User:Palanisamy mechanical

ASHOK LEYLAND ENNORE PLANT INPLANT TRAINING

TRAINEES NAME : L.KARTHI KEYAN C.PALANISAMY R.KRISHNAMOORTHY N.KUMARESAN

COLLEGE	V.S.B.ENGINEERING COLLEGE,KARUR AFFILIATED TO ANNA UNIVERSITY OF TECHNOLOGY COIMBATORE. BRANCH	BE.,MECHANICAL ENGINEERING TRAINING PERIOD	29-11-2011 TO 03-12-2011

DAY 1:          29-nov-2011 (TUESDAY) CHASSIS ASSEMBLY CHASSIS ASSEMBLY is the shop floor (or) assembling floor. In this plant (ennore) there is a single assembly line with eighteen stages. The final assembled structure is made in this chassis assembly. Various components for a lorry (or) truck is brought to chassis assembly in finished stage with approval. The approved, tested parts are assembled by mechanical joints. STAGE :1 FRONT AXLE ASSEMBLY In this stage front axle, leaf spring, track rod is assembled together. STAGE :2 REAR AXLE & CHASSIS FRAME In this stage front &rear axle is attached to chassis frame by bolted joints. The rear axle with double leaf spring is bolted at the back side of the chassis frame and the front axle is bolted at front side of chassis frame. BRAKE CHAMBER HOSE FITTING In this stage the brake chamber hoses are fitted to the chassis frame in their position. The front and rear axle bottom bolts are tightened. STAGE :3 BRAKE CHAMBER From the stage the chassis frame is moved by a conveyor. In the stage the brake chamber is fitted to the chassis frame. STAGE :4 TO 6 STEERING&PROPELLER ASSEMBLY & AIR TANK Propeller shaft is assembled to the rear axle and air chamber, air dryer, air strainer are fitted to the chassis frame. STAGE :7  FUEL FILTER In this stage fuel filter, air tank, compressor pipe, fuel tank bracket, fuel strainer are assembled to the chassis frame STAGE :9 ENGINE MOUNTING In this stage engine is mounted on the chassis frame. Brak lever arm, air cylinders are assembled to the chassis frame. STAGE :10 AIR FUEL PIPING In this stage piping for the air (or) fuel is mount on chassis frame. STAGE :11 PROPELLER SHAFT, TRANSMISSION CONNECTION In this stage the propeller shaft is connected to the transmission system. STAGE :12 RADIATOR ASSEMBLY In this stage radiator, exhaust muffler are assembled to the engine. STAGE :15 TYRE MOUNTING In this stage front and rear tyres are mounted on the rim. STAGE :16 LUBRICATION In this stage fuel tank, steering column, steering wheel are mounted brake pedal, cowl assembly are bolted and attached to the chassis frame. STAGE :17 FRONT END STRUCTURE (FES) In this stage front end structure is mounted on the front axle. STAGE :18 FINAL ASSEMBLY In this stage battery, tyre mounting bracket for stepnie, front bumper are attached. The fuel(diesel) is filled in the fuel tank and the final product is made. In the chassis assembly for every vehicle there is an unique model number, component number and manufacturer’s number. Every parts in the assembly are properly assembled and checking for proper fittings are made. The final assembled structure of a vehicle is checked and approved to pass from the chassis assembly when there is no effects.

DAY :2       30-nov-11 (WEDNESDAY) SHOP-II Shop-II has engine assembly, cylinder head, cam shaft, connecting rod, crank case, flywheel assembly, bearing cap CAM SHAFT : Cam shaft is of theree types EURO 1,EURO 2, EURO 3. The mounting operations far cam shaft are •	Facing and centering •	Straighting •	Rough turning and finish turning •	Straightening •	Keyway milling •	Cam milling •	Gear hobbing •	Through hole •	Front and rear counter boring and tapping •	Oil hole drilling •	Washing and number punching •	Index hardening and tempering •	Hardness testing •	Straightening •	Bearing dia grinding •	Cam grinding •	Crack checking •	Demagneting CYLINDER HEAD : Cylinder head has two faces rocker face and combustion face. The operations performed on cylinder head are •	Rough and finish milling •	Drill and ream holes on combustion face •	Drilling misc holes on rocker face •	Spot facing •	Drill and tap on exhaust manifold •	‘C’ bore on inlet and exhaust ports •	Drilling angular holes •	Radial drilling •	Washing •	Drill and ream injector holes

DAY :3         1-dec-11 (THURSDAY) ENGINE ASSEMBLY 	Fitment of crank shaft : o	Ensure cleanliness of cylinder block, crank shaft and brg shells. o	Ensure oil groove coincedence, with oil hole on cylinder block. o	Screw the dumm plugs on sump face and rear face. o	Fitment of piston cooling nozzles. o	Fitment of dwel pins on front face and rear face of cylinder block. o	Fitment of steel balls and expansion plugs on LH side of cylinder block and on front end. o	Engine number punching. o	Fitment of cam shaft rear plate with ‘O’ ring,idler gear shaft with plate washer. Ensure oil hole direction towards oil pan side,idler gear to the cylinder block. o	Fitment of sub assembly of FIP(fuel injector pump) ,TG case cover assembly,FIP support bracket,oil pipes to fuel pump and compressor. o	Flywheel housing,flywheel sub assembly. Set the ‘O’ mark on flywheel and crank shaft collar,Sub assembly of piston,connecting rod and bearings to the cylinder block. 	Fitment of piston assembly o	Lubricate piston and liner bores. o	Fitment of oil strainer sub assembly,oil mass balancer sub assembly on to engine,oil pan,water pump bolts,Fitment of sub assembly of oil cooler with 4 ‘O’ rings cylinder block. o	Fitment of connector pipe. o	Cleaning of cylinder head assembly, over dowels on block. o	Fitment of push rods. Apply oil to both ends of push rods. o	Angular torque tightening of cylinder head bolts as per sequence. o	Fitment of valve cap with grease,Fitment of rocker assembly. Check free rotation of collars,exhaust manifold. o	Setting of valve clearance. o	Fitment of 2 ‘O’ rings on timing gear case. Ensure cleanliness. And fitting of thermoset and cover, and oil gauge level gauge support bracket. 	Setting of injection timing marks on flywheel and on FIP flange. 	Fitment of vent hoses and routing. Then oil level guide and gauge. 	The inlet manifold is sub assembly and injector sub assembly, turbo charger, oil seperator are mounted. 	Then the injector pipe clamps, over flow pipes,cylinder head cover with rubber gaskets and bolts are mounted. 	Then air compressor,EGR filter with pipings and EGR cooler with pipings and assembled on to the engine.

DAY :4      2-dec-2011(FRIDAY) SHOP-III (FRAME ASSEMBLY) o	Frame assembly consists of 8 stages. The frame for the vehicle is mounted on moving conveyor. The left and right frame is moved and frame assembly parts are fitted and frame assembly parts are fitted to the frame in stage by stage. 	Stage :1 o	In this stage FSM, engine mounting, flitch LH/RH, RSA bracket LH/RH, bumper extension bracket, spring brackets, external and internal flitch, rear spring bracket, FUPD brackets are fitted. 	Stage :2 o	In this stage tie bar member, front x member, center brg x member, rear spring front x member and bracket, rear spring middle x member and bracket, spring brackets(RSF/RSM/RSR)are fitted. 	Stage :3 o	In this stage pintle hook and bumper extension bracket, rear x member are fitted. 	Stage :4 o	In this stage tightening of all x members are done using torque wrench. 	Stage :5 o	In this stage spring brackets are reamed and tightening of spring brackets are done. 	Stage :6 o	Central bracket x members are tightened. 	Stage :7 o	End gussets, front shock absorber and pivot brackets, Elbow adapters and tow brackets are fitted. 	Stage :8 o	In this stage number punching on frame is made.

SHOP-IV (FRONT AXLE & REAR AXLE ASSEMBLY) 	Front axle assembly: o	In this stage, axle arm washing, axle bush pressing, axle arm steering lever fitment, hub washing, D bolt & bearing outer races pressing, oil seal pressing, axle beam washing, fitting of pin & bottom cover, fit track rod and lever, fitting of brake shoes, fitting brake chambers, fitting of end plugs, fit brake drum and hub cap, are done. Then grease is applied to king pin and front axle is painted and stored. 	Rear axle assembly: o	In rear axle assembly, the differential carrier is fitted to the rear axle arm. The differential carrier (or) crown is used to connect propeller shaft to the rear axle. o	Then brake hub is assembly in seperate sub assembly. In some vehicles dummy axle (or) multiple axle is used to carry high amount of load. In the case, dummy axle is fitted to the rear axle. o	Brake os mounted and grease os applied inside the hub and also on bearing surfaces. o	Brake drum is fitted and hub cap is fixed. Then number os punched on rear axle and pointed.