Inplant training done in Ashok Leyland

ENGINE ASSEMBLY STAGE 1: CAM BEARING • Cam bearings are attached to the crankcase of the engine. STAGE 2: CAM SHAFT • Cam shaft is attached in the crankcase. STAGE 3: CRANK SHAFT • It is fixed at the base end of crankcase. STAGE 4: STUDS • M14 studs are fixed to the holes of crankcase. STAGE 5: TIMING BRAKE PLATE • It is fixed to the side of the engine. STAGE 6: CAM GEAR • It is placed on the crankcase to operate cam shafts and to operate valves. STAGE 7: FLYWHEEL • The flywheel is placed on housing; it also consists of seal housing and flange. STAGE 8: OIL PUMP • It is fixed at top of crankcase. It is used to circulate oil to various parts of engine.

STAGE 9: PISTON • The piston is attached inside the bore of crankcase & it is connected to crankshaft. The oil ring and compression rings are also attached on the piston. STAGE 10: CONROD BOLT • It is used to connect piston with crankshaft. STAGE 11: IDLING GEAR • It is used to control the rotations of cam gear, crank gear and compression gear. STAGE 12: CYLINDER HEAD • It is attached at the top of crankcase. STAGE 13: OIL SUMP • It is placed at the bottom of crankcase. STAGE 14: ROCKER • Rocker is fixed with cylinder head. STAGE 15: AIR COMPRESSOR • It is fixed with crankcase. STAGE 16: FUEL INJECTION PUMP STAGE 17: VALVE COVER

STAGE 18: OIL COOLER STAGE 19: INJECTOR PIPE STAGE 20: INLET MANIFOLD STAGE 20: SIDE COVER STAGE 21: WATER PUMP STAGE 22: STARTER MOTOR STAGE 23: EXHAUST MANIFOLD STAGE 24: TURBO CHARGER STAGE 25: EII FITMENTS STAGE 27: FULLY ASSSEMBLED • Finally, the assemble is taken to the testing section for checking the performance.

SHOP III

FRAME ASSEMBLY There are several steps involved in frame assembly. They are as follows:  The side members and engine mounting are lifted using conveyor.  Assemble all cross members, steering mounting bracket, air cooler mounting bracket and rear spring brackets.  On rear end of the frame, both sides are aligned with taper pin.  Cross members are tightened well. Fit and tight FS and BKTS on both sides with dummy bolts.  Reaming process is done in the next step and the dummy bolts are removed.  Torque tightening in the rear brackets using M14 bolts on both sides.  Front and rear ends are fixed with four cab mountings.  Tighten the CB cross members using brake elbow adaptors.  Tilt the frame by 180o using tilting CUM lifting equipment.  Punch frame Sl. No. and spec on rear end of RH FSM.  Air blow the reamed burrs in assembled frame.

 Lift and unload the assembled frame from conveyor on to trolley using tilting CUM lifting equipment.  Finally, the whole frame is carried to chassis assembly centre.

SHOP IV

The shop IV is classified into two departments. They are given below: o Rear axle assembly. o Front axle assembly. REAR AXLE ASSEMBLY The rear axle assembly consists of several stages. They are shown below:  Load rear axle casing on pedestals and remove wire strip, axle shafts.  Assemble dust covers on brake shoes and tighten with bolts and nuts.  Apply torque on mounting nuts.  Assemble inner ring for oil seal.  Distance piece is fixed to align the outer and inner wheel bearings in the same axis.  Fix the wheel drum.  Punch the Sl. No. on the rear axle.

 Unload rear axle from conveyor and it is taken to the chassis assembly centre.

FRONT AXLE ASSEMBLY

The front axle assembly consists of several stages. They are discussed below:

 First, the axle beam is loaded at conveyor belt.  The number is punched in the axle beam.  Next, the axle arm is fixed to beam of steering with pin fin and cotter pin using dummy bolts.  The tracking rod is fixed for the alignment of wheel. This will helps the left side of the tyre to turn along with the right side wheel.  Fix the air chamber and brake shoe.  Fix the hub and lock set using axle arm.  Fix the wheel drum to the both ends of axle arm.  Unload front axle from the conveyor and it is taken to the chassis assembly.

CHASSIS ASSEMBLY

The chassis assembly consists of 14 stages. They are discussed below:  In stage- 1, the front and rear axle is fixed on the main frame which is already fabricated from shop 3.  In stage- 2, the frame assembly is placed on the conveyor belt, and then brake chamber is fitted into it.  In stage- 3, the steering gear box is fitted to the main frame.  In stage- 4, the propeller shaft is connected into the gear box flange. This propeller shaft is also coupled with universal joint.  In stage-5, the Vehicle Identification Number (VIN) is punched into the frame.  In stage- 6, the silencer tank is fixed into the main frame.  In stage- 7, the air tank and fuel tank is fixed at the rear end.  In stage- 8, the engine is mounted on the frame.

 In stage- 9, the radiator is fixed at the front end of engine.  In stage- 10, the lever, fuel filter and accelerator assembly is linked with the engine.  In stage- 11, the tyres for the wheels are fitted to the wheel drum.

 In stage- 12, the battery box and cross bumpers are fitted.  In stage-13, the diesel is filled into the fuel tank.  Finally, the vehicle is taken to another unit for checking its performance.

SHOP II

In this shop, the components used for engine assembly may be manufactured from this department. The facing and centering of the valves are also done in this shop. The parts that are manufactured from this shop are as follows: • Cylinder head • Camshaft • Connecting rod • Piston • Con rod bolt • Crankcase • Spiral gear • Compound gear

For the preparation of con rod bolt, the workpiece is fitted in the multi spindle lathe and the following processes will be done. • Head forming • Step turning • Chamfering

• Eccentric turning • Facing In the camshaft, the processes like taping, drilling, milling, grinding, tempering, checking hardness are done in this shop II. The gear hobbing is also done with the help of gear hobbing machine, after that the oil hole drilling may proceeds. The journal bearing grindings and the cam grindings are done here. The flywheel housing is tested and fitted at engine case. Finally, the parts are taken to another department for assemble.