CHAPTER-1

INTRODUCTION

This industrial training is done at station Workshop of pathankot . Which comes under indan
army. This Workshop are undertaking the work of fabrication/ re fabrication of gypsy and
truck. These workshop are repair of gypsy and truck. This industrial training is describe
under syllabus and required for experience and practical knowledge. We had studied all kind
of theoretical things about fabrication/ re fabrication of gypsy clutch,cooling system,tyer
rotation, Brakes, Engine, Gear Box, Fuel Injection Pump and all the things related to our
"Mechanical Branch" . Here different departments were also made for the repair and
maintenance purposes. Here during this training I have seen all things and done practically
which has helped to enrich my knowledge greatly . This project report is all what I have seen
in the station Workshop(eme) and done practically with my hands. I am really thankful to all
staff members of the station workshop and the workers with whose helpful nature and
guidance I completed my Industrial training and Project Report.

1.1 HISTORY
The maruti gypsy is a four wheel drive vehicle based on the long wheel base Suzuki jimny
SJ40/410 series.It primarily an off road vehicle or a vehicle for rough unprepared roads. It is
sold in new Zealand as the Suzuki farm worker.
It is manufactured in india by maruti Suzuki.It was introduced in the indian market
in December 1985 with the 970 cc F10A Suzuki engine and while sales were never very high
it become very popular with law enforcement.
In july 1993, maruti introduced the widetrack gypsy codenamed MG10W replacing the
MG410.In april 1995, a catalytic converter was fitted to the gypsy sold in the metro cities

1.2

LUBRICATION SYSTEM

I. C. engine is made of many moving parts. Due to continuous movement of two metallic
surfaces over each 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
.Lubrication produces the following effects: (a) Reducing friction effect (b) Cooling effect (c)
Sealing effect and (d) Cleaning effect.
Purpose of Lubrication System

1.3

COOLING SYSTEM
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A system, which controls the engine temperature, is known as a cooling system

Requirement Of An Efficiency Of The Engine
Type Of Cooling System

There are two types of cooling systems:

(i) Air cooling system and
(ii) Water-cooling system.
Parts of Liquid Cooling System
The main parts in the water-cooling system are: (i) water pump, (ii) fan, (iii) radiator and
pressure cap, (iv)fan belt (v) water jacket, (vi) thermostat valve, (vii) temperature gauge and
(viii) hose pipes.

1.4

TURBOCHARGERS

When people talk about race cars or high-performance sports cars, the topic of turbochargers
usually comes up. Turbochargers also appear on large diesel engines. A turbo can
significantly boost an engine's horsepower without significantly increasing its weight, which
is the huge benefit that makes turbochargers beneficial in every possible way.

How it works
The turbocharger is bolted to the exhaust manifold of the engine. The exhaust from the
cylinders spins the turbine, which works like a gas turbine engine. The turbine is connected
by a shaft to the compressor, which is located between the air filter and the intake manifold.
The compressor pressurizes the air going into the pistons.

Intercoolers
When air is compressed, it heats up; and when air heats up, it expands. So some of the
pressure increase from a turbocharger is the result of heating the air before it goes into the
engine. In order to increase the power of the engine, the goal is to get more air molecules into
the cylinder, not necessarily more air pressure

1.5

CLUTCH PARTS AND OPERATION

Clutch parts
- Flywheel
- Pressure plate
- Friction disc
- Release mechanism
Clutch disc pushed against flywheel with enough force
- Clutch Disc
- Pressure Plate
-Diaphragm Clutch
- Clutch Fork

1.6

THE BEARING

As described in Chapter One, a bearing is a device used to support and

guide a rotating, oscillating, or sliding shaft, pivot or wheel. Whenever a
shaft rotates, it needs a bearing for smooth, effective operation.

A bearing is designed to:

Reduce friction
Support a load
Guide moving parts wheel, shafts, pivots

CHAPTER-2 :

LUBRICATION SYSTEM

2.1

DEFINATION

Reduces Frictionby creating a thin film(Clearance)between moving parts (Bearings and

journals)

Fig.(2.1) .Lubrication system

2.2

PURPOSE OF LUBRICATION SYSTEM

(a) Seals
The oil helps form a gastight seal between piston rings and cylinder walls(Reduces Blow
by) Internal oil leak (blow-by) will result in BLUE SMOKEat the tale pipe.

Fig.(2.2).Pistion ring and cylinder wall

(b)Absorbs shock:-When heavy loads are imposed on the bearings, the oil

helps to

cushion the load.

(c)Absorbs Contaminants:-The additives in oil helps in absorbing the contaminantsthat

enter the lubrication system.

2.3

ENGINE LUBRICATION SYSTEM

The lubricating system of an engine is an arrangement of mechanism and devices which

maintains supply of lubricating oil to the rubbing surface of an engine at correct pressure and
temperature.
The parts which require lubrication are: (i) cylinder walls and piston (ii) piston pin (iii)
crankshaft and connecting rod bearings (iv) camshaft bearings (v) valves and valve operating
mechanism (vi) cooling fan (vii) water pump and (viii) ignition mechanism.
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There are three common systems of lubrication used on stationary

engines, tractor engines and automobiles:
(i) Splash system (ii) Forced feed system and (iii) Combination of splash
and forced feed system

CHAPTER-3

3.1

COOLING SYSTEM

DEFINATION

A system, which controls the engine temperature, is known as a cooling system.The cooling
system is provided in the IC engine for the following reasons:
1.The temperature of the burning gases in the engine cylinder reaches up to 1500 to 2000C,
which is above the melting point of the material of the cylinder body and head of the engine.
(Platinum, a metal which has one of the highest melting points, melts at 1750 C, iron at
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1530C and aluminium at 657C.) Therefore, if the heat is not dissipated, it would result in
the failure of the cylinder material.
2.Due to very high temperatures, the film of the lubricating oil will get oxidized, thus
producing carbon deposits on the surface. This will result in piston seizure.
3.Due to overheating, large temperature differences may lead to a distortion of the engine
components due to the thermal stresses set up. This makes it necessary for, the temperature
variation to be kept to a minimum.
4.Higher temperatures also lower the volumetric efficiency of the engine.

Fig.(3.1). Cooling System

3.2

REQUIREMENT OF AN EFFICIENCY OF THE ENGINE

The two main requirements of an efficient cooling system are:

1. It must be capable of removing only about 30% of the heat generated in the combustion
chamber. Too much removal of heat lowers the thermal efficiency of the engine.
2. It should remove heat at a fast rate when the engine is hot. During the starting of the
engine, the cooling should be very slow so that the different working parts reach their
operating temperatures in a short time.

3.3

TYPE OF COOLING SYSTEM

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There are two types of cooling systems:

(i) Air cooling system and
(ii) Water-cooling system.

(a)

Air Cooling System

In this type of cooling system, the heat, which is conducted to the outer parts of the engine, is
radiated and conducted away by the stream of air, which is obtained from the atmosphere. In
order to have efficient cooling by means of air, providing fins around the cylinder and
cylinder head increases the contact area.The fins are metallic ridges, which are formed during
the casting of the cylinder and cylinder head.
The amount of heat carried off by the air-cooling depends upon the following factors:
(i) The total area of the fin surfaces,
(ii) The velocity and amount of the cooling air and
(iii) The temperature of the fins and of the cooling air.
Air-cooling is mostly tractors of less horsepower, motorcycles, scooters, small cars and small
aircraft engines where the forward motion of the machine gives good velocity to cool the
engine. Air-cooling is also provided in some small industrial engines. In this system,
individual cylinders are generally employed to provide ample cooling area by providing fins.
A blower is used to provide air.

(b) Advantages of Air Cooled Engines

Air cooled engines have the following advantages:
1. Its design of air-cooled engine is simple.
2. It is lighter in weight than water-cooled engines due to the absence of water jackets,
radiator,circulating pump and the weight of the cooling water.
3. It is cheaper to manufacture.
4. It needs less care and maintenance.
5. This system of cooling is particularly advantageous where there are extreme climatic
conditions in the arctic or where there is scarcity of water as in deserts.
6. No risk of damage from frost, such as cracking of cylinder jacket radiator water tubes.

3.4 WATER COOLING SYSTEM

It serves two purposes in the working of an engine:
a) It takes away the excessive heat generated in the engine and saves it from over heating.
b) It keeps the engine at working temperature for efficient and economical working.
This cooling system has four types of systems:
(i) Direct or non-return system,
(ii) Thermo-Syphone system,
(iii) Hopper system and
(iv) Pump/forced circulation system.
8

Though the present tractor has a forced circulation system, it is still worthwhile to get
acquainted with the other three systems.

(a)

Non-Return Water Cooling System

This is suitable for large installations and where plenty of water is available. The water from
a storage tank is directly supplied to the engine cylinder. The hot water is not cooled for reuse
but simply discharges. The low H.P. engine, coupled with the irrigation pump is an example.

(b) Thermo-Syphone Water Cooling System

This system works on the principle that hot water being lighter rises up and the cold water
being heavier goes down. In this system the radiator is placed at a higher level than the
engine for the easy flow of water towards the engine. Heat is conducted to the water jackets
from where it is taken away due to convection by the circulating water. As the water jacket
becomes hot, it rises to the top of the radiator. Cold water from the radiator takes the place of
the rising hot water and in this way a circulation of water is set up m the system. This helps in
keeping the engine at working temperature.

(c)

Hopper Water Cooling System

This also works on the same principle as the thermo-syphone system. In this there is a hopper
on a jacket containing water, which surrounds the engine cylinder. In this system, as soon as
water starts boiling, it is replaced by cold water. An engine fitted with this system cannot run
for several hours without it being refilled with water.

(d)

Force Circulation Water Cooling System

This system is similar in construction to the thermo-syphone system except that it makes use
of a centrifugal pump to circulate the water throughout the water jackets and radiator

The water flows from the lower portion of the radiator to the water jacket of the engine
through the centrifugal pump. After the circulation water comes back to the radiator, it loses
its heat by the process of radiation. This system is employed in cars, trucks, tractors, etc.

3.5

WATER PUMP

This is a centrifugal type pump. It is centrally mounted at the front of the cylinder block and
is usually driven by means of a belt. This type of pump consists of the following parts: (i)
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body or casing, (ii) impeller (rotor), (iii) shaft, (iv) bearings, or bush, (v) water pump seal and
(vi) pulley.The bottom of the radiator is connected to the suction side of the pump. The power
is transmitted to the pump spindle from a pulley mounted at the end of the crankshaft.Seals of
various designs are incorporated in the pump to prevent loss of coolant from the system.

3.6

FAN

The fan is generally mounted on the water pump pulley, although on some engines it is
attached directly to the crankshaft. It serves two purposes in the cooling system of a engine.
(a) It draws atmospheric air through the radiator and thus increases the efficiency of the
radiator in cooling hot water.
(b) It throws fresh air over the outer surface of the engine, which takes away the heat
conducted by the engine parts and thus increases the efficiency of the entire cooling system.

3.7

RADIATOR

The purpose of the radiator is to cool down the water received from the engine. The radiator
consists of three main parts: (i) upper tank, (ii) lower tank and (iii) tubes.
Hot water from the upper tank, which comes from the engine, flows downwards through the
tubes. The heat contained in the hot water is conducted to the copper fins provided around the
tubes.
An overflow pipe, connected to the upper1 tank, permits excess water or steam to escape.
There are three types of radiators: (i) gilled tube radiator, (ii) tubular radiator and (iii) honey
comb or cellular radiator

Fig.(3.7).Radiater part

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CHAPTER-4

4.1

TURBOCHARGERS

DEFINATION

When people talk about race cars or high-performance sports cars, the topic of turbochargers
usually comes up. Turbochargers also appear on large diesel engines. A turbo can
significantly boost an engine's horsepower without significantly increasing its weight, which
is the huge benefit that makes turbos so

11

Fig.(4.1) .Turbochargers

Turbochargers are a type of forced induction system. They compress the air flowing into the
engine(see How Car Engines Work for a description of airflow in a normal engine). The
advantage of compressing the air is that it lets the engine squeeze more air into a cylinder,
and more air means that more fuel can be added. Therefore, you get more power from each
explosion in each cylinder. A turbocharged engine produces more power overall than the
same engine without the charging. This can significantly improve the power-to-weight ratio
for the engine (see How Horsepower Works for details). In order to achieve this boost, the
turbocharger uses the exhaust flow from the engine to spin a turbine, which in turn spins an
air pump. The turbine in the turbocharger spins at speeds of up to 150,000 rotations per
minute (rpm) -- that's about 30 times faster than most car engines can go. And since it is
hooked up to the exhaust, the temperatures in the turbine are also very high. In this edition of
How Stuff Works, we'll learn how a turbocharger increases the power output of the engine
while surviving these extreme operating conditions. We'll also learn how waste gates, ceramic
turbine blades and ball bearings help turbochargers do their job even better.

4.2 HOW IT WORKS

The turbocharger is bolted to the exhaust manifold of the engine. The exhaust from the
cylinders spins the turbine, which works like a gas turbine engine. The turbine is connected
by a shaft to the compressor, which is located between the air filter and the intake manifold.
The compressor pressurizes the air going into the pistons.

12

Fig.(4.2). Turbocharger work

4.3

INTERCOOLERS

When air is compressed, it heats up; and when air heats up, it expands. So some of the
pressure increase from a turbocharger is the result of heating the air before it goes into the
engine. In order to increase the power of the engine, the goal is to get more air molecules into
the cylinder, not necessarily more air pressure.
An intercooler or charge air cooler is an additional component that looks something like a
radiator, except air passes through the inside as well as the outside of the intercooler. The
intake air passes through sealed passageways inside the cooler, while cooler air from outside
is blown across fins by the engine cooling fan.
The intercooler further increases the power of the engine by cooling the pressurized air
coming out of the compressor before it goes into the engine. This means that if the
turbocharger is operating at a boost of 7 psi, the intercooled system will put in 7 psi of cooler
air, which is denser and contains more air molecules than warmer air.

13

CHAPTER-5

5.1

CLUTH AND PLATE

CLUTCH PARTS AND OPERATION

Clutch parts
- Flywheel
- Pressure plate
- Friction disc
- Release mechanism
Clutch disc pushed against flywheel with enough force

14

Fig.(5.1).part of the clutch

5.2

CLUTCH DISC

Characteristics :
Clutch hub: inner part of disc and has splines
Torsional dampers: absorb shock
Clutch disc has facings made of friction material
Contain molded or woven asbestos
Facings riveted to both sides of cushion plat
Cushion plate is riveted to disc plate
Clutch is engaged: air is trapped in grooves
Clutch is released: trapped air pushes disc away from pressure plate and flywheel

5.3

PRESSURE PLATE

Pressure plate is cast iron plate.Part of cover assembly Cover assembly is bolted to the
flywheel Clutch disc is wedged between pressure plate and flywheel Space between pressure
plate and flywheel is less than thickness of clutch disc Engine and transmission are physically
connected when clutch pedal released.

5.4.DIAPHRAGM CLUTCH
15

Diaphragm spring replaces release levers and coil springs Diaphragm pivots off pivot rings
when
clutch
pedal
is
depressed

Fig.(5.4).clutch plate and diaphragm spring

Advantages:
Requires less effort and takes up less space
Spring pressure becomes greater as disc wears
Well balanced
Dual mass flywheel: reduces noise and vibration
Allows smoother gear shifting

5.5

CLUTCH FORK

Release bearing hub has provision to attach it to the clutch fork

Clutch fork fits between release bearing and clutch cable or linkage
Has pivot shaft, pivot ball, or raised area in the bell housing off which it pivot.

16

Fig.(5.5).clutch fork

CHAPTER-6

6.1

BEARING SYSTEM

DEFINATION

17

As described in Chapter One, a bearing is a device used to support and guide a rotating,
oscillating, or sliding shaft, pivot or wheel. Whenever a shaft rotates, it needs a bearing for
smooth, effective operation.

6.2

BEARING IS DESIGNED TO:

Reduce friction
Support a load
Guide moving parts wheel, shafts, pivots

(a)

Reduce friction

Whether they are used in fleet, automotive or industrial applications, bearings perform the
same function and have the same objective to keep the shaft moving smoothly and
consistently while reducing friction.
A bearings rolling internal mechanism greatly reduces the effort and energy it takes to slide
or move an object over the surface. This is why the invention of the bearing is so important.

(b)

Support a load

A shaft will try to push the bearing in the same direction in which the load moves. The load is
dependent on both weight and direction. If the wrong type of bearing is used it may not be
able to carry the required load.

6.3

THERE ARE THREE TYPES OF LOADS :

1. When the direction of the load (weight being moved) is at right angles to the shaft, it is
called a radial load.The load pushes down on the bearing.
2. When the direction of the load is parallel to the shaft,it is called a thrust load. The load
pushes sideways on the bearing.
3. When the direction of the load is a combination of radial and thrust, the load pushes down
sideways on the bearing.This combination is called an angular load
The word radial means in the direction of a radius: moving from the circumference inward,
or the center outward. In this case it moves from the outside in. A radial load pushes down,
from the outer race inward to the balls, cage and inner race at the center of the bearing. The
load is at right angles (90) to the shaft on which it is being supported.
Thrust means a pressure or pushing force exerted by one part against a touching part.
Pressure is exerted sideways, pushing the shaft either right or left. This shaft movement then
pushes the inner race of the bearing in the same sideways direction. The line of pressure, that
is, the load, runs parallel to the shaft
An angular load is actually a combination of radial and thrust loads.
As the load moves at an angle toward the shaft, it pushes against the corner of the inner race.
Pressure is transmitted diagonally, through the corner of the race, cage and rolling elements,
to the opposite corner of the outer race
18

6.4 GUIDE MOVING PARTS

The third function, to guide moving parts, is a result of the other two functions. By
supporting a load while reducing friction, a bearing guides shaft operation. It assists the
movement of crucial shafts, wheels and pivots. Without a bearing, the rotating part could not
continue operating

19