INDUSTRIAL TRAINING REPORT

IN
PRODUCTION DEPARTMENT
COMPLETED AT
SML ISUZU LTD, VILL. ASRON
RUPNAGAR, PUNJAB 140001

JAWAHARLAL NEHRU GOVT. ENGINEERING

COLLEGE
SUNDERNAGAR, MANDI (H.P)
SUBMITTED TO:

SUBMITTED BY:

MR. AMITESH SHARMA

DEVENDER SHARMA

HOD, MED

MECH. 7TH SEMESTER

ROLL NO: BT-302294
1

STUDENT DECLARATION
I hereby declare that the industrial training report
entitled on the PRODUCTION is being submitted
to MR. AMITESH SHARMA (HEAD OF MECH.
DEPT.)
according to the fulfilment of the
requirement for the degree of mechanical
engineering.

DEVENDER
SHARMA
ROLL NO:
BT302294

REPORT
ON
SIX WEEKS
INDUSTRI AL TRAINING

PREFACE

NO LEARNING CAN BE COMPLETED WITHOUT PREFACE

As a part of our curriculum for bachelor of Mechanical Engineering. I am
required to undergo industrial training. The objective of this training is to gain an
3

inside information about the functioning of technical departments with respect to

an organization. The practical orientation of technical student is must to quality
as potential engineer.
I got an opportunity to undergo this training in esteemed organization SML
ISUZU Limited Asron.
Entering in the industry is like steeping into the world ever concept which is
taught in the class room is practical in different dimensions in the industry and
the study on the subject practice in the organization gives a deep insight into the
practical side of technique and industry itself.

ACKNOWLEDGEMENT

It is eventful at SML ISUZU ROPAR working with highly devoted employees and will probably
remain the most memorable experience of my life. Hence, this acknowledgement is a humble
attempt to earnest thanks to all those who were directly or indirectly involved in my project work
and were of immense help to me.
4

My heartfelt gratitude towards Mr. MANDEEP SEHGAL (QUALITY MANAGER) for his
valuable guidance and encouragement as a guide during my training period in CHASSIS
PLANT.

I am extremely grateful to Mr. CHANDRESH MISHRA (Dept. Manager Paint Shop), Er.
AMIT KUMAR (Quality) for their kind guidance and help in BUS BODY PLANT as whenever
required.

I am also thankful to Mr. Virender Singh Chandel (Manager H.R.D) and

Mrs. Khusboo (H.R.D) for giving me an opportunity to work in such a
reputed organization.

TABLE OF CONTENTS:
Sr. No.

TITLE

PAGE NO.

DECLARARTION

CERTIFICATE

2i

PREFACE

ACKNOWLEDGEMENT

1.

OBJECTIVES OF TRAINING

2.

INDIAN AUTOMOBILE INDUSTRY

11-12

3.

HISTORY

13

4.

KEY STATICS

14

5.

AUTOMOBILE PRODUCTION

15-16

6.

COMMERCIAL VEHICLE
MANUFACTURERS IN INDIA

17

7.

COMPANY PROFILE

18

8.

VARIOUS DEPARTMENTS OF ISUZU

19-21

9.

CURRENT PRODUCT PORTFOLIO

22

10.

MAJOR MILESTONES

23-24

11.

OVERVIEW OF THE PROCESS

25

VEHICLES PRODUCED AT SML ISUZU

12.

26-42
LIMITED
SML COSMO 3.3 ton

26-29

SML SARTAJ

30-33

SML SAMRAT

34-37

SML SUPER

38-40

SML ISUZU LT 134

41-42

ORGANISATION STRUCURE OF SML

13.

43-74
ISUZU LIMITED

14.

ENGINE SHOP

43
44

15.

ENGINES MADE AT SML ISUZU LIMTED

16.

BHARAT ENGINE NORMS

45

17.

CHASSIS PLANT

46-68

18.

ENGINE ASSEMBLY

48-55

19.

TRANSMISSION SHOP

56-62

20.

TRANSMISION ASSEMBLY

57-62

21.

AXLE SHOP

63-66

22.

FRONT AXLE ASSEMBLY

63-64

23.

DIFFERENTIAL GEAR ASSEMBLY

64

24.

PINION GEAR ASSEMBLY

64-65

25.

DIFRRENTIAL CARRIER ASSEMBLY

65

26.

REAR AXLE ASSEMBLY

66

27.

HOT BED ENGINE TESTING LAB

67

29.

PERFORMANCE ENGINE TESTING LAB

68

30.

BUS BODY PLANT

69-74

31.

BUS BODY SHOP

70

32.

STRUCTURE SHOP

71

33.

SHELL SHOP

72

TYPE OF WELDING OPERATIONS IN BODY

SHOP
34.

35.

(i)
(ii)

GAS METAL ARC WELDING

RESISTANCE SPOT WELDING

REFERENCES

73-74

75

OBJECTIVES OF TRAINING

1.
2.
3.
4.

To study the various processes which are done on various parts of LCV and M&HCV.
To study about Quality Assurance.
To study the function of different departments.
To study about the engine testing.

AN EASY TRAINING BUT A TUFF JOB

- To Be remain On Your Seat

- Active Participation

Interact To Clarify

Note Points Difficult To Memorize

- Improve Listening Habits

Never Neglect Program

Gain As Much You Can

Remain Attentive All time

INDIAN AUTOMOBILE INDUSTRY

10

INTRODUCTION
The Automotive industry in India is one of the largest in the world and one of the fastest growing
globally. India manufactures over 17.5 million vehicles (including 2 wheeled and 4 wheeled) and
exports about 2.33 million every year. It is the world's second largest manufacturer of
motorcycles, with annual sales exceeding 8.5 million in 2009. India's passenger car and
commercial vehicle manufacturing industry is the seventh largest in the world, with an annual
production of more than 3.7 million units in 2010. According to recent reports, India is set to
overtake Brazil to become the sixth largest passenger vehicle producer in the world, growing 1618 per cent to sell around three million units in the course of 2011-12. In 2009, India emerged as
Asia's fourth largest exporter of passenger cars, behind Japan, South Korea, and Thailand.
As of 2010, India is home to 40 million passenger vehicles and more than 3.7 million automotive
vehicles were produced in India in 2010 (an increase of 33.9%), making the country the second
fastest growing automobile market in the world. According to the Society of Indian Automobile
Manufacturers, annual car sales are projected to increase up to 5 million vehicles by 2015 and
more than 9 million by 2020. By 2050, the country is expected to top the world in car volumes
with approximately 611 million vehicles on the nation's roads.
A chunk of India's car manufacturing industry is based in and around Chennai, also known as the
"Detroit of India" with the India operations of Ford, Hyundai, Renault and Nissan headquartered
in the city and BMW having an assembly plant on the outskirts. Chennai accounts for 60 per cent
of the country's automotive exports. Gurgaon and Manesar in Haryana are hubs where all of the
Maruti Suzuki cars in India are manufactured. The Chakan corridor near Pune, Maharashtra is
another vehicular production hub with companies like General Motors, Volkswagen, Skoda,
Mahindra and Mahindra, Tata Motors, Mercedes Benz, Land Rover, Fiat and Force Motors
having assembly plants in the area. Ahmadabad with the Tata Nano plant, Halol again with
General Motors, Aurangabad with Audi, Kolkata with Hindustan Motors, Noida with Honda and
Bangalore with Toyota are some of the other automotive manufacturing regions around the
country.
The Indian Automobile Industry is manufacturing over 11 million vehicles and exporting about
1.5 million every year. The dominant products of the industry are two wheelers with a market
share of over 75% and passenger cars with a market share of about 16%. Commercial vehicles
and three wheelers share about 9% of the market between them. About 91% of the vehicles sold
are used by households and only about 9% for commercial purposes. The industry has attained a
turnover of more than USD 35 billion and provides direct and indirect employment to over 13
million people.
The supply chain of this industry in India is very similar to the supply chain of the automotive
industry in Europe and America. This may present its own set of opportunities and threats. The
orders of the industry arise from the bottom of the supply chain i. e., from the consumers and go
through the automakers and climbs up until the third tier suppliers. However the products, as
11

channeled in every traditional automotive industry, flow from the top of the supply chain to reach
the consumers.
Interestingly, the level of trade exports in this sector in India has been medium and imports have
been low. However, this is rapidly changing and both exports and imports are increasing. The
demand determinants of the industry are factors like affordability, product innovation,
infrastructure and price of fuel. Also, the basis of competition in the sector is high and
increasing, and its life cycle stage is growth. With a rapidly growing middle class, all the
advantages of this sector in India are yet to be leveraged.
Note that, with a high cost of developing production facilities, limited accessibility to new
technology and soaring competition, the barriers to enter the Indian Automotive sector are high.
On the other hand, India has a well-developed tax structure. The power to levy taxes and duties is
distributed among the three tiers of Government. The cost structure of the industry is fairly
traditional, but the profitability of motor vehicle manufacturers has been rising over the past five
years. Major players, like Tata Motors and Maruti Suzuki have material cost of about 80% but
are recording profits after tax of about 6% to 11%.
The level of technology change in the Motor vehicle Industry has been high but, the rate of
change in technology has been medium. Investment in the technology by the producers has been
high. System-suppliers of integrated components and sub-systems have become the order of the
day. However, further investment in new technologies will help the industry be more
competitive. Over the past few years, the industry has been volatile. Currently, Indias increasing
per capita disposable income which is expected to rise by 106% by 2015and growth in exports is
playing a major role in the rise and competitiveness of the industry.
Tata Motors is leading the commercial vehicle segment with a market share of about 64%.Maruti
Suzuki is leading the passenger vehicle segment with a market share of 46%. Hyundai Motor
India and Mahindra and Mahindra are focusing expanding their footprint in the overseas market.
Hero Honda Motors is occupying over 41% and sharing 26% of the two wheeler market in India
with Bajaj Auto. Bajaj Auto in itself is occupying about 58% of the three wheeler market.
Consumers are very important of the survival of the Motor Vehicle manufacturing industry. In
2008-09, customer sentiment dropped, which burned on the augmentation in demand of cars.
Steel is the major input used by manufacturers and the rise in price of steel is putting a cost
pressure on manufacturers and cost is getting transferred to the end consumer. The price of oil
and petrol affect the driving habits of consumers and the type of car they buy.
The key to success in the industry is to improve labor productivity, labor flexibility, and capital
efficiency. Having quality manpower, infrastructure improvements, and raw material availability
also play a major role. Access to latest and most efficient technology and techniques will bring
competitive advantage to the major players. Utilizing manufacturing plants to optimum level and
12

understanding implications from the government policies are the essentials in the Automotive
Industry of India.
Both, Industry and Indian Government are obligated to intervene the Indian Automotive industry.
The Indian government should facilitate infrastructure creation, create favorable and predictable
business environment, attract investment and promote research and development. The role of
Industry will primarily be in designing and manufacturing products of world-class quality
establishing cost competitiveness and improving productivity in labor and in capital. With a
combined effort, the Indian Automotive industry will emerge as the destination of choice in the
world for design and manufacturing of automobiles.

HISTORY
The first car ran on India's roads in 1897. Until the 1930s, cars were imported directly, but in
very small numbers.
Embryonic automotive industry emerged in India in the 1940s. Mahindra & Mahindra was
established by two brothers as a trading company in 1945, and began assembly of Jeep CJ-3A
utility vehicles under license from Willys. The company soon branched out into the manufacture
of light commercial vehicles (LCVs) and agricultural tractors.
Following the independence, in 1947, the Government of India and the private sector launched
efforts to create an automotive component manufacturing industry to supply to the automobile
industry. However, the growth was relatively slow in the 1950s and 1960s due to nationalization
and the license raj which hampered the Indian private sector. After 1970, the automotive industry
started to grow, but the growth was mainly driven by tractors, commercial vehicles and scooters.
Cars were still a major luxury. Japanese manufacturers entered the Indian market ultimately
leading to the establishment of Maruti Udyog. A number of foreign firms initiated joint ventures
with Indian companies.
In the 1980s, a number of Japanese manufacturers launched joint-ventures for building
motorcycles and light commercial-vehicles. It was at this time that the Indian government chose
Suzuki for its joint-venture to manufacture small cars. Following the economic liberalization in
1991 and the gradual weakening of the license raj, a number of Indian and multi-national car
companies launched operations. Since then, automotive component and automobile
manufacturing growth has accelerated to meet domestic and export demands.
Following economic liberalization in India in 1991, the Indian automotive industry has
demonstrated sustained growth as a result of increased competitiveness and relaxed restrictions.
Several Indian automobile manufacturers such as Tata Motors, Maruti Suzuki and Mahindra and
Mahindra, expanded their domestic and international operations. India's robust economic growth
led to the further expansion of its domestic automobile market which has attracted significant
India-specific investment by multinational automobile manufacturers. In February 2009, monthly
13

sales of passenger cars in India exceeded 100,000 units and have since grown rapidly to a record
monthly high of 182,992 units in October 2009. From 2003 to 2010, car sales in India have
progressed at a CAGR of 13.7%, and with only 10% of Indian households owning a car in 2009
(whereas this figure reaches 80% in Switzerland for example) this progression is unlikely to stop
in the coming decade. Congestion of Indian roads, more than market demand, will likely be the
limiting factor.
SIAM is the apex industry body representing all the vehicle manufacturers, home-grown and
international, in India.

KEY STATISTICS
The production of automobiles has greatly increased in the last decade. It passed the 1 million
mark during 2003-2004 and has more than doubled since.
Year

Car
Production

%
Change

Commercial

%
Change

Total Vehicles
Production.

% Change

2010

2,814,584

29.39

722,199

54.86

3,536,783

33.89

2009

2,175,220

17.83

466,330

-4.10

2,641,550

13.25

2008

1,846,051

7.74

486,277

-9.99

2,332,328

3.35

2007

1,713,479

16.33

540,250

-1.20

2,253,999

10.39

2006

1,473,000

16.53

546,808

50.74

2,019,808

19.36

2005

1,264,000

7.27

362, 755

9.00

1,628,755

7.22

2004

1,178,354

29.78

332,803

31.25

1,511,157

23.13

2003

907,968

28.98

253,555

32.86

1,161,523

22.96

2002

703,948

7.55

190,848

19.24

894796

8.96

2001

654,557

26.37

160,054

-43.52

814611

1.62

2000

517,957

-2.85

283,403

-0.58

801360

-2.10

14

Year

20042005

20052006

2006-2007

2007-2008

2008-2009
11,175,479

Motor Vehicle
Production
Industry Revenue

8,467,853

9,743,503

24,379

26,969

11,087,997 10,853,93
0
30,507
32,383

Exports (Units)

629,544

806,222

1,011,529

1,238,333

1,530,660

Exports (Revenue)

1,915

2,231

2,552

3,008

3,718*

33,342*

AUTOMOBILE PRODUCTION:
Type of Vehicle

2005-2006

2006-2007

2007-2008

2008-2009

2009-2010

Passenger Vehicles

1,209,876

1,309,300

1,545,223

1,777,583

1,838,697

Commercial Vehicles

353,703

391,083

519,982

549,006

417,126

Three Wheelers

374,445

434,423

556,126

500,660

501,030

Two Wheelers

6,529,829

7,608,697

8,466,666

8,026,681

8,418,626

Total

8,467,85
3

9,743,50
3

11,087,9
97

10,853,9
30

11,175,4
79

Geographical Segmentation: State-wise motor vehicles registration in India

from 2001 2008
States\Year

2001

2002

2003

2004

2005

2006

2007

2008

Andhra Pradesh

3,966

5,72
0
21
727
751

7,232

8,042

8,989

21
542
949

5,00
2
21
657
1,12
1

6,446

Arunachal Pradesh
Assam
Bihar

4,38
9
21
596
1,02
4

21
798
726

21
883
694

21
973
647

21
1,086
593

15

Chhattisgarh

857

948

1,21
6
436
7,08
7
2,54
8
289
439
1,21
7
3,97
7
2,79
2
3,80
4
8,96
9
106
73
42
172
1,52
5
3,52
9
3,83
4
17
8,57
5
76
516
6,46
0
2,54
8
28

1,367

1,536

1,726

1,939

483
7,892

537
8,785

585
9,633

2,883

3,267

3,689

638
10,54
3
4,164

329
493
1,341

375
556
1,479

421
628
1,630

480
719
1,796

3,63
6
2,31
5
3,17
3
7,41
4
90
67
34
177
1,21
5
3,10
3
3,19
7
13
5,65
8
57
406
5,17
1
1,69
0
28

1,07
6
397
6,50
8
2,27
9
269
399
1,10
1
3,73
8
2,55
2
3,45
9
8,13
4
97
73
37
162
1,35
9
3,30
8
3,48
7
15
8,00
5
66
457
5,92
8
2,36
6
28

Goa
Gujarat

341
5,576

Haryana

1,949

Himachal Pradesh
Jammu & Kashmir
Jharkhand

217
330
909

366
6,00
8
2,12
2
244
364
984

Karnataka

3,537

4,338

4,717

5,036

5,360

Kerala

2,112

3,180

3,612

4,034

4,564

Madhya Pradesh

3,095

4,119

4,442

4,710

4,968

Maharashtra

6,760

10,05
5
114
78
48
186
1,717

11,281
123
84
54
201
1,936

12,47
7
134
89
61
215
2,159

13,81
7
145
95
70
230
2,417

Manipur
Meghalaya
Mizoram
Nagaland
Orissa

77
62
31
160
1,096

Punjab

2,910

3,859

4,225

4,571

4,992

Rajasthan

2,943

4,285

4,791

5,281

5,815

Sikkim
Tamil Nadu

12
5,162

19
10,08
5
85
580
7,271

21
11,901
95
651
8,144

23
13,86
0
105
732
8,970

25
16,20
7
117
822
9,919

Tripura
Uttarakhand
Uttar Pradesh

50
364
4,921

West Bengal

1,690

2,816

3,138

3,464

3,833

Andaman & Nicobar

Islands
Chandigarh
Dadra & Nagar Haveli
Daman & Diu
Delhi

25

31

34

38

42

386
13
37
3,635

386
13
41
3,69
9
5
270

562
31
44
3,97
1
5
293

586
35
48
4,23
7
5
313

629
43
55
4,544

677
54
63
4,868

732
67
71
5,166

799
86
79
5,469

Lakshadweep
Pondicherry

4
252

6
359

7
418

7
495

8
552

16

COMMERCIAL VEHICLE MANUFACTURERS IN INDIA

Indian brands
Force
Hindustan Motors
Premier
Tata
AMW
17

 Eicher Motors
Joint Venture Brands
VE Commercial Vehicles Limited - VE Commercial Vehicles limited - A
JV between Volvo Groups & Eicher Motors Limited.
Ashok Leyland - originally a JV between Ashok Motors and Leyland
Motors, now 51% owned by Hinduja Group
Mahindra Navistar - a 51:49 JV between Mahindra Group and Navistar
International
Swaraj Mazda - originally a JV between Punjab Tractors and Mazda, now
53.5% owned by Sumitomo Group and 4% ISUZU.
Kamaz Vectra - A JV between Russia's KaMAZ and the Vectra Group

COMPANY PROFILE
SML ISUZU LIMITED was incorporated in July 1983 as Swaraj Vehicles Limited
to manufacture Light Commercial Vehicles (LCV) in the state of Punjab. It was the
result of Government of India initiatives for installing the LCV unit in order to
save the fuel consumption in the economy. Punjab State Industrial Development
Corporation (PSIDC) obtained the letter of intent in 1981 and subsequently
transferred the same in favour of the Company in 1983.
18

The project in its concept, aims at breaking new ground not only in terms of
product and production technology, but also in building a new culture and value
system in the organization, which enables it to move forward with confidence into
the era of competitive markets. This guiding philosophy is dictating every facet of
project implementation both in physical facilities and the human side.
The best way to address growth opportunities, harness and open up new markets
was through leadership in product technology. The search for technology brought
the company face to face with Peugeot and renault of France, Volkswagen and Man
of West Germany, Leyland of U.K., TAM of Yugoslavia and Isuju Duihatsu and
Mazda of Japan, while evaluating the relevant technologies of these countries, the
criteria that the Management had kept before itself was to select a vehicle powered
by a four cylinder diesel engine, capable of providing maximum pay-load capacity
best suited for local conditions and fuel efficient thus ensuring best value for
money to the Indian consumer. It was this approach that led the company to Tokyo
Kogyo Company Limited (known as Mazda Motor Corporation) the well know
Japanese manufacturers of the internationally known as Mazda Automobiles and
LCVs.
Subsequently, the Company was renamed as Swaraj Mazda Limited. In addition to
providing technical know how, Mazda Motor Corporation and their associate
trading house the well know Sumitomo Corporation have also agreed to participate
financially in the equity of the project.
In the year 1986, the Company started the commercial operations.

VARIOUS DEPARTMENTS OF SML

ISUZU ROPAR
RESEARCH AND DEVELOPMENT:
A company's research and development department plays an integral role in the life
cycle of a product. While the department usually is separate from sales, production
19

and other divisions, the functions of these areas are related and often require
collaboration. A thorough understanding of the functions of the research and
development department allows you to maximize those duties at your small
business, even if you don't have a big department.

PRODUCTION DEPARTMENT:
Aims and functions of production department. Production is the functional area
responsible for turning inputs into finished outputs through a series of production
processes. The Production Manager is responsible for making sure that raw
materials are provided and made into finished goods effectively.

QUALITY DEPARTMENT:
Each person involved in making a product is responsible for making it a quality
product. Quality departments, such as Quality Control (QC) or Quality Assurance
(QA) cannot inspect quality into the product. The Quality Departments exist as an
audit function within the manufacturing and packaging areas.

MAINTENANCE DEPARTMENT:
The plant maintenance department is responsible for making sure that all machines
are running properly, such that workers are safe and that the plant can perform its
function efficiently. The department makes periodic fixes and upgrades to all
machines and equipment, and it might also perform janitorial and grounds services.

HR DEPARTMENT:
An efficiently run human resources department can provide your
organization with structure and the ability to meet business needs
through managing your company's most valuable resources -- its
employees. There are several HR disciplines, or areas, but HR
practitioners in each discipline may perform more than one of the
more than six essential functions(RECRUITING,SAFETY, EMPLOYEE
RELATION , Compensation and Benefits, Compliance, Training and
Development). In small businesses without a dedicated HR
department, it's possible to achieve the same level of efficiency
and workforce management through outsourcing HR functions or
joining a professional employer organization.
20

PURCHASE DEPARTMENT:
Purchasing is the function of buying Goods & Services from External Source to an
Organization. Purchase department buys Raw Materials, Spare parts, services etc.
as Required by the company or Organization. Purchase management is One of the
most Crucial Area of the Entire Organization.

MARKETTING DEPARTMENT:
The Marketing Department plays a vital role in promoting the business and
mission of an organization. It serves as the face of your company, coordinating and
producing all materials representing the business. It is the Marketing Department's
job to reach out to prospects, customers, investors and/or the community, and
create an overarching image that represents your company in a positive lightthat
is, your brand.

VENDOR DEVELOPMENT DEPARTMENT:

Vendor development is one of the popular techniques of strategic sourcing, which
improves the value we receive from suppliers. Vendor Development can be defined
as any activity that a Buying Firm undertakes to improve a Supplier's performance
and capabilities to meet the Buying Firms' supply needs.

PPC DEPARTMENT:
Production planning is an activity that is performed before the actual production
process takes place. It involves determining the schedule of production, sequence
of operations, economic batch quantities, and also the dispatching priorities for
sequencing of jobs.
Production control is mainly involved in implementing production schedules and is
the corollary to short-term production planning or scheduling. Production control
includes initiating production, dispatching items, progressing and then finally
reporting back to production planning. In general terms, production planning
means planning of the work to be done later and production control refers to
working out or the implementation of the plan.

SERVICING DEPARTMENT:
21

A service department is a cost centre that provides services to the rest of a

company. The manager of a service department is responsible for keeping costs
down, or meeting the costs stated in a budget.

ACCOUNTS:
The accounting department is responsible for recording and reporting the cash flow
transactions of a company. This department has some key roles and
responsibilities, including accounts receivable, accounts payable, payroll, financial
reporting, and maintaining financial controls.

TOOLROOM:
A toolroom is a room where tools are stored or, in a factory, a space where tools are
made and repaired for use throughout the rest of the factory. In engineering and
manufacturing, toolroom activity is everything related to tool-and-die facilities in
contrast to production line activity.

EDP:
Electronic Data Processing (EDP) can refer to the use of automated methods to
process commercial data. Typically, this uses relatively simple, repetitive activities
to process large volumes of similar information.

Current Product Portfolio in the Goods Carrier Category

Models

GVW Range (in tons)

LCV
1. Sartaj

6.1 tons

2. Premium

6.4 tons

3. Prestige

7.5 tons

M&HCV

22

4. Supreme

8.0 tons

5. Super

8.8 tons

6. Samrat

10.2 tons

7. Super 12

12.0 tons

Current Product Portfolio in the Passenger Carrier Category

Category

Number of Seats

GVW Range (in tons)

18 to 41 ordinary seats

6.4 to 8.0 tons

2. Semi-deluxe buses

14 to 32 high back seats

6.4 to 8.0 tons

3. Deluxe buses

10 to 24 reclining seats

6.4 to 8.0 tons

13 reclining seats

5.7 tons

5. Luxury buses

16 to 27 reclining seats

6.4 to 8.0 tons

6. Luxury buses

41 reclining seats

16.2 tons

Non-air Conditioned Buses

1. Standard buses

Air Conditioned Buses and Coaches

4. Luxury executive coaches

MAJOR MILE STONES :

1984 :
The birth of SWARAJ MAZDA LTD

23

Joint Venture and Technical Assistance concluded between Punjab Tractor

Ltd., Mazda Motor Corporation and Sumitomo Corporation, Japan

1985:
Start of commercial operations.

1987:
1st company to offer fully built up buses in INDI A.

1996:
4-Wheel drive truck developed for INDIAN DEFENCE SECTOR.

2006:
TECHNICAL ASSISTANCE agreement concluded with ISUZU MOTORS,
JAPAN
.

2006:
Aggregate vehicle sale crosses 1,00,000 in AUGUST.

2008:
Launch of ULTRA LUXURY BUSES.

24

2011:
SWARAJ MAZDA renamed as SML ISUZU LIMITED.

2012:
Launch of IN-HOUSE RANGE OF S7 BUSES
.

2013:
Launch of XM SERIES TRUCKS and BUSES.

2015:
Vehicles sales crosses 2,00,000 in MARCH.

25

OVERVIEW OF THE PROCESS

As a concept, the organization had decided to outsource all components from

competent Suppliers from all over India accept very few components on which critical
operations are carried out in the plant. On receipt, components are inspected in the plant
as per sampling plan and after passing through this quality check, are shifted to the
Main Store. As per feeding schedule, the components are fed to various shops, where
aggregate assemblies of the required configurations as per production plan are carried
out.
Major aggregates assembled include Engines, Transmission, Front and Rear Axles,
Chassis, Cabin and Cargo. All the aggregates are functionally tested in the respective
shops and only after that these are used for vehicle production. These aggregates are
then transferred to the main vehicle assembly line which starts with Chassis mounting
and end up with fitment of Wheels and Bumpers.
Any fitment problem of components/aggregate or non availability of any component/
aggregate on main assembly line directly affects the vehicle production. To produce as
per the full capacity of plant, it becomes utmost important to make available all the
components and aggregates of desired configuration, in required number and at the
right time. Consequently some quantities of aggregates are assembled in advance as per
next days production plan.
Engine is most important aggregate in terms of performance of vehicle. It has highest
number of configurations; maximum parts are assembled in it and need very careful
functional testing. It has been observed that this one aggregate virtually governs the
production capacity of the plant.

26

VEHICLES PRODUCED AT SML ISUZU LIMITED

1. SML COSMO 3.3 ton

27

SPECIFICATIONS
MODEL

SML COSMO 3.3 ton

ENGINE SL

Bore X Stroke

100x110

No. of Cylinders

4-inline

Displacement

3455 CC

Max. Power BS II

64.7 Kw(88 ps) @ 3000 rpm

Max. Power BS III

75 Kw(102 ps) @ 3000 rpm

Max. Torque BS II

240 Nm(24 kgm) @ 1750-2000 rpm

Max. Torque BS III

270 Nm(28 kgm) @ 1750-2000 rpm

CLUTCH
28

Type

Single Plate Dry friction Type

Hydraulic assisted

Outer Diameter

260 mm

GEAR BOX
Type

Synchromesh

No. of Gears

5 Forward, One Reverse

AXLES
Rear Axle

6.571 : 1

STEERING
Ratio

Recirculating Ball Type, Variable Gear Ratio

CHASSIS FRAME
Type

Box Section 200x65,Ladder Type

SUSPENSION
29

Front

Multi Leaf Spring, Double Acting Shock

Absorber

Rear

Multi Leaf Spring, Double Acting Shock

Absorber

BRAKES
Service Brakes

Dual Circuit Hydraulic,Vacuum Assisted

Front

Hyd. Leading Sliding Shoes

Rear

Hyd. Two Leading Shoes

Parking Brake

Mechanical

WHEELS AND TYRES

Front

7.50x16-16PR

Rear

7.50x16-16PR

RIM SIZE

6.00g

EXHAUST BRAKE
Vacuum operated

ELECTRICAL SYSTEM
30

System Voltage

12 V

Battery Capacity

70 AH

Alternator Type

Built in Regulator with Vacuum Pump

Max.Output

12 V /55 A

Wiper Motor

SRF Nippon Denso

Head Light

60 /55 W, Halogen tube

FUEL TANK
90 Lts.

DIMENSIONS
Wheel Base

2815 mm

Cargo Width

2080 mm / 6.9 ft

Cargo Length

3100 mm / 10.3 ft

Cargo Height

570 mm / 1.9 ft

Min.ground Clearance

206 mm

Version available

Cab Chassis, Fixed Side Deck

31

WEIGHTS
Maximum GVW

5880 Kg

Maximum Permissible FAW

2460 Kg

Maximum Permissible RAW

3680 Kg

Kerb Weight

2570 Kg

(Chassis with Cab & Cargo Box with Spare

Wheel Fuel Tank & Tools)

PERFORMANCE
Gradabilitiy in 1st Gear

17.5

Min.Turning Radius

5.5 m

32

3. SML SARTAJ

33

SPECIFICATIONS
MODEL

WV26-S
ENGINE SL

Bore X Stroke

100x100

No. of Cylinders

4-inline

Displacement

3455 CC

Compression Ratio

17 : 1

Max. Power
Min. Power

79.1 PS at 3000 rpm

Air Cleaner

22.0Kg-m-at 1750 rpm

Oil Filter

Oil Bath Type

Fuel Filter

Full Flow paper Filter

Cooling System Capacity

12.5 lts.

Oil Sump Capacity

8.5 Lts.

Engine Weight(complete & dry)

270 kg(approx)

Radiator Frontal Area

0.245 Sq.m
CLUTCH

Type

Diaphragm Type

Outer Diameter

260 mm
GEAR BOX SL

Type

Synchromesh

No. of Gears

5 Forward, One Reverse

Gear Ratio

1st -5.833, 2nd -2.855

3rd -1.651, 4th - 1.000

34

3. SML SAMRAT

SPECIFICATIONS
ENGINE
Model
Type

SLT3 (BS III Compliant)

4 Cylinder inline, water cooled, Direct
injection diesel engine

Aspiration

Turbocharged inter-cooled

Displacement (cc)

3435

Max.Power

102 bhp @ 3000 RPM

ELECTRICALS

Type

12 VOLTS
35

Battery

1 NOS,12 V, 120 AH

Alternator

12 VOLTS,55A
DRIVE TRAIN

Clutch

Transmission

Dry single plate with diaphragm spring,

Hydraulically controlled
5 Forward, 1 Reverse, Synchromesh
AXLES

Front Axle

Rear Axle

Heavy duty Reverse Elliot

"I" Beam Section
Heavy duty full floating Banjo type
STEERING

Type

Re-Circulating ball type,Manual

SUSPENSION

Front

Rear

Heavy duty Semi elliptical type multi leaf

spring with hydraulic double acting telescopic
shock absorbers
Heavy duty Semi elliptical type multi leaf
spring with helper
BRAKES

Service Brakes

Full air dual circuit S cam roller follower type

Parking Brake

Graduated hand control valve system actuating rear

brakes

Exhaust Brake

Provided
WHEELS AND TYRES

Wheels

8 studs Wheel Discs

36

No.of Tyres

7 (Including 1 Spare Tyre)

Size

8.25 x 20-14 PR (Front)

8.25x 20-16 PR (Rear)
FUEL TANK

Capacity

180 LTRS
SEATS

No.of Seats

1+2 seating in cabin

PERFORMANCE

Max Speed

80 km/hr
DIMENSIONS

Wheel Base

3940mm

Ground Clearance

300mm

Overall Length

7220mm

DIMENSIONS
Wheel Base

3940mm

Ground Clearance

300mm

Overall Length

7220mm

Overall Width

2400mm

Overall height

2460mm
WEIGHT

GVW

11990 kg
LOAD BODY
37

Length X Width

5240mm(17.2ft) x 2280mm(7.5ft)
TRACK

Front

2022mm

Rear

1693mm
SALIENT FEATURES
More driving comfort
Heavy duty suspension
Heavy duty front axle, rear axle & differential
New Strong & sturdy straight chassis frame
Tilt & telescopic steering
Cushioned & adjustable drive seat
Tillable cabin for easy accessibility around the engine
Roof ventilation
Heavy duty bigger air brakes
Heavy duty tyres
8 Hole Heavy Duty Wheel disc with bigger size hub bolts

38

5. SML SUPER

Specially built for

large volume goods.
Cargo box available
High Deck & Half
14ft,17ft or 21.6ft

packed
in Steel
Side Deck

SPECIFICATIONS
VERSION SUPER

SUPER/ZT54LWB

Cabin Type

Wide
DIMENSIONS & WEIGHT

Overall Length (mm)

6974

Overall Width (mm)

2200

Overall Height (mm)

2070 (STD)

Wheelbase (mm)

3940

Cargo Deck length inside (mm)

5238

Cargo Deck Width inside (mm)

2080

Cargo Deck Height (mm)

570 (STD)

Track
Front (mm)

1640

Depth (mm)

1486

Min. Ground Clearance (mm)

206
39

Curb Weight (kg)

2800 (STD),3060(SHD)

GVW (kg)

8800
ENGINE

Type

4 Cylinder,in-line OHV,Diesel

Maximum Power

79.2 PS @/ 3000 RPM

Cooling System

Water Cooled

Bore & Stroke (mm)

100x 110

Displacement (cc)

3455

Compression Ratio

17:1

Max Torque (DIN) (kg-m/rpm)

22.0 /1750

ELECTRICALS
Battery

70 AH

Alternator

12 V-/55 A

Starter

12V-2.7 KW
CAPACITY

Fuel Tank (Ltr.)

180

Oil Pan (ltr.)

7.9
DRIVE TRAIN

Clutch

Single plate Dry Diaphragm

Transmission

5 forward all synchromesh/1 Reverse

Final Drive Ratio

6.571
CHASSIS

Frame-Lader type

Box section,with special reinforcement,

40

Tubular cross braces

SUSPENSION
Front

Multi Leaf Spring,double acting shock

absorber

Rear

Multi Leaf Spring,(twin-stage type) double

acting shock absorber
STEERING

Type

Recirculating ball type with variable gear

ratio
BRAKES
Dual-circuit hydraulic vacuum assisted
TYRES

Front

7.50-16-14 PR (12 PR OPNL)

Rear

7.50-16-14 PR (D)(16 PR OPNL)

TRANSMISSION GEAR RATIO

Gear Ratios

1st -5.833, 2nd -2.855

3rd -1.651, 4th - 1.000
5th -0.800, Rev- 5.372
PERFORMANCE

Max.gradabilitiy (tan O)

0.24

Min.Turning radius (m)

6.4

6. SML ISUZU LT 134

41

ENGINE
Model
Type
Displacement (cc)
Max. Power

6 Hk1-TC EURO-III Compliant Rear Engine

Four Cycle, 6 Cylinders, OHC(over head cam) Direct Injection,
Water Cooled Turbo Charger with Inter Cooler & EGR
7790
230 PS @ 2500 RPM

ELECTRICALS
Type
Battery
Alternator

24 volts
2 Nos 12 V, 150 AH
24V, 110A

DRIVE TRAIN
Clutch
Transmission

Cushioned Single Plate, Dry, Hydraulically Controlled, Air

assisted.
7 Forward 1 Reverse, Synchromesh with overdrive

AXLES
Front Axle
Rear Axle

Reverse Elliot I Beam Section

Full Floating

STEERING
Type

Power Steering, Re Circulating Ball Type with Hydraulic Booster

SUSPENSION
Front
Rear

Air Suspension with 2 Bellows

Air Suspension with 4 Bellows

BRAKES
42

Service Brakes
Parking Brakes
Exhaust Brakes
ABS
Retarder

Full Air, Dual Circuit, S-Cam Type with Auto Slack Adjuster
Spring Actuator on Rear Wheels, Failsafe
Electro-Pneumatic with butterfly Value in Exhaust pipe. Inter
Locking Actuator for exhaust Brake & Foot Brake with canceling
switch
Provided
Provided

WHEELS & TYRES

Wheels
Nos .of Tyres
Size

10 Stud Wheel Discs

7(including 1 Spare Tyre)
11-R22.5-14 P R (BS)

FUEL TANK
Capacity

280 Liters

PERFORMANCE
Max. Speed
Gradabilitiy

115 KM/ HR
34%

SEATS
No. of Seats
Type

40 + 1
Push back, Reclining Comfortable Seats with Padded Arm Rests
and Foot Rest

DIMENSIONS
Wheel Base
Turning Radius
Ground Clearance
Overall Length
Overall Width
Overall Height

5700 MM
9650 MM
250 MM
11400 + 50 MM
2500MM
3700 + 50 MM

TRACK
Front
Rear

1980 MM
1790 MM

ORGANISATION STRUCURE OF SML ISUZU LIMITED

43

ENGINE SHOP
The engine is a device that is used to convert chemical energy of fuel into heat energy and this energy
is then converted into useful work. The engine provides the motive power for the various functions
which the vehicle or any part of it may be required to perform.
Ideally, most engines used in vehicles are of internal combustion type. The internal combustion
engines are further classified according to the following considerations:1. Engine Cycle:- Based on the engine4 cycle an I.C. engine may run on Otto cycle or
Diesel
cycle.
2. Number of Strokes:- Based on strokes the engines are classified as two stroke engine
and four stroke engine.
3. Fuel Used:- Based on fuel used the engines are classified as Petrol engine, Diesel
engine, C.N.G. engine.
4. Type of Ignition:- The fuel inside the cylinder after compression has to be ignited. The
ignition system used in I.C. engine is of two types, spark ignition (S.I.) and
compression ignition (C.I.).
5. Number and Arrangement of Cylinders:- Based on number and arrangement of

cylinders the engines are classified as:

Single cylinder engine
Two cylinder engine Inline Vertical type, V type, Opposed Type
Three Cylinder engine
Four cylinder engine Inline Vertical type, V type, Opposed Type
Six and Eight cylinder engine
Radial engine
6. Valve Arrangement:- The valve arrangement I.C. engines are- Side valve type,

Overhead valve type.

7. Type of Cooling:- Based on adopted mode of cooling the engines are of two types
Air cooled engine
Water cooled engine
Oil cooled engine

ENGINES MADE AT SML ISUZU LIMTED

The SML ISUZU assembles following types of engines: Euro-I
Euro II
Euro _ III
C.N.G.
44

The basic difference between these engines are as follows:-

S.
No.

Euro -I

Euro -II

Euro -III

C.N.G.

In Euro-I engine
the block does not
have a hole for
feed pump

In Euro-II engine
hole for feed pump
are provided on the
back of engine
block.

In Euro-III engine
hole for feed pump
are provided on the
back of engine
block.

In C.N.G engine
the block does not
have a hole for
feed pump

In this fuel
injection pump
used is of inline
type

In this fuel
injection pump
used is of rotary
type

In this fuel
injection pump
used is of rotary
and electronic type

In C.N.G. engine
distributer is used

Here nozzles have

big holes for
spraying diesel

Here nozzles have

smaller holes for
spraying diesel

Here nozzles have

very small holes for
spraying diesel

In C.N.G. engine
spark plug is used

It gives power of
79.2 B.H.P. at
3000 R.P.M

It gives power of 88 It gives power of

B.H.P. at 3000
100 B.H.P. at 3000
R.P.M
R.P.M

It gives power of
72 B.H.P. at 3000
R.P.M

BHARAT STAGE NORMS

Specifications

BS-I

BS-II

BS-III

BS-IV

01.04.2000

2005

2005

01.04.2010

45

CO g/kwh

4.5

4.0

2.0

1.5

HC g/kwh

1.1

1.1

6.66

0.46

NOx g/kwh

8.0

7.0

3.5

PM g/kwh

0.36

0.15

0.1

0.02

SML ISUZU LTD :

CHASSIS PLANT

BUS BODY PLANT

46

CHASSIS PLANT
WORKING
AND LAYOUT:

47

ENGINE ASSEMBLY
Station E-1
1. Engine block is washed and cleaned properly. Then it is sent to the
main line.
2. Engine serial number punching is done.
3. Engine is moved on to the trolley and mounted on the trolley with the
help of bolts.
4. Liners are fitted to the block. Before putting the blocks inside the block
the coding
given on the block is checked.

5. Engine block is rotated and oil jets are attached to the block. The oil
jets are tight and torque up to a value of 1.20-1.80 kgm.
6. Eight tappets are put in their holes. These tappets are operated by
camshaft which in turn operates the push rod, the push rod operate the
rockers and the rockers operate the valves.

Station E-2
1. Here first of all camshaft is inserted in the engine block.
2. To stop sideways movement of camshaft a thrust plate is bolted on one side of the
camshaft.
3. First of all, a sealant is applied to the bolts of the thrust plate and then the thrust plate
is bolted with the help of these bolts. These bolts are tightened up to a torque of 2.3
kgm.
4. Then free movement of camshaft is checked.
5. Now the block is rotated and we have to put crankshaft bearings. Prior to this we have
to match the coding on block with that of crankshaft bearing.
48

6.

Based on this coding and according to the table we are going to put the crankshaft
bearing.
7. Before putting the crankshaft in the crankcase the bearings are cleaned properly and
oil is put both on the bearings and the crankshaft. After this, the crankshaft is placed in
the crankcase along with crank gear.
8. Now key bearing caps are put one by one at their place.
9. To prevent the sideways movement of the crankshaft thrust bearings are inserted in
the central main bearing.
10. Now start tightening up the crankshaft main bearing caps up to a torque of 10-10.7 kgm.
11. All the bolts should have torque marks.
12. Check crankshaft for free movement and end play.
13. Piston assembly is placed according to crank pin depth.

Station E-2A
1.
2.
3.
4.
5.
6.

Attachment of a connecting rod to the piston with the help of gudgeon pin.
Putting up circlips on both sides of gudgeon pin.
Cleaning of connecting rod caps.
Placing of connecting rod bearings in connecting rod and cleaning.
Check for any dent marks.
The pistons for E-I,E-II,E-III and CNG engines differ in the design of crown of the pistons.

Station E-3
1.
2.
3.
4.
5.
6.
7.

Selection of piston with depth gauge is done.

Note all the four readings.
Loose fitment of oil cooler assembly fitment on block.
Piston assembly is attached to the crankshaft.
Connecting rod bolts are tighten up to a torque of 8.2-9.0 kgm.
Check end play in connecting rod.
Check free movement of crankshaft with piston.
49

8. Bring the piston on T.D.C. position. Clean the surface of the piston and then place dial
gauge over the piston such that the tip of the dial gauge first touches the piston surface and
the dial gauge shows reading. Note this reading.

9. Place the dial gauge on the other piston and then note the reading shown by the dial gauge.
10. Now rotate the crankshaft and clean the surface of other two pistons.
11. Place the dial gauge on the piston and take the reading in the similar way as discussed
earlier.
12. Compare the values with the table.
13. The gasket is chose according to these readings. Gasket may be green or white.
14. Place the time case assembly on the trolley and move the trolley ahead.

Station E-4
1. Matching of spindle idle gear hole to done.
2. Mounting of case timing on block with gasket. Tightening of all the bolts of timing case
up to a torque of 2.3 kgm.
3. Tightening and torquing of filter bolts up to a torque of 2.5 kgm.
4. Cleaning and oiling of spindle gear is done.
5. FIP gasket and setting and adjustment.
6. Timing gears (cam gear and idle gear) are fixed with timing matched. For matching the
timing point A, B and C are matched properly.
7. Position of waver washer OK.
8. Idle gear thrust plate fitment and torque is done.
9. Torquing of cam gear bolt with thrust washer up to a torque of 6.4-9.6 kgm.

Station E-5
1.
2.
3.
4.
5.
6.
7.

Pressing of oil seal with oil.

Timing cover fitment and tightening up of bolts up to a torque of 2.5 kgm.
Assembly of water pump gasket and torquing up to 2.5 kgm.
Assembling of rear oil seal and torquing up to 2.5 kgm.
Fitting of oil pump and tightening of of bolts up to a torque of 2.5-3.8 kgm.
Fitting of oil pipe with O ring.
Fitting of bracket of strainer pipe and torquing up to 2.5 kgm.
50

8.

Tightening and torquing of oil pipe up to 2.5 kgm.

Station E-6
1.
2.
3.
4.

Put gasket on both sides ,side setting along with sealant.

Attachment of front/rear 1/2 seal with sealant.
Fitment of oil pan and torque up to 1.7-2.6 kgm.
Loose fitting of lower pan or sump with gasket.

Station E-7
1. Tighten up the lower pan up to torque of 1.7-2.6 kgm.
2. Fitting of end plate with the help of bolts up to a torque of 3.8-5.3 kgm.

3. Fix indicator pin on the end plate. Indicator pin is used to indicate the marking (degrees)
provided on the flywheel. This help in dismantling the FIP or adjusting the tappets.
4. Flywheel is bolted over the end plate. the torque of the flywheel is kept between 21-23 kgm.

Station E-7A
1.
2.
3.
4.
5.

Two cylinder head stud fitment and tight.

Attachment and assembly of inlet manifold with gasket and torque.
Attachment of sub assembly of case thermostat with gasket and torque.
Tightening and torquing of front and rear engine hanger.
Vacuum pipe assembly and torque.

Station E-8
1. Cleaning of flywheel face.
2. Attachment of cover assembly and clutch assembly with centering tool. Tightening and torquing
of bolts up to 2.6 kgm.
3. Matching of indicator pin with TDC.
4. Putting up of cylinder head gasket as indicated at station E 3.
5. Attachment of cylinder head.
6. Oiling and fitment of crank pulley and torque.
7. Attachment of SOBP connector.
51

Station E-9
1. Locate cylinder head bolts after dipping in engine oil.
2. Tighten up cylinder head bolts up to a torque of 6.0 kgm. Then marking and rotation of bolts
90+ 90.

3.
4.
5.
6.

Torquing of rocker arm nut 1.3-1.7 kgm.

Sub assembly of rocker and oiling, cleaning of cap valve.
Oiling of push rod and valve stem.
Engine mounting bracket torque.

Station E-10
1.
2.
3.

Tappet clearance setting (inlet valve 0.30 mm, exhaust valve 0.35 mm).
Nozzles with O ring washer.
Assembly of nozzle holder and torque.

Station E-11
1.
2.
3.
4.
5.
6.

Fitment of return pipe and clipping.

Assembling of fuel filter and torque.
Fitment of alternator bracket, alternator, strap and torquing.
Fitment of water pump pulley.
Cooling fan tightening torque 2.5 kgm.
Belt fitment and torque.

Station E-12
1. Assembly of 810 oil pipe and torquing.
2. Assembly of 560 fuel pipe and torquing.
3. Assembly of 880 fuel pipe and torquing.

52

4. Attachment of stud of manifold.

5. Movement of empty trolley.
6. Temporary attachment of HPP.

Station E-13
1.
2.

Placement of engine on trolley.

Assembly of stud, heater with gasket and torque up to 2.5 kgm

3.
4.
5.
6.

Attachment and oiling of oil gauge pipe and dipstick.

Sub assembly of head cover with sealant.
Attachment of cylinder head cover and torque.
Attachment of mounting bracket and torqueing

Station E-14
1. Attachment of breather pipe and torqueing.

2. SOBP filter clamp fitment and torquing.

53

3.
4.
5.
6.
7.

All bolts torque marking.

Attachment of hose alternator oil pin.
Sub assembly of mounting pad, fitment and torquing.
Sub assembly of insulator cover band torquing.
Tightening and torquing of braided lose.

Station E-15
1.
2.

Attachment of turbo charger with gasket.

Attachment of turbo charger outlet pipe with clamp.

3.

Tightening and torquing of all oil and diesel pipes.

Station E-16
1.
2.
3.

Attachment of exhaust joint and torquing.

Attachment of feed pump and feed pump pipes.
Attachment of diesel pipes (fuel filter- main diesel pipes).

Station E-17
1. Attachment of air pipe bend (turbo charger- air cleaner) with rubber hose and clamp.

54

SUB ASSEMBLY OF CYLINDER HEAD

1.
2.
3.

Cylinder head cleaning.

Valve cleaning and paste application.
Valve assembly depth measurement note.

4.
5.
6.
7.

Seal fitment
Spring fitment and setting.
Cotter pins and locking.
Valve leakage check with soap solution.

SUB ASSEMBLY OF COVER TIMING

1. Rubber seat fitment.
2. Plate fitment and torque.

SUB ASSEMBLY OF OIL COOLER

1.
2.
3.
4.

Gasket fitment on oil cooler.

Attachment of cooler body with cooler and torquing.
Filter gasket with oil and torque 2.5 kgm.
Leak test confirm.

55

TRANSMISSION SHOP

The transmission system of a vehicle consist of a clutch, a gearbox giving three, four or even five
different ratios of torque output to torque input, a propeller shaft to transmit the torque output
from the gearbox to the rear axle, and a differential gear to distribute the final torque equally
between the driving wheels. The gearbox is of three types:1. Sliding mesh type
2. Constant mesh type
3. Synchromesh type
The transmission system used in SML ISUZU vehicles is five speed synchromesh gearbox. In a
synchromesh gearbox there are synchronizers provided in between the 1st, 2nd, 3rd, 4th and 5th
gear. These synchronizers synchronize the speed of the gears on the main shaft and the lay shaft
so that they can engage and disengage smoothly.

56

TRANSMISSION ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.

First put the transmission case on the assembling table and check it.
Fix dowels to the transmission case.
Fit drain plug, level plug and reverse idle gear lock.
Fit PTO (Power Take Off) cover.
Putting up of counter shaft inside the transmission case along with counter gear and lock.
Putting uo idle pin.
Put up idle reverse gear along with needle bearing and two spacer.
Insert the gear inside the transmission case along with pin and lock with the help of reverse
lock screw.
9. Lock the counter shaft.
10. Insert the spacer then put bearing and press with the help of tool.
11. Check the counter shaft for rotation.

Station T-2
1. Put the main shaft inside the transmission case.
2. Insert needle bearing along with synchronizer for 4th gear in the main shaft.
3. Insert the gear main drive.

4. Put bearing on both the sides of the shaft.

5. Lock the clutch shaft.
6. Put up bearing races on both sides of the counter shaft.
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7. Put up spacer and Speedo gear (driver) on either sides of main shaft.
8. Check all the gears on the main shaft for free rotation.

Station T-3
1. Load the transmission case on the trolley.
2. Fitting up of rear cover along with gasket Speedo gear (driven) and seal.
3. With the help of dial gauge measure the value of shim on the rear cover and put the shims.

4. Put the shifter fork for different gears on their hub and sleeve.
5. Put up springs inside the fork.
6. Put the balls inside the shift rod. Press the balls with the help of tool by one hand and insert the
rod by hammering from the other side.
7. Check the neutral position of the gearbox.

Station T-4
1. Measure the shim with the help of dial gauge.
2. After selecting the shim then put up bearing cover.

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3. Attach magnet with two bolts of bearing cover.

4. Apply sealant and put up clutch housing gasket.
5. Put clutch housing along with six bolts and tigten up clutch housing up to a torque of 9.111.7 kgm.

Station T-5
1. Apply sealant, put gasket and fix up front cover.
2. Rotate transmission case and pour 4 liters of transmission oil SAE 90

3. Attach top cover after applying sealant and gasket.

Station T-6
1.
2.
3.
4.
5.

Attach mounting bracket.

Fitting of parking brake assembly.
Put brake drum over the parking brake assembly.
Tightening of brake drum bolts up to a torque of 28-33 kgm.
Adjust the park brake. For this first tighten up the brake shoes fully. After this start rotating
the brake adjustment screw in the reverse direction up tp six threads.
6. Now put the grommet.

Station T-7
1.
2.
3.
4.
5.

Testing of transmission.
Rotate in neutral position in clockwise and anticlockwise direction.
Check 1st, 2nd, 3rd, 4th, 5th,and reverse gear in clockwise and anticlockwise direction.
Check shifting force.
Check selecting force.
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6. Check for any abnormal noise.

7. Check for any leakage.
8. Put up clutch release bearing assembly.
9. Fit breather plug.
10. Fitting of breather cap.
11. Application of grease.
Beside of these seven stations of the main line of transmission there are two sub stations also.

These sub stations are as discussed below

SA-1 MAIN SHAFT SUB ASSEMBLY:1. Put main shaft on the assembling table.
2. Insert needle bearing for first gear in the main shaft.
3. Put first gear in the shaft.
4. Now put synchronizer.
5. Inset hub and sleeve assembly for first and second gear.
6. Again insert synchronizer.
7. Now put steel ball in the main shaft with the help of grease.
8. Put needle bearing for second gear.
9. Put second gear.
10. Put gear sleeve.
11. Put snap ring.
12. Put needle bearing for third gear.

13. Put third gear.

14. Put synchronizer.
15. Put hub and sleeve assembly for third and fourth gear.
16. Insert snap ring.
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17. Rotate the direction of the shaft.

18. Put needle gear for reverse gear.
19. Put reverse gear.
20. Put hub and sleeve assembly for fifth and reverse gear.
21. Put snap ring.
22. Put synchronizer.
23. Put fifth gear.

COUNTER SHAFT ASSEMBLY:1. Assembly of thrust washer diaphragm friction gear and bearing.
2. Snap ring in shaft and counter over top gear.

3. Check for any dent in the teeth.

SA-2 TOP COVERS ASSEMBLY:1. Take top cover.

2. Fix the baffle plate and guide plate and tighten then up to a torque of 1.9-2.6 kgm.

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3.
4.
5.
6.
7.
8.

Fit O ring spring with reverse lock stopper.

Fit change lever and check lever.
Fit shift lever and check it.
Fitment of selection assembly.
Fitment of reverse and neutral switches and tightens them up to a torque of 2.5 to 3.8 kgm.
Apply sealant on plug and tighten them u

AXLE SHOP
The axle shop is another prime area of a vehicle assembly line at SML ISUZU assembling plant,
it holds position of critical credence.
Differential is a mechanism by means of which outer wheels runs faster than the inner wheel
while taking a turn or moving over upheaval road.

FRONT AXLE ASSEMBLY

1. Transport the axle beam on the assembling jig with the help of hoist.
2. Hold the front axle beam with one hand and set it to the attaching hole of the leaf spring.
3. Tighten damper holding bolts on both the sides of the axle beam. The torque of damper
holding bolts should be 5-6 kgm.
4. Place steering knuckle along with thrust bearing on the lower side.
5. Place shims between steering knuckle and front axle beam.
6. Insert king pin guide tool in the king pin hole from upward direction.
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7. Insert king pin guide tool in the king pin hole from upward direction pushing down the king
pin guide tool.
8. Take cotter pin out of part box.
9. Insert cotter pin as the matching face of the pin is parallel to the notch portion of the king
pin.
10. Take a hammer and hit the head of cotter pin and fix king pin.
11. Take flange nut out of part box and tighten the nut to the thread of the cotter pin with hand.
12. Place the cap on the upper side of the steering knuckle and hold it partially with the help of
three bolts.
13. Inject SAE 90 oil in the king pin hole. Inject the oil until completely fill up.
14. Hang the spring balance to the spindle portion of steering knuckle assembly.
15. The turning torque for pulling the spring balance should be 6 kgm.
16. Now place the cap on the lower side of steering knuckle and tighten it with the help of two
bolts up to torque of 1.3-2 kgm.
17. Take knuckle arm and fix crescent key to it with the help of hammer. Now insert knuckle
arm in its hole and tighten it with the help of castle nut.
18. Insert split pin to the hole as the longer side of the split pin being outside. Hit the head of
split pin lightly with hammer, and then bend the fleet of split pin with the notch portion of
the hammer.
19. Take tie rod and fix one of its end to knuckle arm. Adjust its nut so that the remainder of
thread on both sides should be same.
20. Check right and left hand side of tie rod assembly and insert the ball joint to knuckle arm.
Insert castle nut to ball joint inserted to knuckle arm.
21. Insert split pin to ball joint hole fit to ditch of castle nut. Hit the head of split pin lightly with
hammer and bend the fleet of split pin.
22. Repeat the above procedure on the other side of axle beam.
23. Place brake assembly on both sides of the axle beam and tighten with the help of bolts up to
torque of 12-14 kgm.
24. Grease hub on the on the steering knuckle side. Insert the hub completely with the help of
hub assembling tool.
25. Tighten up the lock nut. Check the preload of its value should be between 3.5-5.5 kgm.
Adjust the nut such that the hub rotates freely now insert the lock pin.
26. With the help of width gauge inspect whether the lo9ck nut get seated at its place or not. For
this the value should be 42.3 mm maximum.
27. Now put the hub cover on the both sides of the axle beam. Tighten up the hub cover with the
help of cross head type screws.
28. Fill the bearing cap with grease and fix them at the center of the hub to prevent it from dust.
Hit the cap lightly with hammer so that it gets fix properly.
29. Adjust the brake of the brake drum with the help of brake adjustment and turning tool.
Before adjusting the brakes remove the hole plug. After adjusting the brakes insert the plug
again to its place.
30. Tighten up the tie rod nut up to a torque of 9.0-12.0 kgm.\
31. Lift the axle and put it on the trolley.
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ASSEMBLY OF DIFFRENTIAL GEAR:1.

2.
3.
4.
5.

Place the cage differential gear on the assembling table.

Putting up of sun gear with thrust washer inside the cage.
Insert four planet gear on the cross inside the cage over the sun gear.
Again put a sun gear with thrust washer over the cross assembly.
Place the upper cover of the cage and tighten it with the help of bolts up to torque of 6.5
kgm.
6. Ensure free rotation of gears.
7. Check for any abnormal noise.
8. Press bearings on the both the sides of this assembly.
9. Put the above assembly on the assembling jig. Now put crown wheel on this assembly.
10. Tighten up the crown wheel with the help of bolts up to a torque of 28 kgm.

PINION GEAR ASSEMBLY

1. Take the differential carrier and set MD measurement machine with master tool. Set the dial
reading with master reading consist of measurement tool, spacer, shim adjustment tool,
measurement block and housing bearing.
2. Check MD reading of differential carrier with combination of bearing.
3. Pick up pinion, spacer and pilot bearing.
4. Attach the pinion gear to the pilot bearing inserting a spacer in between the two and press all
of them with the help of hydraulic press.
5. Now put pinion, spacer and pilot bearing assembly on the jig.
6. Put the bearing that is used in the MD machine previously on the above assembly.
7. Now press it with the help of hydraulic press of assembly jig after putting a tool.
8. Now put distance piece, bearing housing along with a small bearing placed on it.
9. Put a seal cover over it.
10. Again pres the whole assembly with the help of hydraulic press with the help of tools.11. Now put the flange with the dust cover.
12. Press it with the help of hydraulic press of jig.
13. Now put a washer and a nut and screw it up to 2-3 nuts.
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14. Check the motion of the pinion gear.

DIFRRENTIAL CARRIER ASSEMBLY

1. According to the reading written on the differential carrier, puts shims of combination of 0.10
mm and 0.15 mm values on differential carrier.
2. Now locate pinion gear assembly on the differential carrier such that the shims are in between
the pinion gear assembly and the differential gear.
3. Tighten up the pinion gear assembly with the help of bolts up to torque 25-40 kgm. Preloading of
pinion nut with multiplier and torque wrench should be done up to a value of 18-20 kgm.
4. Now insert the differential carrier.
5. Lift the differential gear assembly with the help of hydraulic lift and put it in the differential
carrier.
6. Put cone bearing on both sides of differential gear assembly.
7. Now put adjustment screws on both sides of differential gear assembly
8. Turn the adjustment screw with the help of tool.
9. Placing the puppy dial gauge near the crown wheel teeth and turn the pinion gear with the help of
hand so that the crown wheel teeth just touches the puppy dial tip.
10. Bring the dial gauge pointer to zero position.
11. Now see the backlash between the crown wheel and the pinion gear. It should be between 0.22
to 0.27.
12. If it is not between these values then adjust adjustment screws and repeat points 10 and 11 and
check backlash.
13. After adjusting the backlash then apply white paint on the crown wheel teeth and the pinion
gear teeth.
14. Screw up the clips on the adjustment screws.
15. Check preload of final assembly. Its value should be 23-25 kgm.
16. Lift the carrier.

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REAR AXLE ASSEMBLY

1. Place the rear axle beam on the assembling jig and punch serial number over it.
2. Put up brake assemblies on both sides of the axle beam. tighten up the bolts of the
brake assemblies up to a torque of 10-12 kgm.
3. Put up wheel hub over the brake assemblies. Lock the wheel hub with wheel hub lock
plate and tighten up the lock plate with two bolts up to a torque of 2 kgm. Now put
brake drum over the hub.
4. Pour 3.5 liters of differential oil SAE 140 in the axle beam.
5. Insert differential assembly in the center of the axle beam along with the application of
sealant and tighten it up with the help of bolts up to a torque of 4 kgm.
6. Insert axle shafts from the both sides. Ensure that it is properly engaged with the SUN
gear.
7. Tighten up the axle shafts with the help of bolts up to a torque of 10 kgm.
8. Adjust the brake of the brake assembly.
9. Lift the axle beam from the assembly jig with the help of hydraulic hoist

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HOT BED ENGINE TESTING LAB

In this lab 100 % engines which are assembled in the engine assembly shop are tested. in the hot
bed testing lab engine is tested for 5-10 minutes. In this engine is tested for various parameters
which are as follows:
1

Filling of engine oil.

Checking for any leakage.

Checking for any abnormal noise.

Checking of oil pressure at idle RPM which should be 1.8 bar at 650-720 RPM and at 80.

Checking for any vibrations.

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PERFORMANCE ENGINE TESTING LAB

In this lab 10 % engines which are tested in the hot bed testing lab. In the performance testing lab
engine is tested for 4 hours. First of all lapping is done for 1.35 hours. In this engine is tested for
various parameters which are as follows:
1 Power
2 Torque
3 Specific fuel consumption (SFC)
4 Smoke
5 Any abnormal noise.
6 Any leakage.
In performance testing 2 engines are tested at one time i.e. 4 engines are tested In one shift.
The performance testing is done on the two beds namely
1 Shanck Bed
2 SAJ Bed
These are made by the Indian manufacturers. These are fully electronic. In this various sensors
are assembled.

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BUS BODY
PLANT

69

BUS BODY SHOP

Body shop consists of three lines known as Frame line, Cargo line and Cabin line.
After assembly, cabin and cargo sent to the paint shop and the frame to the vehicle
assembly shop. This shop involves the first of operations which finally result in
production in LCV.

This shop contains two lines

Line For Chassis Frame Assembly
Line For Bus Body Assembly Line

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STRUCTURE SHOP:
In this shop make a structure of bus. In this shop GI tubes used to make a structure
of bus.
FIXTURE:
This shop fixture are used to make a structure of bus. Many types of
fixture are used in this shop. These are following;
I. FLOOR FIXTURE
II. ROOF FIXTURE
III. L/S FIXTURE
IV. R/S FIXTURE
V. MAIN FIXTURE

After making all sides of structure then all sides attached each other. Also rear and
front structure attached to this structure.
MIG weld used in this process 220-250A and 20-22V current used in this process.

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TUBES:
Tubes in this shop are GI. Because protect from rust, corrosion etc.

SHELL SHOP:
After structure shop the structure of bus send to the shell shop. It is most important shop of
Bus Body plant. In this shop inspection of structure and after this coating of primer at the
welding joints. The inspections are following:
1. Full Welding
2. Grinding
3. Dents
4. Riveting
5. Counting of screws
6. Wiper bush
7. Wiring of roof
8. Driver window
9. Wheel arcs front &rear
10. Lid cover, etc.
In this shop Plasma cutter is used. After this wheel arcs are sealing and check the gap in this. Lid
cover also welded in this shop which is used for air cleaner. Foot step also welded in this shop.
In this shop also fit GI panels. It panels fixed with the help of MIG weld.
In this shop two types of panels are used. These are following:
GI PANEL
ALUMINIUM PANEL

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TYPE OF WELDING OPERATIONS IN BODY SHOP

Two types of welding operations are used in body shop these are:
Gas Metal Arc welding ( MIG)
Resistance Spot Welding

(i) GAS METAL ARC WELDING

MIG is an arc welding process in which heat for welding is generated by an arc between a
consumable electrode and work metal. The electrode of M.S. Copper coated wire having
diameter 1.2 mm is continuously fed to the weld area by means of a D.C. Motor at speed of 9-12
m/min. This speed of feeding the electrode can be adjusted according to the requirement. No flux
is used but the arc and molten metal are shielded by an inert gas, which may be argon, helium,
carbon dioxide or gas mixture. The steam of CO2 gas is to provide protection from atmospheric
contamination to weld puddle, arc, and adjusted area of base metal and the electrode. The direct
current with reverse Polarity (i.e. electrode is made positive and work is made negative) is used.

Working Specifications of MIG welding instrument are

Voltage 32-36 Volts

Current 180-200 Amp.
High speed Co2 is used as inert gas.
Principle of Operation

Proper current and wire feed speed is set and the electrical connections are ensured. The are is
struck by any one of the two methods. In the first method current and shielding gas flow is
switched on and the electrode is scratched against the job as usual practice for striking the arc. In
the second method, electrode is made to touch the job, is retracted and then moved forward to
carry out welding; but before striking the arc, shielding gas, water and current is switched on.
About 15mm length of the electrode is projected from the torch before striking the arc. During
welding, torch remains about 10-12 mm away from the job and arc length is kept between 1.5 to
4 mm.
EQUIPMENT
a) Welding power source and cables.
b) Welding torch and wire electrode coiled on a spool.
c) Wire feed mechanism and controls consisting of a pair of driving rolls, electric
motor, etc.
d) Shielding gas cylinder, pressure regulator and flow meter.
e) Controls for switching on and off the current, electrode wire and inert gas.

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(ii) RESISTANCE SPOT WELDING

Resistance spot welding is a process in which surfaces are joined by the heat generation by
resistance to the floor of electric current through work piece that are held together under force by
electrodes. The surface in contact is heated, in the region of current concentration by short time
pulse of low voltage, high amperage current to form a fused nugget of weld meta.

74

REFERENCES

MATTER REFERENCES:

www.smlisuzu.com.

www.smlisuzu.in.

en.wikipedia.org.

TABLES REFERENCES:

www.smlisuzu.in.

en.wikipedia.org.

Google search engine.

MENTORS:

Mr. MANDEEP SEHGAL

Mr. CHANDRESH MISHRA

Mr. AMIT

And all the members of PRODUCTION AND QUALITY Department.

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