Vehicle Factory Jabalpur

Government of India
Ministry of Defense

Certificate

This is to certify that Mr. Vansh Shrivas in the 4th Semester of B.Tech in
Mechanical Engineering at Shri ram institute of technology jabalpur has
successfully completed two weeks vocational training from 05/06/2023 to
20/06/2023 at Vehicle Factory Jabalpur. This report does not contain any
classified information.During his tenure, we found him sincere and
hardworking. We wish him all the success in his future endeavor.

Date: 20/06/2023
Mr. Manoj Kumar Jain
Junior Work Manager
Place: Jabalpur
HRD & Training Section
Vehicle Factory Jabalpur
 Introduction

Vehicle Factory Jabalpur (VFJ) is a military motor vehicle manufacturing

company located in Jabalpur, Madhya Pradesh, India functioning under the
aegis of the Ordnance Factories Board controlled by the Ministry of
Defense, Government of India. It has been established by the Government
of India to cater to the transport needs of the Indian Armed Forces, it
manufactures and assembles general staff vehicles, logistics vehicles, light
armored vehicles like bullet-proof vehicles, mine-protected vehicles, and
specialist role vehicles such as water bowsers, fuel tankers, field
ambulances, tippers, battery command posts, generator sets, light recovery
vehicles, field artillery tractors, kitchen containers, etc. It also has some
variants for civilian applications.

The production of Shaktiman trucks, Jonga Light Utility Vehicles (LUV),

and Vahan 1 ton began at the Gun Carriage Factory Jabalpur in 1959.
Pandit Jawaharlal Nehru, the then Prime Minister of India was present to
witness the rolling of the first batch of vehicles at GCF. It was shifted to the
present location in 1969. The factory is headed only by an IOFS officer
called General Manager (ex officio, Additional Secretary to Government of
India) who is the Chief Executive Officer responsible for the overall
management of the company and is the main judicial authority.

It started manufacturing Shaktiman trucks with a license from MAN SE of

Germany along with Jonga and Vahan 1 ton under license from Nissan of
Japan. All three of the above products have been retired and replaced by
new products.
 Acknowledgment

The entire work on this report was done by me at all the plants of this Factory.

I am highly obliged and express my gratitude to Mr. Manoj Kumar Jain (JWM HRD
& TRG Section) for his support and guidance throughout the training at VFJ.

I am thankful for all the charge-men at all the plants of the factory and their
cooperation throughout the training period.

I extend my sincere thanks to the authorities of the vehicle factory Jabalpur

for granting me the permission and providing such a wonderful opportunity to

do my vocational training here at VFJ.

Vansh shrivas
0205ME211057
Mechanical Engineering
SRIT JABALPUR
 TABLE OF CONTENTS

❖ INTRODUCTION..........
❖ PRODUCTION FACILITIES OF VEHICLE FACTORY JABALPUR.
ASHOK LEYLAND-STALLION TATA LPTA-715............
❖ MINE PROTECTED VEHICLES (4X4) & (6X6).
❖ PLANT I.....
❖ GEAR SHOP.
❖ TURNING SECTION, MILLING SECTION, GRINDING SECTION
❖ DRILLING SECTION HOBBING SECTION, OPERATION
SEQUENCE OF GEAR CNC SECTION............
❖ VERTICAL MACHINING CENTER UNIVERSAL GRINDING
MACHINE, JIG BORING MACHINE COORDINATE MEASURING
MACHINE GEAR SHAVING
❖ CUTTER SHARPER MACHINE
❖ TRANSMISSION ASSEMBLY OF
❖ AUXILIARY GEARBOX MAIN GEARBOX REAR-AXLE & FRONT
AXLE PRODUCTION CHAIN OF ERA BOX, SUPPLY CHAIN OF
ERA BOX
❖ HEAT TREATMENT.. CALIBRATION SECTION
❖ GAUGE BLOCKS, V-BLOCKS, CALIPER CHECKER DIGITAL
PRESSURE GAUGE COMPARATOR
❖ ELECTRONIC TORQUE WRENCH TESTER FLOATING
CARRIAGE MICROMETER, DIAL CALIBRATION TESTER
❖ PLANT I
❖ TOOL ROOM 1
❖ BYSTRONIC LASER CUTTING MACHINE, ABRASIVE WATER
JET MACHINE PLASMA CUTTING MACHINE, EDGE MILLING
MACHINE
❖ ASHOK LEYLAND STALLION...
❖ SPECIFICATION FRAME SECTION, AIR TANKS MOUNTING
PARTS
❖ STEERING MECHANISM, ENGINE, LUBRICATION SYSTEM
COOLING SYSTEM MINE PROTECTED VEHICLE (4X4 & 6X6).
❖ GUN SHOP
❖ UP-GUNNING OF 130MM SHARANG GUN
"SHARANG UP-GUNNING 130/155MM CAL45 WORKFLOW
PROCESS
❖ PLANT III
❖ TATA LPTA ASSEMBLY.
❖ STAND O STAND 1 STAND 2, STAND 3 STAND 4, STAND 5
STAND 6 STAND 7 STAND 8 STAND 9, STAND 10, STAND 11
❖ DIFFERENTIAL LOCKOUT
❖ UTD 20 ENGINE OVERHAULING
❖ PLANT IV
❖ SUMMARY
Introduction
Vehicle Factory Jabalpur (VFJ) is a military motor vehicle manufacturing company
located in Jabalpur, Madhya Pradesh, India functioning under the aegis of the
Ordnance Factories Board controlled by the Ministry of Defense, Government of
India. It has been established by the Government of India to cater to the transport
needs of the Indian Armed Forces, it manufactures and assembles general staff
vehicles, logistics vehicles, light armored vehicles like bullet-proof vehicles, mine-
protected vehicles, and specialist role vehicles such as water bowsers, fuel tankers,
field ambulances, tippers, battery command posts, generator sets, light recovery
vehicles, field artillery tractors, kitchen containers, etc. It also has some variants for
civilian applications.

The production of Shaktiman trucks, Jonga Light Utility Vehicles (LUV), and
Vahan 1 ton began at the Gun Carriage Factory Jabalpur in 1959. Pandit Jawaharlal
Nehru, the then Prime Minister of India was present to witness the rolling of the
first batch of vehicles at GCF. It was shifted to the present location in 1969. The
factory is headed only by an IOFS officer called General Manager (ex officio,
Additional Secretary to Government of India) who is the Chief Executive Officer
responsible for the overall management of the company and is the main judicial
authority.

It started manufacturing Shaktiman trucks with a license from MAN SE of Germany

along with Jonga and Vahan 1 ton under license from Nissan of Japan. All three of
the above products have been retired and replaced by new products.
Vehicle Factory Jabalpur is organized in following production facilities :-

Plant-I : Fabrication of Stallion & LPTA Items and Assembly of Stallion Vehicles
Plant-II : Manufacture of Transmission Aggregates
Plant-III : Assembly of LPTA & Water Bowsers
Plant-IV : Vehicles Testing, Final Preparation & Issue to Customers
Test Track : Testing/Running of vehicles under different terrain conditions

Core Competence of VFJ is manufacture of Transmission Assemblies and Gears viz.

Main Gear Boxes
Auxiliary Gear Boxes
Front Axles
Rear Axles

VFJ has modern Gear manufacture machines such as

Gear Hobbing Machines
Gear Shaving Machines
Gear Grinding Machines

VFJ has capacity to undertake fabrication work right from design & Manufacture of Press Tools to
manufacture of Pressings of various shapes & sizes & their welding. It has Presses of various capacities
ranging up to 1500 Tonnes.

VFJ is an ISO 9001-2000 certified factory. Its Laboratories are NABL certified.

VFJ uses SQC & SPC techniques including On-line Gauging for quality control. Its Labs are equipped
with modern & sophisticated Quality Control Machines such as Lead & Profile Testing Machin and 3-
Co-ordinate measuring Machine besides numerous other test equipment’s.

VFJ has a modern Tool Room & Heat Treatment Shop. It has Seal Quench Furnace & Spectrograph
TATA LPTA-715
The Tata LPTA is a military truck family developed and produced by Indian automobile
manufacturer Tata Motors. The trucks are available in 4x4,6×6,8×8,10×10 and 12x12
configurations. With extreme off-road capabilities, they are proposed as a replacement for
Czech-designed Tatra trucks currently used by Indian armed forces.
MINE PROTECTED VEHICLES (4X4) & (6X6 underdevelopment)
The Ordnance Factory Board Mine Protected Vehicle (OFB MPV) is a Mine Resistant Ambush
Protected-type vehicle used by the Indian Army and the Central Reserve Police Force as an
armored personnel carrier to transport personnel with protection from explosives and small
arms fire. The MPV's construction was based on the Casspir Mk II, which India used in the
1990s.
The Mine Protected Vehicle has been improved by Ordnance Factory Board, thanks to criticism
and later, feedback from the CRPF based on their experience in encountering powerful
improvised explosive devices that we're able to destroy and kill the occupants inside during
ambushes.
 Plant II

Several sections of Plant 2 can be found as follows:

• Transmission Assembly LPTA (TATA Motors)
• Transmission Assembly Stallion (Ashok Leyland)

• Transmission Machining LPTA

• Transmission Machining Stallion
• Gear Shop
• General Machining Shop

• Tool Room 2
• Heat Treatment & Material Testing Department
• Calibration Section
Gear Shop
The gear shop in plant-ll is the section where gear teeth are cut using hobbers. The various
subdivision of gear shop are:
Turning Section
The turning section of the gear shop has CNC Turning. The workpiece is fitted into the machine
to get the final job output with the proper dimension.
Milling Section

In this section, the milling machines are used to get job output as per required slots, step-
blocks, etc. are some of the jobs which are being manufactured here.
Grinding section
This is the section where the workpiece is brought into the last stage for the final finishing to
match a perfect fit and interchangeability
Drilling Section
A radial type drilling machine is used for the drilling of holes of high, accuracy. Holes at an angle
to the horizontal can be drilled by using guide holes of Jig.

Hobbing section
This is a section where gear teeth, splines, etc. are being cut. The tools used for hobbing are
generally HSS, silicon carbides, etc.
CNC Section
The CNC Section has a range of machines that are used to manufacture various parts for
STALLION (ASHOK LEYLAND), LPTA 715/32 (TATA), Mine Protected Vehicles, SHARANG Up-
gunning, T-72 & T-90 Tank (ERA Box).
The following machines are part of the CNC section:

• Vertical Machining Center-Jyoti

• Horizontal Machining Center
• Vertical Turning Machine (VTM)
• CNC Universal Grinding Machine – STUDER
• Shaving Cutter Grinding Machine - SAMPUTENSILI
• Jig Boring Machine - SIP (Swiss), HAUSER (German)
• CNC Gear Grinding Machine - LIEBHERR
• Coordinate Measuring Machine (CMM)-ZIESS

Vertical Machining Center

Specification
Company Model VMC 430
Accuracy 0.01 mm
Distance room from table 800 mm
Max. Load on table 200 Kgf
X-Axis Travel 400 mm
Y-Axis Travel 300 mm
Z-Axis Travel 400 mm
Speed Range 0 -10000
rpm
Controller Siemens
No. o Tools in magazines 12
Universal Grinding Machine:

It is a hyper-precise machine powered by machine learning capable of grinding internally,

externally, and angularly with Picto Programming Technology i.e., Simply enter the workpiece
dimension and the material, and Studer Technology generates the grinding program
automatically. It also automatically dresses its grinding wheel at regular intervals.

Jig boring machine

specification
Company Model SIP Hydroptic 6A
Travel X/Y/Z 1000*700*800
Table Load 1000 kg
Accuracy 1 um

Coordinate Measuring Machine:

Coordinate Measuring Machine accurately measures the geometry of an object along X, Y, and
Z axes using a touch-trigger, scanning, or vision probe to take a series of precise points on the
surface of an object.
The probe's position can be manually controlled or, automatically (CNC) through the use of a
computer. The position is defined using a reference sphere in the X-Y-Z coordinate system.
CMM also allows the probe angle to be controlled to enable the measurement of complex
surfaces that may otherwise be unreachable i.e., we can find the center of any irregular-shaped
surface.

Gear Shaving Cutter Sharper Machine

The accuracy of the hobbing process to a large extent on good hob resharpening
and the performance of hob is very much affected by the type of resharpening
carried out. If a hob is resharpened under incorrect working conditions, it may at
times result in tooth breakage. Ceramic grinding wheels (aluminum oxide) are
still widely used for resharpening hobs.

❖ Transmission Assembly of LPTA

To manufacture quality components of Stallion Mk-4 and LPTA-715 vehicles for
the following
1-Gear box
2-Auxiliary gearbox

3- Rear axle
4- Front axle
Auxiliary gearbox
A mechanism that makes possible an increase in the force of a motor vehicle by increasing the
gear ratio of the transmission for example an auxiliary gearbox is used in the transmission
mechanism of heavy-duty motor vehicles and tractors to increase mobility on rough terrains.
Main Gearbox
A machine consists of a power source and a power transmission system, which provides
controlled application of the power, Merriam Webster defines transmission as an assembly of
parts including the speed-changing gears and the propeller shaft by which the power is
transmitted from an engine to the life axle. Often transmission refers simply to the gearbox
that uses gears and gear trains to provide speed and torque conversions from a rotating power
source to another device.
Rear-axle & Front axle
An axle is a central shaft for a rotating wheel or gear. On the wheeled vehicles, the axle may
be fixed to the wheels, rotating with them, or fixed to its surroundings, with the wheels
rotating around the axle in the former case bearings or bushings are provided at the mounting
points where the axle is supported. In the latter case, a bearing or bush sits inside the hole in
the wheel to allow the wheel or gear to rotate around the axle.
ERA Box
ERA Box (Explosive Reactive Armour Box) is used to enhance the protection level of T-72 & T-
90 Army Tanks.
Material: Armored Steel
It Provides Protection against:

➢ Modern Anti-Tank Guided Missiles

➢ Heat and Kinetic Energy Threats
➢ Rocket Propelled Grenade (ROG)
➢ Armor-Piercing fin-stabilized discarding sabot (APFSDS) up to some extent.

Working:
➢ ERA box explosive charges to defend from another explosive which are
fired at it.
➢ When the warhead hits the upper plate, it ignites the shockwave creates
by the explosion and scatters the molten metal jet away. The upper plate flies in the
outward direction.
The ERA is often mounted on the areas that are most likely hit like-
➢ Front part of the hull.
➢ Entire Turret
➢ Side skirt covering the Tracks

Heat Treatment
It is the section of plant-ll where the various components manufactured in other sections are
treated with heat to improve the mechanical properties of the materials of components before
the final finishing of the component. Anti- carburizing paste is usually rubbed over the threads
in order to avoid them getting hardened. Oxygen is avoided during heat treatment in order
not to get scales on the surface.
This section also has various hardness testers to check the hardness of materials after the heat
treatment to ensure the correct quality and also the shot blasting wheel abrader machine for
the purpose of cleaning after heat treatment which uses bombarding of small steel balls over
the surface of the component.

PURPOSE OF HEAT TREATMENT

1. Cause relief of internal stress developed during cold working, Welding,
Machining, etc.
2. Harden and strengthen materials.

3. Improve machinability.
4. Improve ductility and toughness.
5. Increase heat, wear, and corrosion resistance of materials.

This section has various types of furnaces such as low and high-temperature furnaces for
annealing, tempering, and hardening with carburizing, pit gas furnaces, salt bath furnaces, etc.
A high-temperature furnace used for carburizing, and hardening has a closed Furnace, a
circulating fan, and two gravity tanks which are provided with isopropyl alcohol in liquid form
which is used for carburizing the material. In a salt bath furnace, two types of salts are used-
neutral salt which is used for hardening only and has a melting temperature of 660 degrees
Celsius. Another is cyanide salt which is used for both carburizing and hardening.
Heat treatment involves the use of heating or chilling, normally to extreme temperatures,
to achieve the desired result such as hardening or softening of a material. Heat treatment
techniques include annealing, case hardening, precipitation strengthening, tempering,
carburizing, normalizing and quenching.

MECHANICAL PROPERTIES OF MATERIALS

1. Parts/ Components of Automotive Vehicle( Ferrous & Non-Ferrous)
TENSILE TEST
Tensile Strength
Yield stress ,Elongation % - IS 1608: 2005. Upto 400 kN
Rockwell Hardness Test - IS 1586: 2012 30 HRC to70 HRC
Brinell Hardness Test- IS 1500: 2013. Upto 400 HBW, 2.5/187.5 kg

Upto 400 HBW, 10/3000 kg

Vickers Hardness Test. IS 1501: 2013. Upto 600 HV/5
400 HV to 600 HV/30 , Upto 600 HV/0.5, 1
SPRING TEST

Compression IS 7906 (Part 8): 2009 Upto 250 kg

Tension IS 7907 (Part 6): 2008 Upto 250 kg
II. METALLOGRAPHY TEST
1. Ferrous Metals Microstructure Analysis ASM Hand Book Vol. 9 Qualitative

(50X to 2000X)
Estimation of Grain size by
Comparison Method
IS 4748: 2009 1 to 10
Inclusion in Steel IS 4163: 2004 ABCD (Thin & Thick Series)

(1 to 4 Level)
Determination of Case Depth by
Microscopic Method
IS 6416:2007 0.1 mm to 2.0 mm

Calibration Section
There is a variety of measuring instruments and gauges that are calibrated in the calibration
section, including the following:
• Vernier Caliper
• Micrometer (Screw Gauge)
• Pressure Gauge
• Torque Wrenches
• GO & NO-GO Gauges (Thread Plug Gauge, Ring Gauge, Snap Gauge)

• Dial Indicators

Calibration (or error checking) is performed with the following instruments:

• Gauge blocks

Use: Calibration of Micrometers, setting comparator.

• V-Blocks:
When checking the ID of Ring gauges using Height Master, use this as a support.

When checking the cylindricity of a part using Base Comparator.

• Caliper Checker:

A caliper checker is a precision-measuring instrument, dimensionally stabilized hardened

ground, and lapped gauge Blocks are stacked in the rigid housing selected measuring steps
provide calibration of the main Scale as well as vernier scales of the instrument.
Used for calibration of vernier calipers, Dial indicators & height gauges.

• Digital pressure gauge comparator:

If we simplify the principle of a pressure gauge calibration to its minimum, we can say that
when we calibrate a pressure gauge, we provide a known accurate pressure input and read
the indication on the gauge, and then compare these. The difference in the values is the error
and the error should be smaller than the required accuracy for the gauge.

• Electronic torque wrench tester:

The Electronic Torque Wrench is a precision hand tool designed to permit accurate manual
tightening of threaded fasteners. The tool is designed around a conventional ratchet wrench
with a self-contained microprocessor built into the wrench handle.

• Floating Carriage Micrometer:

This instrument is used for accurate measurement of "Thread Plug Gauges ". Gauges
dimensions such as Outside diameter, Pitch diameter, and Root diameter are measured with
the help of this instrument. All these dimensions have a vital role in the thread plug gauges
since the accuracy and interchangeability of the component depend on the gauges used.

• Dial Calibration Tester:

It's based on Abbe's principle and is used for calibration of Dial Gauges (Plunger & Lever type)
and Bore Gauges.

Plant I
Several sections of Plant 1 can be found as follows:

• Press Shop.
• Paint Shop.
• Welding Shop.
• Stallion Assembly Line.
• Tool Room 1
• Gun Shop
• Mined Protected Vehicle Assembly.

• Plasma Cutting Machine:

This machine was not in working condition.
• Edge Milling Machine:
The machine is capable of doing face milling operations. Also, the milling head will be
given a tilting facility for carrying bevelling operations at any required angle. Used for
Edge Preparation of Sheet, Plate Edge Bevelling for Heavy Fabrication Works.The sheet
we saw was cut at an angle of 40deg on one side. On the other side, it was 40deg on
the upper edge and 35deg on the lower edge.

ASHOK LEYLAND STALLION

This vehicle serves as the backbone of the military logistics of the Indian Armed Forces. It is
assembled using parts procured from different plants of VFJ and private firms (Ashok Leyland).
SPECIFICATION:

➢ MK IV, 4X4 Engine: Diesel. 6-cylinder infirm Power: 221 HP

➢ Capacity: 5759 cc
➢ Permissible Payload: 7.5 tons
➢ Max. Speed: 82 km/h
➢ Fuel Capacity: Two diesel tanks are positioned on either side of the chassis each with
180 liters capacity.
The vehicle uses two 12 V batteries to power start the engine.
➢ Frame section:
The chassis is assembled with long members and cross-members at specified distances
for holding the parts of the vehicle. Four pairs of spring hangers are also attached to
the long members. The next step involves reaming the holes for aligning by removing
unnecessary material. Leaf springs arc mounted on the spring hangers which work as
shock absorbers.
➢ Air Tanks:
The air dryer removes the unwanted moisture from the compressed air supplied by the
compressor. There is a dial indicator that checks the pressure; it has to reach a
minimum pressure of 8 bar before the vehicle moves, as it must reach all the peripheral
parts. When this limit is exceeded an unloader valve opens automatically and lets out
the extra pressure. Four pneumatic devices are provided for different purposes. One
for operating the exhaust brake valve. Two, for engaging and disengaging 4x4 and 4x2
drives. Three operates the differential lock attached to the front and rear axles. It
determines the turning ratio which is responsible for turning the vehicle smoothly and
preventing it from slipping.

➢ Mounting parts:

• The engine is connected to the gearbox through the propeller shaft. Front and rear
axles are mounted at the front and rear end of the vehicle. The gearbox in turn is
connected to the auxiliary gearbox again with the propeller shaft. At last, it connects
to the differential gearbox of the rear axle. A steering gearbox is mounted beside the
engine below the steering knuckle. All the pneumatic driven parts arc connected with
their tanks and filters using pipelines. A radiator is mounted in front of the engine which
contains two meshes, one for coolant and the other for the air. • An alternator is
provided in the vehicle to charge up the batteries upon exhaustion.

• The leaf spring assembly is set up below the boosters on both axles on either side.
 • Tires are mounted on the brake drums.
A tow hook is provided at the rear end of the vehicle, to tow another vehicle when in
need.
➢ Steering mechanism:
When the steering wheel is rotated, the steering gearbox operates and sends pressure
to the vehicle's rear and front axles where a booster is placed. This booster tends to
move the wheels in the desired direction.
➢ Engine:
The vehicle is provided with a 6-cylinder diesel engine. A flywheel is attached for a
smooth drive. A turbocharger intakes air from the atmosphere compresses it and
increases its pressure.
➢ Lubrication system:
Done for reduction of wearing, less noise production, low working temperature and
smooth engagement of gears are the objectives of lubrication. It is done by greasing in
a rod spring. propeller shall, crank pin, etc. Done by oiling in gearbox, engine, AGB, and
axles.
➢ Cooling system:
Coolant and water run in the meshes of the radiator and circulate in the water jacket
attached to the periphery of the engine and water head too.

MINE PROTECTED VEHICLE (4X4 & 6X6)

➢ Engine: 6-cylinder inline diesel engine.
➢ Tank Capacity: 200 liters
➢ No. of Firing Ports: 12

Three designs of MPV-

• For Army 4X4 composite armoring of the body, the sheet is done by adding composite
armor and 3mm mild steel in the 6mm size of the body. The range of flame detection
is 10 meters.
• For Army 6X6 the range of detection of flame is increased to 15 meters. The armoring
is the same as 4X4.
• For the Ministry of Home Affairs- the armoring of the vehicle body is not done. Hull
fabrication -
The V-hull is a type of vehicle armor design used on armored personnel carriers. The purpose
of V-hulls is to increase vehicle and crew survivability by deflecting an upward directed blast
away from the vehicle, while also presenting a sloped armor face. This will prevent the ballistic
approach by increasing the amount of material it must penetrate in order to cause damage to
the residing crew. Gun shop

UP-GUNNING OF 130MM SHARANG GUN

130mm M46 field guns were used by artillery cops of the Indian army. The M46 is a Russian
towed field gun. "Sharang is the 130mm artillery gun 'up- gunned' to 155mm, 45 caliber up-
gunning based on the Army's tender," an OFB official said. The Army issued the Request for
Proposal (RFP) in 2013 for both OFB and private industry.
The gun's range has now gone from 27km to over 36km with the upgrade. It also has a more
explosive capability and hence and more damage potential. This step will reduce the logistic
trail of the Army as it does away with the need to carry 130mm shells and support equipment
as the mainstay of the Army's long-range artillery is 155mm guns.

In February 2020, the first 130mm M-46 artillery gun was upgraded to 155mm for the Indian
Army. It was formally handed over by OFB Chairman Hari Mohan to Army Chief Gen. Manoj
Naravane at the ongoing Defexpo.

Comparison Of 130 mm 155 mm

Specification
Range 27.5 km 39 km
Caliber 46 mm 45 mm
Barrel Length 6760 mm 7700 mm
Rifling Length 5860 mm 5851 mm
Muzzle Velocity 930m/sec 880m/sec

PLANT III

TATA LPTA Assembly (LA section)

LPTA ASSEMBLY is mainly conducted in plant III. Approximately 11 vehicles are assembled in a
day. Following procedure is for the same:
 • STAND 0:
It is the starting point of the assembly line. Here frame/chassis of LPTA 715 BS Ill is
assembled by connecting long members and cross members via M12 hex bolt and nut.
Parts required:
➢ RH & LH Bracket assembly
➢ Shackle Pin Rear
➢ Spring and Suspension (Rear) & (Front)
➢ Cotter Pin
➢ Hex bolt M12x1.5x112
➢ Hex Nut M12
➢ Bright washer
➢ Nylon Lock Nut M12
➢ Hex Screw M12
Check: Measuring through measuring tape. Defects: Nut-Bolt is not assembled properly (there
is some play)

• STAND 1:

Here AGB (Auxiliary Gearbox) and leaf springs are mounted on the chassis.

• STAND 2:
Rear and Front axle are mounted in this stand, also brake actuators are connected to both the
axles here itself. Pneumatic Breaking system is used.

• STAND 3:
Following components are connected here:
➢ Drying and Distribution unit (DDU): It is connected to maintain 8 bar pressure.
➢ Palm Coupling
➢ LCR-Auto sensing valve: when load increases up to alarming level it will
supply air to the breaking unit and tires so that they don't lock.All the
required pipeline connections are done.

• STAND 4:
 ➢ Shock ups are installed.
➢ Cobra brackets are fitted which provides space for steering oil and coolant
containers.
➢ LPTA has power steering assembly which is hydraulically operated.

• STAND 5:
➢ Here engine is mounted between 2nd cross member and 3rd cross member.
➢ Auxiliary water tank/coolant tank which has a capacity of 25L is connected.

• STAND 6:
➢ hook is assembled to hold and lock Cabin so that it doesn't fall.
➢ Cab Stand which has inbuilt torsion bars to lift the Cabin for repairing.
➢ Fuel heater is also connected here, its main purpose is to heat up the coolant and
fuel in very cold atmosphere to avoid freezing.

• STAND 7:

The various fitments that are done here are:

➢ Silencer
➢ Water Tank
➢ Fuel Tank
➢ Battery carrier
➢ Air tank
➢ Universal joint: to join steering link to steering gearbox.
➢ Radiator

• STAND 8:
➢ Air Intake and filter is connected
➢ Battery cut-off switch
➢ Water separator and fuel filter are connected
 • STAND 9:
➢ Cabin is mounted in this stand
➢ 24V 180A Amaron Battery

• STAND 10:
➢ Tires are fitted here.
➢ Diesel coolant and steering oil (3.5L) are filled in the respective containers.

• STAND 11:

In this stand, we perform rolling of the vehicle. The following things are tested here before
sending the vehicle for final testing and inspection:

➢ Vehicle Start
➢ Brake
➢ Clutch
➢ Steering
➢ Gears (both drives 4x4 and 2x4)

DIFFERENTIAL LOCKOUT:
When the vehicle is stuck in such a way that both rear and front wheel of any one side is not
movable then there is a mechanism provided which locks that side wheels and provide more
power to the other side wheels helping the vehicle to get out of the pit where it was stuck.

UTD 20 ENGINE OVERHAULING

➢ Capacity: 15896 cc
➢ Bore X stroke: 150mm x 150mm 4 valves per cylinder 2 inlets, 2 outlets 3 crank pins, and
6connecting rods.
Two types of connecting rods
Anti-correlated connecting rod (ACR) Fork connecting rod (FCR) Overhead camshaft
arrangement: T-type
➢ Advance driving unit (AD):
It is responsible for the valve timing regulation according to the change in speed.
➢ Lubrication: Dry sump arrangement
➢ Lubricating oil used: 20W50
➢ Pump used: gear type
 ➢ Self-starter :converts electrical energy to mechanical energy.
➢ Alternator :converts mechanical energy to electrical energy.

Following tests were performed on the engine:

1. Running and schedule-1

2. Performance test

83. Running and schedule-2

4. Specific oil consumption test

5. Control test

6. Acceptance test

The testing of the engine is done using the engineering system (Cadet v14.2c 837 software system) The
engine is connected to the system and input details are fed into the computer. The engine starts
running and the software records observations accordingly. This gives results to all the above-
mentioned tests and likewise, relevant actions are taken.

Some noted observations:

Fuel consumption: 224-245 g/kw/hr.

Max. Dynamometer reading: 785-800 Nm (Torque)

Application:

➢ BMP tanks
➢ Armored Personnel Carriers
➢ Heavy Trucks

Load fabrication section

In this section the load body fabrication will be completed of LPTA 715 .
 Plant IV

First Tender by QA(Internal)

Return Tender by QA (Internal)

Certificate by WI

Goes to CQA (Controllerate of Quality & Assurance)

First Tender Issuance by

COA

Return Tender by CQA

Inspection Note

Dispatch to Military
 SUMMARY

The sole motive of this two weeks vocational training is to

take an idea what a real industry is all about and getting
training in such an esteemed organization is definitely a
thing to be proud of. I got the chance to learn much more
than I expected before I came here. During my training I
learnt how to make Process sheet plan the activities
regarding different work and develop the techniques to
solve the problem. I also learnt the power of team work that
how onerous tasks can be accomplished easily with the help
of team work.