ABOUT R.S.R.T.C.

CENTRAL WORKSHOP

Introduction
In this workshop each problem related to bus is analyzed and solved. To solve problem in
the workshop they have divided the workshop into several sections. That is chassis
section, engine section, gearbox section, electrical section, pump section, major
assembly section, minor assembly section, painting section and many other.

In each section several workers are working finely to repair bus. In RSRTC central
workshop 130 workers are doing their duty honestly.

Vision
To maintain roadways bus and deliver superior value to investor, customer, communities
and excellence

Mission
(1).Offers low fares for passenger’s every day.

(2).Solve the every problem of bus.

(3).Make bus more comfortable.

(4).Make bus noise free as possible.

(5).Reconditioning of different components & parts of buses.

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 OVERVIEW RAJASTHAN ROADWAYS

Introduction
RSRTC was established on 01st October 1964 and is the largest provider of intercity bus
transportation in Rajasthan.

RSRTC is currently transporting about 10.74 lacks passenger daily and operating on
routes connecting 32 Districts of Rajasthan and neighboring states. The network of
R.S.R.T.C.is spread all over Rajasthan and other states providing all sorts of service to
general public. These services are provided by R.S.R.T.C.by its own fleet in which buses
are purchased from various manufactures like TATA, ASHOK LEYLAND etc.

For any faults in buses, R.S.R.T.C. has established workshop in different cities. In Jodhpur
central workshop is the one of biggest workshop of Tata bus. If a bus has been damaged
by an accident of a bus or which has come for regular maintenance of each and every
part of it, from tire to steering, propeller shaft to piston are inspected. There are many
sections in central workshop Jodhpur.

(1).DISMANTLE SECTION (5).DIFFERENTIAL AND GEARBOX SECTION

(2).CHASSIS SECTION (6).MACHINE SECTION

(3).BODY SECTION (7).PUMP SECTION

(4).ENGINE SECTION (8).PAINTING SECTION

(9).ELECTRICAL SECTION (10).D.D.UNIT REPAIR SECTION

(11).SPRING SECTION (13).STORE SECTION

(12).BRACK REPAIR SECTION (14).OTHER SECTION

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Dismantle Section
CHART OF WORKER IN CENTRAL WORKSHOP

CHIEF PRODUCTION MANAGER

(Mr. B. R. Bera)

PRODUCTION MANGER

Manager of Manager of Supervisor

Accountant Administration ( Foremen )

First grade mechanic

Second grade mechanic

Third grade mechanic

(Total worker -130)

When a bus accident occurs many parts of bus are damaged like body, chassis,
front axle, spring etc. So for many reason the bus is required to repair. Also the bus is
running for long time. So internal parts of bus get wear and tear like internal part of
engine, gear box, propeller shaft, tires etc.

So for many causes the bus is required to repair and also to maintain its average,
engine power and to make the bus more comfortable.

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 In dismantle section first we take the bus in dismantle section. In this section all
parts of bus are dismantle and send to other section like as body is send to body section,
engine is send to engine section, axle and gear box send to differential and gear box
repair section.

Machine Section
After engine dismantle many parts of engine are send to machine section for
repair and many machining operation like cylinder head, cylinder block, piston,
connecting rod, crank shaft, clutch plate etc. In machine section there are many
machines installed like crank shaft grinding machine, boring machine, honing machine,
lathe machine, radial drill machine welding machine, cone rod bush grinding machine
etc.

In machine section we study about these machines.

Hydraulic Crank Shaft Grinding Machine:-

This machine is basically special purpose machine .This machine is used

only to grinding the engine crank shaft. This machine designed for grinding engine crank
shaft. This machine is operated by hydraulic pressure.

Specification of hydraulic crank shaft grinding machine-

Sort of machine : crankshaft regrinding machine

Type of machine : GCS-500

Manufacturer : HMT Limited

Overall height : 1,750 mm

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Overall width : 2,100 mm

Overall length : 4,720 mm

Weight of machine including standard : 7,000 kg

Operating voltage of electric motor: 3ph, 415 volt 50 Hz AC

SPECIAL ACCESSORIES:-

Extra grinding wheel flanges

Mirror Device

Snap type size gauge for checking diameter while grinding is progress

Turning Device

Balancing stand

Magnetic filter for coolant

Gauge for measuring stroke of crankpins

Machine lamp

Table setting attachment with 8 adjuster dogs

MAIN PARTS OF HYDRAULIC CRANKSHAFT GRINDING MACHINNE:-

1. WORKHEAD

Drive is taken from two-speed pole-changing electric motor, through

two-speed belt transmission. The spindle is mounted on anti-friction bearing NN 30 K. At
its end it carries the equipment for counterbalancing the crankshaft. The clamping
chucks being removed, it is possible to perform grinding between centers. In this case,
the work is driven by the plate of pulley

2. TAILSTOKE

Its spindle is mounted on anti-friction bearings NN 30 K .The spindle is

provided with a sliding center sleeve for clamping work between centers. At its end, it
carries an equipment for counterbalancing the crankshaft.

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CLAMPING AND COUNTERBALANCING EQUIPMNET:-

The spindle of the work head and of the tailstock are provided with an
equipment for clamping by means of chuck, which are adjustable according to the
amount of eccentricity of the crankshaft to be handled. Both spindle are provided with
counterbalancing equipment including additional weight.

TABLE:-

It is dual. The top table can be swiveled to compensate for eventual iconicity
of crankpin. The amount of swiveling is including with the aid of dial indicator.

Fig. Hydraulic Crankshaft Grinding Machine

BORING MACHINE
In machining, boring is the process of enlarging a
hole that has already been drilled by means of a single point cutting tool, for example as
in boring a gun barrel or an engine cylinder. Boring is used to achieve greater accuracy of
the diameter of a hole.

Boring machine is mainly two type

(A).horizontal boring machine

(B).vertical boring machine

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 In RSRTC central workshop vertical boring machine is there.

BORING TOOL
The boring process can be executed on various machine tools, including (1)General
purpose or universal machine.(2)Machine designed especially for boring as a primary
function.

The boring tool is usually single point tool, made of high speed steel,
carbide etc.

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 HONING MACHINE
Honing is an abrasive machining process that produce a precision surface on a
metal work piece by scrubbing an abrasive stone against it along a controlled path.
Honing is primarily used to improve the geometric form of surface but many also
improve the surface texture.

Typically applications are the finishing of cylinders for internal combustion

engines, air bearing spindles and gear. There are many types of hones but all consist of
one or more abrasive stones that are held under pressure against the surface they are
working on.

Fig. VERTICAL HONING MACHINE

HONING TOOL
Honing uses a special tool, called a honing stone or a hone to achieve a precision
surface. The hone is composed of abrasive grains that are bound together with an
adhesive.

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 Any abrasive material may be used to create a honing stone, but the most commonly
used are corundum, silicon carbide cubic boron-nitride or diamond.––

Fig. HONING TOOL (HONE)

SURFACE GRINDING MACHINE

The surface grinding machine is mainly used for grinding the surface of many
machine parts. In RSRTC central workshop the surface grinding machine is magnetic type
surface grinding machine. In this machine the bed of this machine is magnetic type to
hold the machine parts.

The main use of this machine is to grind the surface of clutch, cylinder head and
cylinder block. But now a days this machine is not in working condition in RSRTC
workshop.

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 Fig. SURFACE GRINDING MACHINE

LATHE MACHINE
Lathe machine is commonly used in small and large workshop. This machine is
more important for workshop. In RSRTC central workshop two lathe machine are there
.Many operation are created in lathe machine like as turning, grinding drilling, surface
finishing, thread cutting boring etc.

TYPE OF LATHE MACHINES:-

Many types of lathe machine are provided by many companies in the world.

(A).CENTRE LATHE

(B).CAPTAN LATHE

(C).TURRET LATHE

(D).CNC LATHE

(E).BENCH LATHE

(F).HOLLOW SPINDLE LATHE

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MAIN PARTS OF LAHTE MACHINE:-

(1).BED

(2).HEAD STOKE

(3)TAIL STOKE

(4).MAIN SPINDLE

(5).GEAR BOX

(6).CARRIAGE

(7).CROSS SLIDE

(8).TOOL POST

(9).CHUCK

(10).LEAD SCREW

In RSRTC central workshop the lathe machines used for surface finishing of clutch
plate. On this machine a surface finishing attachment is installed for operation of surface
finishing.

Fig. LATHE MACHINE

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 There are two lathe machine in machine section (RSRTC central workshop).One
lathe machine is only use for surface grinding of flywheel of engine. And second is used
for other operation like as thread cutting, boring, turning etc.

RADIAL DRILL MACHINE

A radial arm drill press is a large geared head drill machine in which the head can
be moved along an arm that radials from the machine column. As it is possible to swing
the arm relative to the machines base, a radial arm drill press is able to operate over a
large area without having to the work piece.

Fig. RADIAL DRILL MACHINE

MAIN PARTS OF RADIAL DRILL MACHINE:-

(1).BASE

(2).BOX TABLE

(3).RADIAL ARM

(4).COLUMN

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(5).SPINDLE

(6).DRILL CHUCK

DRILL TOOL:-

Drill tool is used to drill the job. Drill tool is made of high speed steel
(H.S.S.), high carbon steel (H.C.S.), Diamond tip tool etc. In RSRTC central workshop H.S.S.
tool is mainly used. There are large range of drill tool from 5mm to 60mm use in RSRSTC
workshop. Drill tool is mounted on drill chuck.

ARC WELDING MACHINE:-

In this case, heat is liberated at the arc terminals and this heat is used to melt the
metals to be welded at the points of contact, so that they will flow together and form an
integral mass. Thus, different parts may be jointed. A filler material is also added to the
surface of the metal. The temperature of arc is of the order of 3600 degree centigrade.
Arc is created by low voltage, high current supply. Flux coated electrodes are used which
on melting from a protective gas shield around the electrode tip and molten weld pool.
On cooling, the residue of this flux solidifies to form a slag.

Power source may be A.C. and D.C. supply, it does not matter whether work or
electrode is positive but with D.C. source, polarity is important. A gap of about 3mm is
maintained for producing sound weld.

Fig. ELECTRIC ARC WELDING MACHINE

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 In RSRTC central workshop rectifier transformer used in arc welding machine. In
this machine rectifier is used for changing the polarity of current. Rectifier transformer
used in ferrous and non-ferrous metal welding. In this machine step up transformer is
use. Capacity of this machine is 50 amp to 400 amp.

CURRENT CONDITION FOR STANDARD WELDING

SIZE OF WORK PIECE AMP.

5.00x450 170-220

4.00x450 140-180

3.15x450 90-130

3.15x350 90-130

2.5x350 50-80

PARTS OF WELDING MACHINE:-

(1).STEP UP TRANSFORMER

(2).ELECRODE

(3).ELECRODE HOLDER

ELECRODE:-

Electrode is use in arc welding as filler metal. It is a consumable electrode.

In different metal different electrodes are used.

For cast iron - cast iron electrode

For M.S. iron - M.S. electrode

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 GAS WELDING MACHINE
Gas welding is a process in which the required heat to melt
the surfaces is supplied by a high temperature flame obtained by a mixture of two gases.
The gases are mixed in proper proportions in a welding blowpipe (torch).For controlling
the weld flame, there are two regulators on the torch by which the quantity of either gas
can be regulated.

In gas welding, the two gases used for producing flame are oxygen and
acetylene. Oxygen is used to support and intensifying combustion.

ENGINE SECTION
An engine section is the main section of RSRTC central workshop
Jodhpur. In the engine section the whole engine is repaired. First the engine is brought to
engine dismantle section. In this section all the parts of the engine are dismantled and
then it is send to machine section and finally all repairing is done and new parts are
assembled in engine assemble section and send to the engine testing machine for testing
the engine and finally it is send to the bus assemble section.

SPECIFICATION OF BS-3 ENGINE

Model type CUMMINS B 5.9 EURO-3

Water cooled direct injection

Turbocharged diesel engine

No. of cylinders 6-cylinder

Bore/stroke 102mm x 120mm

Capacity 5883 cc

Maximum engine Output 132 HP or 98kw at 2500 rpm with viscous fan

Max. Torque 430Nm at 1400-1700 rpm with

Viscous fan

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Compression ratio 16.5:1

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

Air filter Dry type remote mounted

Fuel injection pump MICO ROTARY PUMP (MICO-VP14)

Coolant Water and ethylene glycol

Ratio 1:1

Weight of engine 413 kg (dry) with flywheel & air

Compressor but without electrical

The engine section is divided into sub-section

(1).An engine dismantle section

(2).Cleaning section

(3).Minor assembly section

(4).An engine assembly section

ENGINE DISMANTLE SECTION:-

In the engine dismantle section all parts of an engine are dismantled. First
we take old engine in engine dismantle section for dismantling the engine. All parts of
the engine are dismantled carefully by skilled workers like as engine housing, air
compressor, engine block, engine head, engine valve, flywheel, crankshaft, connecting
rod, piston etc.

CLEANING SECTION:-

In an engine cleaning section all dismantled parts of the engine are

cleaned. There are three tank, filled with chemical (5 litter water +1 litter chemical).The
capacity of per tank is 200 litter. The parts of the engine are dropped in the chemical
tank and put for 24 hours in the tank. After 24 hours all parts are removed and cleaned
by normal water jet.

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MINOR ASSEMBLTY SECTION:-

Many minor parts are mounted on the engine like as turbo charger, air
compressor etc. In minor assembly section turbo charger and air compressor are
dismantled, cleaned in diesel and then all minor parts of air compressor and turbo-
charged are assembled. These repaired air compressor and turbo-charged are send to
the engine assembly section. There are two minor parts which are repaired in minor
assembly section

(A).AIR COMPRESSOR

(b).TURBO-CHARGER

AIR COMPRESSOR:-

An air compressor is mounted with the engine. Main purpose of the air
compressor is to compress the air and supply to an air tank. This compressed air is used
in air brake, air suspension system in bus.

AIR COMPRESSOR PARTS OF AIR COMPRESSOR

MAIN PARTS OF AIR COMPRESSOR:-

(1).Air compressor housing (mild steel)

(2).Connecting rod

(3).Air compressor piston (alloy aluminum)

(4).Piston ring (1 oil ring, 2 compression ring)

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(5).End cover (Right, Left)

(6).Compressor block

(7).Air compressor head

(8).Packing

TURBO-CHARGER
A turbo-charged is a device mounted on the exhaust gas pipe. The main use of
turbo charger to release the burnt gases by force from cylinder head and improve the
engine power .To maintain the engine. Remove the exhaust gases from cylinder head
and intake the fresh air and increase the engine efficiency.

MAIN PARTS OF THE TURBO CHARGER:-

(1).Turbo housing

(2).Turbo impeller

(3).Impeller shaft

(4).Turbo bracket

TURBO BRACKET TURBO CHARGER

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ENGINE ASSEMBLY SECTION:-

In an engine assembly section all repaired and new parts of engine

are assembled giving a new view and then send to engine testing machine

MAIN PARTS OF AN ENGINE:-

(1).ENGINE BLOCK:-

An engine block is the main part of engine. All parts of the engine are
mounted on the engine block. It is made of cast iron.

(2).CYLINDER BLOCK:-

A cylinder block is also main part of the engine. Piston reciprocates in

cylinder block. It is made of cast iron.

(3).CYLINDER HEAD:-

An engine head is a top part of the engine. The engine valves are
mounted on the engine head.

(4).PISTON:-

Piston is the main parts of the engine. Main purpose of the piston is to
compress the air and fuel. It is made of cast iron and aluminum alloy .1 oil ring and 2
compression rings are mounted on piston. Standard diameter of piston is 102mm.

(5).CRANKSHAFT:-

A crankshaft is a rotating part of an engine. Power is supplied to gear box

and propeller shaft by crankshaft.

There are two main parts of crankshaft

(A).Main journal Diameter 83mm, 7 block

(b). Vision journal Diameter 69mm, 6 block

(6).CONNECTING ROD:-

The connecting rod is made of cast iron. It connect the piston with
crankshaft.

(7).CAMSHAFT:-

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 Main purpose of cam shaft is to open the valve at a certain time. Cams are
mounted on camshaft.

(8).LINER,

(9).VALVES (6 CYLINDER BS1, BS2-12 VALVES AND BS3 ENGINE 24 VALVES)

(10).OIL CHAMBER, (11).FLWHEEL, (12).FUEL PUMP etc.

CYLINDER BLOCK (1) CYLINDER HEAD (3)

Fig. PISTON AND CONNECTING ROD (5+6) Fig. CRANK SHAFT (5)

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 FUEL INJECTION PUMP SECTION
Fuel injection pump section is the important section for RSRTC
central workshop. The fuel injection pump is the heart of the engine. In roadways bus 6
cylinder engine is use, six cylinder fuel pump is used in the engine.

Main purpose of fuel injection pump is supply the diesel fuel in all six
cylinder in same quantity. If the engine does not take load, fuel pump is damaged. And it
is required to repair them.

In fuel injection pump section fuel injector pump and injector are repaired
and calibrating the fuel injection pump on fuel injection calibrating machine.

Process of repairing the fuel injection pump in fuel injector pump section:-

First we take old fuel injection pump from oil storage section.

_ Dismantling of all fuel injection parts by skilled worker.

_ washing of all parts of fuel injection pump in diesel and clean the parts by water jet and
finally drying by air jet.

_ assembling all cleaned and new parts then sending for calibration on fuel injection
pump calibrating machine.

MAIN PARTS OF FUEL INJECTION PUMP:-

(1).HYDRAULIC HEAD, (2).CAM PLATE, (3).FULCRUM LEVER, (4).GOVERNOR SHAFT,

(5).GOVERNOR HOUSING WITH DIAPHGRAM, (6).FLY WEIGHT ASSEMBLY

ELEVATION OF F.I. PUMP SIDE VEIW OF F.I. PUMP

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 (7).PRESSURE CONTROL VALVE, (8).VANE PUMP, (9).CONTROL LEVER SHAFT,
(10).CONTROL LEVER BUSH, (11).ROLLER RING SET, (12).MECHANICAL GOVERNOR,
(13).AIR GOVERNOR etc.

CALIBRATION OF FUEL INJECTION PUMP:-

On fuel injector pump calibrating machine we calibrate the fuel injection

pump.

Procedure of calibrating the fuel injection pump-

First we take repair fuel injector pump and set on fuel injection pump calibrating
machine.

All pipes are jointed.

Set the vane pump pressure 6.2 PSI by pressure control valve on 1000 rpm.

TORQUE CONTROL:-

Set 45 cc fuel delivery working on 600 rpm. If 45 cc not available then set
the torque by torque screw.

FULL ON DELIVERY:-

Set the 55 cc fuel delivery on 400 rpm (four stroke, (1 stroke =100 rpm),
when the pressure is found
1kg/cm2.

IDEAL SPEED:-

Set 9.5 PSI vane pump

pressure without air
pressure on 375 rpm.
F.I. PUMP CALLIBRATION MACHINE

STARTING DELIVERY:-

Set 18 cc fuel delivery without air pressure on one stroke or 100 rpm. If this
delivery is not available, tube hydraulic head may be weak so we change the hydraulic
head.

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 INJECTOR
An Injector is a main part of an engine. Main purpose of injector is to atomize
the diesel fuel and send to the engine head for firing. In F.I. pump section injector is also
repaired. First check six hole of injector, then check pressure of injector on injector
testing machine. If the diesel is not atomize by six holes properly, the carbon may be in
injector holes. So we dismantle the injector and repair it.

MAIN PARTS OF INJECTOR:-

(1).INJECTOR BODY, (2).NOZZLE, (3).DISTANCE PIECE,

(4).PRESSURE BOLT, (5).SECOND SIM,

(6).PRESSURE SPRING etc.

AIR BRAKE ASSEMBLY SECTION

Air brake assembly section is divided into two sub-section:-

(A).AIR BRAKE SECTION

(B).HYDRAULIC POWER STEERING SECTION

In air brake assembly section all air brake parts and hydraulic power steering parts are
repaired.

MAIN PARTS OF AIR BRAKE:-

(1).DRYING AND DISTRIBUTION UNIT, (2).AIR DRYER, (3).OIL SEPERATOR, (4).DUAL

BRAKE VALVE, (5).RELAY VALVE, (6).SYSTEM PRODUCTION VALVE etc.

Specification of brakes

Service brake : Fully duplicated full air S-cam brake

System

Brake drum : 410mm diameter

Lining area Front -2180 sq. cm

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 Rear -2470 sq. cm

Total -4650 sq. cm

Parking brake type : Hand operated type spring actuated

Parking brake acting on rear wheel

Procedure of repairing all parts:-

Dismantle all parts.

Wash in diesel carefully.

Clean by water jet and dry by air jet.

Assemble all parts.

Testing on VABCO machine.

Fig. WORKING OF AIR BRAKE

The following components are exclusive to air brake system in a bus:

1. Air compressor: -
Pumps the air into storage tanks to be used in the brake system.
2. Air compressor governor:-
Control the cut-in and cut-out point of the air. Compressor to maintain a set
amount of air in tank.
3. Air reservoir tank:-

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 Hold compressed or pressurized air to be used by the braking system.
4. Drain valves:-
Release valves in the air tanks used to drain the air when the vehicle is not in use.
5. Foot valve (foot pedal):-
When depressed, air is released from the reservoir tank.
6. Brake chamber:-
Cylindrical container that houses a slack pin.
7. Push rod:-
A steel rod similar to a piston that connects the brake chamber to the slack
adjuster. When depressed, the brakes are released. If extended, the brakes are applied.
8. Slack adjusters:-
An arm that connects the push rod to the brake, s-cam to adjust the distance
between the brake shoes.
9. Brake S-cam:-
An S-shaped cam that push brake shoes apart and against the brake drum.
10.Brake shoe:-
Steel mechanism with a lining that causes friction against the brake drum.
11.Return spring:-
A stiff spring connected to each of the brake shoes that returns the shoes to the
open position when not spread by the S-cam or diaphragm.

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 HYDRAULIC POWER STEERING:-
In power steering low power is required for steering the bus. In hydraulic
power steering section all parts of power steering are repaired then tested on machine.

MAIN PARTS OF POWER STEERING:-

(1).OIL PUMP

(2).STEERING GEAR

(3).OIL TANK OR RESERVOIR

Oil pump is the heart of the power steering. An oil pump controls the flow of
oil in power steering system. Main use of oil pump is to suck the oil from reservoir and
deliver the compressed oil in steering gear system.

Procedure of repair oil pump:-

(1).Dismantling of all
parts of oil pump by
skilled worker.

(2).Washing the oil

pump parts in diesel
and clean the parts by
water jet and finally
drying by air jet.

(3).Assemble all clean

and new parts.
HYDRAULIC POWER
STEERING SYSTEM

(4).Test the oil pump on machine.

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 DIFFERENTIAL AND GEAR BOX REPAIR
In differential and gear box repair section differential, gear box, front axle, rear
axle etc… are repaired.

GEAR BOX:-
A Gear box is the main parts of the bus. The Gear box is mounted between the
engine and propeller shaft. The function of gear box is to transfer the power from an
engine to tire through propeller shaft.
Often transmission refers simply to gear box that uses gear and gear trains
to provide speed and torque conversion from rotating power sources to another devices.
Type of gear box: -
Now a days gear box used are of many type in bus and vehicles. In RSRTC bus
synchronous mesh type gear box is mainly used.
(A).Sliding mesh gear box.

(b).synchronous mesh gear box

(c).Epicyclical gear box

(D).Constant mesh gear box

Fig. SYNCHRONOUS MESH GEAR BOX Fig. DIFFERENTIAL

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SPECIFICATION OF GEAR BOX

Model GBS-60

Type synchromesh on all forward gears and

Constant mesh on reverse gear

No. of gear 5 forward and 1 reverse

Gear ratio 1st - 7.51

2nd - 3.99

3rd - 2.30

4th - 1.39

5th - 1.00

Rev. - 6.93

DIFFERENTIAL:-

Differential is the main parts of bus. When turning the inner wheel travels
a shorter distance than the outer wheel, so without a differential either the inner wheel
rotates too fast or the outer wheel drags which result in difficulty and unpredictable
handling, damage to tire and roads, and strain on the entire drive train. Main purpose of
differential in buses and any vehicle is to turn the bus comfortably and easy handling.

Main parts of differential:-

(A).DIFFERENTIAL HOUSING

(B).CROWN AND PINION

(C).SUN GEARS

(D).FLANGE

FRONT AND REAR AXLE:-

Front and rear axle are the main parts of the buses. Tires are mounted
on the axle’s hub and many other parts of bus are mounted on axles like as brake drum,

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push rod, tie rod, differential, slack adjuster, brake chamber, steering attachment etc.
Whole weight of bus and passengers are sustained by front and rear axle.

Main difference between front axle and rear axle are below

Differential is mounted on rear axle.

SPECIFICATION OF FRONT AND REAR AXLE

REAR AXLE

Type Single reduction, hypoid gear, fully

Floating axle shaft

Ratio 5.285:1 (37/7) standard

5.857; 1 (41/7) optional

FRONT AXLE Type Heavy duty forged I beam

Reversed Ellis Type

MAIN PARTS OF AXLE

(1).DIFFERENTIAL, (2).BRAKE CHAMBER

(3).PROPELLER FLANGE (4).BRAKE DRUM

(5).BRAKE SHOE (6) SPINDLE HUB

(7).SLACK ADJUSTER (8).TIE ROD

(9).PUSH ROD (10) CAM SHAFT

(11).STEERING ASSEMBLY (12).LINK ARM

(13).LINK

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 REAR AXLE (ELEVATION) REAR AXLE (SIDE VIEW)

Specification of wheel and tires

Tires 9.00 x20.14 PR

Wheel rim 7.00 x 20

No. of wheels Front- 2 and Rear -4 spare -1

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 SPRING SECTION
In spring section leaf spring of ASHOK LEYLAND and TATA buses are
repaired. A leaf spring is a simple form of the spring commonly used in bus. A leaf spring
takes the form of a slender arc shaped length of spring steel of rectangular cross section.
A leaf spring can either be attached directly to the frame at both ends or attached
directly at one end, usually the front with the other end attached through a shackle a
short swinging arm. In ASHOK LEYLAND bus leaf spring, center bolt is installed in center
of the spring but in TATA bus leaf spring center, bolt is installed slit upset in back side.
The material use for Leaf spring is usually a plan carbon steel having 0.90 to 1% carbon.
The leaves are heat treated after the forming process.

Parts of leaf spring

(A).rebound clip

(b).eye bolt

(c).center bolt

(D).shackle

(e).Main leaf

LEAF SPRING

Specifications of leaf spring

Type Semi elliptical leaf spring at front and

Rear

Spring span front – 1450mm, rear -1600mm

Leaf width front -70mm, rear – 80mm

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 ELECTRICAL SECTION
In electrical section of RSRTC central workshop, electrical parts of buses are
repair. Mainly alternator and self-starter of bus are repaired in electrical section.
Electricity is most important for vehicles

SELF-STARTER:-

Self-starter is a basically D.C. motor. Starting power is given by self-

starter in buses. When the bus is started, Self-starting is by D.C. Current, D.C. current is
supplied from the battery. Then a flywheel of an engine starts to rotate. Flywheel is
connected to self-starter pinion, then the engine is started and bus move to front. When
the bus is made to run, then no use of self-starter in bus and the self-starter is disconnect
by self-switch.

PARTS OF SELF STARTER:-

(1).BODY (YOKE) OF SELF (2).SELF HOUSING, (3).ARMATURE,

(4).MAGNET BLADE (5).PINION (6).COMMUTATOR,

(7).CARBON BRUSH (8).ROCKER (9).SWITCH,

(10).BUSH etc….

In self-starter magnetic type winding is used. Self-boy is made by mild steel and
self-housing is also made by mild steel.

ALTERNATOR:-

An alternator is the main parts for the bus. It is mounted with an engine.
Alternator is rotate by an engine. It is connected by an engine pulley to alternator pulley
by flat belt. It is a generator of vehicles. Alternator generates electricity and charge the
battery. When the bus is running head light, indicator light are ON by alternator. In
alternator copper winding is use. In electrical section alternator is repaired by skilled
worker.

Parts of an alternator:-

(1).ALTERNATOR BODY, (2).HOUSING, (3).STATOR (4).ROTOR,

(5).D-SHIELD, (6).RECTIFIER, (7).CUT-OFF SWITCH, (8).PULLEY

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.

Fig. A SELF STARTER Fig. AN ALTERNATOR

CHASSIS REPAIR SECTION

A Chassis is a main part of the bus. The chassis wear all loads of bus and
passengers. So we can say that the chassis is base of the bus. All other accessories are
mounted on chassis like body. The chassis is made by mild steel. During accident chassis
get damaged, so it is required to repair it. In RSRTC central workshop chassis is repaired.
Chassis is also called frame. In RSRTC buses ladder type frame is commonly used.

TYPES OF CHASSIS (FRAME)

(1).BACHBONE CHASSIS

(2).LADDER CHASSIS

(3).UNIBODY CHASSIS

(4).X-FRAME

(5).PLATEFORM CHASSIS

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(6).SPACE FRAME

(7).PERIMETER FRAME

FUNCTION OF CHASSIS:

(A).To support the vehicle’s mechanical component and body.

(B).To deal with static and dynamic loads, without under deflection or distortion.

BODY REPAIR SECTION

Body is mounted on the chassis. Body is made by aluminum, carbon fiber,
mild steel etc. In olden days RSRTC bus body is made by aluminum but this body did not
succeed for long time. Now a days RSRTC buses body is made by mild steel. This body is
not very costly and its strength is as high as compare to aluminum body.

In body section, bus body is repaired. During an accident bus body get damaged,
so it is required to repair it.

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 CHASSIS AND BODY REPAIR

PAINT SECTION
When whole bus like chassis and body are repaired then it is required to
paint the bus. In paint section, bus body is painted. First the coating of red-oxide is
coated by workers on bus body. After this putty is coated on the bus body by workers.
Then grinding is done by smooth grinder for surface finishing and to create plan surface
of the body. After surface finishing body is painted. Paint is mixed with a 200 ml PU
hardener per 800ml PU color (800 ml PU color +200 ml PU hardener.

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 OTHER SECTION
There are many small section in RSRTC central workshop like as store
section, fuel tank repair section, sheet repair section, radiator repair section, store
section, old storage section, auction section etc.

FUEL TANK REPAIR SECTION:-

In fuel tank repair section fuel tank of the bus is repaired. When the fuel tank
is leaking then it is required to repair. The fuel tank of RSRTC buses are made of mild
steel. The capacity of fuel tank is 125 litters and 200 litters of RSRTC buses.

CAPACITY for LPO -250 Litters

For LP -160 litters

STORE SECTION:-

In workshop store section is most important section because all new

parts are stored in store section. In store section a store keeper is sitting here. He

Issues new parts of machine for workers. In RSRTC central workshop store section, all
new parts of buses are stored here.

OLD STORAGE SECTION:-

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 In RSRTC central workshop an old storage section is also installed outside of
the workshop. In old storage section all old and damaged parts of bus are taken out.

Fig. OLD STORAGE SECTION

SHEETS REPAIR SECTION:-

In sheet repair section, sheets are repaired by worker. Basically sheet cover
is made by regime. It is made of non-flammable material.

RADIATOR SECTION:-

Radiator is a part of bus. Its main purpose is to cool an engine. It is made of

aluminum and brass. In BS1 and BS2 models radiator is made of aluminum but in BS3
model’s radiator is made of brass. In radiator section radiator is repaired and send to the
body repair section.

AUCTION SECTION:-

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 In RSRTC central workshop an auction section is also provided. In auction
section all old and unusable parts of buses, chips etc. are taken and sell out (auction) all
parts from auction section.

REPAIRED BUS

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