Ashokleyland Isan: Indian Automobile Chennai

INTRODUCTION
AshokLeyland isan Indian automobile manufacturing

company based in Chennai, India. Founded in 1948, it is the 2nd
largest commercial vehicle manufacturers in India, 4th largest
manufacturer of buses in the world and 16th largest manufacturer
of trucks globally. Operating six plants, Ashok Leyland also
makes spare parts and engines for industrial and marine
applications. It sells about 60,000 vehicles and about 7,000
engines annually. It is the second largest commercial vehicle
company in India in the medium and heavy commercial vehicle
(M&HCV) segment with a market share of 28% (200708). With
passenger transportation options ranging from 19 seaters to 80
seaters, Ashok Leyland is a market leader in the bus segment.
The company claims to carry over 60 million passengers a day,
more people than the entire Indian rail network. In the trucks
segment Ashok Leyland primarily concentrates on the 16 ton to
25 ton range of trucks. However Ashok Leyland has presence in
the entire truck range starting from 7.5 tons to 49 tons. With a
joint venture with Nissan Motors of Japan the company made its
presence in the Light Commercial Vehicle (LCV) segment (<7.5
tons).
Hinduja Group
In 2007, the Hinduja Group also bought out
IVECO's indirect stake in Ashok Leyland. The promoter
shareholding now stands at 51%. Today the company is the
flagship of the Hinduja Group, a British-based and Indian
originated trans-national conglomerate after Hindujas bought
Ivecos remaining ownership stakes.
CHASIS ASSEMBLY:
In stage 1 and 2 already assembled frond and
rear axles from the machine shop-4 is fixed on the main frame that
fabricated from the machine shop-3 of the vehicle. In stage-3 the fixed
frame assembly is placed on the conveyor belt, where brake chamber is
fitted to it. In stage-4 steering gear box is fitted to the main frame. In
stage-5 silencer tank is fitted tot he main frame. In stage-6 fuel tank is
fixed to the stage of the chasis assembly. In stage-7engine is mounted on
the frame of chasis vehicle. In stage-8 Radiator is fixed at the front
of engine. In stage-9 tyres for all the wheels is fitted to the drums of the
axels. In stage-10 the vehicle is toed then and taken to the another unit to
make it running condition and test is driven out
ENGINE ASSEMBLY:
In Stage-1 crank case swr/plate/EII no is brought to
the engine assembly, here cam bearings are fixed to the crank case of the
engine. In stage-2 cam shaft types EO/EI/No are fixed in the appropriate
places in the crank case. In stage-3 crank shaft make BM/GB is fixed at
the base of the crank case like passing through the hole. In stage-4 m-14
studs are fixed to the holes of the crank case. In stage-5 1stand 6 the
piston is kept at the top dead centre and timing gears are fixed to the side
of the engine of the firing order.
In stage-6crank gears are fixed to the crank case to
operate the cam shafts in order to operate the valves. In stage-7 fly
wheel housing is fitted to the house of the engine. In stage-8 the
flywheel is fitted to the housing and 90 torques is applied to it. The fly
wheel housing consistsof the seal housing, flange and fly wheel. In
stage-9 Oil pump is fixed to the top of the crankcase to circulate oil to
the various parts of the enigne. In stage-10 the readily made piston
isfitted to the bore of the crankcase and connected to the crankshaft.
Before that, Pistonrings are of three types two compression rings and oil
ring is fixed on the piston.
In stage-11the conrod bolt is fixed to connect the
piston with the crank shaft. In stage-12 Idiling gear is fixed on the
spindles which controls the rotations of the cam gear, cam gear and
compression gear
In stage-13 cylinder head is fixed at the top of the
crank case to which rocker arm with valves are fixed. In stage-14 oil
pump is fixed at the bottom of the crank case with the adhesive(RTV)
paste. In stage-15 rocker assembly is fixed at the cylinder head. In stage16air compressor is fixed on the crank case. In stage-17 fuel injection
pump is fixed. In stage-18 valve cover is fixed. In stage-19 oil cover is
fixed. In stage-20 Injector pipe and inlet manifol is fitted. In stage -21
side cover is fixed. In stage-22 oil pump is fixed.
In stage-23starter motor is fixed. In stage-24 Exhaust
manifold is fixed. In stage-25 turbo charger is fixed. In stage-26 EII
fitments are fixed. In stage-27 fully assembled is taken to the testing area
where the testings are taken for the proper function of the engine
CHASIS ASSEMBLY:
The chasis of the vehicle is starts from here at this shop-3. The frames of
the wheels are fixed together to be sent on the chasis assembly. The
skids are mounted on the conveyor belt and frame is placed on the skids.
And frame MTG on which is mounted is fixed across the two frames.
On the rear end of the frame BKTS both sides are aligned with taper pin.
Fit and tight FSR and BKTS on the both sides with dummy bolts. Tilt
both the fsms to 90 degree by turning tackle and insert damps. Tight and
apply torque to the engineMTG Flinches and M12 with bolts.
correspondingly in every stage each workers tight appropriate bolt to the
frame before taken to the chasis assembly to make it a complete frame.
FRONT AND REAL AXIL ASSEMBLY

The Main shop-4 is Mainly divided into the two
departments. They are front axle assembly and rear axle assembly. Front
Axle Assembly: In stage-1 Axle beam is loaded at the conveyor belt. In
stage-2 Number is punched on the axle beam. In stage-3 Axle arm is
fixed to the beam of steering. In stage-4 Steering rods fitted. It is right
end of the axle according to the Indian Standard STDs. In stage5Tracking rod is fitted. It is used for the alignment of the wheel. It helps
left side of the tyre to turn along with the right side wheel. In stage-6
Brake careers with brake linings are fitted to the fr axle beam and taken
to the chasis assembly. Rear Axle Assembly:
In stage-1 Banjo casing from outside is unloaded and
fixed at the conveyor and axle shaft is removed. In stage-2 brake lining
and 10 bolt and washer are fixed on the brake carrer with the spring
washer. In stage-3 Brake nut and bolt are tighten and fitted 50 to
75torques. In stage-4 Ring for oil seal is fitted on the hub shim is fitted
to 3 to 6 tau for the clearance flange cover is fitted with the four bolts. In
stage-5 Inner oil seal is fitted on the ring for inner oil seal.
Then inner wheel bearing is also fitted. In stage-6
Distance Piece is fixed to align the inner and outer wheel bearing in the
same axis. In stage-7 Dry set, where the wheel hub is fixed roughly to
verify whether increase or decrease the shim.
FABRICATION OF VALVE:
In stage-1 Facing and the centering (length) of the
valves are done here. In stage-2Sraightening (Bend removing) is done.
In the stage-3 Rough turning and finish turning are done. In stage-4
again the straightening is done here. In stage-5 Keyway milling(Gear
Fixing, Oil pumping) are done here. In stage-6 am milling(valve inlet,
valve outlet) are done. In stage-7 Gear hobbling is done through gear
hobbling machine. In stage-8 Gun drilling is done(through hole). In
stage-9 counter boring and tapping(nuts, front and rear).In stage-10 oil
hole drilling. In stage-11 Washing and number punching is done. In
stage-12Index hardening and tempering and hardening are done. In

stage-13 Harden testing(moderate hardening) are tested here. In stage-14
once again the straightening are done here. In stage-15 Bearing(journal)
dia grindings are done. In stage-16 cam grindings are done. In stage-17
C
D-crack checkings are done. In stage-18 Inspection of valves are done at
the final.The flywheel housing is tested and fitted at the engine case.

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Ashokleyland Isan: Indian Automobile Chennai

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INTRODUCTION

AshokLeyland isan Indian automobile manufacturing

FRONT AND REAL AXIL ASSEMBLY

stage-12Index hardening and tempering and hardening are done. In

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