles various equipment are needed. They
provide an easier means to perform a task in an easy and efficient manner. Various
modern tools save time and reduce the strength to do a certain job. Material and parts
handling become easier with modern tools so that the parts of the vehicles are not
damaged while repairing.

Some of the equipment that are used are listed below:

3.1.1 Toolbox
Nuts and bolts of various sizes need to be opened during repairing the vehicle. A
toolbox contains many of the tools like sockets, wrenches, combinations, hammer,
screwdrivers, ratchet, claw hammer, L-N keys, T-handle, etc.

Figure 9: Toolbox
a. Wrenches

Wrenches are the tools used to provide grip and mechanical advantage in applying
torque to tighten or loosen nuts and bolts. The most common shapes are called open-
ended spanner and ring spanner.

13
 Figure 10: Wrenches
b. Sockets:

Socket wrenches come in sets for a wide variety of size, depending on requirements.
Socket extenders are indispensable items that help to reach those almost-unreachable
nuts and bolts.

Figure 11: Sockets

c. Screwdrivers:
Screwdriver is a small handy tool, usually manual, for driving or removing screws. It
has a handle, a shaft and a tip. The tip has either plus “+” or minus “-” cross-section
which fits into the screw head while turning the screw. The shaft is usually made up of
toughened steel so that the tip does not wear easily.

Figure 12: Screwdriver

14
d. Pliers

Pliers are hand tool used to hold objects firmly, possibly developed from tongs used to
handle hot metal. They are also useful for bending and compressing a wide range of
materials.

Figure 13: Pliers

e. Hammer

A hammer is a tool or device used to deliver a blow (a sudden impact) to an object.

Most hammers are hand tools used to drive nails, fit parts, forge metal, and break apart
objects. Hammers vary in shape, size, and structure, depending on their purposes.

Figure 14:Hamer(simple)
f. Extension rods

There are many bolts that are hard to reach so that we cannot directly work with
wrenches. These rods are simply rods with ends that fit into the sockets. Whenever a
mechanic is taking off a part deep in the engine bay, or tearing out a transmission, a
variety of extensions will certainly make work easier.

15
 Figure 15: Extension Rods
3.1.2 Hydraulic Jack and Lift
A jack is a device used to lift heavy loads or to apply greater force with minimum
effort. A mechanical jack employs screw thread mechanism while a hydraulic jack uses
fluid power to lift loads.
3.1.2.1 Working of Hydraulic jacks
It depends on force generated by pressure. Essentially, if two cylinders (a large and a
small one) are connected and force is applied to one-cylinder, equal pressure is
generated in both cylinders. However, because one cylinder has a larger area, the force
the larger cylinder produces will be higher, although the pressure in the two cylinders
will remain the same. Hydraulic jacks depend on this basic principle to lift heavy loads:
they use pump plungers to move oil through two cylinders. The plunger is first drawn
back, which opens the suction valve ball within and draws oil into the pump Schamber.
As the plunger is pushed forward, the oil moves through an external discharge check
valve into the cylinder chamber, and the suction valve closes, which results in pressure
building within the cylinder.

Figure 16: Hydraulic Jack

16
3.1.3 Air Compressor
Air compression is essentially a twofold process in which the pressure of air rises while
the volume drops. In most cases, compression is accomplished with reciprocating piston
technology, which makes up the vast majority of compressors on the market. Every
compressor with a reciprocating piston has the following parts:

a. crankshaft

b. connecting rod

c. cylinder

d. piston

e. valve head

Figure 17: Air Compressor

3.1.4 Grinding Machine

Grinding is a material removal and surface generation process used to shape and finish
components made of metals and other materials. The precision and surface finish
obtained through grinding can be up to ten times better than with either turning or
milling. Grinding employs an abrasive product, usually a rotating wheel brought into
controlled contact with a work surface. The grinding wheel is composed of abrasive
grains held together in a binder. These abrasive grains act as cutting tools, removing
tiny chips of material from the work. As these abrasive grains wear and become dull,
the added resistance leads to fracture of the grains or weakening of their bond. The dull
pieces break away, revealing sharp new grains that continue cutting.

3.1.5 Pneumatic Tools

A pneumatic tool or air-powered tool is a type of power tool, driven by compressed air,
supplied by an air compressor. Pneumatic tools are safer to run and maintain than their
electric power tool equivalents, and have a higher power to-weight ratio. In general,
pneumatic tools are cheaper than the equivalent electric-powered tools.

17
Various size sockets fit into the spindle of the pneumatic gun which when rotate using
the pneumatic power can easily open different nuts with minimum effort.

Figure 18: Pneumatic Gun

3.1.6 Gear oil pump
This simple mechanical hand driven device helps to put gear oil in the differential. The
use of this device eliminates the difficulty of putting oil through the horizontal opening
of the differential housing.

Figure 19: Gear Oil Pump

3.1.7 Engine Lifter
Any internal combustion engine used in vehicles is heavy and hence its instalment and
removal are certainly a tedious task. This engine lifter uses hydraulic power to lower or
lift the engine.
`

18
 Figure 20: Engine Lifter
3.1.8 Piston ring assembler
This cylindrical device is very useful during the engine assembly. The three types of
rings in the piston are very sensitive to axial stress and may break easily. To assemble
the piston cylinder arrangement without any damage to the ring or the cylinder liner this
device proves useful.

Figure 21: Piston Ring Assembler

19
3.1.9 Torque wrench
A torque wrench is used where the tightness of screws and bolts is crucial. It allows the
operator to measure the torque applied to the fastener, so it can be matched to the
specifications for a particular application. This permits proper tension and loading of all
parts.
This device was mostly employed during tightening the nuts and bolts of the engine
head.

Figure 22:Torque Wrench

3.1.10 Engine Lifter
When engine is to be removed from the car and the worked upon, engine holder is used.
It gives easy access to distinct parts of the engine which makes their repair efficient.
The one used in the Hyundai service center was of crane type with a hook at last to hold
the engine.

Figure 23: Engine Lifter

20
 CHAPTER FOUR: ENGINE AND ITS PARTS

4.1 Introduction
An internal combustion engine (ICE) is a heat engine where the combustion of a fuel
occurs with an air in combustion chamber in given proportion of air fuel ratio. In an
internal combustion engine, the expansion of the high-temperature and high-pressure
gases produced by combustion applies direct force to some component of the engine.
The force is applied typically to piston that reciprocates. This force moves the
component over a distance, transforming chemical energy into useful mechanical
energy.

Figure 24: Engines

21
4.2 Components
4.2.1 Cylinder block
The cylinder block is the main supporting structure for the various components. The
cylinder of a multicylinder engine is cast as a single unit, called cylinder block. The
cylinder head is mounted on the cylinder block. The cylinder head and cylinder block
are provided with water jackets in the case of water-cooling with cooling fins in the
case of air-cooling. Cylinder head gasket is incorporated between the cylinder block and
cylinder head. The cylinder head is held tight to the cylinder block by number of bolts
or studs. The bottom portion of the cylinder block is called crankcase. A cover called
crankcase, which becomes a sump for lubricating oil is fastened to the bottom of the
crankcase. The inner surface of the cylinder block, which is machined and finished
accurately to cylindrical shape, is called bore.

Figure 25: Cylinder Block

4.2.2 Piston
a cylindrical component fitted into the cylinder forming the moving boundary of the
combustion system. It fits perfectly (snugly) into the cylinder providing a gas-tight
space with the piston rings and the lubricant. It forms the first link in transmitting the
gas forces to the output shaft.

22
 Figure 26: Piston
4.2.3 Inlet Manifold
The pipe which connects the intake system to the inlet valve of the engine and through
which air or air fuel mixture is drawn into the cylinder is called the inlet manifold.

Figure 27: Inlet Manifold

4.2.4 Exhaust Manifold
The pipe that connects the exhaust system to the exhaust valve of the engine and
through which the products of combustion escape into the atmosphere is called the
exhaust manifold.

23
 Figure 28: Exhaust Manifold
4.2.5 Connecting Rod
It interconnects the piston and the crankshaft and transmits the gas forces from the
piston to the crankshaft. The two ends of the connecting rod are called as small end and
the big end. Small end is connected to the piston by gudgeon pin and the big end is
connected to the crankshaft by crankpin.

Figure 29: Connecting Rod

4.2.6 Crankshaft
It converts the reciprocating motion of the piston into useful rotary motion of the output
shaft. In the crankshaft of a single cylinder engine there is pair of crank arms and
balance weights. The balance weights are provided for static and dynamic balancing of
the rotating system. The crankshaft is enclosed in a crankcase.

24
 Figure 30: Crankshaft
4.2.7 Piston Rings
Piston rings, fitted into the slots around the piston, provide a tight seal between the
piston and the cylinder wall thus preventing leakage of combustion gases

4.2.8 Gudgeon Pin

It forms the link between the small end of the connecting rod and the piston.

4.2.9 Camshaft
The camshaft and its associated parts control the opening and closing of the two valves.
The associated parts are push rods, rocker arms, valve springs and tappets. This shaft
also provides the drive to the ignition system. The camshaft is driven by the crankshaft
through timing gears.
Cams

Figure 31:Engine Parts

25
Figure 32: Rocker Shaft

26
 CHAPTER FIVE: DIFFERENT SYSTEM IN AUTOMOBILE

Different systems involved in automobile are:

a) Cooling System

b) Lubrication System

c) Transmission System

d) Braking System

5.1 Cooling System

5.1.1. Introduction
The cooling system forms an intrinsic part of an automobile engine. It performs
multitude of functions such as removing excess heat from the engine, maintaining
efficient temperature and allowing engine to perform its task within a short span of
time. The heat should be prevented from being transferred to the cylinder walls as it
causes pre-ignition of charge. Further, the lubricant might also burn because of
excessive heat. Ideally, automobile cooling system keeps the engine running at an
optimum temperature whatever the operating conditions are. Automobile cooling
system consists of components or equipment installed in vehicles for removing heat
from all the moving parts so that they can work suitably without melting, seizing, and
overheating. More specifically, automotive cooling system makes use of coolant,
lubricating oil, and fan to maintain and regulate the temperature of other parts of an
engine. The burning of the lubricant, in turn, might lead seizure of the piston. While the
engine is running, heat should be continuously removed from the engine. For this
purpose, various methods of cooling the engine are utilized.

5.1.2 Types of cooling system

Mainly there are two types of cooling system

Water cooling

Air cooling

Among these, water cooling system is used widely.

27
5.1.2.1 Water Cooling System
In water cooling system, the cooling medium used is water. In this, engine cylinders are
surrounded by water jackets through which cooling water flows. Heat flows from the
cylinder walls into water which goes to the radiator where it loses its heat to the air.
Usually, some antifreeze is added to the cooling water, due to which it is often referred
to as coolant. There are two types of water-cooling system:

a. Thermo-syphon

b. Forced circulation

These types are described below:

I. Thermo-syphon: In this system, the circulation of water is due to difference in

temperature (i.e., difference in densities) of water. So, in this system pump is not
required but water is circulated because of density difference only. In this system, the
circulating water gets heat from the engine cylinder, there by cooling the same. The
same heat in the water is then dissipated into the atmosphere, through the radiator,
mainly by conduction and convection. In this system there is a fan which is rotated by
the movement of the crankshaft while the engine is running. The fan draws cold air
from outside through the radiator. When the outer surface of the radiator pipes come
into contact with cold air, the hot water passing through the radiator is cooled. Thus, the
engine is also cooled.

Figure 33: Thermo Syphon

II. Forced circulation: It is a simple centrifugal pump driven by a belt connected to the
crankshaft of the engine. The pump circulates fluid whenever the engine is running. The
water pump uses centrifugal force to send fluid to the outside while it spins, causing
fluid to be drawn from the center continuously. The inlet to the pump is located near the
28
center so that fluid returning from the radiator hits the pump vanes. The pump vanes
fling the fluid to the outside of the pump, where it can enter the engine. The fluid
leaving the pump flows first through the engine block and cylinder head, then into the
radiator and finally back to the pump.

Figure 34: Forced Circulation

Components of Water-Cooling System

The various components of water-cooling system are:

(a) Radiator,

(b) Thermostat valve,

(c) Water pump,

(d) Fan,

(e) Water Jackets, and

(f) Antifreeze mixtures.

(g) Pressure cap

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a. Radiator: A radiator is a type of heat exchanger. It is designed to transfer heat
from the hot coolant that flows through it to the air blown through it by the fan. The
upper tank is connected to the water outlets from the engine's jackets by a hose pipe
and the lover tank is connect to the jacket inlet through water pump by means of
hose pipes. In operation, water is pumped from the engine to the top (receiving)
tank, where it spreads over the tops of the tubes. As the water passes down through
the tubes, it loses its heat to the airstream which passes around the outside of the
tubes. To help spread the heated water over the top of all the tubes, a baffle plate is
often placed in the upper tank, directly under the inlet hose from the engine. It is to
be noted that radiators are generally made of copper and brass and their joints are
made by soldering.
Most modern cars use aluminium radiators.

Figure 35: Radiator

b. Thermostat Valve: It is a valve which prevents flow of water from the engine to
radiator, so that engine readily reaches to its maximum efficient operating
temperature. After attaining maximum efficient operating temperature, it
automatically begins functioning. Generally, it prevents the water below 80°C.Once
the temperature of the coolant rises to between 82 to 91 0C, the thermostat starts to
open, allowing fluid to flow through the radiator. By the time the coolant reaches 93
to 1030C, the thermostat is open all the way.

30
 Figure 36: Thermostat Valve
c. Water Pump: The water pump is a simple centrifugal pump driven by a belt
connected to the crankshaft of the engine. The pump circulates fluid whenever the
engine is running. The water pump uses centrifugal force to send fluid to the outside
while it spins, causing fluid to be drawn from the center continuously. The inlet to
the pump is located near the center so that fluid returning from the radiator hits the
pump vanes. The pump vanes fling the fluid to the outside of the pump, where it can
enter the engine. The fluid leaving the pump flows first through the engine block
and cylinder head, then into the radiator and finally back to the pump.
d. Fan: Like the thermostat, the cooling fan has to be controlled so that it allows the
engine to maintain a constant temperature. Front-wheel drive cars have electric fans
because the engine is usually mounted transversely, meaning the output of the
engine points toward the side of the car. The fans are controlled either with a
thermostatic switch or by the engine computer, and they turn on when the
temperature of the coolant goes above a set point. They turn back off when the
temperature drops below that point.

Figure 37: Fan

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e. Water Jackets: Cooling water jackets are provided around the cylinder,
cylinder head, valve seats and any hot parts which are to be cooled. Heat generated in
the engine cylinder, conducted through the cylinder walls to the jackets. The water
flowing through the jackets absorbs this heat and gets hot. This hot water will then be
cooled in the radiator.
f. Antifreeze mixture: In western countries if the water used in the radiator
freezes because of cold climates, then ice formed has more volume and produces cracks
in the cylinder blocks, pipes, and radiator. So, to prevent freezing antifreeze mixtures or
solutions are added in the cooling water (a mixture of water and ethylene glycol
(C2H6O2) is known as antifreeze) example: methanol, ethanol, isopropyl alcohol,
propylene glycol.

g. Pressure Cap: The radiator or pressure cap actually increases the boiling point
of coolant by about 45 F (25 0C). The same way a pressure cooker increases the boiling
temperature of water. The cap is actually a pressure release valve, and on cars it is
usually set to 15 psi. The boiling point of water increases when the water is placed
under pressure. When the fluid in the cooling system heats up, it expands, causing the
pressure to build up. The cap is the only place where this pressure can escape, so the
setting of the spring on the cap determines the maximum pressure in the cooling system.
When the pressure reaches 15 psi, the pressure pushes the valve open, allowing coolant
to escape from the cooling system. This coolant flows through the overflow tube into
the bottom of the overflow tank. This arrangement keeps air out of the system. When
the radiator cools back down, a vacuum is created in the cooling system that pulls open
another spring-loaded valve, sucking water back in from the bottom of the overflow
tank to replace the water that was expelled.

Air cooling system

Air cooling system is generally used in small engines say up to 15-20 kw and in
aeroplane engines, bikes etc. In this system fins or extended surfaces are provided on
the cylinder walls, cylinder head, etc. Heat generated due to combustion in the engine
cylinder will be conducted to the fins and when the air flows over the fins, heat will be
dissipated to air.

32
5.2 Lubrication System
I.C. Engine is made of many moving parts. Due to continuous movement of two
metallic surfaces overreach other, there is wearing moving parts, generation of heat and
loss of power in the engine lubrication of moving parts is essential to prevent all these
harmful effects.
5.2.1 Purpose of Lubrication
a. Reducing frictional effect:
The primary purpose of the lubrication is to reduce friction and wear between two
rubbing surfaces. Two rubbing surfaces always produce friction. The continuous
friction produce heat which causes wearing of parts and loss of power. In order to avoid
friction, the contact of two sliding surfaces must be reduced as far as possible. This can
be done by proper lubrication only.

Lubrication forms an oil film between two moving surfaces. Lubrication also reduces
noise produced by the movement of two metal surfaces over each other.

b. Cooling effect:
The heat, generated by piston, cylinder, and bearings is removed by lubrication to a
great extent. Lubrication creates cooling effect on the engine parts.

c. Sealing effect:
The lubricant enters into the gap between the cylinder liner, piston, and piston rings.
Thus, it prevents leakage of gases from the engine cylinder.

d. Cleaning effect:
Lubrication keeps the engine clean by removing dirt or carbon from inside of the engine
along with the oil

5.2.2 Parts Requiring Lubrication

The following parts require lubrication:

a. Cylinder walls and piston

b. Piston pin

33
c. Crankshaft and connecting rod bearings

d. Camshaft bearings

e. Valve operating mechanism

f. Cooling fan

g. Water pump and

h. Ignition mechanism

5.3 Transmission System

5.3.1. Introduction
A transmission system is a critical component in a vehicle's powertrain. It transfers the
power generated by the engine to the wheels of the vehicle and optimizes the power
flow through the required gear ratios. It ensures the vehicle has sufficient torque to
move forward from rest and sufficient speed while cruising. This optimization is carried
out through gears in the transmission system which vary the gear ratio between the
engine and wheels and optimum transfer of engine power. The mechanism that
transmits the power developed by the engine of automobile to the engine to the driving
wheels is called transmission system (power train).

5.3.2 Parts of Transmission System

a. Clutch
b. The gear box
c. Propeller shaft
d. Universal joint
e. Differential gear
f. Rear axle
g. Wheel
h. Tires

A. Clutch: A clutch is a mechanism which enables the rotary motion of one shaft to be
transmitted to second shaft, whose axis is coincident with that of first. Clutch is located
between engine and gear box. When the clutch is engaged, the power flows from the
engine to the rear wheels through the transmission system and the vehicle moves, when

34
the clutch is disengaged, the power is not transmitted to the rear wheels and the vehicle
stops, while the engine is still running.

Clutch is engaged only when the vehicle is to move and is kept engaged when the
vehicle is moving. Clutch is disengaged when

a) Starting the engine,

b) Shifting the gears,

c) Idling the engine.

Figure 38: Clutch Disc

35
 A. Gear Box: A gear box, also called gear case or gear head, is a gear system
responsible for transmitting mechanical power from a prime mover (an engine or
electric motor) into some form of useful work. A gear box is a set of gears for
transmitting power from one rotating shaft to another. They are used in wide range
of industrial, automotive, and home machinery applications. The functions of a gear
box are

a. A gear box is precisely bored to control gear and shaft alignment.

b. It is a metal casing for protecting gears and lubricant from water, dust, and other
contaminations.

Figure 39: Gear Shifting Fork

36
 Figure 40: Gear Box
Components:

a. Input Shaft

b. Counter Shaft

c. Output Shaft

d. Forward Gear

e. Reversed Gear

f. Synchronizer Assemblies

a. Input Shaft

The input shaft also known as a main drive gear or clutch shaft is driven by the
clutch disc and drives the counter gear shaft. The input shaft is supported by the
pilot bearing at the end of the crankshaft and a bearing at the front of the
transmission case

37
 Figure 41: Input Shaft
b. Counter Shaft

The counter gear shaft also known as a cluster gear drives the gears (1st, 2nd,
3rd, and 5th) on the output shaft. This shaft is supported by bearings in the
intermediate plate, at the front of the transmission case, and in the extension
housing.

Figure 42: Lay Shaft

c. Output Shaft

The output shaft also known as the main shaft drives the propeller shaft. It is
splined at the rear to allow a sliding connection to the propeller shaft. The
output shaft gears rotate on the shaft and are locked to the shaft by
synchronizers. The synchronizers are splined to the output shaft. The output
shaft is supported by a pocket bearing at the rear of the input shaft, a bearing at
38
 the intermediate plate and a bearing at the extension housing of the
transmission.

Figure 43: Output Shaft

d. Forward Gear

All forward motion gears are helical gears because of their smooth and quiet
operating characteristics. Helical gears create end thrust under load, and
therefore have a thrust surface on the side of the gear. Gear side clearance is
limited to reduce noise and potential damage, which could result from gear
motion

Figure 44: Forward Gears

39
e. Reversed Gear

Reverse requires an additional gear in the gear train. A reverse idler gear is used
to change the direction of the output shaft for reverse.
The reverse gear is a straight cut spur gear and does not have a synchronizer.
Spur gears are suitable for this application because they shift into mesh more
easily than helical gears, and they do not generate end thrust under load.
Straight cut gears may create a whine or light growl during operation

Figure 45: Reverse Gear

f. Synchronizer Assemblies

The synchronizer mechanism is constructed of the following components:

• The speed gear is mounted on the output shaft. A needle roller bearing is
installed between the speed gear and the output shaft, allowing the gear to
rotate freely on the shaft.
• The synchronizer ring also called a blocker ring is made of brass and is
installed on the conical portion of the gear. Narrow grooves are cut in the
inside area of the synchronizer ring to provide the necessary clutch action of
the gear. Three equally spaced slots are cut on the outside surface for the
synchronizer keys to fit into.
• Two key springs are installed, one on each side of the clutch hub to hold the
synchronizer keys in place against the hub sleeve.
• The clutch hub is fit to the output shaft on splines and is secured by a snap
ring.

40
 • Three synchronizer keys are installed in the three equally spaced slots in the
clutch hub and are aligned with the slots in the synchronizer ring.
• The hub sleeve has internal splines that slip over the clutch hub splines,
engaging the spline teeth of the speed gear. An internal groove cut in the center
of the hub sleeve splines centers the hub sleeve. The hub sleeve is indexed by
the three spring loaded synchronizer keys
.

Figure 46: Synchronizer Ring Assembly

B. Propeller Shaft: A propeller shaft or drive shaft is a mechanical component for
transmitting torque and rotation, usually used to connect other components of drive
train that cannot be connected directly because of distance or the need to allow for
relative movement between them.

41
 Figure 47: Propeller Shaft
C. Universal Joint: A universal joint is a joint or coupling in a rigid rod that allows
the rod to 'bend' in any direction, and is commonly used in shafts that transmit rotary
motion. It consists of a pair of hinges located close together, oriented at 90° to each
other, connected by a cross shaft.

Figure 48: Universal Joint

D. Differential Gear: A differential is a gear train with three shafts that has the
property that the angular velocity of one shaft is the average of the angular velocities
of the others, or a fixed multiple of that average. In automobiles and other wheeled
vehicles, the differential allows the outer drive wheel to rotate faster than the inner
drive wheel during a turn. This is necessary when the vehicle turns, making the
wheel that is traveling around the outside of the turning curve roll farther and faster
than the other. An increase in the speed of one wheel is balanced by a decrease in
the speed of the other.

42
 Figure 49: Differential Gears

E. Rear Axle: An axle is a central shaft for a rotating wheel. On wheeled vehicles,
the axle may be fixed to the wheels or rotating with them, or fixed to the vehicle,
with the wheels rotating around the axle. A straight axle is a single rigid shaft
connecting a wheel on the left side of the vehicle to a wheel on the right side. The
axis of rotation fixed by the axle is common to both wheels. Such a design can keep
the wheel positions steady under heavy stress, and can therefore support heavy
loads.

43
 Figure 50: Rear Axle
G. Wheels and Tyres: A tire is a ring-shaped vehicle component that covers the
wheel’s rim to protect it and enable better vehicle performance. Most tires, such as
those for automobiles and bicycles, provide traction between the vehicle and the road
while providing a flexible cushion that absorbs shock. Tires are mounted onto wheels
that most often have integral rims on their outer edges to hold the tire. Automotive
wheels are typically made from pressed and welded steel, or a composite of lightweight
metal alloys such as aluminum or magnesium. These alloy wheels maybe either cast or
forged. The mounted tire and wheel assembly is then bolted to the vehicle's hub.

5.3 Braking System

5.3.1 Introduction
Braking System is one of the important control components of vehicle, which helps to
slow down and eventually stop the running vehicle. The brakes must be strong enough
to stop the vehicle within a minimum distance in an emergency.

5.3.2 Types of Braking System

Brakes may be classified according to the construction as:

a. Drum Brake: In this type of brake, a brake drum is attached concentric to the
axle hub whereas the axle casing is mounted on a black plate. The black plate
helps to increase rigidity and to provide support for anchor and brake shoes. It
also protects the drum and shoe assembly from mud and dust. One or two
reactor springs are used which serve to keep the brakes shoes away from the
drum when the brakes are not applied. The brake shoes are anchored at one end,
whereas on the other end, force is applied by means of some brake actuating

44
 mechanism, which forces the brake shoe against the revolving drum, thereby
applying the brakes.

Figure 51: Drum Brake System

b. Disc Brake: Type of brake that uses calipers to squeeze pairs of pads against a
disc in order to create friction that retards the rotation of a shaft, such as a
vehicle axle, either to reduce its rotational speed or to hold it stationary. The
energy of motion is converted into waste heat energy.

Figure 52: Disc Brake System

When the brakes are applied, the pistons are hydraulically operated. They move the
friction pads into contact with the disc, thus applying equal and opposite forces on both
45
sides of the disc. When the brakes are released, the rubber sealing rings act as return
springs, they retract the pistons and the friction pads away from the disc.

Figure 53: Operation of Disc Brake

46
 CHAPTER SIX: FIELD WORK AND ASSIGNMENT

During the time of our industrial OJT period, various tasks were assigned by the
supervisor. We were first trained and then given task of dealing with customers and
enquiring about their problems and then making the job orders, data gathering, service
and warranty check, as well as doing the actual work under the guidance of mechanics
which tremendously helped us in knowing the things that we learned in practical life.

Following field works and assignments were done during our internship days:
6.1 Training Methods

Figure 54: Training Process

6.1.1 Consultant with supervisor
Service advisor is personnel in this service center who takes the complaint from
customer about vehicle problem. Our training program always starts from consultation
with these personnel to what type of and what should we do within our criteria. Service
advisor tells us about different automobile parts and assign us what should we do for
next steps. Consultation with advisor not only we do in beginning but also after
finishing assigned work.

6.1.2 Taking the topic for observation and inspection

It is not possible to do whole work at same time so we always asked service advisor to
give us specific topic for observation and inspection within vehicles. The topic must be
practical tracing its path from theoretical knowledge.
47
6.1.3 Literature review
Theoretical portion and demonstrative video were studied and seen respectively of
different automobile systems and parts for the work assigned for next day. Literature
review of specific system was done thoroughly for our well understanding. Source of
literature review were lecture slides, website articles and other internet source.

6.1.4 Observing the system and its components

After doing the literature review, we observe the real parts in vehicle, track down their
connection from with each part. The real part is entirely different from what we see and
study in theory. Different company have their own designing styles and their own
principal for working which makes hard to identify the components for which we must
find their connection with major components.

6.1.5 Asks with technical supervisor

Technical supervisor was always there for supporting us, they always direct us and
teach us about different components. Technical supervisor directs us how the whole
service plant works and how the work is assigned to each technician.

6.1.6 Asks with technicians

This is main part where our whole time used to be implied for understanding each part
in vehicle. Technician when used to do their work for maintenance we used to talk with
them and ask them about the problem. From the problem to maintenance each portion
we used to ask them in layman terms. They also showed us the job cards and how they
follow the work. We used to ask even small components if it was unique to us with their
name. It was wonderful time for not only to learn but also to earn how to cooperate with
the technician and real work scenario.

6.1.7 Compare parts and components realizing theoretical and practical aspects:
This is the main part of our intern program. The practical or real parts are always
different from what we study in theory. So, we must be able to compare them with our
theoretical study to make it simple to understand. Later this will help to verify the
problem, and how the problem is generating. Each problem whenever generates is
always associated with other parts which need to understand. This possible if we can
relate each part and their working for which we must go on theoretical and practical
aspects.
48
6.1.8 Case study on specific problem:
For case study we take on specific parts which will be associated with specific
problem. We dealt with this problem in detail from their detection, possible other
cause, severity in vehicle, and all possible solution. Fault tree analysis and finding
their root cause of failure will be best way to do case study for this level which will be
included during case study.

6.1.9 Drawing conclusion:

Finally, we draw conclusion about real work scenario and how it should be tackled.
After completion of each system study and observation we consulted with service
advisor again to remark us for more information and to teach us best way to tackle
problem.

6.1.10 Work done

During our industrial training we had learned many things and system used in the
vehicle as mentioned in sections above.

6.2 Managerial and Supervising Works

The following tasks were handed out under the supervision of floor supervisor:

A. A complete list of things done during the previous day’s work were submitted to the
floor supervisor.
B. Customer’s queries and problems were thoroughly noted, analyzed and a convenient
solution was discussed.
C. Identification and drawing of solutions of the vehicles brought for
servicing/maintenance.

D. Opening job card and respective gate pass for all the incoming vehicles.

E. Job order placement to mechanic

F. Data entry on computer (details of customer, vehicles, job order, assigned mechanic
and job completion confirmation)

49
6.3 Mechanic Work
These tasks were done under the supervision of head mechanic and floor supervisor.
General servicing as well as some basic repairing/maintenance jobs were assigned to us
by the head mechanic. Special and difficult works were also inspected.

6.3.1 General servicing

General servicing was done in 3 phases. 1 st servicing was done after the vehicle covered
20,000km distance. Similarly, 2nd and 3rd servicing was done after 40;000km and
60,000km, respectively. The following tasks were done for servicing of vehicles.

A. Changing engine oil and oil filter

B. Cleaning or replacing air filter and check gasket or hoses

C. Changing diesel filters if necessary

D. Checking Gear oils and change if necessary

E. Checking the water separator

F. Washing

6.3.2 General Check-up

General check-ups of vehicles include the following points.

A. Report card inspection

B. Distance travelled

C. Brake’s check-up

D. Door’s check-up

E. Battery and lights check-up

F. Coolant level, brake fluid level, wiper fluid level and power steering fluid level
check-up

50
6.3.3 Clutches and brake:
It includes:
A. Checking front and rear brake pads.

B. Checking brake oil.

C. Cleaning brake shoe, disc, and drum.

6.3.4 Engines
It includes:

A. Tappet setting

B. Timing belt and fan belt check.

C. Coolant level check.

D. Nozzle pressure check.

6.3.5 Gear box

It includes:

A. Checking clutch plate and pressure plate

B. Changing clutch plate

C. Changing gear and counter for increasing pick up

6.4 Case studies

During our internship period we were assigned to diagnose the specific cases, study
related parts, system and mechanism and then find out possible solution for them. The
following are the special cases or problems that we were assigned with:

51
Case 1

Statement of the problem: Half servicing of bus.

Possible causes: According to the guidelines of the vehicle use.

Diagnosis: Following steps were adopted:

a. Analyzed by senior technicians by observing and test drive.

b. Job card was made.

c. Mobile and mobile filter was changed.

d. Fuel strainer was also changed.

e. Diesel filter was changed.

f. Test drive was done.

Findings: Vehicle was near to the servicing time.

Root cause: Diesel filter damage.

Days required: 2 days.

Conclusion: Regular servicing.

Case 2

Statement of the problem: Customer came with the complain of noise from the front
part.

Possible causes: Maybe some parts were worn out on the front.

Findings: After the detailed inspection, it was found that the brake shoes need to be
changed.

52
Solutions: Following steps were adopted to solve the problem:

a. Brake shoes on both front wheel were changed.

b. Also left disc pad need to be machined. So, it was taken to lathe machine for
machining.

Days required: 1 day

Conclusion: Customer was suggested to regularly follow up for vehicle servicing.

Case 3

Statement: Customer came for regular checkup.

Possible causes: Need servicing.

Diagnosis: Following steps were adopted:

A. Analyzed by senior technician by observing and test drive.

B. Problem of brake pads.

C. Job card was made.

D. Brake shoes were changed.

a. Tools used: -

b. 12/13 mm ring spanner

c. 16mm ring spanner

d. 16 mm socket with extension rod

E. Test drive was done.

F. After finding okay, billing was done.

Findings: Brake pads were worn out.

Solutions: Brake pads were changed.

53
Days required: 1 day.

Conclusion: Customer was suggested to do the servicing on recommended time.

Case 4

Statement: Customer came for full servicing.

Possible causes: Servicing time.

Diagnosis: Following steps were adopted:

a. Analyzed by senior technician.

b. Hubs were greased.

c. Electrical parts were changed on the indicators.

d. Mobile, mobile filter and diesel filter was changed.

e. Test drive was done and everything was found okay.

Findings: Servicing was needed.

Solutions: Hubs were greased and mobile parts were changed.

Days required: 1 day.

Conclusion: Customer was suggested to do regular check-up of vehicle.

Case 5

Statement: Customer came with sound from differential.

Possible Cause: The tail pinion may be worn out.

54
Diagnosis: Following steps were adopted:

A. Analyzed by senior technician by observing the sound.

B. The differential box was dissembled.

C. Tools used: -
a. 18 mm one sided ring spanner and open spanner

b. 17 mm and 19mm socket wind extension rod

c. Hammer

D. Tail pinion with other gears were found damaged.

E. Tail pinion with other gears were changed.

F. End play and backlash of gears were checked after fitting the differential.

G. The differential box was then fitted to the vehicles.

H. Test drive was done.

Findings: Tail pinion was found damaged.

Solution: Tail pinion with other gears were changed.

Day Required: 2 days

Conclusion: Customer was suggested not to pull the vehicles forcefully in inclined
plane with overload.

Case 6

Statement: Customer came with problem of excess fuel consumption.

Possible causes: Fuel leaks, Air cleaner clogged Diagnosis: Following steps were
adopted:
• Analyzed by technicians.

• The fuel leakage was checked and was found ok.

55
• Servicing was done which include change of oil filter, by pass filter, change of oil
and clean of air filter.
• Since the air filter was not in good condition so it was changed.

• Tire pressure was also checked.

Findings: Air filter was damaged.

Solution: Air filter was changed along with servicing done.

Day required: 1 day

Conclusion: Customer was suggested to do regular follow up for vehicle servicing.

56
 CHAPTER SEVEN: LESSON LEARNT AND SKILLS GAINED

The main objective of our internship was to familiarize us with real life working
situations. During our internship at Ashok LT Engineering Services Pvt. Ltd., we were
able to enhance our technical and managerial skills. Likewise, that period was a
platform to learn other various social and organizational skills that would help us to be a
successful engineer and entrepreneur. Other various skills that we learned during our
internship can be summarized as follows:

a. Increase profitability of an enterprise.

b. Mobilization of workers and distribution of work load.

c. Eliminate bottlenecks to avoid work congestion.

d. Employee relations and increase efficiency of workers.

e. Delegation of authority and responsibility.

f. Employee and employer’s problems solving.

Besides, we learned through experience how to interact and communicate with people.
We knew that people have distinct characteristics and attitudes. From the interaction
with mechanics and workers we learned how and what types of tools are to be used
according to the type of cases and how to handle and tackle different issues. Although
we worked and interact with them for a brief period of time, we learned a lot from them;
the skills and techniques that they shared with us that cannot be found on the books. We
learned about the management system of a company. We learned warranty policies of
distinct parts of automobile, for example the warranty of an engine is 3 years. We
learned about what is PDI, VIS how it is done and the factors to be considered during
PDI and VIS. OJT helped us to know about distinct parts of automobile and the position
as well as function of these parts. Yes, it is a big deal to buy a vehicle, but the
performance of vehicle should be maintained in optimum condition. To maintain the
optimum performance, the vehicle should service periodically. The following things are
to be checked before running the vehicle

a. Different oil levels should be checked.

b. Before turning on the key, the gear should be in neutral.

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c. Air filter should be cleaned regularly and should be replaced after cleaning three
times.

d. While cleaning air filter, the low-pressure air is blown from inner to outer through
vertical movement.

e. Before placing air filter engine should not be started.

f. Leakage from exhaust manifold should be checked for proper efficiency of turbo
charger.

g. The engine should be raced after placing engine in ideal for one to two minutes.

h. Until the temperature of engine drops to air temperature the pressure cap of radiator
should not be opened.
i. The coolant should be mixed with antifreeze as prescribed by the company.

j. The pressure of tire should be checked always and is as prescribed by the company.

After running vehicle for 20,000 km the following things should be done:

a. King pin, steering shaft, steering linkage, propeller shaft, front and rare spring pin
should be lubricated.
b. Front and rear suspension U bolt should be tightened.

c. Whether the brake oil has leakage or not should be checked.

d. In every six-month, brake oil should be changed.

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 CHAPTER EIGHT: CONCLUSION

Ashok LT Engineering Services Pvt. Ltd. provides genuine parts and satisfactory
servicing and maintenance facilities with a well collaborated group of engineers and
mechanics. During our period of working as an intern, we learnt various skills and woks
like servicing, tool management and handling, work flow management, customer
dealing and advising and spare parts handling. With the help of well managed facilities
and friendly staffs, we were able to learn as well as detect and solve the various
problems that may arise in the vehicles. We were able to excel our theoretical
knowledge into a more meaningful practical life.

Our first few days were training phase wherein we were trained for different managerial
and technical tasks and how the work and information flows at the enterprise. Later, we
were assigned with all the tasks that we were trained to, under the supervision of our
field supervisor. The assigned and accomplished tasks included report making, job card
entry and job order placement, daily record keeping, data entry on computers, customer
dealing and follow ups, problem analysis of customers and drawing possible solution,
general servicing of customer’s vehicles, special problem diagnosis and repairs along
with opportunity to dismantle the damaged and worn automobile parts make practical
learning of several components and mechanisms. Likewise, we also gained several
ideas and skills on working tools, equipment, and machineries during our job
completion at workshop.

Apart from learning, we got chance to interact with people outside the service center.

We learned about the ways of operation of dent paint, showrooms as well as the spare
parts and the works involved in customer care department. Overall, IME MOTORS Pvt.
Ltd. was a suitable place to practically learn what we had been learning in books and
the friendly environment of the company helped us a lot.

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 CHAPTER 9: RECOMMENDATION

Although the Ashok LT Engineering Services Pvt. Ltd. seemed to be running smoothly
and perform the tasks properly, there were still some drawbacks that were worth
noticing. Following recommendations could help solve such problems and benefit the
company even more in the future.

a. Tools should be well managed to avoid the scarcity of tools which was a major
problem during our time in the company. B. Staffs should be well trained.
b. It would be better if mechanics are provided the face mask since they are highly
prone to inhaling high degree of carbon particles emitted by vehicles.
c. Disciplinary and punctuality reward could be given to motivate the workers.

d. Proper and healthy drinking water facility must be set up.

e. Better exhaust system should be incorporated for the entire workshop area.

f. The overall security of the property seemed weak. So, a better security must be
emphasized.

g. The parking of vehicles seemed to be unmanaged. Parking rule must be set up.

h. Customer care was particularly good. During leisure time of customer, short
lessons and courses could be given so as to help them take better care of their
vehicles.
i. The board-mechanic discussion should take place more often.

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 REFRENCES

1. IME Group. (2017). Business. Retrieved from IME Automotives.

2. IME Motors. (2022). Products. Retrieved from IME Motors:

http://www.imemotors.com.np/

3. IME Motors Pvt. Ltd. (2022). About Us. Retrieved from IME MOTORS:
http://www.imemotors.com.np/about-us/

4. https://www.ashokleyland.com/np/en/

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