A
PRACTICAL TRAINING
REPORT ON
“ASHOK LEYLAND TRAINING CENTRE”
PINDWARA, SIROHI (RAJ.)
Submi ed in Par al Fulfilment for the Award
of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
2023-24
Submi ed by:
Submi ed to:
BHAGWAT SINGH SOLANKI
(Roll No.: -2607)
III YR Mechanical
Dr. M.S. KHIDIYA (Associate Professor)
Training & Placement Incharge
DME
DEPARTMENT OF MECHANICAL ENGINEERING
COLLEGE OF TECHNOLOGY AND ENGINEERING
UDAIPUR, RAJASTHAN
CERTIFICATE
ACKNOWLEDGEMENT:
I wish to record my sincere thanks to the RAJESH MOTORS (AUTO) PVT.LTD for
giving permission to undergo training for thirty days (30 days) in the
organiza on. I was given a proper knowledge about the Leyland trucks(mainly)
at the site was kept me on the site for observing each ac vity accomplish over
there.
I take opportunity to thank Mr. Gajendra Singh Chouhan (Works manager) for
se ng a mission with a complete vision.
I have pleased to thank lab technicians, supervisor and workers for the
organiza on for their whole-hearted help as well as coordina on as I have
gained the knowledge about the work culture.
CONTENTS
1. VISION AND MISSION........................................................................... 5
2. HISTORY ............................................................................................... 5
3. PARTNERSHIP ....................................................................................... 6
4. TYPES OF VEHICLE PRODUCED BY ASHOK LEYLAND .............................. 8
5. TECHNOLOGY ..................................................................................... 13
6. TYPES OF SERVICE PROVIDED BY ASHOK LEYLANDError! Bookmark not
defined.
7. SERVICE CENTER ................................................................................. 17
8. REGULAR MAINTAINCE....................................................................... 18
9. RE-PAINTING ...................................................................................... 23
10. WARRENTY CLAIM OF A VEHICLE...................................................... 24
11. SERVICING OF REPAIR VEHICLE ......................................................... 25
12. 3116 ................................................................................................. 25
13. CONCLUSION .................................................................................... 27
1. VISION AND MISSION
1.1 VISION
●
Leadership in Medium and Heavy Segment
●
Significance Presence in Market World
●
Customer Sa sfac on
1.2 MISSION
●
Large Produc on
●
Moderniza on
●
Global Benchmarking our Product, Process & People
●
Good Rela onship Management
2. HISTORY
Ashok Leyland is an Indian automobile company headquartered in Chennai,
India. It is owned by the Hinduja Group. Founded in 1948, it is the second largest
commercial vehicle manufacturer in India, fourth largest manufacturer of buses
in the world and 10th largest manufacturer of trucks globally. Opera ng nine
plants, Ashok Leyland also makes spare parts and engines for industrial and
marine applica ons. It sold approximately 140,000 vehicles (M&HCV + LCV) in
FY 2016. 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 32.1% (FY 2016). With passenger transporta on op ons 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. However, Ashok Leyland has a presence in the en re truck
range, from 7.5 to 49 tons.
2.1 Ashok Motors
Ashok Motors was founded in 1948 by Raghunandan Saran. He was an Indian
freedom fighter from Punjab. A er Independence, he was persuaded by India's
first Prime Minister Nehru to invest in a modern industrial venture. Ashok
Motors was incorporated in 1948 as a company to assemble and manufacture
Aus n cars from England, and the company was named a er the founder's only
son, Ashok Saran. The company had its headquarters in Rajaji Saalai, Chennai
(then Madras) with the plant in Ennore, a small fishing hamlet in the North of
Chennai. The company was engaged in the assembly and distribu on of Aus n
A40 passenger cars in India.
Under Leyland
Raghunandan Saran had previously nego ated with Leyland Motors of England
for assembly of commercial vehicles as he envisioned commercial vehicle were
more in need at that me than were passenger cars. The company later under
Madras State Government and other shareholders finalized for an investment
and technology partner, and thus Leyland Motors joined in 1954 with equity
par cipa on, changing the name of the company to Ashok Leyland. Ashok
Leyland then started manufacturing commercial vehicles. Under Leyland's
management with Bri sh expatriate and Indian execu ves the company grew in
strength to become one of India's foremost commercial vehicle manufacturers.
The collabora on ended some me in 1975 but the holding of Bri sh Leyland,
now a major Bri sh Auto Conglomerate as a result of several mergers, agreed to
assist in technology, which con nued un l the 1980s. A er 1975, changes in
management structures saw the company launch various vehicles in the Indian
market, with many of these models con nuing to this day with numerous
upgrades over the years.
3. PARTNERSHIP
In 1987, the overseas holding by Land Rover Leyland Interna onal Holdings
Limited (LRLIH) was taken over by a joint venture between the Hinduja Group,
the Non-Resident Indian transna onal group and Iveco, part of the Fiat Group.
3.1 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 Bri sh-based and Indian originated transna onal conglomerate.
3.2 Hino Motors
During the early 1980s Ashok Leyland entered into a collabora on with Japanese
company Hino Motors from whom technology for the H-series engines was
sourced. Many indigenous versions of the H-series engine were developed with
4 and 6 cylinders, and also conforming to BS2, BS3 & BS4 emission standards in
India. These engines proved to be extremely popular with the customers
primarily for their excellent fuel efficiency. Most current models of Ashok
Leyland come with H-series engines. Japan entered into a Mutual Coopera on
Agreement (MCA) on 27 November 2017 renewing their coopera ve agreement
that had started in 1986. According to the agreement Ashok Leyland will use
Hino's engine technology for its Euro 6 development and will support in the
development of Hino's engine parts purchasing in India for global opera on.
3.3 Rosoboronexport & ELCOM
Ashok Leyland Defence Systems (ALDS), Russia's Rosoboronexport and ELCOM
Group have signed a coopera on agreement in defence business to provide
tracked vehicles to Indian Armed Forces. The agreement was signed on the side
lines of the Interna onal Military Technical Forum Army – 2017 held at Kubinka,
near Moscow, on 25 August 2017.
3.4 IIT Madras
Ashok Leyland and Indian Ins tute of Technology Madras (IIT Madras) signed a
memorandum of understanding, on 19 August 2017, for Ashok Leyland to
sponsor the Centre of Ba ery Engineering (CoBE) at IIT Madras. As part of the
agreement Ashok Leyland has partnered with IIT Madras to carry out research
and development (R&D) ac vi es for strengthening ba ery engineering and
related sub-parts, especially for electric vehicles.
3.5 Sun Mobility
On 18 July 2017 Ashok Leyland announced the forma on of an alliance with SUN
Mobility, the global partnership aims to develop electric vehicles.
3.6 Iveco partnership
In the late 1980s Iveco investment and partnership resulted in Ashok Leyland
launching the 'Cargo' range of trucks based on European Ford Cargo trucks. The
Cargo entered produc on in 1994, at Ashok Leyland's new plant in Hosur,
southeast of Bengaluru. These vehicles used Iveco engines and for the first me
had factory fi ed cabs. Though the Cargo trucks are no longer in produc on and
the use of Iveco engine was discon nued, the cab con nues to be used on the
Eco met range of trucks as well as for several of Ashok Leyland's military vehicles.
The Cargo was originally introduced in 7 and 9 long tons (7,100 and 9,100 kg)
versions; later, heavier-duty models from 15 to 26 long tons (15,200 to 26,400
kg) were progressively introduced.
4. TYPES OF VEHICLES PRODUCED BY ASHOK LEYLAND
a) Heavy commercial vehicle
● Haulage trucks
● Low floor Buses and heavy commercial bus
● Tractor-trailer/semi-trailer
● Tipper
b) Light commercial vehicle
● Delivery vans
● Mini trucks
● Ambulance
● Staff or school vans
c) MPV
 STILE
d) DEFENSE VEHICLE
● GSUPER STALLION 10x10
● GURU 4x4 – 715
● PPC 4X4
4.1 Buses
Current range
•
MTC
•
12M
•
12M FESLF
•
Viking
•
Cheetah
•
Eagle
•
Electric Bus
•
Freedom
•
Hawk
•
Hybus
•
JanBus
•
Lynx
•
Mitr
Ashok Leyland MiTR (or MiTR) is a Minibus manufactured by Ashok Leyland in
Joint venture with Nissan. The vehicle was unveiled in January 2014 during the
12th Auto Expo 2014 and was launched in July 2014.
•
Oyster
•
12M RE
•
RESLF
•
REULE
•
Sunshine
•
Titan
In 1968, produc on of the Leyland Titan ceased in Britain, but was restarted by
Ashok Leyland in India. The Titan PD3 chassis was modified, and a five-speed
heavy duty constant-mesh gearbox was used together with the Ashok Leyland
version of the O.680 engine. The Ashok Leyland Titan was very successful and
con nued in produc on for many years.
4.2 Former range
•
Comet
Early products included the Leyland Comet bus which was a passenger body built
on a truck chassis sold in large numbers to many operators in India. By 1963, the
Comet was operated by every state transport undertaking in India, and over
8,000 were in service. It was soon joined in produc on by a version of the
Leyland Tiger.
•
Panther
•
Falcon
4.3 TRUCKS
4.4.1 Haulage truck
Haulage truck is the most common form of materials transport in open pit
mines. The trend has been towards larger and larger open pit trucks to match
larger shovels and excavators.
It is used to carry a payload of more than 6ton to 40 ton
It is used in transport of Market load, construc on and parcel.
4.4.2 TRACTOR-TRAILER
A large propor on of a semi-trailer's weight is supported by a tractor unit, or a
detachable front-axle assembly known as a dolly, or the tail of another trailer. A
semi-trailer is normally equipped with landing gear (legs which can be lowered)
to support it when it is uncoupled. It is a combina on of tractor and a trailer
connected by fi h wheel coupling It is used for transpor ng heavy duty
construc on machinery. The tractor usually has tandem axles at the rear, which
provide a fuel saving of 4% It also protects the tyre from the wear
4.4.3 TIPPER
● The pper is used for transpor ng dumps such as gravel, sand or
demoli on waste, which is to be deposited on ground
● A typical pper is equipped with an open-box bed, which is hinged at the
rear
● It contains hydraulic rams to li the open box at front through which the
dumps can be deposited behind the truck
4.5 Trucks
Current range
•
1618
•
2518
•
3118T 8x4
•
Captain 5525 (High demand in market)
•
•
Ecomet
•
U-Truck
Ashok Leyland announced the sale of vehicles on the new U-Truck pla orm in
November 2010 with the rolling out of the first set of 10 models of ppers and
tractor trailers in the 16 to 49-tonne segment. Another 15 models were set to
enter the market in the following 12 months.
•
Boss
Boss is an intermediate commercial vehicle launched by Ashok Leyland. It is
available in the range of 8T to 14T. It is available with two engine op ons 120 IL
(LE) and 130 CRS (LX) engines, and this is the first me such an engine has been
offered in this range of trucks. The LX variant is available with air condi oning
and Leyma c AMT, which are again industry firsts.
Former range
•
Beaver
•
Rhino
4.6 Light Vehicles
Current range
•
Dost
The Dost is a 1.25-ton light commercial vehicle (LCV) that is the first product to
be launched by the Indian-Japanese commercial vehicle joint venture Ashok
Leyland Nissan Vehicles. Dost is powered by a 58 hp high-torque, 3-cylinder,
turbo-charged common rail diesel engine and has a payload capacity of 1.25
tonnes. It is available in both BS3 and BS4 versions. The bodywork and some of
the underpinnings relate to Nissan's C22 Vane e of the 1980s; this is most visible
in the door design. The LCV is produced in Ashok Leyland's Hosur plant in Tamil
Nadu. The LCV is available in three versions. With the launch of Dost Ashok
Leyland has now entered the Light Commercial Vehicle segment in India
•
Guru
•
Partner
4.7 Ashok Leyland Defence Systems
Vehicle Factory Jabalpur (VFJ)'s Stallion 4X4 Truck for the Indian Army An Indian
road-mobile launcher with a ballis c missile Ashok Leyland's Stallion Kavach 4X4
Mine Protec on Armoured Vehicle Ashok Leyland Defence Systems (ALDS) is a
newly floated
5. Technology
Ashok Leyland railbus manufactured by Sri Lanka Railway engineers
It was the first in India to introduce mul -axled trucks, full air brakes and
innova ons like the rear engine and ar culated buses. In 1997, the company
launched the country's first CNG bus, and in 2002 developed the first hybrid
electric vehicle.
A Rural Mobile health clinic built on Ashok Leyland's e-comet truck Ashok
Leyland was already producing low-emission vehicles. Back in the 1980s and
1990s, Ashok Leyland with various Tamil Nadu Transport Corpora on, notably
Cholan Roadways Corpora on based in Tiruchirappalli, experimented with low
pollutant emission based on the CNG technology. In 2002 it developed the first
hybrid electric vehicle. Ashok Leyland has also launched a mobile emission clinic
that operates on highways and at entry points to New Delhi. The clinic checks
vehicles for emission levels, recommends remedies and offers ps on
maintenance and care.Hythane engines
Ashok Leyland has also developed hythane engines in associa on with the
Australian company Eden Energy. Ashok Leyland successfully developed a
6cylinder, 6-litre (370 cu in) 92 kW (123 hp) BS-4 engine which uses hythane
(HCNG,) which is a blend of natural gas and around 20% of hydrogen. Hydrogen
helps improve the efficiency of the engine but the CNG aspect makes sure that
emissions are at a controlled level. A 4-cylinder 4-litre (240 cu in) 63 kW (84 hp)
engine is also being developed for H-CNG blend in a joint R&D program with
MNRE (Ministry of New and Renewable Energy) and Indian Oil Corpora on.
5.1 Euro 6 Truck
AT the Delhi Auto Expo 2016, the company showcased its first indigenously
produced Euro 6 truck 4940. The truck is powered by the company's flagship
range of engine, Neptune, which is an 8l engine that produces 400 hp and
1600Nm of torque. The truck is designed to meet Euro 6 norms.[37]
5.2 IEGR
In 2017, the company showcased IEGR (intelligent exhaust gas recircula on)
technology for its trucks and buses to meet BS-IV emission standards. The
technology also promises other advantages like be er fuel efficiency than BS-III
trucks, and power transmission up to 400 HP.
6. SALES AT RAJESH MOTORS
Rajesh motors Auto Pvt Ltd are not par cularly in sales segment but
they have their good contact in trucks field in Sirohi belt and they have
regular customer NTC(na onal transport company) so they just take
orders for limited firms
Image of delivering of vehicle (captain 5525) to firm ‘person
7. TYPES OF SERVICE PROVIDED BY ASHOK LEYLAND
●
QUICK SERVICE
●
ONSITE SERVICE
●
SERVICE STATION
7.1 QUICK SERVICE
It is an innova ve service offering that customises doorstep service and ensures
faster up me, par cularly at project/remote sites. It offers best-in-class servicing
infrastructure in a mobile unit. The Quick Service vehicle is equipped with
worksta ons, tools, lubricants and spare parts to handle any possible service
requirement and mobile wheel alignment equipment. Each unit is manned by
two or three trained mechanics.
7.1.1 Periodic Maintenance Services:
With a sharp focus on vehicle upkeep for uninterrupted running, Ashok
Leyland’s pre-emp ve maintenance is an integral part of Quick Service.
7.1.2 Break Down Assistance:
It leverages the best of Ashok Leyland’s technology and its vast network to track,
trace and rush to assistance to increase up me.
7.2 ONSITE SERVICE
It is a 20-foot or 40-foot workshop in a container, fully equipped to
provide service to medium and heavy commercial vehicles. Each workshop
comes with the service capacity of one bay and two trained mechanics. Engine
scanning can be set up with minimal support infrastructure and at very short
lead me.
It ensures uninterrupted up me, be er profits and more economy for
customers, through some key features.
7.2.1 Perfect at Project Sites:
Onsite Service can act as a hub for maintenance in loca ons where vehicles are
deployed for a fixed period. These are ideal for project sites locked in for a
specific period, but with significant servicing requirements.
7.2.2 Deep Access:
It is an invaluable ini a ve in remote sites/hill sites, where available space is a
constraint.
SLR SERVICE CENTER
8. SERVICE CENTER
●
Outstanding service marke ng abili es.
●
Capability to invest Rs.25-30 Lakhs on service infrastructure
conforming to Ashok Leyland Standards.
●
Site area of 12000 sq
for a 4 bay facility.
●
Strong commitment to building long term rela onships with
customers.
●
Ambi on to grow the service business.
SLR BAY
8. REGULAR MAINTAINCE
● coolant top-up
● air & oil filter replacement
● engine oil service
● diesel filer replacement
● differen al oil service
● hub greasing
● adjus ng drive belts, ming belts, hoses and brake pads
● monitoring res
● monitoring suspension systems
● inspec on of headlight, tail light, indicators and reverse light
● For a smooth maintenance service must be done every 8000km.
● service is done based on kilometers and hours
Gear box trolly
8.1 BASED ON KILOMETERS
The vehicles that are used for carrying load are serviced based
On kilometers.
Examples:
Trailers and Tarus
8.2 BASED ON HOURS
The vehicles that are used for sta onary opera on are serviced
Based on hours
Examples: Bore vehicles, ppers
Trucks are rugged and reliable machines designed to operate in tough
condi ons.
That doesn’t mean, however, that they don’t’ need maintenance. Regular
maintenance of your truck fleet is cri cally important to ensure good
performance, safe opera on and longevity of your fleet. Scheduled servicing can
detect and rec fy minor problems before they become bigger issues that affect
produc vity. It is self-evident that merely replacing a few light bulbs from me
to me will not prolong a truck’s life.
8.3 COOLANT OIL TOPUP
Coolant oil top up is necessary because it reduce the heat of an engine, top it
up using a 50/50 mixture of water and an freeze (for normal driving
condi ons), or pour pre-mixed an freeze straight into the reservoir. You can
use clean tap water in an emergency, but an freeze should be added as soon
as possible.
8.4 Replacing lubricants (engine & differen al oil)
Oil is used for lubrica on of internal combus on engines. The main func on of
motor oil is to reduce fric on and wear on moving parts and to clean the engine
from sludge (one of the func ons of dispersants) and varnish (detergents).
Lubrica ng the crown assembly
8.5 Inspec ng the brakes
Checking to see if the brakes are working properly is a crucial part of basic truck
maintenance and definitely something you should do at the start of every
working day. In addi on to daily checks, it is vital to regularly have a good
mechanic subject your brake shoes, air dryers and air valves to a check-up to
determine if all parts are in working order.
8.6 Replacing all filters
A truck cannot operate at full capacity with a dirty transmission filter, oil filter,
fuel filter, air filter or exhaust filter. Also remember to check if the cabin air filter
needs replacing.
8.7 Checking of clutch oil
Check the clarity of the oil. If the oil looks like it contains debris or looks cloudy,
it definitely needs to be changed.
8.8 Check the electrical system
Are all fuses s ll in working order? Any light bulbs that need replacing?
8.9 Check all rubber parts
Rubber wears out and becomes hard and bri le with
replacement of all hoses and res is crucial.
me, so
mely
8.9.1 Check all gaskets
Gaskets should be replaced immediately if worn or leaking, or whenever
removed during servicing. Replacing gaskets is a simple task, but you may have
to dismantle the engine in order to reach them. When in doubt, always contact
a technician.
8.9.2 Check the shock absorbers
Shock absorbers are essen al for a smooth and even ride. If your truck doesn’t
se le rela vely quickly a er you’ve driven over a pothole, it’s probably me to
treat your truck to a new set of shock absorbers.
9. RE-PAINTING
10.1 STEPS INVOLVED IN REPAINTING
STEP 1
Remove all of the door handles, trim, emblems and chrome from the truck. Wash
the truck then dry well.
STEP 2
Sand the exis ng paint down on the truck. Pay close a en on to any areas with
paint Chips, making sure they are sanded well to blend into the rest of the truck.
Apply primer and allow to dry completely.
STEP 3
Use a so rubber block to wet-sand over the dried primer. Make sure it is sanded
enough that you can see a shine on the truck from any side angle. Apply dent
filler to any dents in the body of the truck.
STEP 4
Use a 16-inch file board to sand the filler on all flat panels on the truck. Use a
36grit file strip to sand down any larger dents that have a heavier applica on of
filler. Con nue applying more filler and sanding it down un l all surfaces are
equally smooth.
STEP 5
Apply a coat of epoxy primer to the sanded truck.
STEP 6
Use a leaf blower to blow off any remaining dust or debris. Wash the truck with
water. Dry well with a large cloth.
STEP 7
Clean the work area in the garage well, removing all traces of dirt and dust from
the surrounding walls and the floor.
STEP 8
Rremoving any traces of grease or oil on the truck. Apply masking tape to the
truck windows, wheels and any other parts that you do not wish to paint.
STEP 9
Use the paint gun to begin applying paint to the truck. Paint in a horizontal
direc on, from front to back and then again from back to front. Paint slowly but
steadily to avoid paint drips.
Use a ladder to paint the roof. Lie on the floor and spray upwards to paint under
the door. Allow the paint to dry and then apply a second and third coat. Use a
commercial grade automo ve buffer to buff the truck a er the paint has dried,
to produce a clean, shiny finish
11. WARRANTY CLAIM OF A VEHICLE
11.1 CONDITIONS FOR WARRANTY CLAIM
1) The period of warranty on major aggregates - Engine, Gear Box,
Front Axle and Rear Axle, shall be 36 months from the date of sale or
3,00,000 kms, whichever is earlier.
2) The warranty extended to the first registered owner of the vehicle only. In
the event of transfer or any aliena on the warranty shall be terminated
3) In the event of any defect being discovered within the period the vehicle
should be brought to the nearest AL Dealer workshop, to avoid consequen al
damages. Incidental expenses, towing charges have to be borne by the
customer.
4) The obliga on under warranty shall be limited to either repairing or
replacing free of charge such parts of the major aggregates as are deemed to
be defec ve in the opinion of AL and shall not extend to replacement of
assemblies and consequen al losses. The replaced part shall become
property of AL.
5) The customer will be responsible for
●
The cost of non-durable materials (lubricants, fuel, grease, filters
etc.,), rubber items, paint coa ngs etc.
●
The cost of maintenance and lubrica on opera ons
●
The cost of repairs made necessary by normal wear and tear,
accidents or improper use not authorized by AL or by improper storage or
negligence
●
The cost of on-road repairs, towing, parking and insurance
●
The cost of repairs caused by damage due to fire, flood, earthquake
or such natural calami es or by civil disturbances
12. SERVICING OF REPAIR VEHICLE
12.1 MALFUNCTION OF CLUTCH
A tractor had a clutch malfunc on. Even when the clutch pedal is
pressed the clutch was in engaged condi on. Due to this issue there was poor
accelera on, difficulty in gear shi ing. The reason is due to the damaged piston
in the master cylinder. Then the master cylinder is replaced.
12.2 PROPELLER SHAFT UNIVERSAL JOINT
A truck with two live rear axle has one universal joint broken due to
overload. The torque transmi ed was very high the universal joint could not hold
that high torque so it broke. Then the universal joint is replaced
13. 3116
●
31 denotes maximum ton that can be carried by the vehicle
●
16 denotes horsepower of the engine
A 12 wheeled vehicle has 2 front axle, two rear axle front axle can carry a load
of 6.5 ton rear axle can carry a load of 9 ton
6.5 x 2 = 13
9 x 2 = 18
Total = 31 ton
16 should be considered as 160.
THEREFORE, THE VEHICLE HAS 160 HORSEPOWER
Inspec ng the ECU of the trucks for the errors and warranty claim
Genera on of failure report a er the inspec on process
14. CONCLUSION
During our training period we no ced that the technicians are working with all
safety equipment like shoes, mask, gloves, and apron. We were inspired by
seeing this work culture and all the employees were performing their work in
order.
The engines which are claimed through warranty are le to rust in the open
space at the backside of the service centre. So, a separate shed should be built
to prevent the engine from rus ng.
The vehicles which are damaged due to accidents are le in many places of the
service centre, there are glass, sharp metal pieces around. It may injure the
technicians. So, it should be sent to scrap as soon as possible. The vehicles which
are completed service had been let to stay for many hours since the bill was not
cleared. So, a separate staff has to be allo ed for billing sec on.