INDUSTRIAL

TRAINING
REPORT
KSRTC REGIONAL WORKSHOP
ALUVA
12/06/2013 to 17/06/2013



SUBMITTED BY FOURTH SEMESTER
STUDENTS B-TECH IN MECHANICAL ENGINEERING
RAJAGIRI SCHOOL OF ENGINEERING
AND
TECHNOLOGY,KAKANAD, KOCHI
MEMBERS OF THE TEAM
1. Sebin Thomas
2. Kiran Jacob Johny
3. Eldho Samel
!. "ar#hese "in
$. %eb & 'hili(
). *a+ham Saran#
,. Roshan F Koni--ara
.. Ma+he/ Jose
0. Abhilash An+ony
1%TRO23&T1O%
The fourth semester B-Tech in Mechanical
Engineering students of Rajagiri School of Engineering
And Technology , Kakkanad conducted an industrial
training at the KSRTC Regional orksho!, Alu"a#
The !rime o$jecti"e of an engineering student is to
ac%uire kno&ledge and analysing skills on technical
su$jects #As Mechanical Engineering students it is "ery
much essential for us to ha"e hands on e'!erience on
"arious !ractical a!!lications of the su$jects &e study#
(t is "ery hard to achie"e such !ractical e'!erience $y
only a"ailing the facilities and !ractical sessions of our
college#
So &e sa& an o!!ortunity to get this !ractical
e'!erience $y undergoing industrial training at KSRTC
Regional orksho!, Alu"a, &here re!air, maintenance,
and $uilding of KSRTC $uses of central Kerala is done#
This is the re!ort of our industrial training at KSRTC
Regional orksho!, Alu"a dated from )*-+,-*+)- to
).-+,-*+)-#
A&K%O45E2*EME%T
e take this o!!ortunity to e'!ress our sincere
gratitude to all those &ho hel!ed us to com!lete this
industrial training in an enlightening manner#
e thank /od and our !arents for guiding us through
the right !ath# e thank our 0rinci!al 1r# 2# (saac &ho
ga"e us the !ermission and confidence for this training
and our 341 51e!artment of Mechanical Engineering6
, 0rof# Manoj# /# Tharian &hose hel!, stimulating
suggestions and encouragement hel!ed us in all our
endea"ours#
e sincerely thank Mr# M#S# Rajendranath , orks
manager KSRTC R7, Alu"a for gi"ing us the
o!!ortunity to &ork as interns at the KSRTC R7# e
&ould also e'tend our &holehearted gratitude to
Assistant 1e!ot Engineer KSRTC R7 A$oo$ecker sir
for the "alua$le suggestions , guidance and o"erall
direction hel!ed us in com!letion of this industrial
training# e also e'!ress our gratitude to the &orking
staff of all the sections of KSRTC R7, Alu"a &ho in
s!ite of their hectic &ork schedule &ere "ery hel!ful in
clearing our dou$ts in a lucid and understanda$le
manner and e'!laining a$out each of the different
!rocesses#
The different sections of the &orksho!
&here &e under&ent training are8
)# Engine 4"erhaul Section
*# Small 9nit
-# /ear$o' Section
:# 0ro!eller Shaft section
;# <ront A'le Section
,# Rear A'le section
.# =athe and elding Section
># Tyre Sho!
?# <uel (njection Section
)+# Body $uilding Section
1. En#ine O6erhal Sec+ion
The engine of a "ehicle is one of its most im!ortant
!arts and in the engine o"erhaul section &e &ere
introduced to ho& the engine &as disassem$led,
cleaning and ins!ection of the engine !arts and
assem$ly of engine to its com!lete form# The
mechanics of this section e'!lained to us a$out the
different !arts of the engine# Engine o"erhauling means
the reconditioning of engines# An o"erhauled engine is
an engine that is remo"ed from the "ehicle,
disassem$led, cleaned, ins!ected, re!aired &here"er
necessary and tested using suita$le methods in the
factory#
The "arious !rocedures in"ol"ed in o"erhauling include
honing, !lace ne& !iston rings 5oil and com!ression
rings6, $earings, gaskets, oil seals etc#
3oning !rocess is a method of !roducing !recision in
the engine cylinder $y means of ru$$ing &ith any
a$rasi"e# The diameter of the $ore of the engine $lock
is measured using "ernier cali!ers# (f the "ariation is
too much, then the &hole engine $lock is re!laced#
1uring o"erhauling, the engine $lock after ins!ection
and disassem$ly is !laced on a ta$le# The ne& crank
shaft is !laced inside the engine $lock &hich is
su!!orted $y $earings# The crank is designed such that
the !istons that &ill $e !laced in the cylinder &ill mo"e
&ith a !articular firing order#

This is follo&ed $y fitting of gaskets, cam shaft, gear
!um!, &ater !um! for cooling of engine and other
com!onents# The $ottom co"er is !laced and $olted in
!lace after all the com!onents in the lo&er side of the
engine $lock are !laced# The engine is then side&ays to
fit the fuel !um!# Again the engine $lock is turned and
the !istons are fitted to the crank shaft through the
$ore# After !lacing the sealant, the to! co"er &ith the
fuel injectors are !laced and $olted tightly in !lace#
The !rocess of o"erhauling mentioned a$o"e is similar
to $oth =eyland as &ell as Tata engines# 3o&e"er,
some factors such as firing order, design of the engine
$lock, the com!onents used etc "ary# The o"erhauling
&orks of these t&o engine $locks are done se!arately in
t&o different areas of the same sections#
The testing of the engines is done $y attaching them to
their test rigs &hich consists of "arious other
com!onents that make u! the &hole !o&er generation
system in the $us so that they can $e started and run
under no load to check &hether they are &orking
!ro!erly#
2. Small 3ni+
The small unit is section of the &orksho! &hich
undertakes the re!air and re!lacement of "arious
critical com!onents of a $us such as clutch, air $rake
system com!onents, &ater !um!s etc# The small unit
handles the re!air of almost :: different com!onents#
The com!onents &hich &e &orked u!on &ere8
1rying and 1istri$ution 9nit
System !rotection "al"e
9nloader @al"e
Air com!ressor !um!
1ual Brake "al"e
Clutch
1rying and distri$ution 9nit

The drying and distri$ution unit is an integral !art of
the air $rake system# The 1rying and distri$ution unit
51196 com$ines the function of the Air dryer &ith an
unloader "al"e, a !urge tank and a System 0rotection
@al"e 5S0@6#
The s!ecial features of 119 are listed $elo&
Air 1rying A Remo"es moisture com!letely from
the com!ressed air
9nloading A Regulates system !ressure $y
e'hausting the air deli"ered to the com!ressor, to
the atmos!here &hen system !ressure is increasesB
and allo&s re-charging of the system &hen the
system !ressure reduces#
Safety @al"e A (n case of any malfunctioning of
the unloader "al"e, it !rotects the com!ressor and
system $y $lo&ing off the e'cess !ressure# This
de"ice is integrated &ith the unloader "al"e
mechanism#
System 0rotection @al"e 5S0@6 A This function is
integrated into the 119, &hich !rotects the
healthy circuits of the air $rake system, in case of
failure in one of the circuits# The non-return "al"es
in this !ortion !re"ents $ack flo& of stored
com!ressed air u!stream#
0urge tank A This tank &hich is integrated &ith the
119 stores dry air for regeneration of the
desiccant $ed#
The dismantling and cleaning of the 119 &as done at
the &orksho! and the Assem$ly and re!air &as done at
ABC4 Technical Centre in the R7 cam!us#
Air Com!ressor !um!


Com!ressors are used to generate air !ressure in the air
$rake system# 0ressuriCed air is used for actuation of air
$rake e%ui!ment for reducing s!eed, sto!!ing the
"ehicle and other a!!lications# The dismantling and
cleaning of the Air Com!ressor !um! &as done at the
&orksho! and the Assem$ly and re!air &as done at
ABC4 Technical Centre in the R7 cam!us#


1ual Brake "al"e
The 1ual $rake "al"e is either a floor-mounted, treadle-
o!erated ty!e or fire&all-mounted $rake "al"e &ith t&o
se!arate su!!ly and deli"ery circuits for ser"ice and
secondary $raking, &hich !ro"ides the dri"er &ith a
graduated control for a!!lying and releasing the "ehicle
$rakes# The dismantling and cleaning of the 1ual Brake
@al"e &as done at the &orksho! and the Assem$ly and
re!air &as done at ABC4 Technical Centre in the
R7 cam!us#
Clutch

To allo& smooth shifting from one gear to another, a
clutch is !ro"ided to disengage the engine from the
transmission# A clutch is a mechanism for transmitting
rotation, &hich can $e engaged and disengaged#
Clutches are useful in de"ices that ha"e t&o rotating
shafts# (n these de"ices, one shaft is ty!ically dri"en $y
a motor, and the other shaft dri"es another de"ice# The
clutch connects the t&o shafts so that they can either $e
locked together and s!in at the same s!eed or $e
decou!led and s!in at different s!eeds# Clutch friction
disc also called as friction lining is made u! of a s!lined
round metal !art !late co"ered &ith friction material
5lining6 #the S!lines in center of the clutch disc mash
&ith s!lines on the in!ut shaft of manual transmission#
This makes the in!ut shaft and disc turn together#
3o&e"er the disc is free to slide $ack and forth in the
shaft#
3. *earbo7 Sec+ion

(n this section the dismantling, re!air and assem$ly of
=eyland and Tata gear$o'es are done
Manual transmissions come in t&o $asic ty!es8
A sim!le $ut rugged sliding-mesh or
unsynchroniCed7non-synchronous system, &here
straight-cut s!ur gear sets s!in freely, and must $e
synchroniCed $y the o!erator matching engine re"s
to road s!eed, to a"oid noisy and damaging
clashing of the gears
Constant-mesh gear$o'es, &hich can include non-
synchronised, or synchroniCed7synchromesh
systems, &here ty!ically diagonal cut helical 5or
sometimes either straight-cut, or dou$le-helical6
gear sets are constantly DmeshedD together, and a
dog clutch is used for changing gears# 4n
synchromesh $o'es, friction cones or Dsynchro-
ringsD are used in addition to the dog clutch to
closely match the rotational s!eeds of the t&o sides
of the 5declutched6 transmission $efore making a
full mechanical engagement#
Re"erse gear is usually unsynchronised, as the dri"e is
only e'!ected to engage it &hen the "ehicle is at a
standstill, meaning it also could only $e used for
mo"ing a&ay from a sto! unless the dri"er $ecame
ade!t at dou$le-declutching and had a !articular need
to regularly do&nshift into the lo&est gear#
!. 'ro(eller sha8+ Sec+ion
The !ro!eller shaft transmits !o&er from the gear $o'
to the differential of the rear a'le# The gear its !o&er
from the engine &hich is in turn transmitted to the
!ro!eller shaft $y means of a uni"ersal joint#
A uni"ersal joint is em!loyed to accommodate the
angular changes that occur in the shaft# T&o uni"ersal
joints are used for the !ro!eller shaft# 4ne is used
$et&een the gear$o' out!ut and the !ro!eller shaft and
the second is used $et&een the !ro!eller shaft and the
differential of the rear a'le#
<or $uses, hollo& shafts are used instead of solid
!ro!eller# This is $ecause hollo& !ro!eller shafts ha"e
more torsional resistance than solid shaft of the same
dimension and material undergoing the same stresses#

$. Fron+ A7le Sec+ion
The front a'le section deals &ith the dismantling and re!air
of the front a'le of the $us chassis# The major re!air &ork on
the front a'le includes re!air and re!lacement of the king!in
&hich holds the &heel hu$ ,re!lacing old $earings &ith ne&
ones, re!lacement of old oil seals &ith ne& ones, re!lacement
of $rake liner, connecting rod etc#

). Rear a7le sec+ion
The Rear a'le section deals &ith dismantling and re!air
of the rear differential, $rake cham$ers of the front and
rear a'les, slack adjusters etc#
The &orking of differential is that &hen any four
&heeler makes a turn, the rear &heels &ill ha"e
different s!eeds# This is due to the fact that one &heel
&ill ha"e to co"er more distance than the other
de!ending on the direction of turn# <or e'am!le, if a
$us takes a left turn, the left tyre has to co"er more
distance than the right tyre and therefore to adjust &ith
distance, the left tyre &ill ha"e to s!in at a faster s!eed
than the right tyre# Similar !rocess occurs during a right
turn#

This "ariation in s!eed of the tyres is sol"ed $y using a
mechanical setu! called the differential# (t is a system
of gears and !i"ots that accomadate the s!inning of the
rear tyres &ith the same s!eed 5straight dri"e6 and or at
different s!eeds5during cornering6#
The &heels are connected to t&o se!arate a'les &hose
ends are attached &ith t&o gears# The gears are allo&ed
to mesh &ith t&o other gears that are !i"oted so that
they can s!in freely# They are su!!orted $y connecting
them to the a'les of the &heels# The connection is such
that they can s!in around the a'is of the a'les# 0o&er is
transmitted to the a'les $y means of a large gear
attached to the a'le and a gear at the end of a !ro!eller
shaft# <or strong construction and less noise, the gear of
the shaft is made to mesh &ith the larger gear at its
lo&er side# The gears used are thick and the &hole
system is made com!act#
,. 5a+he and 4eldin# Sec+ion
The lathe is used for different turning !rocesses and is
used for remo"ing the &eld of !ro!eller shaft, ta!er
turning, cutting, sanding, knurling, drilling, or
deformation, facing, turning, &ith tools that are a!!lied
to the &ork !iece#
The &elding section deals &ith &elding of different
machine !arts to !recision#
The drilling and other micellenous o!erations are
carried out#
.. Tyre Sho(
The !rocess that takes !lace in the tyre sho! is
Retreading# Retreading is a !rocess for tyres that
re!lace &orn out tyres# Retreading !rocess is a!!lied
for tyres that ha"e $een &orn so that they can $e reused
after !ro!er ins!ection# This hel!s in conser"ing of
resources used for !roduction of fresh tyres from
factories and sa"es material cost#
The first ste! in the !rocess is ins!ection# (ns!ection is
done on &orn tyres to find out &hether there are any
defects in them such as holes, !rojections etc# (f no
such defect is found, then they can !roceed for
retreading#
The ne't ste! is Buffing &hich in"ol"es remo"ing of
the &orn out treads from the tyreEs !eri!hery using a
suita$le $uffing machine# Again, the Buffing !rocess is
different for ordinary K#S#R#T#C "ehicles and lo& floor
$uses# <or ordinary $uses, Buffing is done centrally
&hereas for lo& floor $uses, they are done radially
from one end to another#
After the $uffing !rocess, the tyres are a!!lied &ith an
adhesi"e coating# The adhesi"e is !rimarily a ru$$er
coating# After the last !hase of retreading, the adhesi"e
&ill melt and form a "ery strong $ond &ith the ne&
treads#
Fe't, the tyres are held on a fi'ture and ne& treads are
a!!lied on them $y !ressing on the treads &ith the hel!
of suita$le rollers &ith !ressure#
The tyres are then !laced in a cham$er &here they &ill
$e heated &ith high !ressure# There are three cham$ers#
The first t&o can hold large num$er of tyres and thus
needs to $e heated for a$out t&o and half hours# The
second cham$er can hold se"en tyres and needs only
t&o hours for the same#
0. Fel 1n9ec+ion Sec+ion
(n section the dismantling, re!air and assem$ly of fuel
injection !um!, fuel feed !um! and the atomiser is
done# An (njection 0um! is the de"ice that !um!s fuel
into the cylinders of a diesel engine# Traditionally, the
injection !um! is dri"en indirectly from the crankshaft
$y gears, chains or a toothed $elt 5often the timing $elt6
that also dri"es the camshaft# (t rotates at half
crankshaft s!eed in a con"entional four-stroke engine#
(ts timing is such that the fuel is injected only "ery
slightly $efore to! dead centre of that cylinderGs
com!ression stroke# (t is also common for the !um!
$elt on gasoline engines to $e dri"en directly from the
camshaft# The !istons ha"e a constant stroke "olume,
and injection "olume 5i#e#, throttling6 is controlled $y
rotating the cylinders against a cut-off !ort that aligns
&ith a helical slot in the cylinder# hen all the
cylinders are rotated at once, they simultaneously "ary
their injection "olume to !roduce more or less !o&er
from the engine# All injection !um!s incor!orate a
go"ernor to cut fuel su!!ly if the crank s!eed
endangers the engine - the hea"y mo"ing !arts of diesel
engines do not tolerate o"ers!eeding &ell, and
catastro!hic damage can occur if they are o"er-re""ed#
The fuel is raised to e'treme !ressures $y fuel injection
!um!s and is deli"ered to the com$ustion cham$er $y
!ressure-acti"ated injectors &ithout com!ressed air#
ith direct injected diesels, injectors s!ray fuel
through : to )* small orifices in its noCCle#
The fuel feed !um! is used to dra& the diesel fuel from
the fuel tank#
1:. &oach bildin# sec+ion
The coach $uilding section in K#S#R#T#C deals &ith
construction and re!air &orks of $uses# The $uilding
houses many $uses at a time and different &orks take
!lace inside#
<or construction of $odies of $uses, the first ste! is to
make a steel floor $y !lacing steel sections on to! of
the $ase frame# Then the $ody is se!arately made $y
using sheets of metals# These sheets are made $y
suita$le sheet metal !rocesses#
Before the $ody can $e $uilt using the sheets, the
re%uired sha!e of the coach is made $y using steel
skeleton structure !laced on the $ase# The sheets are
then !laced around this structure# The re%uired
finishing !rocesses such as !ainting and attaching of
other accessories are done after&ards#
S3**EST1O%S
4n account of the training session &e ha"e
undergone, &e &ould like to !ut forth a fe&
suggestions &hich might $e $eneficial for the
firm8
)# 0ro"ide $etter lighting conditions inside the
&orksho! !remises#
*# (ntroduction of integrated crane hoist facilities
in the &orksho!#
-# (ntroduction of air tools for faster and easy
dismantling and assem$ly of machine !arts#
:# (nstallation of an emission testing facility to
cater the needs of stricter emission norms#

&O%&53S1O%
The (ndustrial Training at KSRTC R7, Alu"a
&as a "ery fruitful e'!erience as $udding
Mechanical Engineering students# The training
definitely ga"e us an o!!ortunity to $e a !art of a
/o"ernment institution &hich has "ast e'!erience
in re!air, maintenance and $uilding of KSRTC
$uses# The training at the R(1 &orksho! &ill
definitely hel! us in our future endea"ours# e
take this moment to thank The orks Manager,
A1E, and all the em!loyees of KSRTC R7,
Alu"a for hel!ing us to com!lete this industrial
training in an enlightening manner#