STATE ROAD TRANSPORT CORPORATION

The State Road Transport Corporation is a state owned subsidiary. It has its own
fleet of Vehiles. The vehicles range from passenger bususes to Transport buses.
The vehicles operation both in Intrastate as well as Inter State Routes. The
famous routes are Srinagar to Delhi, Jammu, Leh and also some inter district
routes.
The workshop of SRTC is situated in Pampora and is a well managed through
proper planning for maintaining resource allocations. It is situated on Left side of
the National Highway on way from Srinagar. The employees of this workshop are
well skilled and have good sense of Humour.

The workshop is divided into number of sections viz.,

1. Engine Overhauling Section
a. Dissembling Section
b. Cleaning Section
c. Inspection & Repair
d. Assembling Section
2. Gear Box Section
3. Brake Section
4. Lubrication Section
5. Machine Shop
6. Coach Repair Section etc

ENGINE
An engine is a device which transforms one form of energy into another form.
However while transforming energy from one form to anither the efficiency of
conversion plays an important role. Normally, most of the engines convert
thermal energy into mechanical work and therefor they are called heat
engines.
Broader classification of heat engine

Basic Engine components:

1. CYLINDER: It is a cylindrical vessel or space in which the piston makes
reciprocationg motion.
2. PISTON:
It is a cylindrical componentfited into the cylinder forming the
moving boundary of the combustion system.
3. COMBUSTION CHAMBER: The space enclosed in the upper part of the
cylinder, by the cylinder head & the piston top during the combustion
process.
4. INLET MANIFOLD: The pipe which connects the intake system to the inlet
valve of the engine and through which charge is drawn into the cylinder.
5. EXHAUST MANIFOLD:
The pipe which connects the exhaust msystem
to the exhaust valve of the engine and through which the products of
combustion escape into the atmosphere.
6. INLET & EXHAUST VALVES:
Valves are commonly mushroom shaped
popet type. These are the openings in the cylinder through which charge
and the combustion products enters and leaves the engine cylinder
respectively.
7. SPARK PLUG:It is a component to initiate the combustion process in the
spark ignition engines.
8. CONNECTING ROD: It interconnects the piston and the crankshaft and
transmits the gas forces from the piston to the crank shaft.
9. CRANKSHAFT:
It converts the reciprocating motion of the piston into
the useful rotary motion of the output shaft. The crankshaft is enclosed in
a crank case with balance weights for static and dynamic balancing of the
rotating system.
10.PISTON RINGS:
These are fitted into the slots around the piston and
provide a tight seal between the piston and the cylinder wall thus
preventing leakage of the combustion gases.
11.GUDGEON PIN:
It forms the link between the small end of the
connecting rod and the piston.

12.CAM SHAFT: It along with its associated parts controls the opening and
closing of the valves. The associated are push rods, rocker arms, valve
springs and the tapets.
13.CAM: These are made as integral parts of the cam shaft and their peculiar
design regulstes the opening and closing of the valves.
14.FLYWHEEL: It is the inertia mass attached to the output shaft which
reduces the fluctuation in the torque. Multicylinder engines have smaller
flywheels than single or double cylinder engines owing to their lesser
fluctuation in the net torque at the output shaft.
WORKING PRINCIPLE OF 4 STROKE DIESEL ENGINE
Diesel engine works on diesel cycle the credit for whose invention goes to Rudolf
Diesel (1892). The ideal sequence of operations for the 4 stroke CI Engine is as
follows:
1. SUCTION STROKE: Air alone is inducted into the cylinder during the stroke
intake valve is open and exhaust valce is closed.
2. COMPRESSION STROKE:
The piston moves upwards from the BDC.
The inlet and exhaust valves remain closed. The air is compressed in the
cylinder with the high compression ratio of 10 22 and a high pressure of
40Kg/cm2
3. WORKING STROKE: The fuel injection starts nearly at the end of the
compression. The rate of injection is such that the combustion maintains
the pressure constant inspite of the piston movement on its expansion
stroke. The heat is assumed to have been added at constant pressure.
After the cutoff the products of combustion expand. Both the valves
remain closed during the stroke.
4. EXHAUST STROKE: The piston travelling from the BDC to TDC pushes out
the products of combustion. The xhaust valve is open and intake valve is
closed during the stroke.

OVERHAULING OF DIESEL ENGINE

Following steps are taken during the overhauling of the engine:
1. DISSEMBLING OF ENGINE:
a. Remove the water pumo.
b. Remove the exhaust manifold
c. Remove oil filter tube
d. Remove the water outlet fitting
e. Reove thermostat
f. Remove the crankshaft pulley
g. Remove the oil pump
h. Remove crankcase ventilation valve
i. Remove rocker arm assembly
j. Remove cylinder head
k. Remove oil pan
l. Remove piston and connecting rod assembly
m. Remove timing gear cover
n. Remove front end plate
o. Remove flywheel housing
p. Remove clutch

q.
r.
s.
t.
u.
v.

Remove
Remove
Remove
Remove
Remove
Remove

flywheel
crankshaft
exhaust valve and springs
cam shaft
valve tapets
oil gallery plugs

CHECKING FOR TROUBLES

1. Check the cylinder liners for scuffing and pitting
2. Check the ylinder liner for allowed bore and thickness specification. If
damaged beyond permissible linits change the damaged liners. If damage
is not too serios the go for internal grinding, finishing and finally honing to
abort the liner from removal.
3. Check the cylinder body, water jacket for the proper flow of coolant water.
4. Check the oil pump for the required flow of lubricating oil and flush the
stainer (oil mesh filter) with high pressure water
5. Crankshaft should be inspected for:
a. Soundness to check cracks
b. Roundness and wear of the journals ans crank pins
c. Balancing
d. Alignment of crankpins and journals
e. Cleanliness of oil galleries
6. Check the connecting rod for bending and proper clearance at the big end
between connecting rod cap and the bearings. To compensate for wear of
the bearing and to secure the correct bearing clearance between the
connecting rod and crankshaft, thin pieces of metal called shims are used.
7. The piston rings should be checked for wear and gap. To check this gap,
clean the carbon from the ends of the rinf and then check it with feeler
gauges. The gap may be in the g=region 0.178 to 0.50mm governed by
the diameter of the bore but if it exceed 1mm per 100mm of the bore
diameter, new rings must be fitted.
8. The gap between the ring and the groove in the piston should be checked
by feeler gauges. The gap is usually 0.038 to 0.102mm for the
compression rings and little less for the oil rings.
9. Piston pin should be checked for the wear, cracking or pitting. Circlips
should always be renewed and check they are not loose or cracked.
10.Valve should be checked for proper clearance between cam and the valve
tappet
11.Valve seats should be checked for wear
12.A slight clearance should bemaintained between the valve stem and the
valve tappet =. This is known as valve tappet clearance or valve lash
13.Cam shaft should be checked for proper alignment
ASSEMBLY
The steps following during the disassembly should be followed in the reverse
order. Further following should be noted carefully while assembling the engine.
1. The connecting rods and caps are individually matched to each other and
usually carry identifying numbers so that they may not be mixed after
dissembled.
2. The timing gear should be properly matched with the crankshaft.

TRANSMISSION
The word transmission means the whole of the mechanism that transmits the
power from the engine crankshaft to the rear wheels. However the transmission
is also being used very commonly in the literature for mechanism which
providesus with suitable variation of the engine torque at the road wheels
whenever required.
FUNCTIONS OF TRANSMISSION

The main functions that are performed by the transmission are:

1. The torque or the tractive effort produced by the engine varies with the
speed only within narrow limits. But the practical consideration for the
running of automobile under different conditions demands a large
variation of torque available at the wheels. The main purpose of the
transmission is to provide a means to varythe leverage or torque ratio
between the engine and the road wheels are required.
2. The transmission also provides a neutral position so that the engine and
the road wheels are disconnected even with the clutch in the engage
position.
3. A means to back the car by reversing the direction of rotation of the drive
is alsoprovided by transmission.
Generally two types of transmission are in use:
1. Manually operated type
2. Automatic type
The manual transmission are commonly calle gear boxes.
Here we are mainly concerned with manualled opeared gearbox.
a. Removing the transmission:
The procedure for removing the transmission of a 4 wheeled vehicle is as
follows:
1. Drain the transmission and the transfer case. Replace the trabsfer
plugs.
2. Remove the floor board inspection plate, shift lever, shift housing
assembly and its gasket from the transmission.
3. Remive the set screws from the transfer caseshift lever pivot pin.
Remove the pivot pin shift levers and shift lever springs. If the
vehiclenis equipped with power takeoff, remove the shift lever plate
screws and lift out the lever.
4. Disconnect the frint and rear propeller shafts from the transfer case.
5. Disconnect the speedometer cable at the transfer case
6. Disconnect the handbrake and cluctch control cable.
7. Place jack under transmission and engine protecting the engine oil pan
with a wooden block.
8. Remove the nuts holding rear mounting to frame member.
9. Remove the tranbsfer case snubbing rubber bolt nut at cross member.

10.Remove the bolts holding frame center cross member to frame siderail
and remove cross member.
11.Remove bolts holding transmission to flywheel bell housing.
12.Force transmission away from the clutch control lever tuv=be ball joint
for disengagement.
13.Lower jacks under engine and transfer case assemblies towards rear of
vehicle until main drive gear shaft clears the flywheel housing.
14.Lower jack under transmission. Remove transmission and transfer case
as an assembly from under the vehicle.
b. Separating transmission ans transfer case:
The procedure for separating the transmission and transfer case is as
follows:
1. Remove the screws and lockwashers attaching the transfer case
n=raer cover and remove the cover.
2. Remove cotter pin nut and washer which holds the transfer case main
drive gear on the rear end of the transmission main shaft. Also the
main drive gear.
3. Remove the transmission to transfer case screws.
4. Separate the transmission from transfer case.

Dissembly of transmission:
The procedure for disassembling the transmission is as follows:
1. Remove the shift housing and gasket from the top of the transmission
case.
2. Dissemble the shift housing by removing the shift rails and forks from the
shift housing
3. Remove the screws and washers attaching the front main drive
gearbearing retainer to transmission. Remove the retainer and the gasket.
4. Remove te socket head screws from the front end transmission case.
5. Tap slightly on the front end of the counter shaft to loosen the lock plate.
Remove the lock plate from the slots cut in the rear ends of the counter
shaft and reverse idler shaft.
6. Drive the counter shaft towards the rear of the case and remove it. Re ove
the gears abd the bearings.
7. Remove the main shaft rear bearing adapter
8. Remove the main shaft from the case
9. Drive the main drive gear into the case enough to remove the oil collector
10.Remove the main drive gear
11.Remive the counter shaft gear set, thrust washers, needle bearing rollers
and spacers
12.Remove the reverse idler shaft and gear by driving the shaft into the case.

Overhauling the Transmission

The procedure for overhauling the transmission is as follows:
1. Wash the transmission case thoroughly inside and outside with cleaning
solvent

2. Check bearing and shaft bores and clean them

3. Check the case for cracks if cracks are found or the bores are not true
replace the case.
4. Check and clean all gears for cracks, chipped or cracked teeth or
excessive wear of the teeth.
5. Check all bushings and bearings for wear or damage
6. Check the first and reverse sliding gear for freedom of movement on main
shaft.
7. Check the clutch for free sliding on the hub
8. Check the condition of the bearing retainer oil seals.
Reassembling the transmission:

Assemble the transmission in the reverse order of disassembly noting the

following points:
1. The idler gear is fitted correctly when the chamfered side is facing the
sliding gear
2. Better oil circulation is provided between the transmission and transfer
case by addition of drilled passagesbetween two units.
3. Assemble the spacer washer and countershaft needle roller bearing in the
countershaft gear hub.
4. The countershaft gear set when assemble in case have 0.31 to 0.45mm
end play
5. When assembling the main shaft gears the low and reverse sliding gear is
installed with the shift shoe groove towards the front of the transmission
6. Assemble the sunchronizer unit.
7. When installing the main shaft see that the needle bearing rollers in the
main drive gear are correctly positioned.
8. Attach the transfer case to the transmission before the unit is installed in
the vehicle.
GEAR BOX TROUBLES
The most common troubles of gearbox and their causes are:

1. Grinding noise in neutral: a grinding noise occurs when the engine is

running and vehicle is in neutral. Its major cause is geatbox not properlty
aligned with the engine causing the shaft from the f;ywheel to the gear to
bend.
2. Noise in gear:
when the vehicle is being driven or rear wheels turning
off the ground noise is heard in gear. Its causes are:
a. Dry rear bearing on main shaft
b. Damaged speedometer drive gear
c. The noises heard in neutral will also be heard in hgear but will be more
pronounced.
d. Noise occurring in rear end and in the clutch may also seem to come
from the gear box
3. Ahum or bowl in neutral: when the engine is running it occurs due to the
following reasons:
a. Lack of lubrication

b. Too much backlash in geartrain

c. Too much end play in gears or countershafts
d. Worn shaft
e. Gear chipped, burned, improperly matched or badly machined
f. Gear shift forks, rubbing in grooves causing gear interference
g. Worn bearings
4. Hard shifting, sticking in gear: it occurs due to the following reasons
a. Distorted splines of the main gear
b. Too shport shifter lock spring
c. Improper clutch adjustments
d. Battered gear teeth
e. Reote control shifting mechanism out of adjustment
5. Oil linkage: oil leaks from the gear box due to the following reasons
a. Too high oil level in case
b. Damaged or improperly installed gaskets or oil seals
c. Loose cover bolts
d. Cracked case or cover
e. Loose drain or filler plug
6. Slipping out of gear
a. Too much clearance between teeth in mesh
b. Insufficient mesh or gear
c. Worn gears of busings or bearing retainers
d. Weak or broken shifter lock spring
e. Remote control shifting mechanism out of adjustment
f. Improper alignment of gear box with engine

CLUTCH AND ITS FUNCTIONS

Clutch is a device used in transmission system of a motor vehicle to engage and

disengage the engine to the transmission. Thus the clutch is located between
engine and transmission. When the clutch is engaged, the power follows from
the engine to the drive wheels through the transmission system and vehicle
moves. When the clutch is disengaged, the power is not transmitted to the drive
wheels and the vehicle stops while the engine is still running. The clutch is
disengaged when starting the engine, when shifting the gears, when stopping
the vehicleand when idling the engine. The clutch is engaged only when the
vehicle is to move and is kept engaged when the vehicle is moving. The clutch
also permits the gradual taking up of the load.
When properly operated, it prevents jerky motion of the vehicle.

MAIN PARTS OF THE CLUTCH

1. Driving menbers
2. Driven member
3. Operating member

Driving menbers: consists of a flywheel mounted on the engine

crankshaft
Driven member:
consists of a disc or a platecalled clutch plate
Operating member:
consists of a foot pedal, linkage, release or
throughout bearing, release levers and the springs necessary to ensure
the proper operation of the clutch
TYPES OF CLUTCHES:
1. Friction Clutch
a. Single plate clutch
b. Multiplate clutch
c. Cone clutch
2. Centrifugal clutch
3. Semi centrifugal clutch
4. Diaphgrahm clutch (conical spring clutch)
5. Positive clutch
a. Dog and spline slutch
6. Hydraulic clutch
7. Electromagnetic clutch
8. Vacuum clutch

CLUTCH FAULTS:

DIAGNOSIS AND REMEDY

The various symptoms, their causes and remedies are shown in a tabulated
format:
NO
1.

SYMPTOMS
Drag or Spin

CAUSES
[a] Oil or grease
on the driven
plate facings
[b] Misalignment
between the
engine and
splined clutch
shaft.

REMEDY
Fit new clutch
plate

Check and correct

the alignment

[c] Improper
pedal adjustment
not allowing full
movement to
release bearing

Correct pedal
adjustment

[d] warped or
damaged
pressure plate or
clutch cover

Renew defective
parts

[e] driven plate

hub binding on

Clean splines and

lubricate with

splined shaft
[f] pilot bearing or
bushing or clutch
shaft binding

small quantity of
high melting point
grease
Renew or
lubricate pilot
bearing

[g] Broken facing

od driven plate
[h] Dirt of foreign
matter in the
clutch.

2.

Fit new clutch

plate

Dismantle clutch
from flywheel and
cleen the unit.
See that all
working parts are
free.

Fierceness or
snatch
[a] Oil or grease
on driven plate
facing.

CAUTION: Never
use petrol or
paraffin for
cleaning clutch.

[b] Misalignment
[c] Binding of
clutch plate
mechanism.

3.
Slip

[d] Worn out

driven plate
facings.
[a] Oil or grease
on the driven
plate facings.
[b] Binding of
clutch
mechanism.

4.
Rattle

[c] Improper
pedal adjustment
indicated by lack
of the requisite
free or unload
foot pedal
movements.
[d] Weak pressure

Fit new plate and

eliminate possible
ingress of oil or
grease. Check
and correct the
alignment.
Free and lubricate
journals.
Change clutch
plate.

Fit new plate and

eliminate oil leak
Free and lubricate
journals
Correct pedal
adjustment and/or
clearances.

springs.

Fit new springs

[e] Incorrect
setting of release
lever.

Reset the levers.

[a] Damaged
drivem plate i.e.,
broken springs
etc
[b] worn parts in
release
mechanism.

5.
Tick or Knock

Fit new parts as

necessary

[c] Excessive
back lash in
transmission.
6.
Abnormal facing
wear

[d] Wear in
Transmission
bearings.
[e] bent or worn
splined shaft.

7.
Difficukty in
engaging gear
after vehicle has
been stored for
the length of
period.
8.

9.

10.

Engine runs, but

car doesnot move
when in gear
(propeller shaft
not turning)
Clutch is noisy
when pedal is all
the way out and
engine is running
Clutch noise when
pedal is

[a] Hub splines

worn due to
misalignment.
[b] Worn pilot
bearing.
[a] Usually
caused by
overleading and
the resiltant
excessive
slippage while
starting.
[a] clutch plate
stuck to flywheel
or seized on
transmission shaft
splines

Check and correct

alignment and
then fit new
driven plate
Renew pilot
bearing

Avoid overloading
and excessive
slippage.

Jack up driving
wheels, start
engine in gear,
press clutch pedal
and apply brake.
If not successful,
clutch will have to
be dismantled
and freed off.
Check for correct
free play

depressed

[a] clutch slipping

or failed
Adjust the linkage

11.
[a] clutch linkage
improperly
adjusted.
12.
Noise (thud) when
clutch is released
engine running
and transmission
in gear

13.

Grear griding
while changing
gear
Clutch pedal will
not come all the
way back

[a] clutch release

bearing worn or
damaged.
[b] flywheel spigit
bearing dry.

Replace release
bearing

If particularly
annoying,
lubricate or
release but this
will entail
stripping the
clutch
Correct the play

Free play in rear

axle
Check and correct

Cluctch not
operating
correctly

Check and adjust

Fault in linkage

BRAKES

Introduction
Once the vehicle is started, it must be stopped somewhere. Brakes are applied
on the wheels to stop the vehicle. Brakes serve the following functions in a
vehicle
1. To stop and slow down the vehicle in the shortest possible distance in
emergency.
2. To control the vehicle to be retained when decending the hill.
CLASSIFICATION OF BRAKES:
Automobile brakes can be classified on various basis

1. With the respect to application

a. Foot brake
b. Hand brake
2. With respect to the number of wheels
a. Two wheel brakes
b. Four wheel brakes
3. With respect to brake gear
a. Mechanical brakes
b. Power brakes
4. With respect to nature of power employed
a. Vacuum brakes
b. Air brakes
c. Hydraulic brakes
d. Hydrostatic brakes
e. Electric brakes
5. With respect to the method of braking contact
a. Internal expanding brakes
b. External contracting brakes

MECHANICAL BRAKES

In a motor vehicle the wheel is attached to an auxillary wheel called drum. The
brake shoes are made to contact this drum. In most designs two shoes are used
with each drum. The brake shoes have brake linings on their outer surfaces. The
shoes are generally mounted to rub against the inside surface of the drum. The
shoes are held at a pivot and are fastened to a retractor spring for the braking
action. When the brake pedal is pressed, the brake linkage makes the shoes to
expand against the drum.

DISC BRAKE

The motor vhicles are now being fitted with the disc brakes. A disc brake
consistes of a rotating disc and two friction pads which are actuated by four
hydraulic wheel pistons contacining in two halves of an assembly called caliper.
To apply the brake the hydraulic pressure is applied to the fluid inlet tube due to
which wheel cylinder pistons force the friction pads against the rotating discs.

HYDRAULIC BRAKES

These are applied by liquid pressure. The pedal force is transmitted to the brake
shoe by means of a confined liquid through a system of force transmission. The
system is based upon pascals principle which states that the confined liquids
transmit pressure without loss equally in all directions. The system consists of

master cylinder and wheel cylinder. The master cylinder is connected by tubing
to the wheel cylinders. The system is filled with the liquid called brake fluid,
which is usually a mixture of glycerine and alcohol or caster oil, denatured
alcohol and some additives. When the brake pedal is pressed to fluid from the
master cylinderto the wheel cylinders which in turn due to high pressure pushes
the brake drum against the wheel drum, thereby stopping the wheels.

BRAKE SERVICE

Following is the procedure to service the brakes:

1.
2.
3.
4.

Check the fluid level in the master cylinder

Check brake pedal adjustment
Check brake pedal travel
If the brakes pull to the one side after adjustment, check tyre pressure.
Check brake linings for fpreign material and clean as required.
5. Check the brake system for leaks by applying a steady pressure on the
brake pedal. If the pedal falls away the brake system hs the leak
somewhere. Find the leak points and remove them.
6. A spongy brake pedal indicates the presence of air in the hydraulic
system. The condition must be corrected by b;leeding the brakes.
7. If the brakes become locked, the brakes must be released by opening the
bleeder screw on any one of the wheel cylinders.

MAINTENANCE OF BRAKES
1. There should be no oil or grease between the drum and the brake.
2. Care should be taken to see that the excessive amount of the lubricant is
not put into the rear axle bearings or the front hubs or the differential.
3. Keep the grease retainers in good condition.
4. Glazed surface (if any) of the brake lining may be removed by stiff wire
brush.
5. The drum surface should be clean. In extreme cases it may be refaced.
6. Rattles in the brakes occur due to improper tension in the return springs of
the brakes. This may be avoided if the springs holding the shoes are kept
at proper tension.

ENGINE COOLING
METHODS OF ENGINE COOLING

There are four methods of engine cooling:

1.
2.
3.
4.

Air cooling
Water cooling
Liquid cooling
Steam cooling

Most automatic engines uses air cooling and water cooling methods. Liquid
cooling and steam coling are rarely used in actua practice

AIR COOLING
In this method of cooling, the heat is dissipated directly to the air after being
conducted through the cylinder walls. Fins and flanges on the outer surfaces of
the cylinders and heads serve to increase the area exposed to cooling area, raise
the rate of cooling. The basic principle involved in this method is to have a
current of air flowing continuously over the heated surface of thew engine from
where heat is to be removed. The amount of heat dissipated depends upon the
following factors:
1.
2.
3.
4.

Surface area of the metal in contact with air.

Rate of air flow
Temperature difference between heated surfsace and the air
Conductivity of the metal.

WATER COOLING
In this method of cooling, water is circulated through water jacket around each of
the combustion chamber, cylinders, valve seat and valve stems. The circulsated
water, when passes through the engine jackets in the block and cylinder head,
takes heat of combustion. When it passes through the radiator, it is cooled by air
drawn through the radisator by fan and by air flow developed by the forward
motion of the vehicle. After passing through the water the radiator the water
again goes in the engine jackets.

MAINTENANCE OF THE COOLING SYSTEM

The proper operation of the cooling system gives satisfactory performance of the
engine. The cylinder bores are completely surrounded by a water jacket which
presents distortion of the cylinder walls, direct cooling and large water holes,
properly placed in the cylinder head gasket cause more water to flow past the
valve seat and carry the heat away from the valves giving positive cooling of the
v alves and seats.
It is recommended that the cooling system be flushed twice a year, preferably in
the fall before antifreeze is added and in the spring when the antifreeze is
drained. Additional flushing will aid great in rmevong rust and scale especially
when used with a pushing solution. A cleaning solution should be used to loosen
the rust and scale in additional flushing of the cooling system.

Flushing is accompanied through the system in a direct opposite to the normal

coolant flow. The action causes the water to get behind the corrosion deposits
and force them out. To do this, remove the upper and lower radiatpor hoses.

Then attach a drain hose at the top of the radiator. Attach a new piece of hose to
the radiator outlet at the bottom and insert the flushing gun. Connect the water
hose of the flushing gun to the water line and the air hose to the air line. Turn on
the water and when the radiator is full apply the air in the short blasts.
Continuw=e thus flushing operatoion until the water runs clear through the top
hose.
COOLING SYSTEM TROUBLES
S.No
1.

TROUBLES
External leakage

2.

Internal Leakage

3.

4.

5.

6.

Water loss

Poor circulation

Corrosion

Overheating

POSSIBLE CAUSES
[a] Loose hose clips.
[b] Defective rubber hose.
[c] Damaged radiator
seams.
[d] Excessive wear in the
water pump.
[e] Loose core plugs.
[f] Damaged Gaskets.
[a] Defective cylinder
head gasket.
[b] Cracked cylinder wall.
[c] Loose cylinder head
bolt.
[a] Boiling.
[b] External or Internal
Leakage.
[c] Restricted radiator or
inoperative thermostat.
[a] Restriction in system.
[b] Insufficient coolant.
[c] inoperative water
pump.
[d] loose fan belt.
[e] Inperative thermostat.
[a] Excessive impurity in
water.
[b] Infrequent flushing &
draining of system.
[c] Incorrect antifreeze
mixture.
[a] Poor circulation due to
any reason.
[b] Dirty oil and sludge in
the engine.
[c] Radiator fins choked.
[d] Incorrect ignition

timing.
[e] Incorrect valve timing.
[f] Low oil level
COACH REPAIR WORK

1. Check an attend passenger seat cushions and upholstery, driver seat

cushions.
2. Check up items such as destination boards, vision mirrors, bulb horn,
conductor call bell.
3. Check passenger door, driver door for proper functioning and locking
arrangements.
4. Attend to any defector damages observed etc.
5. Check for any broken window pans, if any replace with new ones.