Sr. No.

Content

Particulars

Page No.

1.

Introduction

1.1. Introduction about company

1.2. Company Profile

4

5

2.

Practical work at mechanical Workshop

2.1. Servicing and maintenance of

Vehicle

2.1.1. Tools and parts required

2.1.2. Servicing procedure

2.2. Lathe operations

2.2.1. Introduction to lathe

2.2.2. Components of lathe

2.2.3. Operations on lathe

2.3. Engine maintenance

2.3.1. Remove and refit engine from

Vehicle

2.3.2. Assembly and dismantling of

Engine

2.3.3. Assembly and dismantle of

Crankshaft and pistons.

2.3.4. Valve clearance Methods

2.4. Synchromesh Gearbox

2.4.1. Design and operations

2.4.2. Description of components

2.4.3. Synchromesh mechanism

2.4.4. Remove and refit gearbox from

Vehicle

2.4.5. Dismantling of gearbox

2.4.6. Assembly of gearbox

6

6-9

9-12

12

12-13

13-14

14-18

19

19-20

20-23

23-29

29-31

31

31-32

32-33

33-35

35

35-38

39-44

3.

Reference

45

1.INTRODUCTION:

1.1 INTRODUCTION ABOUT HINDUSTAN CONSTRUCTION COMPANY:

ASHOKA LEYLAND(ASHOKA LEYLAND) is headquartered in Mumbai, India. ASHOKA LEYLAND's businesses span the sectors of Engineering & Construction, Real Estate, Infrastructure, Urban development & Management. The ASHOKA LEYLAND group of companies comprises ASHOKA LEYLAND Ltd., and its subsidiaries ASHOKA LEYLAND Real Estate Ltd, ASHOKA LEYLAND Infrastructure Co. Ltd, Lavasa Corporation Ltd, Steiner AG in Switzerland and Highbar Technologies Ltd.The company is headed by AjitGulabchand, Chairman and Managing Director. ASHOKA LEYLAND Ltd. executes large-scale civil engineering and infrastructure main agenciess such as hydro power plants, nuclear power plants, expressways and highways, tunnels and bridges. ASHOKA LEYLAND currently serves the infrastructure sectors of transportation, power and water.

ASHOKA LEYLAND is the first Asian company to endorse the United Nations Global Compact (UNGC)'s CEO Water Mandate. ASHOKA LEYLAND initiatives towards achieving water neutrality was featured amongst ten global company case studies in a Climate Report issued by the UNGC and United Nations' Environment Programme at the Rio+20 conferences organised by the United Nations at Brazil in June 2012. ASHOKA LEYLAND was adjudged for Best Social Investment Strategy by the World CSR Congress in February 2013.Some leading main agenciess executed by ASHOKA LEYLAND include:

Bandra-Worli Sea Link ( Mumbai), Kolkata Metro, Kudankulam Nuclear Power Plant (Tamil Nadu), Lavasa City (near Pune), Mughal Road Main agencies,J&K, Mumbai Pune Expressway ,NathpaJhakri Hydroelectric Main agencies: Head Race Tunnel and Surge Shaft , NimooBazgoHydel Power Main agencies ( J&K), PirPanjal Rail Tunnel ( J&K), Rajasthan Atomic Power Plant (Rajasthan)

1.2. COMPANY PROFILE:

Type

Public private company

Traded as

BSE: 500477

NSE: ASHOKALEY

Founder

Seth WalchandHirachand

Founded

1948

Headquarters

CHENNAI, India

Certifications

ISO 9001 (For quality)

ISO14001 (Environmental)

OHSAS 18001(Occupational health and safety management system)

Key people

AjitGulabchand (Chairman and Managing director- ASHOKA LEYLAND Ltd.)

Revenue

Rs.81.50 billion (US$1.2 billion) (2012-2013)

Employees

15812 (2013)

Website

www.ashokaleyland.com

2. PRACTICAL WORK DONE AT THE MECHANICAL WORKSHOP-

2.1. SERVICING OF VEHICLE:

It really is quite simple to perform a basic full service and does not require any more than the ability to tighten or loosen a nut or screw.

2.1.1. Tools required for servicing of a vehicle-

An oil filter removal tool which looks a bit like a bicycle chain with a handle Spark plug removal tool Spanner or socket set for the sump plug (the oil drain plug). Screw driver for the air filter housing (many have snapped on clips instead!) Jack - raise the car to check each wheels bearing by rocking the wheel and seeing if there is excess play. Tyre Pump - to ensure the tyres are all at the correct pressure. Anti freeze gravity gauge - looks a bit like a turkey bester. Oil catch pan to collect the old engine oil for safe disposal.

PARTS REQUIRED-

Oil-See vehicles instruction book and note that sports (thin) oil can actually cause damage in an old or low performance engine just as too thick oil can clog up the fuel pump and fail to lubricate the engine. Use a funnel if you have shaky hands - you don't want oil on the engine. Oil should be changed every 6000 miles and certainly at least once per year. Because oil degrades over time it should be regularly replaced and is the best way to guarantee a long engine life.

Oil Filter- I prefer to avoid non brand makes as the filtration is sometimes much worse. A magnet that attaches to the oil filtercatches small metal particles and stops engine wearis worth getting if you can source one. Use a proper oil filter removal tool or alternatively a piece of sandpaper may help you togrip it.

Sump washer- Never use the old sump plug washer either - keep a few as spares.

Spark Plugs- Get a good quality brand with a copper core electrode (quads, splits and triples not really necessary for most road cars.) Plugs last for 1 year although some cars use iridium or platinum plugs which are rated for 40,000 miles or 4 years.

Leads - These only need replacing if they start to deteriorate and a good set of leads should last easily for 10 years.

Filters (air filter) - Typically the air filter housing is secured with a few screws or clips. You may have to unplug sensor cables and the air flow meter to gain access but you can normally get away without doing that in most cars. An air filter will last for 1 year, unless you live in a very dusty area. A visual check will reveal if it is dirty. Change air filters with regular intervals.

Anti freeze- Gravity gauge will do this for you and top up as required. Always ensure that you have sufficient antifreeze to cope with a-20 degree temperature below your expected lowest temperature. Antifreeze acts as a coolant so it has a benefit in the summer as well.

Washers- Top up washers with a screen cleaner and clean water - cold pre boiled water will reduce bodywork streaking as does filtered water (Do not use washing up liquid).

Engine Oil- Drain the old oil from the engine. First run the engine so that the oil is warm, place the catch pan under the sump and loosen the sump nut taking vehicle that it does not fall in to the hole of the catch pan.Be careful as the oil is very hot. When the engine is empty of oil replace the sump washer and sump nut and then fillthe engine to top of mark on dipstick never over or under the lower mark. Pour slowly pausing and allowing the dipstick level to settle and check.

It is generally better to be slightly under than over as it is much easier to top up than drain off the oil. It can take 5-10 minutes for the level to settle; aim to get half the dipstick level at first.

Suspension- Check shock absorbers for leaks and wear (bounce each corner of the car and it should settle again within 3 bounces). Check all bushes (rubber blocks and mounting points) and ball joints for signs of wear and play.

Lights- Check all lights (use a mirror or reflection ina windowplaced behind the car to check rears if you don't have a second pair of eyes to help). Don't forget the number plate light. Oil door hinges with white grease (close and open the greased doors fully to ensure the surface is covered).

Steering- Check rack and track rod ends for play. Wobble thewheel as youdrive along and you should get aslightwobble from the car. If there is free play and the vehicle takes a fraction of a turn to respond then get your steering checked out.

CV Boots (FWD)- These are the rubber covers over the flexible joint from the gearbox to the wheels. Check these at full right and left lock for cracks. They will need replacing if they are cracked as the joint will dry out and wear very quickly.

Brakes- Do the pads still have good depth left on them. Replace brakes if they start to squeal and preferably just before.If the disc is becoming glazed you can rough it up a little with a course grade sandpaper or wire brush. Apply a little copper grease to the movable parts taking care not to get this on the discs or pads.

Check the brake fluid level and gravity - this should be renewed every 2-3 years in most cars. (Do not leave the top off the brake fluid reservoir as it sucks in water vapour and this is really bad for braking).

Exhaust- Check for leaks/severe corrosion and make sure all hanger rubbers are there and not split. With a torch at night you can see very clearly any cracks or gaps in the exhaust. This is particularly handy for tracking down tiny exhaust leaks.

Seatbelts- Make sure all seat belts fasten and give them a good tug to ensure they lock. If belts have become frayed, fail to lock or do not recoil when released replace them.

Tyres- Check all tyres for cuts and damage to the sidewall. Check that the tread depth is legal and also take time to check the tyre pressures - this is something you should do weekly. If the pressure is low suspect a slow puncture and check thoroughly with water mixed with washing up liquid - bubbles will form where the puncture is.

All vehicles have a service schedule - Filters, fluids, belts, brakes, pads, spark plugs and many other components need to be changed at specific intervals.

Not all vehicles services are the same. There are different types of vehicle service such as an interim service, a full service and a major service. If the vehicle is taken to be serviced annually, or if the vehicle you have bought has been serviced regularly, then a full service will service. If the vehicle hasn't been service for over a year then go for a major service.

2.1.2.