Acknowledgment

I would like to thank Eng. yasser for his effort to guide in company. I own
my deepest gratitude to Eng.sayed and his help and care during all
training duration. I would like to show my gratitude to Eng. milad for his
encourage.

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Abstract

This report will cover training period and knowledge gained in CENTRAL
WORKSHOPS OF BRIDGES DEPARTMENT OF THE ARAB
CONTRACTORS and here will focus on the main workshop of BRIDGES
DEPARTMENT, that it individually workshop that have all equipment for
her own to service its equipment that used in its construction and will
take some of Sub-sections workshop that are production workshop,
engine overhaul workshop and in this workshop we will study step by
step how make overhaul for motor and then we will have the air braking
system and its type and then we will have the steps for start the motor
and we will get that step by step.

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1 CHAPTER 1
INTRODUCTION

In this report will focus on CENTRAL WORKSHOPS OF BRIDGES

DEPARTMENT OF THE ARAB CONTRACTORS and will take some of
Sub-sections workshop that service its equipment that used in
construction at first we have production workshop that responsible for
produce spare parts for car or truck and service other workshop and
make mold that used in construction. At second have engine overhaul
workshop that responsible for make overhaul for motor that have
problem effect on its performance and get it back with full efficiency and
make periodic maintenance for vehicles. At third have study the air
braking system and how it work and the parts that responsible for this
system. At fourth we will see how the motor is start and steps of that. At
fifth we will study the movement transport devices that are gearbox and
the clutch. And we will get that in details with step by step.

1
2 CHAPTER 2
PRODUCTION WORKSHOP

In this work shop the machining department is serving on all other

departments by making some of the spare parts that the other
department need to complete their works. In the machining department
there are some machines that make that work done.

2.1 Lathe

Lathe was actually the first machine tool which came into being as a
useful machine for metal cutting. Lathe can be defined as a machine tool
which holds the work between two rigid and strong supports, called
centers, or in a chuck or Face plate while the lathe revolves. The
following are some of the important Parts of lathe machine.

Fig 2-1 Lathe machine

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2.2 MILL

Milling is a process performed with a machine in which the cutters rotate

to remove the material from the work piece present in the direction of the
angle with the tool axis. With the help of the milling machines one can
perform many operations and functions starting from small objects to
large ones.

Milling machining is one of the very common manufacturing processes

used in machinery shops and industries to manufacture high precision
products and parts in different shapes and sizes.

Fig 2-2 milling machine

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2.3 Electric arc welding

Arc welding is a type of fusion process to join two metals. As in any

fusion process an intense amount of heat is required for melting the
pieces to be joined or the filler material in some cases. In arc welding
this heat is achieved by forming an arc between the welding electrode
and the work piece.

Fig 2-3 welding

2.3.1 Oxy acetylene welding

Oxy-acetylene welding is simple in concept - two pieces of metal are

brought together, and the touching edges are melted by the flame with
or without the addition of filler rod. Cutting with the oxy-fuel process is
just the opposite from of welding. Oxy-fuel cutting uses acetylene and
oxygen to preheat metal to red hot and then uses pure oxygen to burn
away the preheated metal. Because this is achieved by oxidation, it is
only effective on metals that are easily oxidized at this temperature.
Such metals are mild steel and low allow steels.

A standard oxy-acetylene equipment setup consists of an oxygen tank,

an acetylene tank, regulator and gauges, gas hoses, a torch and tip.
Characteristics of the oxy-acetylene welding process include.

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3 CHAPTER 3
ENGINE OVERHAUL WORKSHOP

3.1 Parts of engine

1-cylinder block

2-cylinder head

3-piston

4-connecting rod

5-crank shaft

6-fly wheel

7-valves

8-spark plug

9-cam shaft

10-cylinder liner

3.1.1 Cylinder block:

-It is a container fitted with the piston, where the fuel is burnt and power
is produce.

-for cooling of cylinder a water jacket or fin are situated at the outer side
of cylinder.

-manufacturing method: casting, forging, machining

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 Fig 3-1 cylinder block

Fig 3-2 cylinder block

3.1.2 Cylinder head

Manufacturing: casting

Fig 3-3 Cylinder head

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3.1.3 Piston

-it transmits the energy to crank shaft through connecting rod.

-it rotates inside the cylinder.

Fig 3-4 piston

3.1.4 Connecting rod

One end of the rod is connecting with the piston the other side is
connecting with the crank shaft. It is fitted between the crosshead and
the crankshaft.

It transmits the firing force, and together with the crankshaft converts the
reciprocating motion to a rotary motion.

Fig 3-5 connecting rod

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3.1.5 Crank shaft

-the function of it is to transform the reciprocating motion into a rotary

Motion and One of the largest moving parts.

-It consists of a series of cranks formed in a shaft.

-Converts reciprocating motion of the piston into rotary motion.

-Counterweights for balancing purposes.

- Manufacturing: casting then machining by 45 processes.

Fig 3-6 crank shaft

3.1.6 Fly wheel

-Is secured in the crank shaft the function of it is to rotate the shaft
during strokes and make crank shaft rotate uniformly.

Fig 3-7 fly wheel

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3.1.7 Valves

-the device which regulate and control the flow of fluid by opining or
closing

-the intake valves open in the proper time to let the air and fluid enterand
let the exhaust to go out.

Fig 3-8 intake valves

3.1.8 Spark plug

-the main function is to conduct the high potential from ignition

system into the combustion chamber.

Fig 3-9 spark plug

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3.1.9 Cam shaft

-it use to control the opening and closing of valves at proper timing .

-it is drive by crank shaft, and placed on the top or at the bottom of the
cylinder.

Fig 3-10 cam shaft

3.1.10 Cylinder linear

A bore in which an engine piston moves back and forth. The material of
the liner must withstand extreme heat and pressure developed within the
combustion space at the top of the cylinder, and at the same time must
permit the piston and its sealing rings to move with a minimum of friction.

Fig 3-11 cylinder head

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3.2 Engine runs

For Drive 4 runs at one session so it is called the four-stroke engines:

1-Pull-out.
2-stroke.
3-run power (burn) .
4. Exhaust.

1. Pull-out: in which the fuel valve is opened to enter the gasoline and air
mixture into the combustion chamber and during the downward down,
the fuel ratio is small for air...

2-Stroke: The valve is closed and the cylinder rises to the top to
compress the mixture to increase its temperature so as to help its
combustion efficiency....

3. Capacity-building (incineration): the mixture is burned by an electrical

spark from the burning Candle (the Buj) and the mixture is inflamed,
driven down by a huge force....

4. Exhaust: When the slander reaches the bottom, the exhaust valve
opens and starts to rise again and the gases resulting from the burn are
fired to the Shoman and from it to the outside of the car.

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3.3 Engine types

3.3.1 Straight drive:

Which is found in most cars in Egypt and the cylinders

Next to each other in a linear way I mean every cylinder moves up and
down Vertical and 4 or 6 cylinders with one engine head (one cylinder).

Its advantages: It's the most old and most affordable engine, and the
least complex and easy in maintenance.

3.3.2 The V-shaped engine

The order of the cylinders in the form of 7

It is divided into two parties for each side of the engine's head. It's
probably 8 cylinders and in
Sometimes 6 cylinders are rarely 4 cylinders

Features:

1-it provides a large space in the engine compartment, which is easy to

reduce the size of the car.
Though the engine is huge and reduces its weight.

2-faster and more active than the rectum because when the cylinders
tend to be less resistant to their gravity.

3.3.3 T-drive

Rarely does this engine exist and there are opposite cylinders (as in the
picture) to reduce gravity more and there are some Ford cars and most
cars: Porsche and Subaru.
Features: These engines give abnormal torque compared to their small
size.

Disadvantages: Needs to be maintained more especially in the head

cylinder because most of the pressure is on it.

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4 CHAPTER 4
AIR BRAKING SYSTEM

Definition

It is used in heavy vehicles depending on the pressured air instead of

hydraulic oil to stop the wheels because of the distance between
accelerator and the wheels.

Components

1- Compressor
2- Pressure regulator
3- Protection valve (4 ways distributor )
4- Tanks
5- Hand brake
6- Main brake
7- Brake pressure regulator
8- brake cylinders

4.1 Compressor

It is the main part in the system.

It gives the system the compressed air.

It run mechanically and takes its motion directly from the engine by one
method (belt or gears).

4.2 Pressure regulator

It regulates the air pressure which coming from compressor to a suitable

pressure after this the overload air is go out of the system.

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4.3 Protection valve (four ways distributor)

It distributes the air to 4 ways and keep the pressure in the system
suitable.

It works on keep the pressure and gives it to the system in case of any
damage in the main part in the system by stop the flow of air in the
damage line.

4.4 Tanks
It keeps the pressured air inside it.

4.5 Hand brake

It works on stopping the vehicle when pull this.

4-1 hand brake

4.6 Main brake

It works on stopping the vehicle when push on the brake pedal.

4-2 Main brake

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4.7 Brake pressure regulator

It is positioned between the brake valve and the brake cylinders .

It regulates the air pressure which passes to the wheels cylinders as the
load of the vehicle.

If the vehicle loaded it allow a high pressure to pass to be able to stop

this.

If the vehicle is not loaded it allow a low pressure to pass to stop this.

4.8 Brake cylinders

There are 2 types of cylinders one for hand brake and the other one is
for the main brake.

There is a mixed cylinder.

The hand brake cylinder: it consists of spiral in cylinder which already full
by air and the spiral is compressed in the normal case when the hand
brake pulled it allowed the air to go out and the spiral stretched.

The main brake cylinder: it consists of a piston in cylinder when the

brake pedal pushed the air enters the cylinder and pushing the piston to
stop the wheels.

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5 CHAPTER 5
STARTER (MARSH)

5.1 Definition

It is an electric motor, pneumatic motor, hydraulic motor, or other device

for rotating an internal-combustion engine so as to initiate the engine's
operation under its own power .

Assumes motor DC current, and its usefulness: giving a crank shaft a

machine number of certain rolls (from 400 to 450 roll/s) in The beginning
so that the car's engine can start to fire and spin.

5-1 starter

5.2 Parts of starter

1. Main Housing (yoke)

2. Fixed member or stator
3. Rotor Armature (Rotating or moving member)
4. Overrunning clutch
5. Field coils ( the marsh automatically contains both the tow and the
clamping files) file drag (to pull the pendulum to the voltage with the
filter or the Flam). And the clamping file to make the electrical
connection between the battery and the stationary member of the
marsh through a bridge Electrical between automatic and fixed
member as soon as the pendulum is pulled in the direction of the
Flam.
6. Solenoid

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7. Brushes
8. These parts are attached to the clutch
9. The group of coal houses in Charpon and Susat are riding on the end
of the rotating member ( comutator member).

5-2 Parts of starter

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6 CHAPTER 6
MOVEMENT TRANSPORT DEVICES

6. the movement transmission device (manual):

Consists of two main parts:

1-Gear Box.
2- The clutch Kit.

The yellow part is the clutch and the red part is the Gear Box. The green part is
the column (Cardan) which moves the movement to the wheels in the case of
the rear propulsion vehicles.

6.1: Gear Box :

The idea of the work of the Gear Box:
The Gear Box often contains 5 speed front (spares) + rear velocity (rivers).
Can be 4 front-end transports in some old cars... And it is possible that 6
transports rarely in modern cars.

Red-colored gears come from the motor, and it's gears.

Blue gears are the first and second gears of gears.
Violet Gear (Guisha) is the one connected to the wheels by the yellow column.

When we push the Phitos stick to the first spare... The Guisha's spear is in gear
1 until the car starts to steady.
And when we return it to the back, we love the second spare and so on.

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6.1.1.Why should we go to the beginning not for example on fourth
or fifth?
Because we need a strong push at the beginning of the car movement we carry
on the number 1 gear because it is big and it means it takes a few laps.
I mean all that the gear reduces the speed of Arabic increase but its intention
is less...
Because of this we should choose the suitable parts for the speed of the car
The first spare: from 0 to 25 km/s
Second spare : 25 to 40 km/s
Third spare: 40-60 km/s
Fourth spare : 60 to 85 km/s
Fifth spare V: over 85 km/s
These speeds vary according to the type or payload of the car.

6.1.2.The important question how the car gets back ?

The car goes back through a small gear (idler gear) whose function is to
reverse the movement of the rivers so we can return in car behind
Picture showing how to gear (idler gear).

6.2: the Clutch:

His job: separates the motor movement from the Gear Box and thus about the
wheels by pressing the clutch pedal so that we can change gears.

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6.3:automatic transmission device:
Its components are very complex compared to manual and mechanical
transfers are dispensed with hydraulic (oil pressure)...
His idea is that the moves are automatically changed in a sensitive Way
(sinsor): The speed of the car, the number of motor rolls (RPM) and the
appropriate spare parts, without the intervention of the driver....
And the car in it is automatic and it doesnt have a clutch pedal because there is
something called a torque converter does the diesel automatically by
compressing the oil (hydraulic).

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