JAN NAYAK. CH.

DEVI LAL
POLYTECHNIC,
POST BOX NO. 81

BARNALA ROAD, SIRSA-125055

Training report
OF
DIPLOMA IN MECH. ENGG.
IN
HARYANA ROADWAYS
SUBMITTED TO: SUBMITTED BY:
ER. GYAN JAIN RAKESH KUMAR
T.P.O. JCD POLYTECHNIC 11039171208
 Preface
I am the student of Mechanical and my subject is more practical so

training play an important part in our life.i have taken training from

Haryana Roadways Sirsa .A humble attempt has been made to make

training simple exhaustive & intelligible so as to sustain the interest of

students in training.training is of Four weeks and I am very thankful

to Mechanical Deptt. & training & placement cell of our college for

support and encouragement.

I am thankful to Er. Gyan Jain for the pain he had taken to bring out

training in this form, I would also like to extend my heartily thank to

Mr. Manoj Sharma of Haryana Roadways Sirsa who have taken great

pain and really worked harh during our training period.

ACKNOWLEDGEMENT
A formal statement of acknowledgement is hardly sufficient to
express my gratitude towards the personalities who have
helped me in training. First and foremost I take this
opportunity to express my sincere gratitude & sincere thanks
to Mr. Manoj Sharma for providing me at Haryana
Roadways Sirsa..

I hereby convey my thanks to Er. RINKLE GARG Head of

Department of Mechanical and all the faculty members of
Mechanical Deptt. for their valuable help and constant co-
operation.

I also want to thanks to my parents for providing me financial

assistance and moral support rendered by my parents in
making this effort a success. All this has become a reality
because of their blessings.

CONTENTS
 TEXT PAGE NO.

CHAPTER - 1 : INTRODUCTION

1.1 About The Company 1

CHAPTER - 2 : CHASIS 2

CHAPTER - 3 : TECHANICAL SPECIFICATIONS 3-6

CHAPTER - 4 : POWER GENERATING SYSTEM 7-13

4.1 INTERNAL COMBUSTION DIESEL ENGINE

CHAPTER - 5 : TIGHTING TORQUES OF ENGINE PARTS 14-15

CHAPTER - 6 : POWER TRANSMISSION STSTEM 16-20

CHAPTER - 7 : BRAKING SYSTEM 21-24

CHAPTER - 8 : FUEL INJECTION SYSTEM 25-26

CHAPTER -9 : COOLING SYSTEM 27-28

INTRODUCTION
ABOUT THE COMPANY
The central workshop & the workshop of Haryana roadways Sirsa are

one of the best workshop of buses in state having all those facilities
which are necessary to bring a vehicle i.e. bus in its best running

conditions. Situated in the premises of Sirsa bus stand , both these

workshop provide full technical support to near by bus depot & are

well connected with on road services.

As central workshop mostly undertakes the repairing or over hauling

of engine & have a cold resolving plant, workshop of Sirsa depot

under takes complete servicing of buses including repairing of

different bus parts i.e. gear box , differential , radiator , fuel injection

pump , clutch & pressure plate etc. Both these workshop have

sufficient well educated & highly technical staff provided with all

proper machine, tool & equipments.

CHASIS
Chasis is a French term used to denote the frame or main structure of a vehicle.
The chasis contain all the major unit necessary to propel the vehicle , directs its
motion , stop it and allow it to run smoothly over uneven surfaces. It is also
called as carrying unit
.

The chasis is subdivided in to the running gear & the power plant. The gear
includes the frame , steering system , suspension system , brakes , wheels &
tyres. The power plant include the engine assembly & power transmission
assembly.In bus chasis, the whole engine is fitted in the driver cabin.

The chasis includes the following components :

Frame Storage battery

Front suspension Universal joints

Steering mechanism Silencer

Radiator Shock absorber

Engine, clutch, gearbox Fuel tank

Propeller shaft Hydraulic pipes

Leaf spring Differential,halt shaft etc.

TECHNICAL SPECIFICATION

1.Engine

Model Cummins 6BT5.9

LP 1510/1512/1610 & 1521LPO

Type Water cooled,direct injection

Turbo charged

Diesel Engine

No. of cylinders 6 inline

Stroke 102mm*120mm

Capacity 5833cc

Comparession ratio 17.6:1

Firing order 1-5-3-6-2-4

Oil filter Spin on full flow paper type with

Water separator

Fuel injection pumps MicoAtype inline

(1510LPOI/II/1616LP

OI/II/LP15121/161LPOI)

Governor Built in centrifugal type

Turbo charger Holset HX35-LPO1512 II/1616II

Coolant capacity of engine 9 liters

Coolant Water & Ethylene glycol,ratio 1:1

Crank case oil Max. 14.3 liters

Capacity Min. 12.3 liters

2. Clutch

Pull type clutch (LPO1616I/II/LPO161610II)

Type Single plate dry friction

Outside diameter 352 mm

Fraction area 302 mm

Type Single plate coil type with ceramic

Friction area 435.6 sq.cm

3. Gear Box

No. of gears 5 Forward 6 Forward

1 Reverse 1 Reverse

Type TATA TATA TATA

GBS-50 GBS-40 GBS-600

Gear ratio 1st 7.83 7.51 9.19

2nd 4.18 3.99 5.29

3rd 2.43 2.30 3.21

4th 1.58 1.39 2.09

5th 1.00 1.00 1.39

6th - - 1.00

4.Rear Axle

Model Tata RA 108 RR

Tata RA 109/109R/109RR

Type Single reduction hypoid gears,fully

floating axel shafts.

5.Front Axle

Type Heavy duty forged I-beam, reverse

Elliot Type.
6.Steering

Type Integral Power Steering

Ratio 20.2:1

7.Brakes

Service brakes Dual circuit,ful air S-cam brake

system

Brake drum diameter 410 mm

Parking brake Hand operated

Type Spring actuated parking brake.

8.Frame

Type Ladder type heavy duty frame.

9.Suspenshion

Type Semi-elliptical leaf spring at front

& rear

Leaf width Front-70 mm , Rear-80 mm

Antiroll bar At front & rear

5

10.Wheel & Tyre

Tyre size 10.00*20-16 Diagonal ply

Wheel rims 7.00*20 7.50*20

 POWER GENERATING SYSTEM

INTERNAL COMBUSTION ENGINE

Introduction

Internal combustion engine are those heat engine that burn there fuel inside the engine
cylinder. The heat energy obtained by burning fuel is connected into mechanical energy by
the expansion of gases against the piston attached to crankshaft that can rotate. In IC engines,
the working temperature & pressure are much higher.

Diesel Engine

It was introduced by Dr. Rudolf Diesel in 1897. In this engine, the heat is added at constant
pressure instead of at constant volume. In diesel cycle engines only air is compressed in the
cylinder & the temp. of this compressed air become sufficiently high to ignite fuel. Diesel is
injected in the cylinder at the end of compression stroke.
In diesel cycle, compression ignition engine, four strokes are as follow :

1.Suction stroke : In this, the pistion moves down from top dead centre position. Air is
sucked into the cylinder from inlet valve exaust valve remain closed.

2.Compression stroke : The piston moves upward from bottom dead centre which
compress the air as inlet & exhaust valve remains closed. The air is finally compressed to
high pressure of 40kg/cm2 at 100 degree Celsius, enough to ignite the fuel.

3.Power stroke : The fuel is injected into the hot compressed air where it start burning
maintaining constant pressure. The hot gases adiabatically pushing piston down. Both valves
remain closed.

4.Exhaust stroke : The piston moves upward. The inlet valve remain closed while
exhaust valve open. The upward movement of piston pushes the gases into atm from exhaust
valve.

MAIN PARTS

1.Cylinder Block : It is usually made of from grey cast iron with addition of nickel &
chromium because it has better wearing & heat resisting qualities. The upper part of cylinder
block has six cylindrical holes containing piston & connecting rod. The bottom part of block
support the crankshaft,camshaft & also the oil pan.
2.Cylinder Head : The top pf the cylinder block is coverd by a separate cast iron piece
known as cylinder head. It contains nozzles,valves, air inlet & exhaust outlet etc. It
incorporates passage for the flow of cooling water. The combustion chamber is made b/w the
cylinder head & the piston crown. In order to avoid gas leakage, gasket are providing b/w
cylinder head & block.

3.Crank Case : It attached to the bottom face of the cylinder. It acts the base of the engine.
It supports the crank shaft & camshaft in the suitable bearing & provides the arms for
supporting the engine on the frame.

4.Cylinder Liners : The cylinder in the forfeit of barrels, made of iron alloy containing
Si,Mn,Ni & Cr. They cast centrifugally. They are replaceable & avoid the use of new block
when gets destroyed.

There are two types of liners:

(a).Dry Liner : It is made up of such shape that its entire outer surface bears against the
cylinder block casting & since it is not in direct contact with coling water , it is known as dry
liners. Its thichness ranges from 1.5 to 3 mm.

(b).Wet Liners : This types of liners comes in dircct contact with water & have three
thickness from 1.5 to 6 mm.
5.Piston: The movement of in the cylinder provides rotary motion to crankshaft via
connecting rod without any losses. Its smaller diameter is 0.025 to 0.1 mm.

6.Piston Rings : It is provided on the circumference of piston to maintain a good seal b/w

the piston & the cylinder valve. Usually three ring provided, first to for avoiding gas leakage

& creating pressure known as compression ring & third used for fuel leakage is called oil
control ring.

The piston ring are mainly provided to

1.To provide a pressure seal to prevent blow by of gases from the combustion chamber, past
the piston.

2.To control the flow of oil to the skrit & the ring adequate quantity.
Piston rings are usually made of grained alloy cast iron as this material possesses excellent
heat & wear resistant qualities.

7.Gidgeon Pin : It connect the piston & the small end of connecting rod. Piston pin
generally hollow & made from case hardened steel. Usually the pin floats in both piston
bosses & the connecting rod & is fitted by two lock rings placed in grooves in outer end of
the piston bases. These pins are called circlips

8.Connecting Rod : It the connection b/w the piston & crankshaft to convert linear
motion of the piston into rotatory motion of the crankshaft. The connecting rod is usually
made from forged steel. As the connecting rod has to carry the power thrust from piston to
crankpin, hence it must be strong,rigid & as light as possible

9.Crank Shaft : It get the rotatory motion from the linear motion of the piston with the
help of connecting rod. Crankshaft consists of crankpins, webs balancing weights & main
journals.

Crankshafts standard size

Main bearing 4.268
Big bearing 2.717
Crankshaft has drilled oil passage through which oil can can flow from main bearing to
collecting. The front end of the crankshaft carries the gear that drives the camshaft & the
vibration damper. The rear end of crankshaft carries the flywheel.

A six cylinder engine has 120 degree crankshaft having the crank throw no.1&6,2&5,&3&4
in the same radial plane. There six power impulses during two revolution of the crank shaft.
With arrangement, a six cylinder engine having proper firing order has perfect inherent
balance of both primary & secondary inertia forces.Generally, standred firing order is 1-5-3

-6-2-4.

10.Fly Wheel : A flywheel os fairly heavy steel wheel attached to the rear end of the crank
shaft. Generally, flywheel is a device which stores energy obtained during the power stroke &
provide this operation of remaining three stroke i.e. it is required for the leveling of power
impulse. It also teeth on its periphery to mesh with electric motor drive pinon when engine is
being cranked to start it

11.Valves : It is a device to open close the passage for supply. In engine, two valve are used
for each cylinder an intake valve & an exhaust valve. Exhaust is usually made of austenite
steel which is highly heat & corrosion resistant. Intake valve being subjected to less heat &
resistant so it is made of nickel chromium allow sreel. The valves are operated by camshaft
which itself get motion fromcrankshaft

Usually, when valves are located in cylinder head, overhead poppet valve mechanism is used
to operate valve. In the mechanism , as the cam rotates , its lifts the valve tappet which actute
the push rod.The push rod rotates the rocker arm about a shaft to cause one end to push down
12.Camshaft : It is a device which changes its rotatory motion into linear motion of the
follower or lifter. It is a mounting in the lower part of the cylinder block in most in the engine

A camshaft is responsible for opening the valve. It has a no. of cam along its lenth, two cam
for each cylinder one to operate exhaust valve. In addition, camshaft has ecentric to operate
the fuel pump & gear to drive the ignition gear & camshaft gear has twice the teeth as on
crankshaft gear.

14.Oil Pump : It is located inside the crank case below the oil level & supplies under
pressure to various engine part to be lubricated.It consist of two gears, driving & driven gear
15.Gaskets : It is placed b/w cylinder head & cylinder blocks so as to retain compression
in the cylinder to prevent leakage & to ensure metallic fit joint. It should be able to withstand
both high temp. as well as pressure.
Other Integral Parts

1.Vibration Damper: The engine is in operation,the torsional vibration of the crankshaft

causes the oscillation to build up so much that the crankshaft might actually brake at a certain
speed.To control these torsional vibration,vibration damper are used. They are mounted on
the front end of the crankshaft & the fan belt pulley is in corporate in to them.

2.Turbocharger: It is an integral part on an engine , is a device which supplies air

pressure inside engine air inlet.There is no mechanical drive connection b/w engine & the
turbocharger & the roter assembly of turbocharger,suppoted by two floating lead bronze
sleeve bearing in the bearing housing,gets the motion from the rotation of radiator fan. It
sucks air from air intake system & further supplies to intake manifold.A new bus, hot air
coming out turbocharger flow through the charge air cooler & get cooled & clean before
entering the intake manifold. 12

Turbocharger Engine had the following advantages over naturally aspirated engine:

(a)Increase in power from the same engine dimensions there by increasing the power to
weight ratio.

(b) A turbocharged engine has a lower specific fuel consumption

(c)It reduces black smokes in exhaust.

 TIGHTING TORQUES

692 DIESEL ENGINES

Parts Torques(m.kg)

Main bearing cap bolts 12

Connecting rod bearing cap bolt 09

Cylinder head bolt 11

Heat exanger bolt 3.5

Vibration damper bolt 05

Flywheel mounting bolt 10

Centre bolt of engine oil filter 05

Counter weight bolt of crantshaft 09

Timing gear case cover bolt 1.5

Cylinder head cover bolt 2.5

Nuts on injection pump gear 08

Air compressor cam rod bolt 02

Clutch housing mounting bolt 09

Exhaust manifold bolts 3.5

Mounting screw for clutch to flywheel 3.5

Rocker shaft supporting bolt 09

Protective sleeve in cylinder head 06

Nozzle in nozzle holder 07

Nozzle holder in cylinder head

Cap nut on high pressure lines

POWER TRAMISSION SYSTEM
Introduction

The power developed inside the engine cylinder is aimed to turn the wheel. The power from
the engine is transmitted to rear wheels through the clutch, gearbox, universial joint, propeller
shaft, differential & rear axel extended to wheel. The application of engine power to the
driving wheels through all these part is called power tramission.

Components

1.Clutch Plate : It is located b/w engine & Tramission, is a device used in tramission
system to engage & disengage the engine to the tramission. It also permits the gradual taking
up of the load. When properly operated, it prevent jerky motion to the vehicle & avoids
putting undue strain on remaining parts of tramission system.

The clutch works on the principle of friction. When the clutch padel movement, bearings
presses on clutch plate forcing clutch release lever forward.
 CLUTCH PLATE

This cause the pressure plate spring to compress allowing pressure plate to move away from
clutch plate. This section releases the pressure on driven plate & flywheel, make a them
rotating without tramission. When clutch padel is released, reverse action take place.

2.Pressure Plate : It is made of special cast iron, is the heaviest part of the cover
assembly. Its function is to establish even contact with the driven plate facing, through which
the pressure spring can exert sufficient force to transmit the full torqe of the engine.
 PESSURE PLATE

The pressure plate should be able to absorb much more than the normal heat generated during
clutch operation without getting wrapped.

3.Gear Box : The gear box is generally a meatallic box containing a set of gear used to
provide high torqe to the driving wheels at the time of ,say, starting,hill climbing,accelerating
& meeting other resistances. It permits the engine crankshaft to revolve a slower speed.
Heavy tata buses have six forward & one reverse gear. All forward gear are constantly

meshed, only the reverse is sliding mesh. The first & reverse gear are spur gear while other

gear have helical teeth. Enagagment of all the gear is achieved by moving the shifter sleeve in
mesh with the dogs teeth of the gear on main shaft. These gears transmit power to the
engaging gear fixed on the main shaft , by sliding the shifter sleeve, operated by shifter forks,
on the dog the concerned gear.

GEAR BOX

4.Propeller Shaft : It is a driving shaft that connects the tramission to the differential.The
rotatory motion of transmission main shaft is carried out through the propeller shaft to the
differential causing the rear wheel to rotate. The propeller shaft has to be withstand the
torsional stresses of the transmitting torque & yet it must be balanced & light so that vibration
& whip will not occur at high speed. On some of application, the propeller shaft is in two
sections, supported by a central bearing & coupled together by universial joints.

5.Differential : It is a part of the inner axel housing assembly, which include the
differential, rear axel, wheels & bearings. The differential consists of a gear arranged in such

a way that it connects the propeller shaft with the gear axel.The purpose of differentialis is to
provide when the vehicle is taking a turn. The torque transmitted to each wheel is always
equal.

It consists of sun gear mounted on each inner side of the rear axel. A differential cage is
assembled on the left axel carrying crown gear driven by bevel pinion. When the differential
cage is rotated, both wheels turns attached to the outer end of rear axel.
 DIFFERENTIAL

When vehicle is taking a turn, the planet gears spin on its shaft transmitting more rotatory
motion to one rear wheel than the outer as to carry a more distance. When both wheels turn at
the same speed of the planet pinion do not rotate on shaft.
6.Rear Axel : It transmit power from the differential to the driving wheels.It is in two
halves connected by differential. Inner end of the half shaft is connected to the sun gear of the
differential & outer end to the driving wheels.

BRAKING SYSTEM

S Cam Full Air Brakes

Stopping of the vehicle is as necessary as its starting & brakes are applied on the wheels to
stop the vehicle.Before applying the brakes, the accelertor is released to stop the fuel supply
so that engine develop no more power to run the vehicle & then brakes are applied to stop the
vehicle. The braking system used in TATA buses in air braking system.

S-cam brakes are fully air operated brakes.Brakes actuators at front & rear axel are externally
mounted outside the foundation brakes assemblies. The compressor sends compressed air the
reservoirs & then air is fed to brakes actuators through dual brake valve proportional to
braking requirements. Push rod of brake actuators act on slack adjusters,which convert linear
motion in to circular motion of cam shaft.S-shaped can portion of the shaft expand brakes
shoe against drums , thus applying brakes.

S-cam is of equal displacement design , resulting equal wear of leading & trailing shoes.In
addition, wider ,thicker & tapered lining result in high brake life. The braking system
provides a safe & reliable of dual circuit full air brakes.

Services brake consists of two separate circuits. One of the front wheels & other for rear
wheels. Both are operated by single brake paddle.

Minium air pressure : 5.4 0.5 bar in front & rear circuit.

System pressure :

Cut out : 7.4 - 0.2 bar

Cut in : 6.2 bar min

Components Of Braking System

1.Air Resvervoir : The function of reservoir is to provide a place to store compressed air
so that there will always be an ample supply available for intermediate use in braking
operation. It als provides storage sufficient compreesed air to permit several brake application
even after the engine stopped. The compressed air is obtained from compressure situated
bellow fuel injection pump, getting crank shaft motion of engine through gear arrangement.

2. Brake Chamber : It convert the energy of compressed air into mechanical force &
motion nessary to operate the vehicle brakes. It consists of rubber dish shaped diapharam
clamped b/n two halves off the body.

VIEW OF BRAKE CHAMBER

A return spring hold the push rod assembly against the diaphragm whilist a seal assembly
prevent the ingress of road dust , dirt & moisture under the tension of spring located over the
behind the diaphragm, the diaphragm forces the push rod outword thus rotating the slack
adjuster, brake cam shaft & brake cam to apply the brakes. The higher the air pressure
admitted to brake chamber , greater will be the force to push brake lining against brake drum
producing greater retarding force. Conversely, the lower the air pressure , lesser the retarding
force.

4.Slack Adjuster : The compressed air supplied to the brakes chamber makes the push
rod to move the slack adjuster , mounted on the crankshsaft. This movement of slack adjuster
causes the camshaft to rotate against a pair of roller mounted on the ends of brake shoes,
forcing the outword against the brake drum.
 SLACK ADJUSTER

5.Brake Valve : It consist of a plunger bearing on a pistion & graduating spring assembly
which based to the upper position by a retun spring. Compressed air from the reservoir enter
though an air dryer in the of the valve . One outer port is provided for connection to brake
chamber & one for stop light switch air line connection.

As the driver depresses the pedel , force is exerted on the graduated spring & pistion. Down
word of pistion seal the exhaust valve & pressurized air flow through the inlet valve & out
through delivery ports to brake chamber, thus applying brakes.

On the releasing the brake paddle , the air pressure below the piston over come the
mechanical force on top of it & inlet Valve close while exhaust valve open to exhaust air to
atmosphere there realeasing the brakes.

6.Air Dryer : An air dryer come unloader valve is fitted b/w air compressor & system
protection valve along with purge tank.Air dryer in sure clean & dry in the braking system
resulting in enhacced life of brake valve.

7.Hand Breake : One of the auxiliary outlet of system protection valve is connected
through a graduated hand brake valve to spring brake chamber portion, integral with rear
brake actuator. During normal running, inside spring are kept in cpmpressed position by air
pressure, thus releasing parking brake. For parking braking, hand brake valve is operated for
depleting air into atmosphere, thus applying parking brake.

Parking brake holds : 4.6 to 0.4 bars off pressure.

Note : The braking system in TATA buses is provided with latest generation polymide nylon
tubing for air brake.
It is preferred for this application for :

(a)Excellent chemical resistance

(b)Dimensional stability & impact resistance

(c)Eliminates rusting problem, gives lower leakage

(d)Rust particales are not generated & thus protect valve.

FUEL INJECTION SYSTEM

Introduction
In diesel an engine, the fuel stored in the fuel tank is supplied to the Fuel injection
pump by means of a fuel feed pump through filters. The fuel injection pump forces the
fuel under very high pressure to the fuel injector which injects the fuel into the engine
cylinder in the form of affine sprayat prpper instant.

Components
1.Fuel Tank : The fuel acts as a reservoir in which fuel is stored. It is a provided
with a air vent so that the pressure inside the fuel tank always remains equal to
atmosphere pressure.

2.Fuel Feed Pump : It is used to supply the fuel to the filter & injection pump.
The pressure developed by the pump is 1 to 2 bar. The fuel feed pump is usually
operated by a spectional cam on ignition pump cam shaft, so that the feed & injection
pump from a single unit.

3.Fuel Filters : It used in buses, two stage filter with felt tube primary & micro
secondary filters element is used i.e. the fuel first flow through the primary filters &
Then through the secondary micro filters continuing to the fuel injection pump.
4.Fuel Injection Pump : It is used to deliver accurately measured amounts of fuel
at high pressure to the injectors according to the firing order& according to the load.

The puping unit comprises of the following essential components :

1.Pumping element

2.Delivery valve & seating

The pump consists of an in built centrifugal governor connected by a shaft getting
motion from crankshaft via gears arrangement. The plunger moves in the barrel
getting motion from shaft & the pressure exerted by the rising plunger upon oil cause
this to lift the valve & to enter the pipe which connects the pump to the injeftors

5.Fuel Injectors : The purpose of the fuel injector a spring loaded valve is to
injecta small volume of the fuel in a fine spray & ti assist in bringing each droplet into
contact with sufficient oxygen to give quick & complete combustion.

Pressure with which fuel is injected into the cylinder from nozzle varies 220 to 240
bars.
 COOLING SYSTEM
Introduction
The purpose of cooling system is to keep the engine at its most efficient operating
temperature at all engine speeds & all driving condition.It is also used to avoid braking
of lubrication film , welded moving parts or any mechanical breakage of engine parts.
In Tata buses , water cooling system is used.Water is circulated through water jackets
around each of the combustion , cylinder ,valve sheets & valve stems.Water the heat of
the combustion when passes through the engine jackets. It is then passed through the
radiator where it is cooled by air drawn through the radiator by fan & by air flow
developed due to the forward motion of the viechle. After passing through the radiator ,
it again goes to the engine jackets.

Main Parts
1.Radiator : The component which help in dissipating the heat from the circulating
water to air current is known as radiator.It provides a large amount of cooling surface to
the air stream , so that circulating water is cooled down efficiently.It consist of three
parts , namely
(a)Upper tank
(b)Core
(c)Lower tank
The upper tank & lower tank are connected by means of core. Hot water from the jackets
enter to the upper tank & flows to the lower tank core where they cooled down as it
steam on passing through core. Water from lower tank is sent back to engine jacket.
2.Fan : A fan is mounted behind the radiator on the water pump shaft. It is driven by
the same belt that drives the pump.This belt gets its motion from damper. The purpose of
the fan is to draw air through the radiator.When the viechle is going at high speed the
natural draught of air is sufficient for cooling but at low speed or moving upside hill ,
natural drafts is certainly insufficient to produce the desired cooling effects.Here the fan
serves the purpose.

3.Water Pump : A pump in thecooling system is used to increase the velocity of the
circulating water.Impeller type pump is mounted at the front end of the engine block.
The pump is driven by a belt mounted on the damper.

4.Thermostat : A thermostat valve is used to regulate the circulation of water in

system to maintain the normal working temperature of the engine parts during different
operating condition. When the engine is started from the cold, the thermos tat valve
prevent the flow of water from engine to radiator so that the engine reaches to its normal
working temperature after which it automatically c omes into action. Generally, the
thermostat valve does not permit the water below the 70 degree Celsius.
In the below type thermostat, liquid vapourise when bellow is heated & ceates enough
pressure to expand the below opening the valve the to the water pass the water through
it.When the bellowsare cooled , the gas condenses , the pressure is reduced & the bellow
close the valve , thus stops water circulations.

COLD RESOLVING PLANT

Cold resolving plant at central workshop is an set up for providing a new base on older
tyres i.e. in this plant, the tyre whose outer rubber has been wearied out or become flat
are provided with new spoked rubber layer on outer side.
In this processes, firstly, the old tyre is mounted on a machine having a multiple teeth
cutter on one side. Both the tyre & the cutter are rotated & cutter is brought in contact
with tyre so as to make flat smooth surface into rough one. The machine is connected
with a chamber through a pipe which remove the smoke & rubber particles generated
during operation from the work place.
After roughening operation, the vulcanizing solution is applied on the rough surface of
tyre & left to drive for around 1-2 hours.After drying, it is provided with a compound
coushan all around the circumference. After this, the tyre is mounted on a roller pressing
machine where the pressure is applied by rollers som that air, if ,entrap b/w the
compound coushan & the tyre gets removed &coushan gets properly stick on tyres
surface.The rubber pad is placed on compound coushan & is press fitted by means of
rollers.
Finally , the tyre is enclosed in a parachute cover & its heated in a chamber from 110-
120 degree Celsius at an air pressure of about 65kg/cm2. The air pressure acting on a
upper & inner part of tyre is provided a firm grip b/w old tyre & new rubber pad &
refined grain structure due to proper heating provide sufficient strength to new rubber
pad to bear road condition.