GEETANJALI INSTITUTE OF TECHNICAL STUDIES

(Affiliated to Rajasthan Technical University, Kota, Rajasthan)

A
Industrial Training Seminar
Report on
“Ashok Leyland Sandeep motors pvt. ltd.”
Submitted in Partial Fulfillment of The Requirement
For the Award of Degree of

Bachelor of Technology
In
Mechanical Engineering
Session: 2023 - 24

Project Guide HOD

Ms. Surbhi mishra Dr. Deepak Paliwal
Asst. Professor, ME Dept. Professor, ME Dept.

I.
 ACKNOWLEDGEMENT

As a part of our final year course in engineering I underwent practical training from 19/07/23
to 19/08/23 at Sandeep motors pvt. Ltd. Bhilwara .I extremely greatful to my mentor for
giving me opportunity to undergo the industrial training at their reputed premises

I also pay thanks to my training guide for his guidance , supervision and criticism throught
my training.It is just his guidance because of which I was able to know every aspects of the
equipment used here

Finally it is indeed a great pleasure & privilege to express my thanks to colleagues, my

friends and my family members for their help.

Mihir Menariya
(IV Year, ME.)

II.
CERTIFICATE

III
.
 PREFACE

Industrial training plays a vital role in the progress of future engineers. Not only does it
provide onsognts about the industry concerned it also bridges the gap between theory and
practical knowledge. I was fortunate with an opportunity to undergo industrial training at
Sandeep Motors pvt ltd, Bhilwara . The experience gained during this short period was
fascinating to say. It was tremendous feeling to observe the operation of different equipment
abd process. During my training I realized that in order to be successful mechanical engineer
one needs to possess a sound theoretical base along with the acumen for effective practical
application of the theory.

Thus I hope that this industrial training serve as a stepping stone for me in future and
help me crave a nice for myself In this field

IV
.
 STUDENT DECLARATION
We hereby declare that the industrial training report entitled ashok Leyland Sandeep motors pvt. Ltd. is
the work done by us during the academic year 2023-24 and is submitted in partial fulfillment of the
requirement for the award of fourth year Degree in MECHANICAL ENGINEERING from
RAJASTHAN TECHNICAL UNIVERSITY (KOTA).

Mihir menariya

(20EGIME039
)

V.
 LIST OF FIGURES

1. Ashok Leyland products …………………………………………….fig.1

2. Products …………………………………………………..………….fig.2
3. Truck Engine……………………………….………..……………….fig.3
4. Neptune Engine……………………………...……………………….fig.4
5. Oil Sump…………………………………………….……………….fig.5
6. Oil cooler and filter……………………….………………………….fig.6
7. Fuel Injection system…………………..…………………………….fig.7
8. Scan Tool…………………………………………………………….fig.8

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2
 TABLE OF CONTENTS

Acknowledgement i
Certification ii
Preface iii
Student declaration iv
List of Figure v

 Introduction 3
 Products 4
o Buses 5
o Trucks 5
o Light vehicles 5
o Defence 6
 Truck engine 7
o Introduction 7
o Study of truck engine 8
o Sailent features 9
o Noman clature 10
 Parts of truck engine 11
 Tool 16
o Scan tool 16
 Safety precaution 18
 Conclusion 19
 Reference 20

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Introduction

Ashok Leyland is an Indian multinational automotive manufacturer,

headquartered in Chennai. It is owned by the Hinduja Group. It was founded in
1948 as Ashok Motors and became Ashok Leyland in the year 1955. Ashok
Leyland is the second-largest manufacturer of commercial vehicles in India
(with a market share of 32.1% (FY 2016)), the third-largest manufacturer of
buses in the world, and the tenth-largest manufacturers of trucks.

With the corporate office located in Chennai its manufacturing facilities are
in Ennore , Bhandara, two in Hosur, Alwar and Pantnagar. Ashok Leyland also
has overseas manufacturing units with a bus manufacturing facility in Ras Al
Khaimah (UAE), one at Leeds, United Kingdom and a joint venture with the
Alteams Group for the manufacture of high-press die-casting
extruded Aluminium components for the automotive and telecommunications
sectors.Operating nine plants, Ashok Leyland also makes spare parts and
engines for industrial and marine applications.

Ashok Leyland has a product range from 1T GVW (Gross Vehicle Weight) to
55T GTW (Gross Trailer Weight) in trucks, 9 to 80-seater buses, vehicles for
defence and special applications, and diesel engines for industrial, genset and
marine applications. In 2019, Ashok Leyland claimed to be in the top 10 global
commercial vehicle makers. It sold approximately 140,000 vehicles (M&HCV
and LCV) in FY 2016. With passenger transportation options ranging from 10
seaters to 74 seaters (M&HCV = LCV), Ashok Leyland is a market leader in the
bus segment. In the trucks segment Ashok Leyland primarily concentrates on
the 16 to 25-ton range and has a presence in the 7.5 to 49 ton range.

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Ashok Leyland products

From 18 seated mini buses used by schools and cooperate to 82 seated to double
decker buses from 7.5 ton to 49 ton in haulage vehicles from numerous special
vehicle applications to diesel engines for industrial, marines and genset
applications.

Ashok Leyland offers a wide range of products though timely innovations the
company has created new products and application segments there by
expanding the market from eggs to steel …what dose not moves Ashok Leyland
vehicles.
The bus run on Delhi-lahore route is also made by Ashok Leyland.

Apart from these Ashok Leyland makes the engine which are being used for
generators, marines and industrial application. Ashok Leyland makes AI
engines, lveco engine mostly hino engines are being used.

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Products

Buses:
From 18 seaters to 80 seaters, our buses move 70 million people every day.

Trucks:
We have a comprehensive range of truck for a variety of applications: long-
hauls, distribution, construction or mining.

Light vehicles:
Dost, the first LCV from the Ashok Leyland Nissan jv, rolls out to the market.

6
Defence:
We offer end to end solutions to meet the logistics requirement of the armed
forces with our platforms stallion, Rhino and fox.

7
Truck Engine

Ashok Leyland industrial engine product range extends from the compact 4 to 6
cylinder engines producing 71 hp to 360 hp. These engines offer enhanced
productivity and low cost of ownership.
Tailor made Ashok Leyland industrial engines had been catering to the
powering need of various industrial applications like construction, air
compressor, road construction, concrete pumps, lift and shift etc.
Across India and globally for past many years. Ashok Leyland industrial
engine are compact, having low running cost, continuous duty Power rating and
highly rugged and reliable engines

8
Introduction to Neptune Engine

The future-ready 'Neptune' engine will be available in BS-III and BS-IV

versions and is also pakage protected for BS-V and BS-VI. The highly
modular sub-system design ensures
maximum vehicle uptime and better N VH characteristics while the CRS with
electronic-governance ensures high fuel efficiency, easy serviceability, lower
life cycle cost and reliability.

NEPTUNE engines will range from 160 HP to 380 HP and will be deployed
across a range offtrucks and buses in a phased manner.
15

9
Salient Features of This Engine are:

 It is an inline, four cylinders, water cooled, 4-stroke Diesel Engine with

direct fuel injection into a hemispherical combustion chamber arranged
in the piston crown.
 The engine employs the Micro Mixing Combustion System (MMCS)
which features aspecially shaped combustion chamber in the piston
crown.
 Another characteristic is the special shape and arrangement of the intake
ducts in the cylinder head which allows the air to enter only from one
direction.Upon entering, the air is given a swirling motion causing the
fuel to mix, which is injected through a multi hole nozzle into the
combustion chamber.
 Combustion is initiated at the end of compression stroke. The shape of
the combust ionchamber allows full use of the energy contained in the
fuel, because the cooling surface sare comparatively small in relation to
the volume of the combustion chamber whilst the air swirls ensures that
air and fuel are mixed uniformly.

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Nomenclature

 Cylinder bore: the inner diameter of the cylinder is called the cylinder
bore. For Hseries engine its value is 104mm.
 Stroke: the distance between the two dead centers is called stroke. For H-
series engine it is 113mm.
 Dead centre: The position of the piston and the moving parts which are
mechanically connected to it, at the moment when the direction of piston
movement is reversed during either end of the stroke is called dead
center. There are two dead centers in an engine:

l. Top dead center (TDC)

2. Bottom dead center (BDC)

 Crank end float: It is the axial gap provided in the crankshaft for free
rotation of the shaft between its two ends. It ranges between
 Breakaway torque: It is the minimum torque required to set the stationary
shaft into
 motion.
 Runaway torque: It is the average running torque at given RPM.
 Idler gear backlash: It is the gap between the meshing teeth of idler gear
and other timing gears. It ranges between O, 138—0.265mm.
 Idler gear endplay: It is the distance by which the idler gear can slide over
the idler gear shaft. It ranges between 0.04--0.095 mm.
 Compression ratio : it is the ratio of the total cylinder volume to the
clearance volume. Compression ratio for H-series engine is 17.7: I.
 Displacement volume: The nominal volume swept by the piston when
travelling from one dead center to another. Displacement of H-series
engine is 5.759 liters.
 Injection timing: The fuel is injected a few degrees before TDC for better
performance of engine. For H-series engine this angle is about 10
degrees.
 Tappet clearance: A very small space is given between the rocker arm
and valve cap for smooth and timely opening of valves. For H-series
engine this clearance is 0.30mm for in take valve and 0.45 mm for
exhaust valve.

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 Firing order: It is the order in which power stroke is observed in various
cylinders of a multi cylinder engine. Firing order in H-series engine is I -4-2-
6-3-5.Components of an H-series engine:
 Oil pump—An H series engine employs a force feed gear type lubrication
pump. Oil is drawn from the sump through the strainer by the gear type
oil pump. The pump is driven by timing gears.

 Oil Sump-The bottom of crankcase contains an oil sump on which the

lubricating oil is pumped to various engine components. After lubricating
these parts, the oil flows back to the sump by gravity.

Fig. Oil pump

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 Oil filter and cooler —A full flow type paper filter is provided to keep the
dust particles away from lubrication system and plate type cooler is used

to cool the oil.

Fig. Oil cooler and filter

 Fuel injection pump -Three different types of fuel injection pump (FIP)
are employed in various models of H-series engine, viz. l. Inline 2.
Distributor type 3.Common rail type
 Air compressor— reciprocating type air compressor, meshed with the
idler gear is incorporated in the engine.
 Water pump - The engine is water cooled, and forced circulated by a
volute type water pump. It is driven by the poly v belt.
 Alternator -24V - 55 Amps alternator is used which is driven by poly v
belt.
 Starter motor - 24V, Axial type, pre-engaged

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 Turbocharger- It is driven by the exhaust gases which are normally
wasted.
 Thermostat- Wax type thermostat with bottom bypass system is used.
 Flywheel housing- It is the casting that encloses the flywheel. It is
attached to the cylinder block by eight M12 and six M8 bolts
 TG Case - It is casing that forms the outer cover of timing gears.

 Timing gears — It consists of following five gears: l. Crankshaft Gear 2.

Idler Gear 3. Injection Pump Drive Gear 4. Oil Pump Drive Gear 5.
Camshaft Gear The gear train is to be matched as per matching punch
marks on gear circumference.

» Miscellaneous
» Screw plugs
» Steel balls
» Gaskets
» Timing back plate
» sealant
» bolts
» studs
» bearings
» Spacer
» rings
» dowel pins
» washers

14
» crankshaft collar
» banjo strainer
» oil sealant
» valve cap
» poly v belt
» link bolt
» oil seal
» Vent hose

15
Various systems of N-series engine

Fuel Injection system

The fuel injection system is the most vital component in the working of CI
engines. The engine performance viz. power output, economy etc. is greatly
dependent on the effectiveness of the
fuel injection system. In a fuel injection system the amount of fuel delivered
into the air stream going into the engine is controlled by a pump which forces
the fuel under pressure.

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 Components of Fuel Injection System
The main components of a fuel injection system in an N-series engine are:

 Fuel Tank
 Fuel Filter
 Feed pump
 Fuel Injection Pump
 High pressure pipes
 Injector nozzles
 Fuel return line

Feed Pump: The feed pump is of spring loaded plunger type, the plunger is
actuated through a push rod from the camshaft. At minimum lift position of
cam, the spring force on the plunger creates a suction which causes fuel flow
from the main tank into the pump. When the cam is turned to its maximum lift
position the plunger is lifted upwards. At the same time the inlet valve is closed
and fuel is forced through the outlet valve.

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 Scan Tool

An automotive scan tool (scanner) is an electronic tool used to interface with,

diagnose and, sometimes, reprogram vehicle control modules.
There are many types from just as many manufacturers, one of the most familiar
being the Snap-On Inc. "brick", or MT2500/MTG2500. Snap-On, Hella
Gutmann Solutions, OTC/SPX, Xtool india, Autel, Launch, Vetronix/Bosch and
a number of other companies produce various types of scan tools, from simple
code readers to highly capable bi-directional computers with programming
capabilities. The scan tool is connected to the vehicle's data link
connector (DLC) and, depending on the particular tool, may only read out
diagnostic trouble codes or DTC's (this would be considered a "code reader") or
may have more capabilities.
Actual scan tools will display live data stream (inputs and outputs), have bi-
directional controls (the ability to make the controllers do things outside of
normal operations) and may even be able to calibrate/program modules within
certain parameters.

However, a typical scan tool does not have the ability to fully reprogram
modules because it requires a J-2534 pass-through device and specific software.

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Voltas IT created a new generation diagnostic tool – OBDeleven, the device
which easily connects to the car, monitors all systems, and activates new car's
features. It suppors Audi, Volkswagen, SEAT, Škoda, Lamborghini,
and Bentley.

OBD 1 vs OBD 2 the vehicle will also dictate what the scan tool is able to
display. If the vehicle is equipped with OBD 1 it will have significantly less
available data when compared to a vehicle equipped with OBD 2.

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Safety precautions
 Never trust a jack. Rather buy some sturdy stands and use them whenever
you need to crawl underneath the car.
 Remove the earth strap (almost always the negative pole) at the battery,
to avoid accidentally activating the starter, starting a fire, or heating up
your jewelry or watch, if you accidentally touch an open wire.
 Make sure that all electrical components are switched off when you
remove the strap, otherwise a spark may occur, which could cause the
battery to explode.
 Never leave tools on the battery, where they might short the terminals and
create a spark.
 Keep loose clothing and long hair away from moving parts.
 Wear eye protection when your eyes are at risk, such as when you grind,
or drill upside down.
 Don't overfill the sump, or any other reservoir, because it may cause
damage to the seals, or an even more serious malfunction.
 Don't remove the radiator cap from a hot cooling system. If you really
have to open up, use a cloth over the cap, and stand to one side, releasing
it slowly.
 Don't add cold water to a hot engine, because the subsequent distortion
may cause damage. If you have no choice, pour the water in slowly while
the engine is running.
 Don't allow small children or animals near the car while working on it.
 Keep a fire extinguisher near your working space.
 Don't try to extinguish a fuel or electrical fire with water; rather use sand.
 Take care when carrying a battery, or working with one, because spilt
acid will eat holes in your clothes and irritate your skin.
 Don't run the engine for long in an enclosed space.

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 CONCLUSION

Industrial training is significantly beneficial to all concerned parties in

contributing towards the development of the nation.
Being a student, one can acquire Industrial experiences and at the same time
familiarize themselves with the real working environment at the Industrial
training site. This opportunity also enables them to further expand their
creativity while seizing the profession ethical values as basis to venture into
professional career in the future. Therefore, students must develop themselves
to become a valuable asset to the esteemed organization or industry.

In the meantime, the industry or organization shall be able to recognize, assess

and guide their potential future employees. For some organizations, the students
undertaking the Industrial training have in fact overcome the scarcity of
professional workforce within the organization. On top of that, the
industry/organization may also indirectly acquire professional consultation from
the Faculty Supervisor during their visits to the organization.
On the other hand, the Faculty Supervisors, apart from guiding, supervising and
assessing the students, may also obtain enormous information on the current
developments in the industry/organization, which will enrich themselves as
academic staffs.

By realising the advantages and the limitless amount of benefits that can be
accomplished by all parties through this Industrial training, the excellent
collaboration between the University and the industry must be greatly
considered. The students and the Faculty Supervisors as the unification chain
between the University and the organization must play their considerable parts
so that the Industrial training will turn out as the most awaited activity by all
parties in order to achieve common aims and aspirations.

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 REFERENCE

Ashok Leyland Sandeep motors pvt. Ltd.

Mandal chauraha,Bhilwara,Rajasthan

https://www.wikipedia.com.org
https://www.google.co.in
https://in.yahoo.com

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