cummins

59
7/18/2019 cummins http://slidepdf.com/reader/full/cummins-5697a4f70e68e 1/59 INDUSTRIAL TRAINING REPORT ON “Manufacturing of Turbochargers” IN CUMMINS TURBO TECHNOLOGIES,DEWAS (M.P.) For the parta! "#!"!$e%t o" the &e'ree o" Bahe!or o" Teh%o!o'*+ I% Meha%a! E%'%eer%' ECHELON INSTITUTE OF TECHNOLOGY Maharh Da*a%a%& U%-ert*Rohta/ Seo%(01220123) UNDER THE GUIDANCE OF !U"MITTED "#  MR. AMIT SHARMA SHI4AM SARASWAT (DEPUT5 GENERAL MANAGER) (22ME6107) 2

Upload: gaurav-mehta

Post on 14-Jan-2016

15 views

Category:

Documents


0 download

DESCRIPTION

project file

TRANSCRIPT

Page 1: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 159

INDUSTRIAL TRAINING REPORT

ON

ldquoManufacturing of Turbochargersrdquo

IN

CUMMINS TURBO TECHNOLOGIESDEWAS (MP)

For the parta $et o the amperee o

Baheor o Tehoo+

I

Mehaa Eeer

ECHELON INSTITUTE OF TECHNOLOGY

Maharh Daaaamp U-ertRohta

Seo(01220123)

UNDER THE GUIDANCE OF UMITTED

MR AMIT SHARMA SHI4AM SARASWAT

(DEPUT5 GENERAL MANAGER) (22ME6107)

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 259

CERTIFICATE

It erteamp that the 8or otaeamp the the tteamp Manufacturing of Turbochargers+

9 hi$a arasampat+aat h amptra tra ha 9ee arreamp ot amper $

per-o aamp that he ha 9ee rear h eort

Satre o per-or

Mr A$t Shar$a

Mateae Fat Proltet

C$$ Tehooe Iampa Ltamp

ACKNOWLEDGEMENT

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 359

It is my pleasure to be indebted to various people o diretly or

indiretly ontributed in te development o te or$ o inampuened

my tin$in beavior ats durin te ourse o study(I e)press my sinere ratitude to Mr Amit Sharma+y(G- or providin

me an opportunity to undero Industrial Trainin at Cummins Turbo

Technologies

I am tan$ul to Mr Lokesh ain or is support ooperation

motivation provided to me durin te trainin or onstant inspiration

presene blessins(

I also e)tend my sinere appreiation to Mr Sanee Mali EngineerCTT$ o provided er valuable suestion preious time in

aomplisment o tis proet report(

Lastly I ould li$e to tan$ te almity my parents or te moral

support my parents it om I sared my day to day e)periene

reeived lots o suestions tat improved my 0uality o or$(

Shiam Sarasampat

11E2345-

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 459

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 559

AST(ACT

Te trainin as arried out in Cummins Turbo Tenoloies at +eas in

te adya prades State o Central India in maintenane department(It

manaesdevelopsand leadste daily ativities o multiple prodution units or team ma$es

reommendations to improve produtivity 0ualitysaetyand e6ieny o

operations(

7rovides uidane and eedba$ or team members in aomplisin tas$s

and oals8sets e)petations and lari9es responsibilities(Coaes and

mentors team members (Identi9es trainin needs8develops and

implement trainin plans(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 659

)NDE

SNO CONTENTS +AGE NO

1 INTO+UCTION lt

4 CUINS TU=O TECHNOLOGY 7LgtNTS IN

IN+Igt

513

OUNEY OF CUINS TU=O

TECHNOLOGIES IN IN+Igt

11

2 HEgtLTH SgtFETY gtN+ ENAIONENT 7OLICIES 12

B TU=OCHgtGE ODING 1B15

gtCHINING O7EgtTION 4323

TECHNICgtL +ETgtILS OF SG CG CNC 212

lt gtINTENgtNCE 22

5 CHECD SHEET 2BB3

13 gtINTENgtNCE O7EgtTION 7EFOE+ IN7LgtNT

B1B4

11 CONCLUSION

COM+AN +(O-)LE

)NT(ODCT)ON

Cummins India Limited CIL- is a B1 perent subsidiary o Cummins In(

USgt te orlds larest independent diesel enine desiner and

gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 759

manuaturer above 433 H7( Cummins In te maority sareolder

Cummins is te leadin orldide desiner and manuaturer o diesel

enines rom 1H7 to B33 H7( Cummins pioneer and mar$et leader in

desin development and manuaturer o diesel enines is te leadinpoer solutions provider to te Indian industry( CIL as set up in 154 as

Dirlos$ar Cummins Limited and beame Cummins India Limited CIL- in

155 en Cummins inreased its sta$e( Today CIL is Indias larest

manuaturer o diesel enines it a rane rom 1B$Agt to 4333$Agt and

value pa$aes servin te 7oer Generation Industrial and gtutomotive

ar$ets(

CILs produts inlude diesel enines in te rane o 3 H7 to 433H7( It

manuaturers over 13333 enines per annum and is amon Indias

larest e)porters o enineerin produts( CIL oers omplete rane o

Cummins orldide produts( ere indienous prodution is not

available Cummins assists in te imports o a produt rom one o te

Cummins Group Companies(

CILs ustomers in te 7oer Generation solutions setor inlude

businesses in all sements sine te rane produed by CIL oers poer

ba$up or industrial and business units o all sies( Important setors or

poer eneration solutions are all enters realty ospitality te)tiles

auto anillaries and IT( In order to ensure ustomer ous te 7oer

Generation division is divided into to business units Lo Horse 7oer

=usiness Unit and te Hi Horse 7oer =usiness +ivision( Te Hi Horse

7oer =usiness Unit as tree subdivisionsJ Cummins 7oer 7roets

Cummins 7oer House Consultin and Cummins 7oer ent(

Te Cummins Industrial =usiness Unit mar$ets diesel as enines in te

rane o B to 433H7( Tese enines are available on a variety o mobile

and stationary e0uipment used in various setors li$e Construion inin

Compressor and Fire Industrial pumps ail arine Oil9eld and

+eene( Enines are ustomied to te demands o te appliation and

are oered it oolin e)aust and air inta$e systems ully interated

it e0uipment desin or optimum perormane

Te gtutomotive Setor ouses on oners and operators o Tru$s and

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 859

oter eavyduty veiles( It is primarily enaed in distribution o parts

omponents servie support and value added servies or Kbumper to

bumper support( Cummins India Limiteds Lo Horse 7oer =usiness

Unit i manuatures and mar$ets small orsepoer enines in terane 1B$Agt to 14B$Agt is partially enaed in te manuature o Telos

CNG enines Cummins SA as enines- urrently used to poer +elis

publi transport system( Te Cummins SA as enine as been desined

to ombine ompat sie lo emission levels and e)ellent perormane

arateristis o ispeed tenoloy it te medium speed bene9ts

or loest lieyle osts in terms o uel e6ieny reliability and

durability(

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 959

Cummins Generator Technologies

Cummins Generator Tenoloies onentrates on enerators( ItMs not ust

te produts e ma$e tat set us apart itMs o e enae our

ustomers everyday( Te uni0ue ombination o $nolede

dependability and innovation e brin to ea ustomer relationsip turns

everyday servie into e)ellent ustomer support( gts a result e elp our

ustomers operate it reater e6ieny ma$in it possible or tem to

ompete more suessully trouout te orld(

Tata Cummins

Tata Cummins Limited TCL- is a B3JB3 oint Aenture beteen Tata otors

Limited IndiaMs larest gtutomobile manuaturer and Cummins Enine

Company In( o USgt orld leaders in desin and manuature o diesel

enines( Te s 33 Crore proet it an autoried sare apital o s

4B3 Crore as been set up at amsedpur or te manuature o +iesel

enines to poer Tata otors LimitedMs ommerial veiles( Te deision

to loate at amsedpur as based on te desire to be near te ustomer(

Commerial prodution o enines rom $its ommened in anuary 155

and te mainin lines or inouse manuature o omponents started

in ar 155(

The Cummins )nia -ounation C)-$

Te Cummins India Foundation CIF- as instituted in 1553 by Te

Cummins Group in India to annelie CumminsM ommitment toards

Corporate esponsibility( CIF is reistered it =ombay Caritable Trust

gtt as a Trust under Inome Ta) gtt it inistry o Home gtairs Govt(

o India under Forein Contributions eulations gtt FCgt-(

K+)T Cummins

D7IT Cummins enables tenoloy solutions tat enerate measurable

and tanible value or your business( Customers all it results o te

7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1059

ampe)ibility e oer and te relationsips e nurture(

aloline

In India Aalvoline Cummins Ltd a A beteen gtsland In( USgt and

Cummins Sales Servies India- Ltd a olly oned subsidiary o Cummins India Ltd( is one o te Indias astest roin lubriant

mar$eters and produer o 0uality branded automotiveindustrial

produts(

Cummins Turbo Technologies +lants in )nia

Cummins Turbo Tenoloies part o Cummins In(- ompletes 3 years

15B4 4314- o operations orldide( Cummins Turbo Tenoloies is a

leadin manuaturer o Turboarers it presene in most parts o te

orld(

In India Cummins Turbo Tenoloies as its plants and oies in

+eas 7itampur udrapur and 7une(

+ithamur 0 une 123 4514

Cummins Turbo Tenoloies CTT- is elebratin its 3t anniversary

year( it sales o over USP1 billion CTT as ron to be a lobalompany it operations in most parts o te orld( Tenial Centres in

21

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1159

UD Cina USgt and India ontinue to develop air andlin tenoloies or

lobal ustomers in diverse mar$ets inludin oniay ommerial

veile industrial onstrution ariulture marine and poer

eneration(

In India CTT bean as a A it Tata otors in deas in 1552( In 433 te

oint venture Tata Holset Limited beame a olly oned subsidiary o

Cummins and as renamed as Cummins Turbo Tenoloies(

Te CTT plant at deas ommened operations in 155B it merely 1B

employees( In line it CumminsQ pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at deas is no bein pratied by over 533

employees o CTT aross all sites in India(

RTere are many e)amples itin te oraniation tat testiy o

employees ave ron itin te Company( Several amonst tose

employees o oined te sop ampoor are today oldin senior positions

itin te oraniation( Tis demonstrates te oraniations ommitment

to nurturin talent and providin lonterm areers( as 0uoted by an

employee o as been assoiated it Cummins Turbo Tenoloies

sine te last 1B years

To boost te e)port business CTT set up a ne plant in 7itampur in 433lt(

Tis plant is itnessin urter e)pansion( In line it CumminsQ pratie

o truly partnerin it its ustomers8 CTT India ommissioned an entire

assembly line at udrapur(

=ein a tenoloy partner CTT upraded te bran o6e tat bean its

operations in 433B to te India Tenial Center supportin international

and domesti proets( Today Cummins Turbo Tenoloies India employs

nearly 533 employees inludin 1 speialist enineers(

Tray Embree 7resident Cummins Turbo Tenoloies omments ROur

22

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1259

leay and eritae ave e0uipped us ell or te allenes aead as e

enter a ne deade o aelerated lobal rot( ile e ontinue to

partner it our ustomers to deliver te best produts and tenoloies

our ommitment to te environment and te ommunities itin ie live remains at te eart o our business(

CTT as not only ron its business but as also played a sini9ant role

in orporate responsibility(

Re are very ommitted to our vision o a$in peopleQs lives better by

unleasin te 7oer o CumminsQ( e ave been and aim to be a ood

itien o India( e loo$ orard to strentenin our partners and

ommunities and ontinue to ro rom strent to strent ile stayin

rooted to te CompanyQs vision mission and si) ore values o interity

innovation deliverin superior results diversity lobal involvement and

orporate responsibility( added gtrun amaandran India =usiness

Country Leader or Cummins Turbo Tenoloies(

ourne6 o7 Cummins Turbo Technologies in )nia

1882 Sined te oint venture areement to operate as Tata

Holset Limited in India(

1889 anuaturin operations started at te 9rst plant in India(

Te e)istin Tata plant as upraded to te turboarer plant at

+eas(

4552 +eas plant e)pansion( Te plant as built to orld lass

standards to aieve ero deets( To support te e)pandin

business a bran o6e as set up in 7une(

455 Tata Holset Limited beame a olly oned subsidiary o

Cummins( Holset as renamed as Cummins Turbo Tenoloies(

20

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1359

gtnoter important landmar$ as layin te oundation stone o te

7itampur plant(

455 Te 7itampur plant bean its operations( Te 7itampurplant is one o te best manuaturin ailities anyere in te

orld(

4558 To support te roin domesti business Cummins Turbo

Tenoloies started its operations in udrapur(

4515 it inreased business and enineerin ous omin toIndia te India Tenial Center as establised in 7une( Currently

te tenial entre as over 13 speialised desin enineers o

atively support domesti as ell international proets(

AOT CMM)NS T(O TECltNOLOG)ES DEWAS

2=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1459

In India CTT bean as a A it Tata otors in Deampas in 188=( In 433

te oint venture Tata Holset Limited beame a olly oned subsidiary

o Cummins and as renamed as Cummins Turbo Tenoloies

Te CTT plant at +eas ommened operations in 155B it merely 1B

employees( In line it Cummins pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at +eas is no bein pratied by over 533

employees o CTT aross te plant (

Te plant as a apaity o 2B333 it 442 employees( CTT is supported

by sales and tenial o6e in 7une( It produes midrane and lit duty

apaity produts li$e ltgt2 ltgt2W3 lt=53 ltEgt21W3 Clt(A core$3

haing caacit6 o7 4K an 1K

Te manuaturin system as Gaues it Online S7C and data

entralied Server( CTT ouses on improvin proess apability rater

tan inspetion( 7roess and produts are reularly audited by 0uality

team(

Environment System is erti9ed it ISO 12331 and Healt and saety

System by OHSgtS 1lt331( CTT alays $eeps Heat and Saety as its top

priority( It as a team based or$ ulture it sel manaed team at sop

26

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1559

ampoor(

Te gtssembly ell as ommissioned in 155 it te initial setup o

benes 9)ture as data plate m rom HUD( Te urrent SetU7 as

Failsae Conveyor gtssembly Line( Tree sit run in a day it Bassoiates( ore tan 433 parts are assembled in te plant(

23

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1659

ltEALTlt SA-ET AND EN)(ONMENTAL +OL)C

Cummins is ommitted to osterin a leaner ealtier and saer

environment in every ommunity in i our people live and or$( gtllour ailities ill employ te Cummins Saety and Environmental

anaement Systems i are desined to protet our personnel and

te environment to preserve natural resoures and to prevent arm to

loal ommunities( Our approa in tis endeavor is multi aeted( e ill

systemially and aressively assess operations tat ave te potential to

arm individuals or impat te environment( e ill also set substantial

and measurable obetives in manain saety and te environment(

Finally e ill periodially revie our proress aainst our obetives(

Sustainable improvement is an essential element o bot systems and is

aimed at ontributin positively to personal saety environmental ell

bein and onservation o natural resoures(

Cummins ill ontinue to implement manaement prorams developed to

ensure tat our produts servies and ativities alays omply it loal

las and ompany standards establised to protet ealt saety and te

environment( e are ommitted to minimiin

potentially armul eets resultin rom our operations and to

implementin improvements assoiated it te prevention o pollution

inury and illness(

tis Healt Saety and Environmental 7oliy ill be applied trouout

Cummins via a set o doumented ompanyide and loal poliies and

proedures( It ill be ommuniated to all employees at least annually(

Upon re0uest te poliy ill be made available to te publi(

Tim Solso

Cairman CEO

November 15 4331

2gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1759

WO(K)NG O- T(OCltA(GE(

Te turbine omprises o to omponents8 te turbine ee l and te

olletor ommonly reerred to as te turbine ousin ( Te e)aust as is

uided into te turbine eel by te ousin( Te enery in te e)aust as

turns te turbine( One te as as passed trou te blades o te eel

it leaves te turbine ousin via te e)aust outlet area(

Te speed o te enine determines o ast te turbine eel spins( I te

enine is in idle mode te eel ill be spinnin at a minimal speed( gts

more as passes trou te turbine ousin te aster te turbine eel

rotates(

Compressors are te opposite o turbines( Tey omprise o to setions

te impeller or ompressor eel and te ompressor ousin ( Te

ompressor eel is onneted to te turbine by a ored steel sat( gts te

ompressor eel spins air is dran in and is ompressed as te blades

spin at a i veloity( Te ousin is desined to onvert te i veloity

lo pressure air stream into a i pressure lo veloity air stream trou

a proess alled diusion(

gtir enters te ompressor at a temperature e0uivalent to atmospere8

oever it leaves te ompressor over at a temperature up to 433 de

Celsius( =eause te density o te air dereases as it is eated up even

more air an be ored into te enine i te air is ooled ater te

ompressor( Tis is alled inter oolin or ater oolin and is aieved by

oolin te are air eiter it ater air(

Te turboarer bearin system is lubriated by oil rom te enine( Te

oil is ed under pressure into te bearin ousin trou to te ournal

bearins and trust system( Te oil also ats as a oolant ta$in aay eat

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1859

enerated by te turbine(

Te ournal =earins are a reeampoatin rotational type( To perorm orretly

te ournal bearins sould ampoat beteen a 9lm o oil i(e( beteen bearin sat and bearin and bearin ousin-( Te bearin learanes are very

small less tan te idt o a uman air( +irty oil or blo$aes in te oil

supply oles an ause serious damae to te turboarer(

In simple terms a turboarer omprises o a turbine and a ompressor

onneted by a ommon sat supported on a bearin system( Te

turboarer onverts aste enery rom te e)aust maniold into

ompressed air i it puses into te enine( Tis allos te enine to

produe more poer and tor0ue and improves te overall e6ieny o te

ombustion proess(

Detaile amporking o7 turbocharger ampith iagram

bull Te turbine ousin is bolted to te e)aust maniold o te enine(

bull Te aste e)aust asses are used to rotate a turbine eel i

is oused in te turbine asin(

bull Te turbine eel is onneted to a ommon sat i in turn

rotates a ompressor eel(

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1959

Fi(1

bull otatin te turbine eel is te only use or te aste e)aust as(

bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(

Fi(4

bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(

bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$in proess and pulls air into teompressor over rom te atmospere9ltered-(

Te aster te eel spin te more air is su$ed in(

Fi(

bull gts te air is su$ed into te ompressor overit is ored trou a

diuser area(

bull Tis ompressors te air and ores it into te enine(

27

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2059

bull Tis proess auses te air to inrease in temperaturesometimes

upto 433 derees C(

Fi(2

bull Te oil used in a turboarer is te same as tat used or your

turboarer(

bull Te oil is used as bot a lubriant and a oolant(

bull It is ed under pressure into te bearin ousintrou to te

ournal bearins and trust system(

01

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 2: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 259

CERTIFICATE

It erteamp that the 8or otaeamp the the tteamp Manufacturing of Turbochargers+

9 hi$a arasampat+aat h amptra tra ha 9ee arreamp ot amper $

per-o aamp that he ha 9ee rear h eort

Satre o per-or

Mr A$t Shar$a

Mateae Fat Proltet

C$$ Tehooe Iampa Ltamp

ACKNOWLEDGEMENT

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 359

It is my pleasure to be indebted to various people o diretly or

indiretly ontributed in te development o te or$ o inampuened

my tin$in beavior ats durin te ourse o study(I e)press my sinere ratitude to Mr Amit Sharma+y(G- or providin

me an opportunity to undero Industrial Trainin at Cummins Turbo

Technologies

I am tan$ul to Mr Lokesh ain or is support ooperation

motivation provided to me durin te trainin or onstant inspiration

presene blessins(

I also e)tend my sinere appreiation to Mr Sanee Mali EngineerCTT$ o provided er valuable suestion preious time in

aomplisment o tis proet report(

Lastly I ould li$e to tan$ te almity my parents or te moral

support my parents it om I sared my day to day e)periene

reeived lots o suestions tat improved my 0uality o or$(

Shiam Sarasampat

11E2345-

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 459

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 559

AST(ACT

Te trainin as arried out in Cummins Turbo Tenoloies at +eas in

te adya prades State o Central India in maintenane department(It

manaesdevelopsand leadste daily ativities o multiple prodution units or team ma$es

reommendations to improve produtivity 0ualitysaetyand e6ieny o

operations(

7rovides uidane and eedba$ or team members in aomplisin tas$s

and oals8sets e)petations and lari9es responsibilities(Coaes and

mentors team members (Identi9es trainin needs8develops and

implement trainin plans(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 659

)NDE

SNO CONTENTS +AGE NO

1 INTO+UCTION lt

4 CUINS TU=O TECHNOLOGY 7LgtNTS IN

IN+Igt

513

OUNEY OF CUINS TU=O

TECHNOLOGIES IN IN+Igt

11

2 HEgtLTH SgtFETY gtN+ ENAIONENT 7OLICIES 12

B TU=OCHgtGE ODING 1B15

gtCHINING O7EgtTION 4323

TECHNICgtL +ETgtILS OF SG CG CNC 212

lt gtINTENgtNCE 22

5 CHECD SHEET 2BB3

13 gtINTENgtNCE O7EgtTION 7EFOE+ IN7LgtNT

B1B4

11 CONCLUSION

COM+AN +(O-)LE

)NT(ODCT)ON

Cummins India Limited CIL- is a B1 perent subsidiary o Cummins In(

USgt te orlds larest independent diesel enine desiner and

gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 759

manuaturer above 433 H7( Cummins In te maority sareolder

Cummins is te leadin orldide desiner and manuaturer o diesel

enines rom 1H7 to B33 H7( Cummins pioneer and mar$et leader in

desin development and manuaturer o diesel enines is te leadinpoer solutions provider to te Indian industry( CIL as set up in 154 as

Dirlos$ar Cummins Limited and beame Cummins India Limited CIL- in

155 en Cummins inreased its sta$e( Today CIL is Indias larest

manuaturer o diesel enines it a rane rom 1B$Agt to 4333$Agt and

value pa$aes servin te 7oer Generation Industrial and gtutomotive

ar$ets(

CILs produts inlude diesel enines in te rane o 3 H7 to 433H7( It

manuaturers over 13333 enines per annum and is amon Indias

larest e)porters o enineerin produts( CIL oers omplete rane o

Cummins orldide produts( ere indienous prodution is not

available Cummins assists in te imports o a produt rom one o te

Cummins Group Companies(

CILs ustomers in te 7oer Generation solutions setor inlude

businesses in all sements sine te rane produed by CIL oers poer

ba$up or industrial and business units o all sies( Important setors or

poer eneration solutions are all enters realty ospitality te)tiles

auto anillaries and IT( In order to ensure ustomer ous te 7oer

Generation division is divided into to business units Lo Horse 7oer

=usiness Unit and te Hi Horse 7oer =usiness +ivision( Te Hi Horse

7oer =usiness Unit as tree subdivisionsJ Cummins 7oer 7roets

Cummins 7oer House Consultin and Cummins 7oer ent(

Te Cummins Industrial =usiness Unit mar$ets diesel as enines in te

rane o B to 433H7( Tese enines are available on a variety o mobile

and stationary e0uipment used in various setors li$e Construion inin

Compressor and Fire Industrial pumps ail arine Oil9eld and

+eene( Enines are ustomied to te demands o te appliation and

are oered it oolin e)aust and air inta$e systems ully interated

it e0uipment desin or optimum perormane

Te gtutomotive Setor ouses on oners and operators o Tru$s and

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 859

oter eavyduty veiles( It is primarily enaed in distribution o parts

omponents servie support and value added servies or Kbumper to

bumper support( Cummins India Limiteds Lo Horse 7oer =usiness

Unit i manuatures and mar$ets small orsepoer enines in terane 1B$Agt to 14B$Agt is partially enaed in te manuature o Telos

CNG enines Cummins SA as enines- urrently used to poer +elis

publi transport system( Te Cummins SA as enine as been desined

to ombine ompat sie lo emission levels and e)ellent perormane

arateristis o ispeed tenoloy it te medium speed bene9ts

or loest lieyle osts in terms o uel e6ieny reliability and

durability(

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 959

Cummins Generator Technologies

Cummins Generator Tenoloies onentrates on enerators( ItMs not ust

te produts e ma$e tat set us apart itMs o e enae our

ustomers everyday( Te uni0ue ombination o $nolede

dependability and innovation e brin to ea ustomer relationsip turns

everyday servie into e)ellent ustomer support( gts a result e elp our

ustomers operate it reater e6ieny ma$in it possible or tem to

ompete more suessully trouout te orld(

Tata Cummins

Tata Cummins Limited TCL- is a B3JB3 oint Aenture beteen Tata otors

Limited IndiaMs larest gtutomobile manuaturer and Cummins Enine

Company In( o USgt orld leaders in desin and manuature o diesel

enines( Te s 33 Crore proet it an autoried sare apital o s

4B3 Crore as been set up at amsedpur or te manuature o +iesel

enines to poer Tata otors LimitedMs ommerial veiles( Te deision

to loate at amsedpur as based on te desire to be near te ustomer(

Commerial prodution o enines rom $its ommened in anuary 155

and te mainin lines or inouse manuature o omponents started

in ar 155(

The Cummins )nia -ounation C)-$

Te Cummins India Foundation CIF- as instituted in 1553 by Te

Cummins Group in India to annelie CumminsM ommitment toards

Corporate esponsibility( CIF is reistered it =ombay Caritable Trust

gtt as a Trust under Inome Ta) gtt it inistry o Home gtairs Govt(

o India under Forein Contributions eulations gtt FCgt-(

K+)T Cummins

D7IT Cummins enables tenoloy solutions tat enerate measurable

and tanible value or your business( Customers all it results o te

7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1059

ampe)ibility e oer and te relationsips e nurture(

aloline

In India Aalvoline Cummins Ltd a A beteen gtsland In( USgt and

Cummins Sales Servies India- Ltd a olly oned subsidiary o Cummins India Ltd( is one o te Indias astest roin lubriant

mar$eters and produer o 0uality branded automotiveindustrial

produts(

Cummins Turbo Technologies +lants in )nia

Cummins Turbo Tenoloies part o Cummins In(- ompletes 3 years

15B4 4314- o operations orldide( Cummins Turbo Tenoloies is a

leadin manuaturer o Turboarers it presene in most parts o te

orld(

In India Cummins Turbo Tenoloies as its plants and oies in

+eas 7itampur udrapur and 7une(

+ithamur 0 une 123 4514

Cummins Turbo Tenoloies CTT- is elebratin its 3t anniversary

year( it sales o over USP1 billion CTT as ron to be a lobalompany it operations in most parts o te orld( Tenial Centres in

21

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1159

UD Cina USgt and India ontinue to develop air andlin tenoloies or

lobal ustomers in diverse mar$ets inludin oniay ommerial

veile industrial onstrution ariulture marine and poer

eneration(

In India CTT bean as a A it Tata otors in deas in 1552( In 433 te

oint venture Tata Holset Limited beame a olly oned subsidiary o

Cummins and as renamed as Cummins Turbo Tenoloies(

Te CTT plant at deas ommened operations in 155B it merely 1B

employees( In line it CumminsQ pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at deas is no bein pratied by over 533

employees o CTT aross all sites in India(

RTere are many e)amples itin te oraniation tat testiy o

employees ave ron itin te Company( Several amonst tose

employees o oined te sop ampoor are today oldin senior positions

itin te oraniation( Tis demonstrates te oraniations ommitment

to nurturin talent and providin lonterm areers( as 0uoted by an

employee o as been assoiated it Cummins Turbo Tenoloies

sine te last 1B years

To boost te e)port business CTT set up a ne plant in 7itampur in 433lt(

Tis plant is itnessin urter e)pansion( In line it CumminsQ pratie

o truly partnerin it its ustomers8 CTT India ommissioned an entire

assembly line at udrapur(

=ein a tenoloy partner CTT upraded te bran o6e tat bean its

operations in 433B to te India Tenial Center supportin international

and domesti proets( Today Cummins Turbo Tenoloies India employs

nearly 533 employees inludin 1 speialist enineers(

Tray Embree 7resident Cummins Turbo Tenoloies omments ROur

22

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1259

leay and eritae ave e0uipped us ell or te allenes aead as e

enter a ne deade o aelerated lobal rot( ile e ontinue to

partner it our ustomers to deliver te best produts and tenoloies

our ommitment to te environment and te ommunities itin ie live remains at te eart o our business(

CTT as not only ron its business but as also played a sini9ant role

in orporate responsibility(

Re are very ommitted to our vision o a$in peopleQs lives better by

unleasin te 7oer o CumminsQ( e ave been and aim to be a ood

itien o India( e loo$ orard to strentenin our partners and

ommunities and ontinue to ro rom strent to strent ile stayin

rooted to te CompanyQs vision mission and si) ore values o interity

innovation deliverin superior results diversity lobal involvement and

orporate responsibility( added gtrun amaandran India =usiness

Country Leader or Cummins Turbo Tenoloies(

ourne6 o7 Cummins Turbo Technologies in )nia

1882 Sined te oint venture areement to operate as Tata

Holset Limited in India(

1889 anuaturin operations started at te 9rst plant in India(

Te e)istin Tata plant as upraded to te turboarer plant at

+eas(

4552 +eas plant e)pansion( Te plant as built to orld lass

standards to aieve ero deets( To support te e)pandin

business a bran o6e as set up in 7une(

455 Tata Holset Limited beame a olly oned subsidiary o

Cummins( Holset as renamed as Cummins Turbo Tenoloies(

20

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1359

gtnoter important landmar$ as layin te oundation stone o te

7itampur plant(

455 Te 7itampur plant bean its operations( Te 7itampurplant is one o te best manuaturin ailities anyere in te

orld(

4558 To support te roin domesti business Cummins Turbo

Tenoloies started its operations in udrapur(

4515 it inreased business and enineerin ous omin toIndia te India Tenial Center as establised in 7une( Currently

te tenial entre as over 13 speialised desin enineers o

atively support domesti as ell international proets(

AOT CMM)NS T(O TECltNOLOG)ES DEWAS

2=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1459

In India CTT bean as a A it Tata otors in Deampas in 188=( In 433

te oint venture Tata Holset Limited beame a olly oned subsidiary

o Cummins and as renamed as Cummins Turbo Tenoloies

Te CTT plant at +eas ommened operations in 155B it merely 1B

employees( In line it Cummins pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at +eas is no bein pratied by over 533

employees o CTT aross te plant (

Te plant as a apaity o 2B333 it 442 employees( CTT is supported

by sales and tenial o6e in 7une( It produes midrane and lit duty

apaity produts li$e ltgt2 ltgt2W3 lt=53 ltEgt21W3 Clt(A core$3

haing caacit6 o7 4K an 1K

Te manuaturin system as Gaues it Online S7C and data

entralied Server( CTT ouses on improvin proess apability rater

tan inspetion( 7roess and produts are reularly audited by 0uality

team(

Environment System is erti9ed it ISO 12331 and Healt and saety

System by OHSgtS 1lt331( CTT alays $eeps Heat and Saety as its top

priority( It as a team based or$ ulture it sel manaed team at sop

26

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1559

ampoor(

Te gtssembly ell as ommissioned in 155 it te initial setup o

benes 9)ture as data plate m rom HUD( Te urrent SetU7 as

Failsae Conveyor gtssembly Line( Tree sit run in a day it Bassoiates( ore tan 433 parts are assembled in te plant(

23

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1659

ltEALTlt SA-ET AND EN)(ONMENTAL +OL)C

Cummins is ommitted to osterin a leaner ealtier and saer

environment in every ommunity in i our people live and or$( gtllour ailities ill employ te Cummins Saety and Environmental

anaement Systems i are desined to protet our personnel and

te environment to preserve natural resoures and to prevent arm to

loal ommunities( Our approa in tis endeavor is multi aeted( e ill

systemially and aressively assess operations tat ave te potential to

arm individuals or impat te environment( e ill also set substantial

and measurable obetives in manain saety and te environment(

Finally e ill periodially revie our proress aainst our obetives(

Sustainable improvement is an essential element o bot systems and is

aimed at ontributin positively to personal saety environmental ell

bein and onservation o natural resoures(

Cummins ill ontinue to implement manaement prorams developed to

ensure tat our produts servies and ativities alays omply it loal

las and ompany standards establised to protet ealt saety and te

environment( e are ommitted to minimiin

potentially armul eets resultin rom our operations and to

implementin improvements assoiated it te prevention o pollution

inury and illness(

tis Healt Saety and Environmental 7oliy ill be applied trouout

Cummins via a set o doumented ompanyide and loal poliies and

proedures( It ill be ommuniated to all employees at least annually(

Upon re0uest te poliy ill be made available to te publi(

Tim Solso

Cairman CEO

November 15 4331

2gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1759

WO(K)NG O- T(OCltA(GE(

Te turbine omprises o to omponents8 te turbine ee l and te

olletor ommonly reerred to as te turbine ousin ( Te e)aust as is

uided into te turbine eel by te ousin( Te enery in te e)aust as

turns te turbine( One te as as passed trou te blades o te eel

it leaves te turbine ousin via te e)aust outlet area(

Te speed o te enine determines o ast te turbine eel spins( I te

enine is in idle mode te eel ill be spinnin at a minimal speed( gts

more as passes trou te turbine ousin te aster te turbine eel

rotates(

Compressors are te opposite o turbines( Tey omprise o to setions

te impeller or ompressor eel and te ompressor ousin ( Te

ompressor eel is onneted to te turbine by a ored steel sat( gts te

ompressor eel spins air is dran in and is ompressed as te blades

spin at a i veloity( Te ousin is desined to onvert te i veloity

lo pressure air stream into a i pressure lo veloity air stream trou

a proess alled diusion(

gtir enters te ompressor at a temperature e0uivalent to atmospere8

oever it leaves te ompressor over at a temperature up to 433 de

Celsius( =eause te density o te air dereases as it is eated up even

more air an be ored into te enine i te air is ooled ater te

ompressor( Tis is alled inter oolin or ater oolin and is aieved by

oolin te are air eiter it ater air(

Te turboarer bearin system is lubriated by oil rom te enine( Te

oil is ed under pressure into te bearin ousin trou to te ournal

bearins and trust system( Te oil also ats as a oolant ta$in aay eat

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1859

enerated by te turbine(

Te ournal =earins are a reeampoatin rotational type( To perorm orretly

te ournal bearins sould ampoat beteen a 9lm o oil i(e( beteen bearin sat and bearin and bearin ousin-( Te bearin learanes are very

small less tan te idt o a uman air( +irty oil or blo$aes in te oil

supply oles an ause serious damae to te turboarer(

In simple terms a turboarer omprises o a turbine and a ompressor

onneted by a ommon sat supported on a bearin system( Te

turboarer onverts aste enery rom te e)aust maniold into

ompressed air i it puses into te enine( Tis allos te enine to

produe more poer and tor0ue and improves te overall e6ieny o te

ombustion proess(

Detaile amporking o7 turbocharger ampith iagram

bull Te turbine ousin is bolted to te e)aust maniold o te enine(

bull Te aste e)aust asses are used to rotate a turbine eel i

is oused in te turbine asin(

bull Te turbine eel is onneted to a ommon sat i in turn

rotates a ompressor eel(

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1959

Fi(1

bull otatin te turbine eel is te only use or te aste e)aust as(

bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(

Fi(4

bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(

bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$in proess and pulls air into teompressor over rom te atmospere9ltered-(

Te aster te eel spin te more air is su$ed in(

Fi(

bull gts te air is su$ed into te ompressor overit is ored trou a

diuser area(

bull Tis ompressors te air and ores it into te enine(

27

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2059

bull Tis proess auses te air to inrease in temperaturesometimes

upto 433 derees C(

Fi(2

bull Te oil used in a turboarer is te same as tat used or your

turboarer(

bull Te oil is used as bot a lubriant and a oolant(

bull It is ed under pressure into te bearin ousintrou to te

ournal bearins and trust system(

01

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 3: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 359

It is my pleasure to be indebted to various people o diretly or

indiretly ontributed in te development o te or$ o inampuened

my tin$in beavior ats durin te ourse o study(I e)press my sinere ratitude to Mr Amit Sharma+y(G- or providin

me an opportunity to undero Industrial Trainin at Cummins Turbo

Technologies

I am tan$ul to Mr Lokesh ain or is support ooperation

motivation provided to me durin te trainin or onstant inspiration

presene blessins(

I also e)tend my sinere appreiation to Mr Sanee Mali EngineerCTT$ o provided er valuable suestion preious time in

aomplisment o tis proet report(

Lastly I ould li$e to tan$ te almity my parents or te moral

support my parents it om I sared my day to day e)periene

reeived lots o suestions tat improved my 0uality o or$(

Shiam Sarasampat

11E2345-

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 459

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 559

AST(ACT

Te trainin as arried out in Cummins Turbo Tenoloies at +eas in

te adya prades State o Central India in maintenane department(It

manaesdevelopsand leadste daily ativities o multiple prodution units or team ma$es

reommendations to improve produtivity 0ualitysaetyand e6ieny o

operations(

7rovides uidane and eedba$ or team members in aomplisin tas$s

and oals8sets e)petations and lari9es responsibilities(Coaes and

mentors team members (Identi9es trainin needs8develops and

implement trainin plans(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 659

)NDE

SNO CONTENTS +AGE NO

1 INTO+UCTION lt

4 CUINS TU=O TECHNOLOGY 7LgtNTS IN

IN+Igt

513

OUNEY OF CUINS TU=O

TECHNOLOGIES IN IN+Igt

11

2 HEgtLTH SgtFETY gtN+ ENAIONENT 7OLICIES 12

B TU=OCHgtGE ODING 1B15

gtCHINING O7EgtTION 4323

TECHNICgtL +ETgtILS OF SG CG CNC 212

lt gtINTENgtNCE 22

5 CHECD SHEET 2BB3

13 gtINTENgtNCE O7EgtTION 7EFOE+ IN7LgtNT

B1B4

11 CONCLUSION

COM+AN +(O-)LE

)NT(ODCT)ON

Cummins India Limited CIL- is a B1 perent subsidiary o Cummins In(

USgt te orlds larest independent diesel enine desiner and

gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 759

manuaturer above 433 H7( Cummins In te maority sareolder

Cummins is te leadin orldide desiner and manuaturer o diesel

enines rom 1H7 to B33 H7( Cummins pioneer and mar$et leader in

desin development and manuaturer o diesel enines is te leadinpoer solutions provider to te Indian industry( CIL as set up in 154 as

Dirlos$ar Cummins Limited and beame Cummins India Limited CIL- in

155 en Cummins inreased its sta$e( Today CIL is Indias larest

manuaturer o diesel enines it a rane rom 1B$Agt to 4333$Agt and

value pa$aes servin te 7oer Generation Industrial and gtutomotive

ar$ets(

CILs produts inlude diesel enines in te rane o 3 H7 to 433H7( It

manuaturers over 13333 enines per annum and is amon Indias

larest e)porters o enineerin produts( CIL oers omplete rane o

Cummins orldide produts( ere indienous prodution is not

available Cummins assists in te imports o a produt rom one o te

Cummins Group Companies(

CILs ustomers in te 7oer Generation solutions setor inlude

businesses in all sements sine te rane produed by CIL oers poer

ba$up or industrial and business units o all sies( Important setors or

poer eneration solutions are all enters realty ospitality te)tiles

auto anillaries and IT( In order to ensure ustomer ous te 7oer

Generation division is divided into to business units Lo Horse 7oer

=usiness Unit and te Hi Horse 7oer =usiness +ivision( Te Hi Horse

7oer =usiness Unit as tree subdivisionsJ Cummins 7oer 7roets

Cummins 7oer House Consultin and Cummins 7oer ent(

Te Cummins Industrial =usiness Unit mar$ets diesel as enines in te

rane o B to 433H7( Tese enines are available on a variety o mobile

and stationary e0uipment used in various setors li$e Construion inin

Compressor and Fire Industrial pumps ail arine Oil9eld and

+eene( Enines are ustomied to te demands o te appliation and

are oered it oolin e)aust and air inta$e systems ully interated

it e0uipment desin or optimum perormane

Te gtutomotive Setor ouses on oners and operators o Tru$s and

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 859

oter eavyduty veiles( It is primarily enaed in distribution o parts

omponents servie support and value added servies or Kbumper to

bumper support( Cummins India Limiteds Lo Horse 7oer =usiness

Unit i manuatures and mar$ets small orsepoer enines in terane 1B$Agt to 14B$Agt is partially enaed in te manuature o Telos

CNG enines Cummins SA as enines- urrently used to poer +elis

publi transport system( Te Cummins SA as enine as been desined

to ombine ompat sie lo emission levels and e)ellent perormane

arateristis o ispeed tenoloy it te medium speed bene9ts

or loest lieyle osts in terms o uel e6ieny reliability and

durability(

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 959

Cummins Generator Technologies

Cummins Generator Tenoloies onentrates on enerators( ItMs not ust

te produts e ma$e tat set us apart itMs o e enae our

ustomers everyday( Te uni0ue ombination o $nolede

dependability and innovation e brin to ea ustomer relationsip turns

everyday servie into e)ellent ustomer support( gts a result e elp our

ustomers operate it reater e6ieny ma$in it possible or tem to

ompete more suessully trouout te orld(

Tata Cummins

Tata Cummins Limited TCL- is a B3JB3 oint Aenture beteen Tata otors

Limited IndiaMs larest gtutomobile manuaturer and Cummins Enine

Company In( o USgt orld leaders in desin and manuature o diesel

enines( Te s 33 Crore proet it an autoried sare apital o s

4B3 Crore as been set up at amsedpur or te manuature o +iesel

enines to poer Tata otors LimitedMs ommerial veiles( Te deision

to loate at amsedpur as based on te desire to be near te ustomer(

Commerial prodution o enines rom $its ommened in anuary 155

and te mainin lines or inouse manuature o omponents started

in ar 155(

The Cummins )nia -ounation C)-$

Te Cummins India Foundation CIF- as instituted in 1553 by Te

Cummins Group in India to annelie CumminsM ommitment toards

Corporate esponsibility( CIF is reistered it =ombay Caritable Trust

gtt as a Trust under Inome Ta) gtt it inistry o Home gtairs Govt(

o India under Forein Contributions eulations gtt FCgt-(

K+)T Cummins

D7IT Cummins enables tenoloy solutions tat enerate measurable

and tanible value or your business( Customers all it results o te

7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1059

ampe)ibility e oer and te relationsips e nurture(

aloline

In India Aalvoline Cummins Ltd a A beteen gtsland In( USgt and

Cummins Sales Servies India- Ltd a olly oned subsidiary o Cummins India Ltd( is one o te Indias astest roin lubriant

mar$eters and produer o 0uality branded automotiveindustrial

produts(

Cummins Turbo Technologies +lants in )nia

Cummins Turbo Tenoloies part o Cummins In(- ompletes 3 years

15B4 4314- o operations orldide( Cummins Turbo Tenoloies is a

leadin manuaturer o Turboarers it presene in most parts o te

orld(

In India Cummins Turbo Tenoloies as its plants and oies in

+eas 7itampur udrapur and 7une(

+ithamur 0 une 123 4514

Cummins Turbo Tenoloies CTT- is elebratin its 3t anniversary

year( it sales o over USP1 billion CTT as ron to be a lobalompany it operations in most parts o te orld( Tenial Centres in

21

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1159

UD Cina USgt and India ontinue to develop air andlin tenoloies or

lobal ustomers in diverse mar$ets inludin oniay ommerial

veile industrial onstrution ariulture marine and poer

eneration(

In India CTT bean as a A it Tata otors in deas in 1552( In 433 te

oint venture Tata Holset Limited beame a olly oned subsidiary o

Cummins and as renamed as Cummins Turbo Tenoloies(

Te CTT plant at deas ommened operations in 155B it merely 1B

employees( In line it CumminsQ pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at deas is no bein pratied by over 533

employees o CTT aross all sites in India(

RTere are many e)amples itin te oraniation tat testiy o

employees ave ron itin te Company( Several amonst tose

employees o oined te sop ampoor are today oldin senior positions

itin te oraniation( Tis demonstrates te oraniations ommitment

to nurturin talent and providin lonterm areers( as 0uoted by an

employee o as been assoiated it Cummins Turbo Tenoloies

sine te last 1B years

To boost te e)port business CTT set up a ne plant in 7itampur in 433lt(

Tis plant is itnessin urter e)pansion( In line it CumminsQ pratie

o truly partnerin it its ustomers8 CTT India ommissioned an entire

assembly line at udrapur(

=ein a tenoloy partner CTT upraded te bran o6e tat bean its

operations in 433B to te India Tenial Center supportin international

and domesti proets( Today Cummins Turbo Tenoloies India employs

nearly 533 employees inludin 1 speialist enineers(

Tray Embree 7resident Cummins Turbo Tenoloies omments ROur

22

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1259

leay and eritae ave e0uipped us ell or te allenes aead as e

enter a ne deade o aelerated lobal rot( ile e ontinue to

partner it our ustomers to deliver te best produts and tenoloies

our ommitment to te environment and te ommunities itin ie live remains at te eart o our business(

CTT as not only ron its business but as also played a sini9ant role

in orporate responsibility(

Re are very ommitted to our vision o a$in peopleQs lives better by

unleasin te 7oer o CumminsQ( e ave been and aim to be a ood

itien o India( e loo$ orard to strentenin our partners and

ommunities and ontinue to ro rom strent to strent ile stayin

rooted to te CompanyQs vision mission and si) ore values o interity

innovation deliverin superior results diversity lobal involvement and

orporate responsibility( added gtrun amaandran India =usiness

Country Leader or Cummins Turbo Tenoloies(

ourne6 o7 Cummins Turbo Technologies in )nia

1882 Sined te oint venture areement to operate as Tata

Holset Limited in India(

1889 anuaturin operations started at te 9rst plant in India(

Te e)istin Tata plant as upraded to te turboarer plant at

+eas(

4552 +eas plant e)pansion( Te plant as built to orld lass

standards to aieve ero deets( To support te e)pandin

business a bran o6e as set up in 7une(

455 Tata Holset Limited beame a olly oned subsidiary o

Cummins( Holset as renamed as Cummins Turbo Tenoloies(

20

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1359

gtnoter important landmar$ as layin te oundation stone o te

7itampur plant(

455 Te 7itampur plant bean its operations( Te 7itampurplant is one o te best manuaturin ailities anyere in te

orld(

4558 To support te roin domesti business Cummins Turbo

Tenoloies started its operations in udrapur(

4515 it inreased business and enineerin ous omin toIndia te India Tenial Center as establised in 7une( Currently

te tenial entre as over 13 speialised desin enineers o

atively support domesti as ell international proets(

AOT CMM)NS T(O TECltNOLOG)ES DEWAS

2=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1459

In India CTT bean as a A it Tata otors in Deampas in 188=( In 433

te oint venture Tata Holset Limited beame a olly oned subsidiary

o Cummins and as renamed as Cummins Turbo Tenoloies

Te CTT plant at +eas ommened operations in 155B it merely 1B

employees( In line it Cummins pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at +eas is no bein pratied by over 533

employees o CTT aross te plant (

Te plant as a apaity o 2B333 it 442 employees( CTT is supported

by sales and tenial o6e in 7une( It produes midrane and lit duty

apaity produts li$e ltgt2 ltgt2W3 lt=53 ltEgt21W3 Clt(A core$3

haing caacit6 o7 4K an 1K

Te manuaturin system as Gaues it Online S7C and data

entralied Server( CTT ouses on improvin proess apability rater

tan inspetion( 7roess and produts are reularly audited by 0uality

team(

Environment System is erti9ed it ISO 12331 and Healt and saety

System by OHSgtS 1lt331( CTT alays $eeps Heat and Saety as its top

priority( It as a team based or$ ulture it sel manaed team at sop

26

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1559

ampoor(

Te gtssembly ell as ommissioned in 155 it te initial setup o

benes 9)ture as data plate m rom HUD( Te urrent SetU7 as

Failsae Conveyor gtssembly Line( Tree sit run in a day it Bassoiates( ore tan 433 parts are assembled in te plant(

23

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1659

ltEALTlt SA-ET AND EN)(ONMENTAL +OL)C

Cummins is ommitted to osterin a leaner ealtier and saer

environment in every ommunity in i our people live and or$( gtllour ailities ill employ te Cummins Saety and Environmental

anaement Systems i are desined to protet our personnel and

te environment to preserve natural resoures and to prevent arm to

loal ommunities( Our approa in tis endeavor is multi aeted( e ill

systemially and aressively assess operations tat ave te potential to

arm individuals or impat te environment( e ill also set substantial

and measurable obetives in manain saety and te environment(

Finally e ill periodially revie our proress aainst our obetives(

Sustainable improvement is an essential element o bot systems and is

aimed at ontributin positively to personal saety environmental ell

bein and onservation o natural resoures(

Cummins ill ontinue to implement manaement prorams developed to

ensure tat our produts servies and ativities alays omply it loal

las and ompany standards establised to protet ealt saety and te

environment( e are ommitted to minimiin

potentially armul eets resultin rom our operations and to

implementin improvements assoiated it te prevention o pollution

inury and illness(

tis Healt Saety and Environmental 7oliy ill be applied trouout

Cummins via a set o doumented ompanyide and loal poliies and

proedures( It ill be ommuniated to all employees at least annually(

Upon re0uest te poliy ill be made available to te publi(

Tim Solso

Cairman CEO

November 15 4331

2gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1759

WO(K)NG O- T(OCltA(GE(

Te turbine omprises o to omponents8 te turbine ee l and te

olletor ommonly reerred to as te turbine ousin ( Te e)aust as is

uided into te turbine eel by te ousin( Te enery in te e)aust as

turns te turbine( One te as as passed trou te blades o te eel

it leaves te turbine ousin via te e)aust outlet area(

Te speed o te enine determines o ast te turbine eel spins( I te

enine is in idle mode te eel ill be spinnin at a minimal speed( gts

more as passes trou te turbine ousin te aster te turbine eel

rotates(

Compressors are te opposite o turbines( Tey omprise o to setions

te impeller or ompressor eel and te ompressor ousin ( Te

ompressor eel is onneted to te turbine by a ored steel sat( gts te

ompressor eel spins air is dran in and is ompressed as te blades

spin at a i veloity( Te ousin is desined to onvert te i veloity

lo pressure air stream into a i pressure lo veloity air stream trou

a proess alled diusion(

gtir enters te ompressor at a temperature e0uivalent to atmospere8

oever it leaves te ompressor over at a temperature up to 433 de

Celsius( =eause te density o te air dereases as it is eated up even

more air an be ored into te enine i te air is ooled ater te

ompressor( Tis is alled inter oolin or ater oolin and is aieved by

oolin te are air eiter it ater air(

Te turboarer bearin system is lubriated by oil rom te enine( Te

oil is ed under pressure into te bearin ousin trou to te ournal

bearins and trust system( Te oil also ats as a oolant ta$in aay eat

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1859

enerated by te turbine(

Te ournal =earins are a reeampoatin rotational type( To perorm orretly

te ournal bearins sould ampoat beteen a 9lm o oil i(e( beteen bearin sat and bearin and bearin ousin-( Te bearin learanes are very

small less tan te idt o a uman air( +irty oil or blo$aes in te oil

supply oles an ause serious damae to te turboarer(

In simple terms a turboarer omprises o a turbine and a ompressor

onneted by a ommon sat supported on a bearin system( Te

turboarer onverts aste enery rom te e)aust maniold into

ompressed air i it puses into te enine( Tis allos te enine to

produe more poer and tor0ue and improves te overall e6ieny o te

ombustion proess(

Detaile amporking o7 turbocharger ampith iagram

bull Te turbine ousin is bolted to te e)aust maniold o te enine(

bull Te aste e)aust asses are used to rotate a turbine eel i

is oused in te turbine asin(

bull Te turbine eel is onneted to a ommon sat i in turn

rotates a ompressor eel(

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1959

Fi(1

bull otatin te turbine eel is te only use or te aste e)aust as(

bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(

Fi(4

bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(

bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$in proess and pulls air into teompressor over rom te atmospere9ltered-(

Te aster te eel spin te more air is su$ed in(

Fi(

bull gts te air is su$ed into te ompressor overit is ored trou a

diuser area(

bull Tis ompressors te air and ores it into te enine(

27

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2059

bull Tis proess auses te air to inrease in temperaturesometimes

upto 433 derees C(

Fi(2

bull Te oil used in a turboarer is te same as tat used or your

turboarer(

bull Te oil is used as bot a lubriant and a oolant(

bull It is ed under pressure into te bearin ousintrou to te

ournal bearins and trust system(

01

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 4: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 459

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 559

AST(ACT

Te trainin as arried out in Cummins Turbo Tenoloies at +eas in

te adya prades State o Central India in maintenane department(It

manaesdevelopsand leadste daily ativities o multiple prodution units or team ma$es

reommendations to improve produtivity 0ualitysaetyand e6ieny o

operations(

7rovides uidane and eedba$ or team members in aomplisin tas$s

and oals8sets e)petations and lari9es responsibilities(Coaes and

mentors team members (Identi9es trainin needs8develops and

implement trainin plans(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 659

)NDE

SNO CONTENTS +AGE NO

1 INTO+UCTION lt

4 CUINS TU=O TECHNOLOGY 7LgtNTS IN

IN+Igt

513

OUNEY OF CUINS TU=O

TECHNOLOGIES IN IN+Igt

11

2 HEgtLTH SgtFETY gtN+ ENAIONENT 7OLICIES 12

B TU=OCHgtGE ODING 1B15

gtCHINING O7EgtTION 4323

TECHNICgtL +ETgtILS OF SG CG CNC 212

lt gtINTENgtNCE 22

5 CHECD SHEET 2BB3

13 gtINTENgtNCE O7EgtTION 7EFOE+ IN7LgtNT

B1B4

11 CONCLUSION

COM+AN +(O-)LE

)NT(ODCT)ON

Cummins India Limited CIL- is a B1 perent subsidiary o Cummins In(

USgt te orlds larest independent diesel enine desiner and

gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 759

manuaturer above 433 H7( Cummins In te maority sareolder

Cummins is te leadin orldide desiner and manuaturer o diesel

enines rom 1H7 to B33 H7( Cummins pioneer and mar$et leader in

desin development and manuaturer o diesel enines is te leadinpoer solutions provider to te Indian industry( CIL as set up in 154 as

Dirlos$ar Cummins Limited and beame Cummins India Limited CIL- in

155 en Cummins inreased its sta$e( Today CIL is Indias larest

manuaturer o diesel enines it a rane rom 1B$Agt to 4333$Agt and

value pa$aes servin te 7oer Generation Industrial and gtutomotive

ar$ets(

CILs produts inlude diesel enines in te rane o 3 H7 to 433H7( It

manuaturers over 13333 enines per annum and is amon Indias

larest e)porters o enineerin produts( CIL oers omplete rane o

Cummins orldide produts( ere indienous prodution is not

available Cummins assists in te imports o a produt rom one o te

Cummins Group Companies(

CILs ustomers in te 7oer Generation solutions setor inlude

businesses in all sements sine te rane produed by CIL oers poer

ba$up or industrial and business units o all sies( Important setors or

poer eneration solutions are all enters realty ospitality te)tiles

auto anillaries and IT( In order to ensure ustomer ous te 7oer

Generation division is divided into to business units Lo Horse 7oer

=usiness Unit and te Hi Horse 7oer =usiness +ivision( Te Hi Horse

7oer =usiness Unit as tree subdivisionsJ Cummins 7oer 7roets

Cummins 7oer House Consultin and Cummins 7oer ent(

Te Cummins Industrial =usiness Unit mar$ets diesel as enines in te

rane o B to 433H7( Tese enines are available on a variety o mobile

and stationary e0uipment used in various setors li$e Construion inin

Compressor and Fire Industrial pumps ail arine Oil9eld and

+eene( Enines are ustomied to te demands o te appliation and

are oered it oolin e)aust and air inta$e systems ully interated

it e0uipment desin or optimum perormane

Te gtutomotive Setor ouses on oners and operators o Tru$s and

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 859

oter eavyduty veiles( It is primarily enaed in distribution o parts

omponents servie support and value added servies or Kbumper to

bumper support( Cummins India Limiteds Lo Horse 7oer =usiness

Unit i manuatures and mar$ets small orsepoer enines in terane 1B$Agt to 14B$Agt is partially enaed in te manuature o Telos

CNG enines Cummins SA as enines- urrently used to poer +elis

publi transport system( Te Cummins SA as enine as been desined

to ombine ompat sie lo emission levels and e)ellent perormane

arateristis o ispeed tenoloy it te medium speed bene9ts

or loest lieyle osts in terms o uel e6ieny reliability and

durability(

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 959

Cummins Generator Technologies

Cummins Generator Tenoloies onentrates on enerators( ItMs not ust

te produts e ma$e tat set us apart itMs o e enae our

ustomers everyday( Te uni0ue ombination o $nolede

dependability and innovation e brin to ea ustomer relationsip turns

everyday servie into e)ellent ustomer support( gts a result e elp our

ustomers operate it reater e6ieny ma$in it possible or tem to

ompete more suessully trouout te orld(

Tata Cummins

Tata Cummins Limited TCL- is a B3JB3 oint Aenture beteen Tata otors

Limited IndiaMs larest gtutomobile manuaturer and Cummins Enine

Company In( o USgt orld leaders in desin and manuature o diesel

enines( Te s 33 Crore proet it an autoried sare apital o s

4B3 Crore as been set up at amsedpur or te manuature o +iesel

enines to poer Tata otors LimitedMs ommerial veiles( Te deision

to loate at amsedpur as based on te desire to be near te ustomer(

Commerial prodution o enines rom $its ommened in anuary 155

and te mainin lines or inouse manuature o omponents started

in ar 155(

The Cummins )nia -ounation C)-$

Te Cummins India Foundation CIF- as instituted in 1553 by Te

Cummins Group in India to annelie CumminsM ommitment toards

Corporate esponsibility( CIF is reistered it =ombay Caritable Trust

gtt as a Trust under Inome Ta) gtt it inistry o Home gtairs Govt(

o India under Forein Contributions eulations gtt FCgt-(

K+)T Cummins

D7IT Cummins enables tenoloy solutions tat enerate measurable

and tanible value or your business( Customers all it results o te

7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1059

ampe)ibility e oer and te relationsips e nurture(

aloline

In India Aalvoline Cummins Ltd a A beteen gtsland In( USgt and

Cummins Sales Servies India- Ltd a olly oned subsidiary o Cummins India Ltd( is one o te Indias astest roin lubriant

mar$eters and produer o 0uality branded automotiveindustrial

produts(

Cummins Turbo Technologies +lants in )nia

Cummins Turbo Tenoloies part o Cummins In(- ompletes 3 years

15B4 4314- o operations orldide( Cummins Turbo Tenoloies is a

leadin manuaturer o Turboarers it presene in most parts o te

orld(

In India Cummins Turbo Tenoloies as its plants and oies in

+eas 7itampur udrapur and 7une(

+ithamur 0 une 123 4514

Cummins Turbo Tenoloies CTT- is elebratin its 3t anniversary

year( it sales o over USP1 billion CTT as ron to be a lobalompany it operations in most parts o te orld( Tenial Centres in

21

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1159

UD Cina USgt and India ontinue to develop air andlin tenoloies or

lobal ustomers in diverse mar$ets inludin oniay ommerial

veile industrial onstrution ariulture marine and poer

eneration(

In India CTT bean as a A it Tata otors in deas in 1552( In 433 te

oint venture Tata Holset Limited beame a olly oned subsidiary o

Cummins and as renamed as Cummins Turbo Tenoloies(

Te CTT plant at deas ommened operations in 155B it merely 1B

employees( In line it CumminsQ pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at deas is no bein pratied by over 533

employees o CTT aross all sites in India(

RTere are many e)amples itin te oraniation tat testiy o

employees ave ron itin te Company( Several amonst tose

employees o oined te sop ampoor are today oldin senior positions

itin te oraniation( Tis demonstrates te oraniations ommitment

to nurturin talent and providin lonterm areers( as 0uoted by an

employee o as been assoiated it Cummins Turbo Tenoloies

sine te last 1B years

To boost te e)port business CTT set up a ne plant in 7itampur in 433lt(

Tis plant is itnessin urter e)pansion( In line it CumminsQ pratie

o truly partnerin it its ustomers8 CTT India ommissioned an entire

assembly line at udrapur(

=ein a tenoloy partner CTT upraded te bran o6e tat bean its

operations in 433B to te India Tenial Center supportin international

and domesti proets( Today Cummins Turbo Tenoloies India employs

nearly 533 employees inludin 1 speialist enineers(

Tray Embree 7resident Cummins Turbo Tenoloies omments ROur

22

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1259

leay and eritae ave e0uipped us ell or te allenes aead as e

enter a ne deade o aelerated lobal rot( ile e ontinue to

partner it our ustomers to deliver te best produts and tenoloies

our ommitment to te environment and te ommunities itin ie live remains at te eart o our business(

CTT as not only ron its business but as also played a sini9ant role

in orporate responsibility(

Re are very ommitted to our vision o a$in peopleQs lives better by

unleasin te 7oer o CumminsQ( e ave been and aim to be a ood

itien o India( e loo$ orard to strentenin our partners and

ommunities and ontinue to ro rom strent to strent ile stayin

rooted to te CompanyQs vision mission and si) ore values o interity

innovation deliverin superior results diversity lobal involvement and

orporate responsibility( added gtrun amaandran India =usiness

Country Leader or Cummins Turbo Tenoloies(

ourne6 o7 Cummins Turbo Technologies in )nia

1882 Sined te oint venture areement to operate as Tata

Holset Limited in India(

1889 anuaturin operations started at te 9rst plant in India(

Te e)istin Tata plant as upraded to te turboarer plant at

+eas(

4552 +eas plant e)pansion( Te plant as built to orld lass

standards to aieve ero deets( To support te e)pandin

business a bran o6e as set up in 7une(

455 Tata Holset Limited beame a olly oned subsidiary o

Cummins( Holset as renamed as Cummins Turbo Tenoloies(

20

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1359

gtnoter important landmar$ as layin te oundation stone o te

7itampur plant(

455 Te 7itampur plant bean its operations( Te 7itampurplant is one o te best manuaturin ailities anyere in te

orld(

4558 To support te roin domesti business Cummins Turbo

Tenoloies started its operations in udrapur(

4515 it inreased business and enineerin ous omin toIndia te India Tenial Center as establised in 7une( Currently

te tenial entre as over 13 speialised desin enineers o

atively support domesti as ell international proets(

AOT CMM)NS T(O TECltNOLOG)ES DEWAS

2=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1459

In India CTT bean as a A it Tata otors in Deampas in 188=( In 433

te oint venture Tata Holset Limited beame a olly oned subsidiary

o Cummins and as renamed as Cummins Turbo Tenoloies

Te CTT plant at +eas ommened operations in 155B it merely 1B

employees( In line it Cummins pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at +eas is no bein pratied by over 533

employees o CTT aross te plant (

Te plant as a apaity o 2B333 it 442 employees( CTT is supported

by sales and tenial o6e in 7une( It produes midrane and lit duty

apaity produts li$e ltgt2 ltgt2W3 lt=53 ltEgt21W3 Clt(A core$3

haing caacit6 o7 4K an 1K

Te manuaturin system as Gaues it Online S7C and data

entralied Server( CTT ouses on improvin proess apability rater

tan inspetion( 7roess and produts are reularly audited by 0uality

team(

Environment System is erti9ed it ISO 12331 and Healt and saety

System by OHSgtS 1lt331( CTT alays $eeps Heat and Saety as its top

priority( It as a team based or$ ulture it sel manaed team at sop

26

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1559

ampoor(

Te gtssembly ell as ommissioned in 155 it te initial setup o

benes 9)ture as data plate m rom HUD( Te urrent SetU7 as

Failsae Conveyor gtssembly Line( Tree sit run in a day it Bassoiates( ore tan 433 parts are assembled in te plant(

23

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1659

ltEALTlt SA-ET AND EN)(ONMENTAL +OL)C

Cummins is ommitted to osterin a leaner ealtier and saer

environment in every ommunity in i our people live and or$( gtllour ailities ill employ te Cummins Saety and Environmental

anaement Systems i are desined to protet our personnel and

te environment to preserve natural resoures and to prevent arm to

loal ommunities( Our approa in tis endeavor is multi aeted( e ill

systemially and aressively assess operations tat ave te potential to

arm individuals or impat te environment( e ill also set substantial

and measurable obetives in manain saety and te environment(

Finally e ill periodially revie our proress aainst our obetives(

Sustainable improvement is an essential element o bot systems and is

aimed at ontributin positively to personal saety environmental ell

bein and onservation o natural resoures(

Cummins ill ontinue to implement manaement prorams developed to

ensure tat our produts servies and ativities alays omply it loal

las and ompany standards establised to protet ealt saety and te

environment( e are ommitted to minimiin

potentially armul eets resultin rom our operations and to

implementin improvements assoiated it te prevention o pollution

inury and illness(

tis Healt Saety and Environmental 7oliy ill be applied trouout

Cummins via a set o doumented ompanyide and loal poliies and

proedures( It ill be ommuniated to all employees at least annually(

Upon re0uest te poliy ill be made available to te publi(

Tim Solso

Cairman CEO

November 15 4331

2gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1759

WO(K)NG O- T(OCltA(GE(

Te turbine omprises o to omponents8 te turbine ee l and te

olletor ommonly reerred to as te turbine ousin ( Te e)aust as is

uided into te turbine eel by te ousin( Te enery in te e)aust as

turns te turbine( One te as as passed trou te blades o te eel

it leaves te turbine ousin via te e)aust outlet area(

Te speed o te enine determines o ast te turbine eel spins( I te

enine is in idle mode te eel ill be spinnin at a minimal speed( gts

more as passes trou te turbine ousin te aster te turbine eel

rotates(

Compressors are te opposite o turbines( Tey omprise o to setions

te impeller or ompressor eel and te ompressor ousin ( Te

ompressor eel is onneted to te turbine by a ored steel sat( gts te

ompressor eel spins air is dran in and is ompressed as te blades

spin at a i veloity( Te ousin is desined to onvert te i veloity

lo pressure air stream into a i pressure lo veloity air stream trou

a proess alled diusion(

gtir enters te ompressor at a temperature e0uivalent to atmospere8

oever it leaves te ompressor over at a temperature up to 433 de

Celsius( =eause te density o te air dereases as it is eated up even

more air an be ored into te enine i te air is ooled ater te

ompressor( Tis is alled inter oolin or ater oolin and is aieved by

oolin te are air eiter it ater air(

Te turboarer bearin system is lubriated by oil rom te enine( Te

oil is ed under pressure into te bearin ousin trou to te ournal

bearins and trust system( Te oil also ats as a oolant ta$in aay eat

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1859

enerated by te turbine(

Te ournal =earins are a reeampoatin rotational type( To perorm orretly

te ournal bearins sould ampoat beteen a 9lm o oil i(e( beteen bearin sat and bearin and bearin ousin-( Te bearin learanes are very

small less tan te idt o a uman air( +irty oil or blo$aes in te oil

supply oles an ause serious damae to te turboarer(

In simple terms a turboarer omprises o a turbine and a ompressor

onneted by a ommon sat supported on a bearin system( Te

turboarer onverts aste enery rom te e)aust maniold into

ompressed air i it puses into te enine( Tis allos te enine to

produe more poer and tor0ue and improves te overall e6ieny o te

ombustion proess(

Detaile amporking o7 turbocharger ampith iagram

bull Te turbine ousin is bolted to te e)aust maniold o te enine(

bull Te aste e)aust asses are used to rotate a turbine eel i

is oused in te turbine asin(

bull Te turbine eel is onneted to a ommon sat i in turn

rotates a ompressor eel(

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1959

Fi(1

bull otatin te turbine eel is te only use or te aste e)aust as(

bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(

Fi(4

bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(

bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$in proess and pulls air into teompressor over rom te atmospere9ltered-(

Te aster te eel spin te more air is su$ed in(

Fi(

bull gts te air is su$ed into te ompressor overit is ored trou a

diuser area(

bull Tis ompressors te air and ores it into te enine(

27

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2059

bull Tis proess auses te air to inrease in temperaturesometimes

upto 433 derees C(

Fi(2

bull Te oil used in a turboarer is te same as tat used or your

turboarer(

bull Te oil is used as bot a lubriant and a oolant(

bull It is ed under pressure into te bearin ousintrou to te

ournal bearins and trust system(

01

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 5: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 559

AST(ACT

Te trainin as arried out in Cummins Turbo Tenoloies at +eas in

te adya prades State o Central India in maintenane department(It

manaesdevelopsand leadste daily ativities o multiple prodution units or team ma$es

reommendations to improve produtivity 0ualitysaetyand e6ieny o

operations(

7rovides uidane and eedba$ or team members in aomplisin tas$s

and oals8sets e)petations and lari9es responsibilities(Coaes and

mentors team members (Identi9es trainin needs8develops and

implement trainin plans(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 659

)NDE

SNO CONTENTS +AGE NO

1 INTO+UCTION lt

4 CUINS TU=O TECHNOLOGY 7LgtNTS IN

IN+Igt

513

OUNEY OF CUINS TU=O

TECHNOLOGIES IN IN+Igt

11

2 HEgtLTH SgtFETY gtN+ ENAIONENT 7OLICIES 12

B TU=OCHgtGE ODING 1B15

gtCHINING O7EgtTION 4323

TECHNICgtL +ETgtILS OF SG CG CNC 212

lt gtINTENgtNCE 22

5 CHECD SHEET 2BB3

13 gtINTENgtNCE O7EgtTION 7EFOE+ IN7LgtNT

B1B4

11 CONCLUSION

COM+AN +(O-)LE

)NT(ODCT)ON

Cummins India Limited CIL- is a B1 perent subsidiary o Cummins In(

USgt te orlds larest independent diesel enine desiner and

gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 759

manuaturer above 433 H7( Cummins In te maority sareolder

Cummins is te leadin orldide desiner and manuaturer o diesel

enines rom 1H7 to B33 H7( Cummins pioneer and mar$et leader in

desin development and manuaturer o diesel enines is te leadinpoer solutions provider to te Indian industry( CIL as set up in 154 as

Dirlos$ar Cummins Limited and beame Cummins India Limited CIL- in

155 en Cummins inreased its sta$e( Today CIL is Indias larest

manuaturer o diesel enines it a rane rom 1B$Agt to 4333$Agt and

value pa$aes servin te 7oer Generation Industrial and gtutomotive

ar$ets(

CILs produts inlude diesel enines in te rane o 3 H7 to 433H7( It

manuaturers over 13333 enines per annum and is amon Indias

larest e)porters o enineerin produts( CIL oers omplete rane o

Cummins orldide produts( ere indienous prodution is not

available Cummins assists in te imports o a produt rom one o te

Cummins Group Companies(

CILs ustomers in te 7oer Generation solutions setor inlude

businesses in all sements sine te rane produed by CIL oers poer

ba$up or industrial and business units o all sies( Important setors or

poer eneration solutions are all enters realty ospitality te)tiles

auto anillaries and IT( In order to ensure ustomer ous te 7oer

Generation division is divided into to business units Lo Horse 7oer

=usiness Unit and te Hi Horse 7oer =usiness +ivision( Te Hi Horse

7oer =usiness Unit as tree subdivisionsJ Cummins 7oer 7roets

Cummins 7oer House Consultin and Cummins 7oer ent(

Te Cummins Industrial =usiness Unit mar$ets diesel as enines in te

rane o B to 433H7( Tese enines are available on a variety o mobile

and stationary e0uipment used in various setors li$e Construion inin

Compressor and Fire Industrial pumps ail arine Oil9eld and

+eene( Enines are ustomied to te demands o te appliation and

are oered it oolin e)aust and air inta$e systems ully interated

it e0uipment desin or optimum perormane

Te gtutomotive Setor ouses on oners and operators o Tru$s and

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 859

oter eavyduty veiles( It is primarily enaed in distribution o parts

omponents servie support and value added servies or Kbumper to

bumper support( Cummins India Limiteds Lo Horse 7oer =usiness

Unit i manuatures and mar$ets small orsepoer enines in terane 1B$Agt to 14B$Agt is partially enaed in te manuature o Telos

CNG enines Cummins SA as enines- urrently used to poer +elis

publi transport system( Te Cummins SA as enine as been desined

to ombine ompat sie lo emission levels and e)ellent perormane

arateristis o ispeed tenoloy it te medium speed bene9ts

or loest lieyle osts in terms o uel e6ieny reliability and

durability(

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 959

Cummins Generator Technologies

Cummins Generator Tenoloies onentrates on enerators( ItMs not ust

te produts e ma$e tat set us apart itMs o e enae our

ustomers everyday( Te uni0ue ombination o $nolede

dependability and innovation e brin to ea ustomer relationsip turns

everyday servie into e)ellent ustomer support( gts a result e elp our

ustomers operate it reater e6ieny ma$in it possible or tem to

ompete more suessully trouout te orld(

Tata Cummins

Tata Cummins Limited TCL- is a B3JB3 oint Aenture beteen Tata otors

Limited IndiaMs larest gtutomobile manuaturer and Cummins Enine

Company In( o USgt orld leaders in desin and manuature o diesel

enines( Te s 33 Crore proet it an autoried sare apital o s

4B3 Crore as been set up at amsedpur or te manuature o +iesel

enines to poer Tata otors LimitedMs ommerial veiles( Te deision

to loate at amsedpur as based on te desire to be near te ustomer(

Commerial prodution o enines rom $its ommened in anuary 155

and te mainin lines or inouse manuature o omponents started

in ar 155(

The Cummins )nia -ounation C)-$

Te Cummins India Foundation CIF- as instituted in 1553 by Te

Cummins Group in India to annelie CumminsM ommitment toards

Corporate esponsibility( CIF is reistered it =ombay Caritable Trust

gtt as a Trust under Inome Ta) gtt it inistry o Home gtairs Govt(

o India under Forein Contributions eulations gtt FCgt-(

K+)T Cummins

D7IT Cummins enables tenoloy solutions tat enerate measurable

and tanible value or your business( Customers all it results o te

7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1059

ampe)ibility e oer and te relationsips e nurture(

aloline

In India Aalvoline Cummins Ltd a A beteen gtsland In( USgt and

Cummins Sales Servies India- Ltd a olly oned subsidiary o Cummins India Ltd( is one o te Indias astest roin lubriant

mar$eters and produer o 0uality branded automotiveindustrial

produts(

Cummins Turbo Technologies +lants in )nia

Cummins Turbo Tenoloies part o Cummins In(- ompletes 3 years

15B4 4314- o operations orldide( Cummins Turbo Tenoloies is a

leadin manuaturer o Turboarers it presene in most parts o te

orld(

In India Cummins Turbo Tenoloies as its plants and oies in

+eas 7itampur udrapur and 7une(

+ithamur 0 une 123 4514

Cummins Turbo Tenoloies CTT- is elebratin its 3t anniversary

year( it sales o over USP1 billion CTT as ron to be a lobalompany it operations in most parts o te orld( Tenial Centres in

21

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1159

UD Cina USgt and India ontinue to develop air andlin tenoloies or

lobal ustomers in diverse mar$ets inludin oniay ommerial

veile industrial onstrution ariulture marine and poer

eneration(

In India CTT bean as a A it Tata otors in deas in 1552( In 433 te

oint venture Tata Holset Limited beame a olly oned subsidiary o

Cummins and as renamed as Cummins Turbo Tenoloies(

Te CTT plant at deas ommened operations in 155B it merely 1B

employees( In line it CumminsQ pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at deas is no bein pratied by over 533

employees o CTT aross all sites in India(

RTere are many e)amples itin te oraniation tat testiy o

employees ave ron itin te Company( Several amonst tose

employees o oined te sop ampoor are today oldin senior positions

itin te oraniation( Tis demonstrates te oraniations ommitment

to nurturin talent and providin lonterm areers( as 0uoted by an

employee o as been assoiated it Cummins Turbo Tenoloies

sine te last 1B years

To boost te e)port business CTT set up a ne plant in 7itampur in 433lt(

Tis plant is itnessin urter e)pansion( In line it CumminsQ pratie

o truly partnerin it its ustomers8 CTT India ommissioned an entire

assembly line at udrapur(

=ein a tenoloy partner CTT upraded te bran o6e tat bean its

operations in 433B to te India Tenial Center supportin international

and domesti proets( Today Cummins Turbo Tenoloies India employs

nearly 533 employees inludin 1 speialist enineers(

Tray Embree 7resident Cummins Turbo Tenoloies omments ROur

22

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1259

leay and eritae ave e0uipped us ell or te allenes aead as e

enter a ne deade o aelerated lobal rot( ile e ontinue to

partner it our ustomers to deliver te best produts and tenoloies

our ommitment to te environment and te ommunities itin ie live remains at te eart o our business(

CTT as not only ron its business but as also played a sini9ant role

in orporate responsibility(

Re are very ommitted to our vision o a$in peopleQs lives better by

unleasin te 7oer o CumminsQ( e ave been and aim to be a ood

itien o India( e loo$ orard to strentenin our partners and

ommunities and ontinue to ro rom strent to strent ile stayin

rooted to te CompanyQs vision mission and si) ore values o interity

innovation deliverin superior results diversity lobal involvement and

orporate responsibility( added gtrun amaandran India =usiness

Country Leader or Cummins Turbo Tenoloies(

ourne6 o7 Cummins Turbo Technologies in )nia

1882 Sined te oint venture areement to operate as Tata

Holset Limited in India(

1889 anuaturin operations started at te 9rst plant in India(

Te e)istin Tata plant as upraded to te turboarer plant at

+eas(

4552 +eas plant e)pansion( Te plant as built to orld lass

standards to aieve ero deets( To support te e)pandin

business a bran o6e as set up in 7une(

455 Tata Holset Limited beame a olly oned subsidiary o

Cummins( Holset as renamed as Cummins Turbo Tenoloies(

20

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1359

gtnoter important landmar$ as layin te oundation stone o te

7itampur plant(

455 Te 7itampur plant bean its operations( Te 7itampurplant is one o te best manuaturin ailities anyere in te

orld(

4558 To support te roin domesti business Cummins Turbo

Tenoloies started its operations in udrapur(

4515 it inreased business and enineerin ous omin toIndia te India Tenial Center as establised in 7une( Currently

te tenial entre as over 13 speialised desin enineers o

atively support domesti as ell international proets(

AOT CMM)NS T(O TECltNOLOG)ES DEWAS

2=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1459

In India CTT bean as a A it Tata otors in Deampas in 188=( In 433

te oint venture Tata Holset Limited beame a olly oned subsidiary

o Cummins and as renamed as Cummins Turbo Tenoloies

Te CTT plant at +eas ommened operations in 155B it merely 1B

employees( In line it Cummins pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at +eas is no bein pratied by over 533

employees o CTT aross te plant (

Te plant as a apaity o 2B333 it 442 employees( CTT is supported

by sales and tenial o6e in 7une( It produes midrane and lit duty

apaity produts li$e ltgt2 ltgt2W3 lt=53 ltEgt21W3 Clt(A core$3

haing caacit6 o7 4K an 1K

Te manuaturin system as Gaues it Online S7C and data

entralied Server( CTT ouses on improvin proess apability rater

tan inspetion( 7roess and produts are reularly audited by 0uality

team(

Environment System is erti9ed it ISO 12331 and Healt and saety

System by OHSgtS 1lt331( CTT alays $eeps Heat and Saety as its top

priority( It as a team based or$ ulture it sel manaed team at sop

26

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1559

ampoor(

Te gtssembly ell as ommissioned in 155 it te initial setup o

benes 9)ture as data plate m rom HUD( Te urrent SetU7 as

Failsae Conveyor gtssembly Line( Tree sit run in a day it Bassoiates( ore tan 433 parts are assembled in te plant(

23

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1659

ltEALTlt SA-ET AND EN)(ONMENTAL +OL)C

Cummins is ommitted to osterin a leaner ealtier and saer

environment in every ommunity in i our people live and or$( gtllour ailities ill employ te Cummins Saety and Environmental

anaement Systems i are desined to protet our personnel and

te environment to preserve natural resoures and to prevent arm to

loal ommunities( Our approa in tis endeavor is multi aeted( e ill

systemially and aressively assess operations tat ave te potential to

arm individuals or impat te environment( e ill also set substantial

and measurable obetives in manain saety and te environment(

Finally e ill periodially revie our proress aainst our obetives(

Sustainable improvement is an essential element o bot systems and is

aimed at ontributin positively to personal saety environmental ell

bein and onservation o natural resoures(

Cummins ill ontinue to implement manaement prorams developed to

ensure tat our produts servies and ativities alays omply it loal

las and ompany standards establised to protet ealt saety and te

environment( e are ommitted to minimiin

potentially armul eets resultin rom our operations and to

implementin improvements assoiated it te prevention o pollution

inury and illness(

tis Healt Saety and Environmental 7oliy ill be applied trouout

Cummins via a set o doumented ompanyide and loal poliies and

proedures( It ill be ommuniated to all employees at least annually(

Upon re0uest te poliy ill be made available to te publi(

Tim Solso

Cairman CEO

November 15 4331

2gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1759

WO(K)NG O- T(OCltA(GE(

Te turbine omprises o to omponents8 te turbine ee l and te

olletor ommonly reerred to as te turbine ousin ( Te e)aust as is

uided into te turbine eel by te ousin( Te enery in te e)aust as

turns te turbine( One te as as passed trou te blades o te eel

it leaves te turbine ousin via te e)aust outlet area(

Te speed o te enine determines o ast te turbine eel spins( I te

enine is in idle mode te eel ill be spinnin at a minimal speed( gts

more as passes trou te turbine ousin te aster te turbine eel

rotates(

Compressors are te opposite o turbines( Tey omprise o to setions

te impeller or ompressor eel and te ompressor ousin ( Te

ompressor eel is onneted to te turbine by a ored steel sat( gts te

ompressor eel spins air is dran in and is ompressed as te blades

spin at a i veloity( Te ousin is desined to onvert te i veloity

lo pressure air stream into a i pressure lo veloity air stream trou

a proess alled diusion(

gtir enters te ompressor at a temperature e0uivalent to atmospere8

oever it leaves te ompressor over at a temperature up to 433 de

Celsius( =eause te density o te air dereases as it is eated up even

more air an be ored into te enine i te air is ooled ater te

ompressor( Tis is alled inter oolin or ater oolin and is aieved by

oolin te are air eiter it ater air(

Te turboarer bearin system is lubriated by oil rom te enine( Te

oil is ed under pressure into te bearin ousin trou to te ournal

bearins and trust system( Te oil also ats as a oolant ta$in aay eat

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1859

enerated by te turbine(

Te ournal =earins are a reeampoatin rotational type( To perorm orretly

te ournal bearins sould ampoat beteen a 9lm o oil i(e( beteen bearin sat and bearin and bearin ousin-( Te bearin learanes are very

small less tan te idt o a uman air( +irty oil or blo$aes in te oil

supply oles an ause serious damae to te turboarer(

In simple terms a turboarer omprises o a turbine and a ompressor

onneted by a ommon sat supported on a bearin system( Te

turboarer onverts aste enery rom te e)aust maniold into

ompressed air i it puses into te enine( Tis allos te enine to

produe more poer and tor0ue and improves te overall e6ieny o te

ombustion proess(

Detaile amporking o7 turbocharger ampith iagram

bull Te turbine ousin is bolted to te e)aust maniold o te enine(

bull Te aste e)aust asses are used to rotate a turbine eel i

is oused in te turbine asin(

bull Te turbine eel is onneted to a ommon sat i in turn

rotates a ompressor eel(

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1959

Fi(1

bull otatin te turbine eel is te only use or te aste e)aust as(

bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(

Fi(4

bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(

bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$in proess and pulls air into teompressor over rom te atmospere9ltered-(

Te aster te eel spin te more air is su$ed in(

Fi(

bull gts te air is su$ed into te ompressor overit is ored trou a

diuser area(

bull Tis ompressors te air and ores it into te enine(

27

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2059

bull Tis proess auses te air to inrease in temperaturesometimes

upto 433 derees C(

Fi(2

bull Te oil used in a turboarer is te same as tat used or your

turboarer(

bull Te oil is used as bot a lubriant and a oolant(

bull It is ed under pressure into te bearin ousintrou to te

ournal bearins and trust system(

01

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 6: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 659

)NDE

SNO CONTENTS +AGE NO

1 INTO+UCTION lt

4 CUINS TU=O TECHNOLOGY 7LgtNTS IN

IN+Igt

513

OUNEY OF CUINS TU=O

TECHNOLOGIES IN IN+Igt

11

2 HEgtLTH SgtFETY gtN+ ENAIONENT 7OLICIES 12

B TU=OCHgtGE ODING 1B15

gtCHINING O7EgtTION 4323

TECHNICgtL +ETgtILS OF SG CG CNC 212

lt gtINTENgtNCE 22

5 CHECD SHEET 2BB3

13 gtINTENgtNCE O7EgtTION 7EFOE+ IN7LgtNT

B1B4

11 CONCLUSION

COM+AN +(O-)LE

)NT(ODCT)ON

Cummins India Limited CIL- is a B1 perent subsidiary o Cummins In(

USgt te orlds larest independent diesel enine desiner and

gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 759

manuaturer above 433 H7( Cummins In te maority sareolder

Cummins is te leadin orldide desiner and manuaturer o diesel

enines rom 1H7 to B33 H7( Cummins pioneer and mar$et leader in

desin development and manuaturer o diesel enines is te leadinpoer solutions provider to te Indian industry( CIL as set up in 154 as

Dirlos$ar Cummins Limited and beame Cummins India Limited CIL- in

155 en Cummins inreased its sta$e( Today CIL is Indias larest

manuaturer o diesel enines it a rane rom 1B$Agt to 4333$Agt and

value pa$aes servin te 7oer Generation Industrial and gtutomotive

ar$ets(

CILs produts inlude diesel enines in te rane o 3 H7 to 433H7( It

manuaturers over 13333 enines per annum and is amon Indias

larest e)porters o enineerin produts( CIL oers omplete rane o

Cummins orldide produts( ere indienous prodution is not

available Cummins assists in te imports o a produt rom one o te

Cummins Group Companies(

CILs ustomers in te 7oer Generation solutions setor inlude

businesses in all sements sine te rane produed by CIL oers poer

ba$up or industrial and business units o all sies( Important setors or

poer eneration solutions are all enters realty ospitality te)tiles

auto anillaries and IT( In order to ensure ustomer ous te 7oer

Generation division is divided into to business units Lo Horse 7oer

=usiness Unit and te Hi Horse 7oer =usiness +ivision( Te Hi Horse

7oer =usiness Unit as tree subdivisionsJ Cummins 7oer 7roets

Cummins 7oer House Consultin and Cummins 7oer ent(

Te Cummins Industrial =usiness Unit mar$ets diesel as enines in te

rane o B to 433H7( Tese enines are available on a variety o mobile

and stationary e0uipment used in various setors li$e Construion inin

Compressor and Fire Industrial pumps ail arine Oil9eld and

+eene( Enines are ustomied to te demands o te appliation and

are oered it oolin e)aust and air inta$e systems ully interated

it e0uipment desin or optimum perormane

Te gtutomotive Setor ouses on oners and operators o Tru$s and

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 859

oter eavyduty veiles( It is primarily enaed in distribution o parts

omponents servie support and value added servies or Kbumper to

bumper support( Cummins India Limiteds Lo Horse 7oer =usiness

Unit i manuatures and mar$ets small orsepoer enines in terane 1B$Agt to 14B$Agt is partially enaed in te manuature o Telos

CNG enines Cummins SA as enines- urrently used to poer +elis

publi transport system( Te Cummins SA as enine as been desined

to ombine ompat sie lo emission levels and e)ellent perormane

arateristis o ispeed tenoloy it te medium speed bene9ts

or loest lieyle osts in terms o uel e6ieny reliability and

durability(

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 959

Cummins Generator Technologies

Cummins Generator Tenoloies onentrates on enerators( ItMs not ust

te produts e ma$e tat set us apart itMs o e enae our

ustomers everyday( Te uni0ue ombination o $nolede

dependability and innovation e brin to ea ustomer relationsip turns

everyday servie into e)ellent ustomer support( gts a result e elp our

ustomers operate it reater e6ieny ma$in it possible or tem to

ompete more suessully trouout te orld(

Tata Cummins

Tata Cummins Limited TCL- is a B3JB3 oint Aenture beteen Tata otors

Limited IndiaMs larest gtutomobile manuaturer and Cummins Enine

Company In( o USgt orld leaders in desin and manuature o diesel

enines( Te s 33 Crore proet it an autoried sare apital o s

4B3 Crore as been set up at amsedpur or te manuature o +iesel

enines to poer Tata otors LimitedMs ommerial veiles( Te deision

to loate at amsedpur as based on te desire to be near te ustomer(

Commerial prodution o enines rom $its ommened in anuary 155

and te mainin lines or inouse manuature o omponents started

in ar 155(

The Cummins )nia -ounation C)-$

Te Cummins India Foundation CIF- as instituted in 1553 by Te

Cummins Group in India to annelie CumminsM ommitment toards

Corporate esponsibility( CIF is reistered it =ombay Caritable Trust

gtt as a Trust under Inome Ta) gtt it inistry o Home gtairs Govt(

o India under Forein Contributions eulations gtt FCgt-(

K+)T Cummins

D7IT Cummins enables tenoloy solutions tat enerate measurable

and tanible value or your business( Customers all it results o te

7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1059

ampe)ibility e oer and te relationsips e nurture(

aloline

In India Aalvoline Cummins Ltd a A beteen gtsland In( USgt and

Cummins Sales Servies India- Ltd a olly oned subsidiary o Cummins India Ltd( is one o te Indias astest roin lubriant

mar$eters and produer o 0uality branded automotiveindustrial

produts(

Cummins Turbo Technologies +lants in )nia

Cummins Turbo Tenoloies part o Cummins In(- ompletes 3 years

15B4 4314- o operations orldide( Cummins Turbo Tenoloies is a

leadin manuaturer o Turboarers it presene in most parts o te

orld(

In India Cummins Turbo Tenoloies as its plants and oies in

+eas 7itampur udrapur and 7une(

+ithamur 0 une 123 4514

Cummins Turbo Tenoloies CTT- is elebratin its 3t anniversary

year( it sales o over USP1 billion CTT as ron to be a lobalompany it operations in most parts o te orld( Tenial Centres in

21

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1159

UD Cina USgt and India ontinue to develop air andlin tenoloies or

lobal ustomers in diverse mar$ets inludin oniay ommerial

veile industrial onstrution ariulture marine and poer

eneration(

In India CTT bean as a A it Tata otors in deas in 1552( In 433 te

oint venture Tata Holset Limited beame a olly oned subsidiary o

Cummins and as renamed as Cummins Turbo Tenoloies(

Te CTT plant at deas ommened operations in 155B it merely 1B

employees( In line it CumminsQ pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at deas is no bein pratied by over 533

employees o CTT aross all sites in India(

RTere are many e)amples itin te oraniation tat testiy o

employees ave ron itin te Company( Several amonst tose

employees o oined te sop ampoor are today oldin senior positions

itin te oraniation( Tis demonstrates te oraniations ommitment

to nurturin talent and providin lonterm areers( as 0uoted by an

employee o as been assoiated it Cummins Turbo Tenoloies

sine te last 1B years

To boost te e)port business CTT set up a ne plant in 7itampur in 433lt(

Tis plant is itnessin urter e)pansion( In line it CumminsQ pratie

o truly partnerin it its ustomers8 CTT India ommissioned an entire

assembly line at udrapur(

=ein a tenoloy partner CTT upraded te bran o6e tat bean its

operations in 433B to te India Tenial Center supportin international

and domesti proets( Today Cummins Turbo Tenoloies India employs

nearly 533 employees inludin 1 speialist enineers(

Tray Embree 7resident Cummins Turbo Tenoloies omments ROur

22

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1259

leay and eritae ave e0uipped us ell or te allenes aead as e

enter a ne deade o aelerated lobal rot( ile e ontinue to

partner it our ustomers to deliver te best produts and tenoloies

our ommitment to te environment and te ommunities itin ie live remains at te eart o our business(

CTT as not only ron its business but as also played a sini9ant role

in orporate responsibility(

Re are very ommitted to our vision o a$in peopleQs lives better by

unleasin te 7oer o CumminsQ( e ave been and aim to be a ood

itien o India( e loo$ orard to strentenin our partners and

ommunities and ontinue to ro rom strent to strent ile stayin

rooted to te CompanyQs vision mission and si) ore values o interity

innovation deliverin superior results diversity lobal involvement and

orporate responsibility( added gtrun amaandran India =usiness

Country Leader or Cummins Turbo Tenoloies(

ourne6 o7 Cummins Turbo Technologies in )nia

1882 Sined te oint venture areement to operate as Tata

Holset Limited in India(

1889 anuaturin operations started at te 9rst plant in India(

Te e)istin Tata plant as upraded to te turboarer plant at

+eas(

4552 +eas plant e)pansion( Te plant as built to orld lass

standards to aieve ero deets( To support te e)pandin

business a bran o6e as set up in 7une(

455 Tata Holset Limited beame a olly oned subsidiary o

Cummins( Holset as renamed as Cummins Turbo Tenoloies(

20

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1359

gtnoter important landmar$ as layin te oundation stone o te

7itampur plant(

455 Te 7itampur plant bean its operations( Te 7itampurplant is one o te best manuaturin ailities anyere in te

orld(

4558 To support te roin domesti business Cummins Turbo

Tenoloies started its operations in udrapur(

4515 it inreased business and enineerin ous omin toIndia te India Tenial Center as establised in 7une( Currently

te tenial entre as over 13 speialised desin enineers o

atively support domesti as ell international proets(

AOT CMM)NS T(O TECltNOLOG)ES DEWAS

2=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1459

In India CTT bean as a A it Tata otors in Deampas in 188=( In 433

te oint venture Tata Holset Limited beame a olly oned subsidiary

o Cummins and as renamed as Cummins Turbo Tenoloies

Te CTT plant at +eas ommened operations in 155B it merely 1B

employees( In line it Cummins pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at +eas is no bein pratied by over 533

employees o CTT aross te plant (

Te plant as a apaity o 2B333 it 442 employees( CTT is supported

by sales and tenial o6e in 7une( It produes midrane and lit duty

apaity produts li$e ltgt2 ltgt2W3 lt=53 ltEgt21W3 Clt(A core$3

haing caacit6 o7 4K an 1K

Te manuaturin system as Gaues it Online S7C and data

entralied Server( CTT ouses on improvin proess apability rater

tan inspetion( 7roess and produts are reularly audited by 0uality

team(

Environment System is erti9ed it ISO 12331 and Healt and saety

System by OHSgtS 1lt331( CTT alays $eeps Heat and Saety as its top

priority( It as a team based or$ ulture it sel manaed team at sop

26

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1559

ampoor(

Te gtssembly ell as ommissioned in 155 it te initial setup o

benes 9)ture as data plate m rom HUD( Te urrent SetU7 as

Failsae Conveyor gtssembly Line( Tree sit run in a day it Bassoiates( ore tan 433 parts are assembled in te plant(

23

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1659

ltEALTlt SA-ET AND EN)(ONMENTAL +OL)C

Cummins is ommitted to osterin a leaner ealtier and saer

environment in every ommunity in i our people live and or$( gtllour ailities ill employ te Cummins Saety and Environmental

anaement Systems i are desined to protet our personnel and

te environment to preserve natural resoures and to prevent arm to

loal ommunities( Our approa in tis endeavor is multi aeted( e ill

systemially and aressively assess operations tat ave te potential to

arm individuals or impat te environment( e ill also set substantial

and measurable obetives in manain saety and te environment(

Finally e ill periodially revie our proress aainst our obetives(

Sustainable improvement is an essential element o bot systems and is

aimed at ontributin positively to personal saety environmental ell

bein and onservation o natural resoures(

Cummins ill ontinue to implement manaement prorams developed to

ensure tat our produts servies and ativities alays omply it loal

las and ompany standards establised to protet ealt saety and te

environment( e are ommitted to minimiin

potentially armul eets resultin rom our operations and to

implementin improvements assoiated it te prevention o pollution

inury and illness(

tis Healt Saety and Environmental 7oliy ill be applied trouout

Cummins via a set o doumented ompanyide and loal poliies and

proedures( It ill be ommuniated to all employees at least annually(

Upon re0uest te poliy ill be made available to te publi(

Tim Solso

Cairman CEO

November 15 4331

2gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1759

WO(K)NG O- T(OCltA(GE(

Te turbine omprises o to omponents8 te turbine ee l and te

olletor ommonly reerred to as te turbine ousin ( Te e)aust as is

uided into te turbine eel by te ousin( Te enery in te e)aust as

turns te turbine( One te as as passed trou te blades o te eel

it leaves te turbine ousin via te e)aust outlet area(

Te speed o te enine determines o ast te turbine eel spins( I te

enine is in idle mode te eel ill be spinnin at a minimal speed( gts

more as passes trou te turbine ousin te aster te turbine eel

rotates(

Compressors are te opposite o turbines( Tey omprise o to setions

te impeller or ompressor eel and te ompressor ousin ( Te

ompressor eel is onneted to te turbine by a ored steel sat( gts te

ompressor eel spins air is dran in and is ompressed as te blades

spin at a i veloity( Te ousin is desined to onvert te i veloity

lo pressure air stream into a i pressure lo veloity air stream trou

a proess alled diusion(

gtir enters te ompressor at a temperature e0uivalent to atmospere8

oever it leaves te ompressor over at a temperature up to 433 de

Celsius( =eause te density o te air dereases as it is eated up even

more air an be ored into te enine i te air is ooled ater te

ompressor( Tis is alled inter oolin or ater oolin and is aieved by

oolin te are air eiter it ater air(

Te turboarer bearin system is lubriated by oil rom te enine( Te

oil is ed under pressure into te bearin ousin trou to te ournal

bearins and trust system( Te oil also ats as a oolant ta$in aay eat

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1859

enerated by te turbine(

Te ournal =earins are a reeampoatin rotational type( To perorm orretly

te ournal bearins sould ampoat beteen a 9lm o oil i(e( beteen bearin sat and bearin and bearin ousin-( Te bearin learanes are very

small less tan te idt o a uman air( +irty oil or blo$aes in te oil

supply oles an ause serious damae to te turboarer(

In simple terms a turboarer omprises o a turbine and a ompressor

onneted by a ommon sat supported on a bearin system( Te

turboarer onverts aste enery rom te e)aust maniold into

ompressed air i it puses into te enine( Tis allos te enine to

produe more poer and tor0ue and improves te overall e6ieny o te

ombustion proess(

Detaile amporking o7 turbocharger ampith iagram

bull Te turbine ousin is bolted to te e)aust maniold o te enine(

bull Te aste e)aust asses are used to rotate a turbine eel i

is oused in te turbine asin(

bull Te turbine eel is onneted to a ommon sat i in turn

rotates a ompressor eel(

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1959

Fi(1

bull otatin te turbine eel is te only use or te aste e)aust as(

bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(

Fi(4

bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(

bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$in proess and pulls air into teompressor over rom te atmospere9ltered-(

Te aster te eel spin te more air is su$ed in(

Fi(

bull gts te air is su$ed into te ompressor overit is ored trou a

diuser area(

bull Tis ompressors te air and ores it into te enine(

27

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2059

bull Tis proess auses te air to inrease in temperaturesometimes

upto 433 derees C(

Fi(2

bull Te oil used in a turboarer is te same as tat used or your

turboarer(

bull Te oil is used as bot a lubriant and a oolant(

bull It is ed under pressure into te bearin ousintrou to te

ournal bearins and trust system(

01

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 7: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 759

manuaturer above 433 H7( Cummins In te maority sareolder

Cummins is te leadin orldide desiner and manuaturer o diesel

enines rom 1H7 to B33 H7( Cummins pioneer and mar$et leader in

desin development and manuaturer o diesel enines is te leadinpoer solutions provider to te Indian industry( CIL as set up in 154 as

Dirlos$ar Cummins Limited and beame Cummins India Limited CIL- in

155 en Cummins inreased its sta$e( Today CIL is Indias larest

manuaturer o diesel enines it a rane rom 1B$Agt to 4333$Agt and

value pa$aes servin te 7oer Generation Industrial and gtutomotive

ar$ets(

CILs produts inlude diesel enines in te rane o 3 H7 to 433H7( It

manuaturers over 13333 enines per annum and is amon Indias

larest e)porters o enineerin produts( CIL oers omplete rane o

Cummins orldide produts( ere indienous prodution is not

available Cummins assists in te imports o a produt rom one o te

Cummins Group Companies(

CILs ustomers in te 7oer Generation solutions setor inlude

businesses in all sements sine te rane produed by CIL oers poer

ba$up or industrial and business units o all sies( Important setors or

poer eneration solutions are all enters realty ospitality te)tiles

auto anillaries and IT( In order to ensure ustomer ous te 7oer

Generation division is divided into to business units Lo Horse 7oer

=usiness Unit and te Hi Horse 7oer =usiness +ivision( Te Hi Horse

7oer =usiness Unit as tree subdivisionsJ Cummins 7oer 7roets

Cummins 7oer House Consultin and Cummins 7oer ent(

Te Cummins Industrial =usiness Unit mar$ets diesel as enines in te

rane o B to 433H7( Tese enines are available on a variety o mobile

and stationary e0uipment used in various setors li$e Construion inin

Compressor and Fire Industrial pumps ail arine Oil9eld and

+eene( Enines are ustomied to te demands o te appliation and

are oered it oolin e)aust and air inta$e systems ully interated

it e0uipment desin or optimum perormane

Te gtutomotive Setor ouses on oners and operators o Tru$s and

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 859

oter eavyduty veiles( It is primarily enaed in distribution o parts

omponents servie support and value added servies or Kbumper to

bumper support( Cummins India Limiteds Lo Horse 7oer =usiness

Unit i manuatures and mar$ets small orsepoer enines in terane 1B$Agt to 14B$Agt is partially enaed in te manuature o Telos

CNG enines Cummins SA as enines- urrently used to poer +elis

publi transport system( Te Cummins SA as enine as been desined

to ombine ompat sie lo emission levels and e)ellent perormane

arateristis o ispeed tenoloy it te medium speed bene9ts

or loest lieyle osts in terms o uel e6ieny reliability and

durability(

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 959

Cummins Generator Technologies

Cummins Generator Tenoloies onentrates on enerators( ItMs not ust

te produts e ma$e tat set us apart itMs o e enae our

ustomers everyday( Te uni0ue ombination o $nolede

dependability and innovation e brin to ea ustomer relationsip turns

everyday servie into e)ellent ustomer support( gts a result e elp our

ustomers operate it reater e6ieny ma$in it possible or tem to

ompete more suessully trouout te orld(

Tata Cummins

Tata Cummins Limited TCL- is a B3JB3 oint Aenture beteen Tata otors

Limited IndiaMs larest gtutomobile manuaturer and Cummins Enine

Company In( o USgt orld leaders in desin and manuature o diesel

enines( Te s 33 Crore proet it an autoried sare apital o s

4B3 Crore as been set up at amsedpur or te manuature o +iesel

enines to poer Tata otors LimitedMs ommerial veiles( Te deision

to loate at amsedpur as based on te desire to be near te ustomer(

Commerial prodution o enines rom $its ommened in anuary 155

and te mainin lines or inouse manuature o omponents started

in ar 155(

The Cummins )nia -ounation C)-$

Te Cummins India Foundation CIF- as instituted in 1553 by Te

Cummins Group in India to annelie CumminsM ommitment toards

Corporate esponsibility( CIF is reistered it =ombay Caritable Trust

gtt as a Trust under Inome Ta) gtt it inistry o Home gtairs Govt(

o India under Forein Contributions eulations gtt FCgt-(

K+)T Cummins

D7IT Cummins enables tenoloy solutions tat enerate measurable

and tanible value or your business( Customers all it results o te

7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1059

ampe)ibility e oer and te relationsips e nurture(

aloline

In India Aalvoline Cummins Ltd a A beteen gtsland In( USgt and

Cummins Sales Servies India- Ltd a olly oned subsidiary o Cummins India Ltd( is one o te Indias astest roin lubriant

mar$eters and produer o 0uality branded automotiveindustrial

produts(

Cummins Turbo Technologies +lants in )nia

Cummins Turbo Tenoloies part o Cummins In(- ompletes 3 years

15B4 4314- o operations orldide( Cummins Turbo Tenoloies is a

leadin manuaturer o Turboarers it presene in most parts o te

orld(

In India Cummins Turbo Tenoloies as its plants and oies in

+eas 7itampur udrapur and 7une(

+ithamur 0 une 123 4514

Cummins Turbo Tenoloies CTT- is elebratin its 3t anniversary

year( it sales o over USP1 billion CTT as ron to be a lobalompany it operations in most parts o te orld( Tenial Centres in

21

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1159

UD Cina USgt and India ontinue to develop air andlin tenoloies or

lobal ustomers in diverse mar$ets inludin oniay ommerial

veile industrial onstrution ariulture marine and poer

eneration(

In India CTT bean as a A it Tata otors in deas in 1552( In 433 te

oint venture Tata Holset Limited beame a olly oned subsidiary o

Cummins and as renamed as Cummins Turbo Tenoloies(

Te CTT plant at deas ommened operations in 155B it merely 1B

employees( In line it CumminsQ pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at deas is no bein pratied by over 533

employees o CTT aross all sites in India(

RTere are many e)amples itin te oraniation tat testiy o

employees ave ron itin te Company( Several amonst tose

employees o oined te sop ampoor are today oldin senior positions

itin te oraniation( Tis demonstrates te oraniations ommitment

to nurturin talent and providin lonterm areers( as 0uoted by an

employee o as been assoiated it Cummins Turbo Tenoloies

sine te last 1B years

To boost te e)port business CTT set up a ne plant in 7itampur in 433lt(

Tis plant is itnessin urter e)pansion( In line it CumminsQ pratie

o truly partnerin it its ustomers8 CTT India ommissioned an entire

assembly line at udrapur(

=ein a tenoloy partner CTT upraded te bran o6e tat bean its

operations in 433B to te India Tenial Center supportin international

and domesti proets( Today Cummins Turbo Tenoloies India employs

nearly 533 employees inludin 1 speialist enineers(

Tray Embree 7resident Cummins Turbo Tenoloies omments ROur

22

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1259

leay and eritae ave e0uipped us ell or te allenes aead as e

enter a ne deade o aelerated lobal rot( ile e ontinue to

partner it our ustomers to deliver te best produts and tenoloies

our ommitment to te environment and te ommunities itin ie live remains at te eart o our business(

CTT as not only ron its business but as also played a sini9ant role

in orporate responsibility(

Re are very ommitted to our vision o a$in peopleQs lives better by

unleasin te 7oer o CumminsQ( e ave been and aim to be a ood

itien o India( e loo$ orard to strentenin our partners and

ommunities and ontinue to ro rom strent to strent ile stayin

rooted to te CompanyQs vision mission and si) ore values o interity

innovation deliverin superior results diversity lobal involvement and

orporate responsibility( added gtrun amaandran India =usiness

Country Leader or Cummins Turbo Tenoloies(

ourne6 o7 Cummins Turbo Technologies in )nia

1882 Sined te oint venture areement to operate as Tata

Holset Limited in India(

1889 anuaturin operations started at te 9rst plant in India(

Te e)istin Tata plant as upraded to te turboarer plant at

+eas(

4552 +eas plant e)pansion( Te plant as built to orld lass

standards to aieve ero deets( To support te e)pandin

business a bran o6e as set up in 7une(

455 Tata Holset Limited beame a olly oned subsidiary o

Cummins( Holset as renamed as Cummins Turbo Tenoloies(

20

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1359

gtnoter important landmar$ as layin te oundation stone o te

7itampur plant(

455 Te 7itampur plant bean its operations( Te 7itampurplant is one o te best manuaturin ailities anyere in te

orld(

4558 To support te roin domesti business Cummins Turbo

Tenoloies started its operations in udrapur(

4515 it inreased business and enineerin ous omin toIndia te India Tenial Center as establised in 7une( Currently

te tenial entre as over 13 speialised desin enineers o

atively support domesti as ell international proets(

AOT CMM)NS T(O TECltNOLOG)ES DEWAS

2=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1459

In India CTT bean as a A it Tata otors in Deampas in 188=( In 433

te oint venture Tata Holset Limited beame a olly oned subsidiary

o Cummins and as renamed as Cummins Turbo Tenoloies

Te CTT plant at +eas ommened operations in 155B it merely 1B

employees( In line it Cummins pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at +eas is no bein pratied by over 533

employees o CTT aross te plant (

Te plant as a apaity o 2B333 it 442 employees( CTT is supported

by sales and tenial o6e in 7une( It produes midrane and lit duty

apaity produts li$e ltgt2 ltgt2W3 lt=53 ltEgt21W3 Clt(A core$3

haing caacit6 o7 4K an 1K

Te manuaturin system as Gaues it Online S7C and data

entralied Server( CTT ouses on improvin proess apability rater

tan inspetion( 7roess and produts are reularly audited by 0uality

team(

Environment System is erti9ed it ISO 12331 and Healt and saety

System by OHSgtS 1lt331( CTT alays $eeps Heat and Saety as its top

priority( It as a team based or$ ulture it sel manaed team at sop

26

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1559

ampoor(

Te gtssembly ell as ommissioned in 155 it te initial setup o

benes 9)ture as data plate m rom HUD( Te urrent SetU7 as

Failsae Conveyor gtssembly Line( Tree sit run in a day it Bassoiates( ore tan 433 parts are assembled in te plant(

23

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1659

ltEALTlt SA-ET AND EN)(ONMENTAL +OL)C

Cummins is ommitted to osterin a leaner ealtier and saer

environment in every ommunity in i our people live and or$( gtllour ailities ill employ te Cummins Saety and Environmental

anaement Systems i are desined to protet our personnel and

te environment to preserve natural resoures and to prevent arm to

loal ommunities( Our approa in tis endeavor is multi aeted( e ill

systemially and aressively assess operations tat ave te potential to

arm individuals or impat te environment( e ill also set substantial

and measurable obetives in manain saety and te environment(

Finally e ill periodially revie our proress aainst our obetives(

Sustainable improvement is an essential element o bot systems and is

aimed at ontributin positively to personal saety environmental ell

bein and onservation o natural resoures(

Cummins ill ontinue to implement manaement prorams developed to

ensure tat our produts servies and ativities alays omply it loal

las and ompany standards establised to protet ealt saety and te

environment( e are ommitted to minimiin

potentially armul eets resultin rom our operations and to

implementin improvements assoiated it te prevention o pollution

inury and illness(

tis Healt Saety and Environmental 7oliy ill be applied trouout

Cummins via a set o doumented ompanyide and loal poliies and

proedures( It ill be ommuniated to all employees at least annually(

Upon re0uest te poliy ill be made available to te publi(

Tim Solso

Cairman CEO

November 15 4331

2gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1759

WO(K)NG O- T(OCltA(GE(

Te turbine omprises o to omponents8 te turbine ee l and te

olletor ommonly reerred to as te turbine ousin ( Te e)aust as is

uided into te turbine eel by te ousin( Te enery in te e)aust as

turns te turbine( One te as as passed trou te blades o te eel

it leaves te turbine ousin via te e)aust outlet area(

Te speed o te enine determines o ast te turbine eel spins( I te

enine is in idle mode te eel ill be spinnin at a minimal speed( gts

more as passes trou te turbine ousin te aster te turbine eel

rotates(

Compressors are te opposite o turbines( Tey omprise o to setions

te impeller or ompressor eel and te ompressor ousin ( Te

ompressor eel is onneted to te turbine by a ored steel sat( gts te

ompressor eel spins air is dran in and is ompressed as te blades

spin at a i veloity( Te ousin is desined to onvert te i veloity

lo pressure air stream into a i pressure lo veloity air stream trou

a proess alled diusion(

gtir enters te ompressor at a temperature e0uivalent to atmospere8

oever it leaves te ompressor over at a temperature up to 433 de

Celsius( =eause te density o te air dereases as it is eated up even

more air an be ored into te enine i te air is ooled ater te

ompressor( Tis is alled inter oolin or ater oolin and is aieved by

oolin te are air eiter it ater air(

Te turboarer bearin system is lubriated by oil rom te enine( Te

oil is ed under pressure into te bearin ousin trou to te ournal

bearins and trust system( Te oil also ats as a oolant ta$in aay eat

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1859

enerated by te turbine(

Te ournal =earins are a reeampoatin rotational type( To perorm orretly

te ournal bearins sould ampoat beteen a 9lm o oil i(e( beteen bearin sat and bearin and bearin ousin-( Te bearin learanes are very

small less tan te idt o a uman air( +irty oil or blo$aes in te oil

supply oles an ause serious damae to te turboarer(

In simple terms a turboarer omprises o a turbine and a ompressor

onneted by a ommon sat supported on a bearin system( Te

turboarer onverts aste enery rom te e)aust maniold into

ompressed air i it puses into te enine( Tis allos te enine to

produe more poer and tor0ue and improves te overall e6ieny o te

ombustion proess(

Detaile amporking o7 turbocharger ampith iagram

bull Te turbine ousin is bolted to te e)aust maniold o te enine(

bull Te aste e)aust asses are used to rotate a turbine eel i

is oused in te turbine asin(

bull Te turbine eel is onneted to a ommon sat i in turn

rotates a ompressor eel(

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1959

Fi(1

bull otatin te turbine eel is te only use or te aste e)aust as(

bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(

Fi(4

bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(

bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$in proess and pulls air into teompressor over rom te atmospere9ltered-(

Te aster te eel spin te more air is su$ed in(

Fi(

bull gts te air is su$ed into te ompressor overit is ored trou a

diuser area(

bull Tis ompressors te air and ores it into te enine(

27

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2059

bull Tis proess auses te air to inrease in temperaturesometimes

upto 433 derees C(

Fi(2

bull Te oil used in a turboarer is te same as tat used or your

turboarer(

bull Te oil is used as bot a lubriant and a oolant(

bull It is ed under pressure into te bearin ousintrou to te

ournal bearins and trust system(

01

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 8: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 859

oter eavyduty veiles( It is primarily enaed in distribution o parts

omponents servie support and value added servies or Kbumper to

bumper support( Cummins India Limiteds Lo Horse 7oer =usiness

Unit i manuatures and mar$ets small orsepoer enines in terane 1B$Agt to 14B$Agt is partially enaed in te manuature o Telos

CNG enines Cummins SA as enines- urrently used to poer +elis

publi transport system( Te Cummins SA as enine as been desined

to ombine ompat sie lo emission levels and e)ellent perormane

arateristis o ispeed tenoloy it te medium speed bene9ts

or loest lieyle osts in terms o uel e6ieny reliability and

durability(

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 959

Cummins Generator Technologies

Cummins Generator Tenoloies onentrates on enerators( ItMs not ust

te produts e ma$e tat set us apart itMs o e enae our

ustomers everyday( Te uni0ue ombination o $nolede

dependability and innovation e brin to ea ustomer relationsip turns

everyday servie into e)ellent ustomer support( gts a result e elp our

ustomers operate it reater e6ieny ma$in it possible or tem to

ompete more suessully trouout te orld(

Tata Cummins

Tata Cummins Limited TCL- is a B3JB3 oint Aenture beteen Tata otors

Limited IndiaMs larest gtutomobile manuaturer and Cummins Enine

Company In( o USgt orld leaders in desin and manuature o diesel

enines( Te s 33 Crore proet it an autoried sare apital o s

4B3 Crore as been set up at amsedpur or te manuature o +iesel

enines to poer Tata otors LimitedMs ommerial veiles( Te deision

to loate at amsedpur as based on te desire to be near te ustomer(

Commerial prodution o enines rom $its ommened in anuary 155

and te mainin lines or inouse manuature o omponents started

in ar 155(

The Cummins )nia -ounation C)-$

Te Cummins India Foundation CIF- as instituted in 1553 by Te

Cummins Group in India to annelie CumminsM ommitment toards

Corporate esponsibility( CIF is reistered it =ombay Caritable Trust

gtt as a Trust under Inome Ta) gtt it inistry o Home gtairs Govt(

o India under Forein Contributions eulations gtt FCgt-(

K+)T Cummins

D7IT Cummins enables tenoloy solutions tat enerate measurable

and tanible value or your business( Customers all it results o te

7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1059

ampe)ibility e oer and te relationsips e nurture(

aloline

In India Aalvoline Cummins Ltd a A beteen gtsland In( USgt and

Cummins Sales Servies India- Ltd a olly oned subsidiary o Cummins India Ltd( is one o te Indias astest roin lubriant

mar$eters and produer o 0uality branded automotiveindustrial

produts(

Cummins Turbo Technologies +lants in )nia

Cummins Turbo Tenoloies part o Cummins In(- ompletes 3 years

15B4 4314- o operations orldide( Cummins Turbo Tenoloies is a

leadin manuaturer o Turboarers it presene in most parts o te

orld(

In India Cummins Turbo Tenoloies as its plants and oies in

+eas 7itampur udrapur and 7une(

+ithamur 0 une 123 4514

Cummins Turbo Tenoloies CTT- is elebratin its 3t anniversary

year( it sales o over USP1 billion CTT as ron to be a lobalompany it operations in most parts o te orld( Tenial Centres in

21

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1159

UD Cina USgt and India ontinue to develop air andlin tenoloies or

lobal ustomers in diverse mar$ets inludin oniay ommerial

veile industrial onstrution ariulture marine and poer

eneration(

In India CTT bean as a A it Tata otors in deas in 1552( In 433 te

oint venture Tata Holset Limited beame a olly oned subsidiary o

Cummins and as renamed as Cummins Turbo Tenoloies(

Te CTT plant at deas ommened operations in 155B it merely 1B

employees( In line it CumminsQ pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at deas is no bein pratied by over 533

employees o CTT aross all sites in India(

RTere are many e)amples itin te oraniation tat testiy o

employees ave ron itin te Company( Several amonst tose

employees o oined te sop ampoor are today oldin senior positions

itin te oraniation( Tis demonstrates te oraniations ommitment

to nurturin talent and providin lonterm areers( as 0uoted by an

employee o as been assoiated it Cummins Turbo Tenoloies

sine te last 1B years

To boost te e)port business CTT set up a ne plant in 7itampur in 433lt(

Tis plant is itnessin urter e)pansion( In line it CumminsQ pratie

o truly partnerin it its ustomers8 CTT India ommissioned an entire

assembly line at udrapur(

=ein a tenoloy partner CTT upraded te bran o6e tat bean its

operations in 433B to te India Tenial Center supportin international

and domesti proets( Today Cummins Turbo Tenoloies India employs

nearly 533 employees inludin 1 speialist enineers(

Tray Embree 7resident Cummins Turbo Tenoloies omments ROur

22

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1259

leay and eritae ave e0uipped us ell or te allenes aead as e

enter a ne deade o aelerated lobal rot( ile e ontinue to

partner it our ustomers to deliver te best produts and tenoloies

our ommitment to te environment and te ommunities itin ie live remains at te eart o our business(

CTT as not only ron its business but as also played a sini9ant role

in orporate responsibility(

Re are very ommitted to our vision o a$in peopleQs lives better by

unleasin te 7oer o CumminsQ( e ave been and aim to be a ood

itien o India( e loo$ orard to strentenin our partners and

ommunities and ontinue to ro rom strent to strent ile stayin

rooted to te CompanyQs vision mission and si) ore values o interity

innovation deliverin superior results diversity lobal involvement and

orporate responsibility( added gtrun amaandran India =usiness

Country Leader or Cummins Turbo Tenoloies(

ourne6 o7 Cummins Turbo Technologies in )nia

1882 Sined te oint venture areement to operate as Tata

Holset Limited in India(

1889 anuaturin operations started at te 9rst plant in India(

Te e)istin Tata plant as upraded to te turboarer plant at

+eas(

4552 +eas plant e)pansion( Te plant as built to orld lass

standards to aieve ero deets( To support te e)pandin

business a bran o6e as set up in 7une(

455 Tata Holset Limited beame a olly oned subsidiary o

Cummins( Holset as renamed as Cummins Turbo Tenoloies(

20

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1359

gtnoter important landmar$ as layin te oundation stone o te

7itampur plant(

455 Te 7itampur plant bean its operations( Te 7itampurplant is one o te best manuaturin ailities anyere in te

orld(

4558 To support te roin domesti business Cummins Turbo

Tenoloies started its operations in udrapur(

4515 it inreased business and enineerin ous omin toIndia te India Tenial Center as establised in 7une( Currently

te tenial entre as over 13 speialised desin enineers o

atively support domesti as ell international proets(

AOT CMM)NS T(O TECltNOLOG)ES DEWAS

2=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1459

In India CTT bean as a A it Tata otors in Deampas in 188=( In 433

te oint venture Tata Holset Limited beame a olly oned subsidiary

o Cummins and as renamed as Cummins Turbo Tenoloies

Te CTT plant at +eas ommened operations in 155B it merely 1B

employees( In line it Cummins pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at +eas is no bein pratied by over 533

employees o CTT aross te plant (

Te plant as a apaity o 2B333 it 442 employees( CTT is supported

by sales and tenial o6e in 7une( It produes midrane and lit duty

apaity produts li$e ltgt2 ltgt2W3 lt=53 ltEgt21W3 Clt(A core$3

haing caacit6 o7 4K an 1K

Te manuaturin system as Gaues it Online S7C and data

entralied Server( CTT ouses on improvin proess apability rater

tan inspetion( 7roess and produts are reularly audited by 0uality

team(

Environment System is erti9ed it ISO 12331 and Healt and saety

System by OHSgtS 1lt331( CTT alays $eeps Heat and Saety as its top

priority( It as a team based or$ ulture it sel manaed team at sop

26

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1559

ampoor(

Te gtssembly ell as ommissioned in 155 it te initial setup o

benes 9)ture as data plate m rom HUD( Te urrent SetU7 as

Failsae Conveyor gtssembly Line( Tree sit run in a day it Bassoiates( ore tan 433 parts are assembled in te plant(

23

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1659

ltEALTlt SA-ET AND EN)(ONMENTAL +OL)C

Cummins is ommitted to osterin a leaner ealtier and saer

environment in every ommunity in i our people live and or$( gtllour ailities ill employ te Cummins Saety and Environmental

anaement Systems i are desined to protet our personnel and

te environment to preserve natural resoures and to prevent arm to

loal ommunities( Our approa in tis endeavor is multi aeted( e ill

systemially and aressively assess operations tat ave te potential to

arm individuals or impat te environment( e ill also set substantial

and measurable obetives in manain saety and te environment(

Finally e ill periodially revie our proress aainst our obetives(

Sustainable improvement is an essential element o bot systems and is

aimed at ontributin positively to personal saety environmental ell

bein and onservation o natural resoures(

Cummins ill ontinue to implement manaement prorams developed to

ensure tat our produts servies and ativities alays omply it loal

las and ompany standards establised to protet ealt saety and te

environment( e are ommitted to minimiin

potentially armul eets resultin rom our operations and to

implementin improvements assoiated it te prevention o pollution

inury and illness(

tis Healt Saety and Environmental 7oliy ill be applied trouout

Cummins via a set o doumented ompanyide and loal poliies and

proedures( It ill be ommuniated to all employees at least annually(

Upon re0uest te poliy ill be made available to te publi(

Tim Solso

Cairman CEO

November 15 4331

2gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1759

WO(K)NG O- T(OCltA(GE(

Te turbine omprises o to omponents8 te turbine ee l and te

olletor ommonly reerred to as te turbine ousin ( Te e)aust as is

uided into te turbine eel by te ousin( Te enery in te e)aust as

turns te turbine( One te as as passed trou te blades o te eel

it leaves te turbine ousin via te e)aust outlet area(

Te speed o te enine determines o ast te turbine eel spins( I te

enine is in idle mode te eel ill be spinnin at a minimal speed( gts

more as passes trou te turbine ousin te aster te turbine eel

rotates(

Compressors are te opposite o turbines( Tey omprise o to setions

te impeller or ompressor eel and te ompressor ousin ( Te

ompressor eel is onneted to te turbine by a ored steel sat( gts te

ompressor eel spins air is dran in and is ompressed as te blades

spin at a i veloity( Te ousin is desined to onvert te i veloity

lo pressure air stream into a i pressure lo veloity air stream trou

a proess alled diusion(

gtir enters te ompressor at a temperature e0uivalent to atmospere8

oever it leaves te ompressor over at a temperature up to 433 de

Celsius( =eause te density o te air dereases as it is eated up even

more air an be ored into te enine i te air is ooled ater te

ompressor( Tis is alled inter oolin or ater oolin and is aieved by

oolin te are air eiter it ater air(

Te turboarer bearin system is lubriated by oil rom te enine( Te

oil is ed under pressure into te bearin ousin trou to te ournal

bearins and trust system( Te oil also ats as a oolant ta$in aay eat

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1859

enerated by te turbine(

Te ournal =earins are a reeampoatin rotational type( To perorm orretly

te ournal bearins sould ampoat beteen a 9lm o oil i(e( beteen bearin sat and bearin and bearin ousin-( Te bearin learanes are very

small less tan te idt o a uman air( +irty oil or blo$aes in te oil

supply oles an ause serious damae to te turboarer(

In simple terms a turboarer omprises o a turbine and a ompressor

onneted by a ommon sat supported on a bearin system( Te

turboarer onverts aste enery rom te e)aust maniold into

ompressed air i it puses into te enine( Tis allos te enine to

produe more poer and tor0ue and improves te overall e6ieny o te

ombustion proess(

Detaile amporking o7 turbocharger ampith iagram

bull Te turbine ousin is bolted to te e)aust maniold o te enine(

bull Te aste e)aust asses are used to rotate a turbine eel i

is oused in te turbine asin(

bull Te turbine eel is onneted to a ommon sat i in turn

rotates a ompressor eel(

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1959

Fi(1

bull otatin te turbine eel is te only use or te aste e)aust as(

bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(

Fi(4

bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(

bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$in proess and pulls air into teompressor over rom te atmospere9ltered-(

Te aster te eel spin te more air is su$ed in(

Fi(

bull gts te air is su$ed into te ompressor overit is ored trou a

diuser area(

bull Tis ompressors te air and ores it into te enine(

27

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2059

bull Tis proess auses te air to inrease in temperaturesometimes

upto 433 derees C(

Fi(2

bull Te oil used in a turboarer is te same as tat used or your

turboarer(

bull Te oil is used as bot a lubriant and a oolant(

bull It is ed under pressure into te bearin ousintrou to te

ournal bearins and trust system(

01

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 9: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 959

Cummins Generator Technologies

Cummins Generator Tenoloies onentrates on enerators( ItMs not ust

te produts e ma$e tat set us apart itMs o e enae our

ustomers everyday( Te uni0ue ombination o $nolede

dependability and innovation e brin to ea ustomer relationsip turns

everyday servie into e)ellent ustomer support( gts a result e elp our

ustomers operate it reater e6ieny ma$in it possible or tem to

ompete more suessully trouout te orld(

Tata Cummins

Tata Cummins Limited TCL- is a B3JB3 oint Aenture beteen Tata otors

Limited IndiaMs larest gtutomobile manuaturer and Cummins Enine

Company In( o USgt orld leaders in desin and manuature o diesel

enines( Te s 33 Crore proet it an autoried sare apital o s

4B3 Crore as been set up at amsedpur or te manuature o +iesel

enines to poer Tata otors LimitedMs ommerial veiles( Te deision

to loate at amsedpur as based on te desire to be near te ustomer(

Commerial prodution o enines rom $its ommened in anuary 155

and te mainin lines or inouse manuature o omponents started

in ar 155(

The Cummins )nia -ounation C)-$

Te Cummins India Foundation CIF- as instituted in 1553 by Te

Cummins Group in India to annelie CumminsM ommitment toards

Corporate esponsibility( CIF is reistered it =ombay Caritable Trust

gtt as a Trust under Inome Ta) gtt it inistry o Home gtairs Govt(

o India under Forein Contributions eulations gtt FCgt-(

K+)T Cummins

D7IT Cummins enables tenoloy solutions tat enerate measurable

and tanible value or your business( Customers all it results o te

7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1059

ampe)ibility e oer and te relationsips e nurture(

aloline

In India Aalvoline Cummins Ltd a A beteen gtsland In( USgt and

Cummins Sales Servies India- Ltd a olly oned subsidiary o Cummins India Ltd( is one o te Indias astest roin lubriant

mar$eters and produer o 0uality branded automotiveindustrial

produts(

Cummins Turbo Technologies +lants in )nia

Cummins Turbo Tenoloies part o Cummins In(- ompletes 3 years

15B4 4314- o operations orldide( Cummins Turbo Tenoloies is a

leadin manuaturer o Turboarers it presene in most parts o te

orld(

In India Cummins Turbo Tenoloies as its plants and oies in

+eas 7itampur udrapur and 7une(

+ithamur 0 une 123 4514

Cummins Turbo Tenoloies CTT- is elebratin its 3t anniversary

year( it sales o over USP1 billion CTT as ron to be a lobalompany it operations in most parts o te orld( Tenial Centres in

21

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1159

UD Cina USgt and India ontinue to develop air andlin tenoloies or

lobal ustomers in diverse mar$ets inludin oniay ommerial

veile industrial onstrution ariulture marine and poer

eneration(

In India CTT bean as a A it Tata otors in deas in 1552( In 433 te

oint venture Tata Holset Limited beame a olly oned subsidiary o

Cummins and as renamed as Cummins Turbo Tenoloies(

Te CTT plant at deas ommened operations in 155B it merely 1B

employees( In line it CumminsQ pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at deas is no bein pratied by over 533

employees o CTT aross all sites in India(

RTere are many e)amples itin te oraniation tat testiy o

employees ave ron itin te Company( Several amonst tose

employees o oined te sop ampoor are today oldin senior positions

itin te oraniation( Tis demonstrates te oraniations ommitment

to nurturin talent and providin lonterm areers( as 0uoted by an

employee o as been assoiated it Cummins Turbo Tenoloies

sine te last 1B years

To boost te e)port business CTT set up a ne plant in 7itampur in 433lt(

Tis plant is itnessin urter e)pansion( In line it CumminsQ pratie

o truly partnerin it its ustomers8 CTT India ommissioned an entire

assembly line at udrapur(

=ein a tenoloy partner CTT upraded te bran o6e tat bean its

operations in 433B to te India Tenial Center supportin international

and domesti proets( Today Cummins Turbo Tenoloies India employs

nearly 533 employees inludin 1 speialist enineers(

Tray Embree 7resident Cummins Turbo Tenoloies omments ROur

22

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1259

leay and eritae ave e0uipped us ell or te allenes aead as e

enter a ne deade o aelerated lobal rot( ile e ontinue to

partner it our ustomers to deliver te best produts and tenoloies

our ommitment to te environment and te ommunities itin ie live remains at te eart o our business(

CTT as not only ron its business but as also played a sini9ant role

in orporate responsibility(

Re are very ommitted to our vision o a$in peopleQs lives better by

unleasin te 7oer o CumminsQ( e ave been and aim to be a ood

itien o India( e loo$ orard to strentenin our partners and

ommunities and ontinue to ro rom strent to strent ile stayin

rooted to te CompanyQs vision mission and si) ore values o interity

innovation deliverin superior results diversity lobal involvement and

orporate responsibility( added gtrun amaandran India =usiness

Country Leader or Cummins Turbo Tenoloies(

ourne6 o7 Cummins Turbo Technologies in )nia

1882 Sined te oint venture areement to operate as Tata

Holset Limited in India(

1889 anuaturin operations started at te 9rst plant in India(

Te e)istin Tata plant as upraded to te turboarer plant at

+eas(

4552 +eas plant e)pansion( Te plant as built to orld lass

standards to aieve ero deets( To support te e)pandin

business a bran o6e as set up in 7une(

455 Tata Holset Limited beame a olly oned subsidiary o

Cummins( Holset as renamed as Cummins Turbo Tenoloies(

20

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1359

gtnoter important landmar$ as layin te oundation stone o te

7itampur plant(

455 Te 7itampur plant bean its operations( Te 7itampurplant is one o te best manuaturin ailities anyere in te

orld(

4558 To support te roin domesti business Cummins Turbo

Tenoloies started its operations in udrapur(

4515 it inreased business and enineerin ous omin toIndia te India Tenial Center as establised in 7une( Currently

te tenial entre as over 13 speialised desin enineers o

atively support domesti as ell international proets(

AOT CMM)NS T(O TECltNOLOG)ES DEWAS

2=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1459

In India CTT bean as a A it Tata otors in Deampas in 188=( In 433

te oint venture Tata Holset Limited beame a olly oned subsidiary

o Cummins and as renamed as Cummins Turbo Tenoloies

Te CTT plant at +eas ommened operations in 155B it merely 1B

employees( In line it Cummins pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at +eas is no bein pratied by over 533

employees o CTT aross te plant (

Te plant as a apaity o 2B333 it 442 employees( CTT is supported

by sales and tenial o6e in 7une( It produes midrane and lit duty

apaity produts li$e ltgt2 ltgt2W3 lt=53 ltEgt21W3 Clt(A core$3

haing caacit6 o7 4K an 1K

Te manuaturin system as Gaues it Online S7C and data

entralied Server( CTT ouses on improvin proess apability rater

tan inspetion( 7roess and produts are reularly audited by 0uality

team(

Environment System is erti9ed it ISO 12331 and Healt and saety

System by OHSgtS 1lt331( CTT alays $eeps Heat and Saety as its top

priority( It as a team based or$ ulture it sel manaed team at sop

26

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1559

ampoor(

Te gtssembly ell as ommissioned in 155 it te initial setup o

benes 9)ture as data plate m rom HUD( Te urrent SetU7 as

Failsae Conveyor gtssembly Line( Tree sit run in a day it Bassoiates( ore tan 433 parts are assembled in te plant(

23

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1659

ltEALTlt SA-ET AND EN)(ONMENTAL +OL)C

Cummins is ommitted to osterin a leaner ealtier and saer

environment in every ommunity in i our people live and or$( gtllour ailities ill employ te Cummins Saety and Environmental

anaement Systems i are desined to protet our personnel and

te environment to preserve natural resoures and to prevent arm to

loal ommunities( Our approa in tis endeavor is multi aeted( e ill

systemially and aressively assess operations tat ave te potential to

arm individuals or impat te environment( e ill also set substantial

and measurable obetives in manain saety and te environment(

Finally e ill periodially revie our proress aainst our obetives(

Sustainable improvement is an essential element o bot systems and is

aimed at ontributin positively to personal saety environmental ell

bein and onservation o natural resoures(

Cummins ill ontinue to implement manaement prorams developed to

ensure tat our produts servies and ativities alays omply it loal

las and ompany standards establised to protet ealt saety and te

environment( e are ommitted to minimiin

potentially armul eets resultin rom our operations and to

implementin improvements assoiated it te prevention o pollution

inury and illness(

tis Healt Saety and Environmental 7oliy ill be applied trouout

Cummins via a set o doumented ompanyide and loal poliies and

proedures( It ill be ommuniated to all employees at least annually(

Upon re0uest te poliy ill be made available to te publi(

Tim Solso

Cairman CEO

November 15 4331

2gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1759

WO(K)NG O- T(OCltA(GE(

Te turbine omprises o to omponents8 te turbine ee l and te

olletor ommonly reerred to as te turbine ousin ( Te e)aust as is

uided into te turbine eel by te ousin( Te enery in te e)aust as

turns te turbine( One te as as passed trou te blades o te eel

it leaves te turbine ousin via te e)aust outlet area(

Te speed o te enine determines o ast te turbine eel spins( I te

enine is in idle mode te eel ill be spinnin at a minimal speed( gts

more as passes trou te turbine ousin te aster te turbine eel

rotates(

Compressors are te opposite o turbines( Tey omprise o to setions

te impeller or ompressor eel and te ompressor ousin ( Te

ompressor eel is onneted to te turbine by a ored steel sat( gts te

ompressor eel spins air is dran in and is ompressed as te blades

spin at a i veloity( Te ousin is desined to onvert te i veloity

lo pressure air stream into a i pressure lo veloity air stream trou

a proess alled diusion(

gtir enters te ompressor at a temperature e0uivalent to atmospere8

oever it leaves te ompressor over at a temperature up to 433 de

Celsius( =eause te density o te air dereases as it is eated up even

more air an be ored into te enine i te air is ooled ater te

ompressor( Tis is alled inter oolin or ater oolin and is aieved by

oolin te are air eiter it ater air(

Te turboarer bearin system is lubriated by oil rom te enine( Te

oil is ed under pressure into te bearin ousin trou to te ournal

bearins and trust system( Te oil also ats as a oolant ta$in aay eat

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1859

enerated by te turbine(

Te ournal =earins are a reeampoatin rotational type( To perorm orretly

te ournal bearins sould ampoat beteen a 9lm o oil i(e( beteen bearin sat and bearin and bearin ousin-( Te bearin learanes are very

small less tan te idt o a uman air( +irty oil or blo$aes in te oil

supply oles an ause serious damae to te turboarer(

In simple terms a turboarer omprises o a turbine and a ompressor

onneted by a ommon sat supported on a bearin system( Te

turboarer onverts aste enery rom te e)aust maniold into

ompressed air i it puses into te enine( Tis allos te enine to

produe more poer and tor0ue and improves te overall e6ieny o te

ombustion proess(

Detaile amporking o7 turbocharger ampith iagram

bull Te turbine ousin is bolted to te e)aust maniold o te enine(

bull Te aste e)aust asses are used to rotate a turbine eel i

is oused in te turbine asin(

bull Te turbine eel is onneted to a ommon sat i in turn

rotates a ompressor eel(

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1959

Fi(1

bull otatin te turbine eel is te only use or te aste e)aust as(

bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(

Fi(4

bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(

bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$in proess and pulls air into teompressor over rom te atmospere9ltered-(

Te aster te eel spin te more air is su$ed in(

Fi(

bull gts te air is su$ed into te ompressor overit is ored trou a

diuser area(

bull Tis ompressors te air and ores it into te enine(

27

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2059

bull Tis proess auses te air to inrease in temperaturesometimes

upto 433 derees C(

Fi(2

bull Te oil used in a turboarer is te same as tat used or your

turboarer(

bull Te oil is used as bot a lubriant and a oolant(

bull It is ed under pressure into te bearin ousintrou to te

ournal bearins and trust system(

01

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 10: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1059

ampe)ibility e oer and te relationsips e nurture(

aloline

In India Aalvoline Cummins Ltd a A beteen gtsland In( USgt and

Cummins Sales Servies India- Ltd a olly oned subsidiary o Cummins India Ltd( is one o te Indias astest roin lubriant

mar$eters and produer o 0uality branded automotiveindustrial

produts(

Cummins Turbo Technologies +lants in )nia

Cummins Turbo Tenoloies part o Cummins In(- ompletes 3 years

15B4 4314- o operations orldide( Cummins Turbo Tenoloies is a

leadin manuaturer o Turboarers it presene in most parts o te

orld(

In India Cummins Turbo Tenoloies as its plants and oies in

+eas 7itampur udrapur and 7une(

+ithamur 0 une 123 4514

Cummins Turbo Tenoloies CTT- is elebratin its 3t anniversary

year( it sales o over USP1 billion CTT as ron to be a lobalompany it operations in most parts o te orld( Tenial Centres in

21

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1159

UD Cina USgt and India ontinue to develop air andlin tenoloies or

lobal ustomers in diverse mar$ets inludin oniay ommerial

veile industrial onstrution ariulture marine and poer

eneration(

In India CTT bean as a A it Tata otors in deas in 1552( In 433 te

oint venture Tata Holset Limited beame a olly oned subsidiary o

Cummins and as renamed as Cummins Turbo Tenoloies(

Te CTT plant at deas ommened operations in 155B it merely 1B

employees( In line it CumminsQ pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at deas is no bein pratied by over 533

employees o CTT aross all sites in India(

RTere are many e)amples itin te oraniation tat testiy o

employees ave ron itin te Company( Several amonst tose

employees o oined te sop ampoor are today oldin senior positions

itin te oraniation( Tis demonstrates te oraniations ommitment

to nurturin talent and providin lonterm areers( as 0uoted by an

employee o as been assoiated it Cummins Turbo Tenoloies

sine te last 1B years

To boost te e)port business CTT set up a ne plant in 7itampur in 433lt(

Tis plant is itnessin urter e)pansion( In line it CumminsQ pratie

o truly partnerin it its ustomers8 CTT India ommissioned an entire

assembly line at udrapur(

=ein a tenoloy partner CTT upraded te bran o6e tat bean its

operations in 433B to te India Tenial Center supportin international

and domesti proets( Today Cummins Turbo Tenoloies India employs

nearly 533 employees inludin 1 speialist enineers(

Tray Embree 7resident Cummins Turbo Tenoloies omments ROur

22

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1259

leay and eritae ave e0uipped us ell or te allenes aead as e

enter a ne deade o aelerated lobal rot( ile e ontinue to

partner it our ustomers to deliver te best produts and tenoloies

our ommitment to te environment and te ommunities itin ie live remains at te eart o our business(

CTT as not only ron its business but as also played a sini9ant role

in orporate responsibility(

Re are very ommitted to our vision o a$in peopleQs lives better by

unleasin te 7oer o CumminsQ( e ave been and aim to be a ood

itien o India( e loo$ orard to strentenin our partners and

ommunities and ontinue to ro rom strent to strent ile stayin

rooted to te CompanyQs vision mission and si) ore values o interity

innovation deliverin superior results diversity lobal involvement and

orporate responsibility( added gtrun amaandran India =usiness

Country Leader or Cummins Turbo Tenoloies(

ourne6 o7 Cummins Turbo Technologies in )nia

1882 Sined te oint venture areement to operate as Tata

Holset Limited in India(

1889 anuaturin operations started at te 9rst plant in India(

Te e)istin Tata plant as upraded to te turboarer plant at

+eas(

4552 +eas plant e)pansion( Te plant as built to orld lass

standards to aieve ero deets( To support te e)pandin

business a bran o6e as set up in 7une(

455 Tata Holset Limited beame a olly oned subsidiary o

Cummins( Holset as renamed as Cummins Turbo Tenoloies(

20

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1359

gtnoter important landmar$ as layin te oundation stone o te

7itampur plant(

455 Te 7itampur plant bean its operations( Te 7itampurplant is one o te best manuaturin ailities anyere in te

orld(

4558 To support te roin domesti business Cummins Turbo

Tenoloies started its operations in udrapur(

4515 it inreased business and enineerin ous omin toIndia te India Tenial Center as establised in 7une( Currently

te tenial entre as over 13 speialised desin enineers o

atively support domesti as ell international proets(

AOT CMM)NS T(O TECltNOLOG)ES DEWAS

2=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1459

In India CTT bean as a A it Tata otors in Deampas in 188=( In 433

te oint venture Tata Holset Limited beame a olly oned subsidiary

o Cummins and as renamed as Cummins Turbo Tenoloies

Te CTT plant at +eas ommened operations in 155B it merely 1B

employees( In line it Cummins pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at +eas is no bein pratied by over 533

employees o CTT aross te plant (

Te plant as a apaity o 2B333 it 442 employees( CTT is supported

by sales and tenial o6e in 7une( It produes midrane and lit duty

apaity produts li$e ltgt2 ltgt2W3 lt=53 ltEgt21W3 Clt(A core$3

haing caacit6 o7 4K an 1K

Te manuaturin system as Gaues it Online S7C and data

entralied Server( CTT ouses on improvin proess apability rater

tan inspetion( 7roess and produts are reularly audited by 0uality

team(

Environment System is erti9ed it ISO 12331 and Healt and saety

System by OHSgtS 1lt331( CTT alays $eeps Heat and Saety as its top

priority( It as a team based or$ ulture it sel manaed team at sop

26

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1559

ampoor(

Te gtssembly ell as ommissioned in 155 it te initial setup o

benes 9)ture as data plate m rom HUD( Te urrent SetU7 as

Failsae Conveyor gtssembly Line( Tree sit run in a day it Bassoiates( ore tan 433 parts are assembled in te plant(

23

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1659

ltEALTlt SA-ET AND EN)(ONMENTAL +OL)C

Cummins is ommitted to osterin a leaner ealtier and saer

environment in every ommunity in i our people live and or$( gtllour ailities ill employ te Cummins Saety and Environmental

anaement Systems i are desined to protet our personnel and

te environment to preserve natural resoures and to prevent arm to

loal ommunities( Our approa in tis endeavor is multi aeted( e ill

systemially and aressively assess operations tat ave te potential to

arm individuals or impat te environment( e ill also set substantial

and measurable obetives in manain saety and te environment(

Finally e ill periodially revie our proress aainst our obetives(

Sustainable improvement is an essential element o bot systems and is

aimed at ontributin positively to personal saety environmental ell

bein and onservation o natural resoures(

Cummins ill ontinue to implement manaement prorams developed to

ensure tat our produts servies and ativities alays omply it loal

las and ompany standards establised to protet ealt saety and te

environment( e are ommitted to minimiin

potentially armul eets resultin rom our operations and to

implementin improvements assoiated it te prevention o pollution

inury and illness(

tis Healt Saety and Environmental 7oliy ill be applied trouout

Cummins via a set o doumented ompanyide and loal poliies and

proedures( It ill be ommuniated to all employees at least annually(

Upon re0uest te poliy ill be made available to te publi(

Tim Solso

Cairman CEO

November 15 4331

2gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1759

WO(K)NG O- T(OCltA(GE(

Te turbine omprises o to omponents8 te turbine ee l and te

olletor ommonly reerred to as te turbine ousin ( Te e)aust as is

uided into te turbine eel by te ousin( Te enery in te e)aust as

turns te turbine( One te as as passed trou te blades o te eel

it leaves te turbine ousin via te e)aust outlet area(

Te speed o te enine determines o ast te turbine eel spins( I te

enine is in idle mode te eel ill be spinnin at a minimal speed( gts

more as passes trou te turbine ousin te aster te turbine eel

rotates(

Compressors are te opposite o turbines( Tey omprise o to setions

te impeller or ompressor eel and te ompressor ousin ( Te

ompressor eel is onneted to te turbine by a ored steel sat( gts te

ompressor eel spins air is dran in and is ompressed as te blades

spin at a i veloity( Te ousin is desined to onvert te i veloity

lo pressure air stream into a i pressure lo veloity air stream trou

a proess alled diusion(

gtir enters te ompressor at a temperature e0uivalent to atmospere8

oever it leaves te ompressor over at a temperature up to 433 de

Celsius( =eause te density o te air dereases as it is eated up even

more air an be ored into te enine i te air is ooled ater te

ompressor( Tis is alled inter oolin or ater oolin and is aieved by

oolin te are air eiter it ater air(

Te turboarer bearin system is lubriated by oil rom te enine( Te

oil is ed under pressure into te bearin ousin trou to te ournal

bearins and trust system( Te oil also ats as a oolant ta$in aay eat

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1859

enerated by te turbine(

Te ournal =earins are a reeampoatin rotational type( To perorm orretly

te ournal bearins sould ampoat beteen a 9lm o oil i(e( beteen bearin sat and bearin and bearin ousin-( Te bearin learanes are very

small less tan te idt o a uman air( +irty oil or blo$aes in te oil

supply oles an ause serious damae to te turboarer(

In simple terms a turboarer omprises o a turbine and a ompressor

onneted by a ommon sat supported on a bearin system( Te

turboarer onverts aste enery rom te e)aust maniold into

ompressed air i it puses into te enine( Tis allos te enine to

produe more poer and tor0ue and improves te overall e6ieny o te

ombustion proess(

Detaile amporking o7 turbocharger ampith iagram

bull Te turbine ousin is bolted to te e)aust maniold o te enine(

bull Te aste e)aust asses are used to rotate a turbine eel i

is oused in te turbine asin(

bull Te turbine eel is onneted to a ommon sat i in turn

rotates a ompressor eel(

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1959

Fi(1

bull otatin te turbine eel is te only use or te aste e)aust as(

bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(

Fi(4

bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(

bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$in proess and pulls air into teompressor over rom te atmospere9ltered-(

Te aster te eel spin te more air is su$ed in(

Fi(

bull gts te air is su$ed into te ompressor overit is ored trou a

diuser area(

bull Tis ompressors te air and ores it into te enine(

27

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2059

bull Tis proess auses te air to inrease in temperaturesometimes

upto 433 derees C(

Fi(2

bull Te oil used in a turboarer is te same as tat used or your

turboarer(

bull Te oil is used as bot a lubriant and a oolant(

bull It is ed under pressure into te bearin ousintrou to te

ournal bearins and trust system(

01

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 11: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1159

UD Cina USgt and India ontinue to develop air andlin tenoloies or

lobal ustomers in diverse mar$ets inludin oniay ommerial

veile industrial onstrution ariulture marine and poer

eneration(

In India CTT bean as a A it Tata otors in deas in 1552( In 433 te

oint venture Tata Holset Limited beame a olly oned subsidiary o

Cummins and as renamed as Cummins Turbo Tenoloies(

Te CTT plant at deas ommened operations in 155B it merely 1B

employees( In line it CumminsQ pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at deas is no bein pratied by over 533

employees o CTT aross all sites in India(

RTere are many e)amples itin te oraniation tat testiy o

employees ave ron itin te Company( Several amonst tose

employees o oined te sop ampoor are today oldin senior positions

itin te oraniation( Tis demonstrates te oraniations ommitment

to nurturin talent and providin lonterm areers( as 0uoted by an

employee o as been assoiated it Cummins Turbo Tenoloies

sine te last 1B years

To boost te e)port business CTT set up a ne plant in 7itampur in 433lt(

Tis plant is itnessin urter e)pansion( In line it CumminsQ pratie

o truly partnerin it its ustomers8 CTT India ommissioned an entire

assembly line at udrapur(

=ein a tenoloy partner CTT upraded te bran o6e tat bean its

operations in 433B to te India Tenial Center supportin international

and domesti proets( Today Cummins Turbo Tenoloies India employs

nearly 533 employees inludin 1 speialist enineers(

Tray Embree 7resident Cummins Turbo Tenoloies omments ROur

22

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1259

leay and eritae ave e0uipped us ell or te allenes aead as e

enter a ne deade o aelerated lobal rot( ile e ontinue to

partner it our ustomers to deliver te best produts and tenoloies

our ommitment to te environment and te ommunities itin ie live remains at te eart o our business(

CTT as not only ron its business but as also played a sini9ant role

in orporate responsibility(

Re are very ommitted to our vision o a$in peopleQs lives better by

unleasin te 7oer o CumminsQ( e ave been and aim to be a ood

itien o India( e loo$ orard to strentenin our partners and

ommunities and ontinue to ro rom strent to strent ile stayin

rooted to te CompanyQs vision mission and si) ore values o interity

innovation deliverin superior results diversity lobal involvement and

orporate responsibility( added gtrun amaandran India =usiness

Country Leader or Cummins Turbo Tenoloies(

ourne6 o7 Cummins Turbo Technologies in )nia

1882 Sined te oint venture areement to operate as Tata

Holset Limited in India(

1889 anuaturin operations started at te 9rst plant in India(

Te e)istin Tata plant as upraded to te turboarer plant at

+eas(

4552 +eas plant e)pansion( Te plant as built to orld lass

standards to aieve ero deets( To support te e)pandin

business a bran o6e as set up in 7une(

455 Tata Holset Limited beame a olly oned subsidiary o

Cummins( Holset as renamed as Cummins Turbo Tenoloies(

20

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1359

gtnoter important landmar$ as layin te oundation stone o te

7itampur plant(

455 Te 7itampur plant bean its operations( Te 7itampurplant is one o te best manuaturin ailities anyere in te

orld(

4558 To support te roin domesti business Cummins Turbo

Tenoloies started its operations in udrapur(

4515 it inreased business and enineerin ous omin toIndia te India Tenial Center as establised in 7une( Currently

te tenial entre as over 13 speialised desin enineers o

atively support domesti as ell international proets(

AOT CMM)NS T(O TECltNOLOG)ES DEWAS

2=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1459

In India CTT bean as a A it Tata otors in Deampas in 188=( In 433

te oint venture Tata Holset Limited beame a olly oned subsidiary

o Cummins and as renamed as Cummins Turbo Tenoloies

Te CTT plant at +eas ommened operations in 155B it merely 1B

employees( In line it Cummins pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at +eas is no bein pratied by over 533

employees o CTT aross te plant (

Te plant as a apaity o 2B333 it 442 employees( CTT is supported

by sales and tenial o6e in 7une( It produes midrane and lit duty

apaity produts li$e ltgt2 ltgt2W3 lt=53 ltEgt21W3 Clt(A core$3

haing caacit6 o7 4K an 1K

Te manuaturin system as Gaues it Online S7C and data

entralied Server( CTT ouses on improvin proess apability rater

tan inspetion( 7roess and produts are reularly audited by 0uality

team(

Environment System is erti9ed it ISO 12331 and Healt and saety

System by OHSgtS 1lt331( CTT alays $eeps Heat and Saety as its top

priority( It as a team based or$ ulture it sel manaed team at sop

26

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1559

ampoor(

Te gtssembly ell as ommissioned in 155 it te initial setup o

benes 9)ture as data plate m rom HUD( Te urrent SetU7 as

Failsae Conveyor gtssembly Line( Tree sit run in a day it Bassoiates( ore tan 433 parts are assembled in te plant(

23

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1659

ltEALTlt SA-ET AND EN)(ONMENTAL +OL)C

Cummins is ommitted to osterin a leaner ealtier and saer

environment in every ommunity in i our people live and or$( gtllour ailities ill employ te Cummins Saety and Environmental

anaement Systems i are desined to protet our personnel and

te environment to preserve natural resoures and to prevent arm to

loal ommunities( Our approa in tis endeavor is multi aeted( e ill

systemially and aressively assess operations tat ave te potential to

arm individuals or impat te environment( e ill also set substantial

and measurable obetives in manain saety and te environment(

Finally e ill periodially revie our proress aainst our obetives(

Sustainable improvement is an essential element o bot systems and is

aimed at ontributin positively to personal saety environmental ell

bein and onservation o natural resoures(

Cummins ill ontinue to implement manaement prorams developed to

ensure tat our produts servies and ativities alays omply it loal

las and ompany standards establised to protet ealt saety and te

environment( e are ommitted to minimiin

potentially armul eets resultin rom our operations and to

implementin improvements assoiated it te prevention o pollution

inury and illness(

tis Healt Saety and Environmental 7oliy ill be applied trouout

Cummins via a set o doumented ompanyide and loal poliies and

proedures( It ill be ommuniated to all employees at least annually(

Upon re0uest te poliy ill be made available to te publi(

Tim Solso

Cairman CEO

November 15 4331

2gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1759

WO(K)NG O- T(OCltA(GE(

Te turbine omprises o to omponents8 te turbine ee l and te

olletor ommonly reerred to as te turbine ousin ( Te e)aust as is

uided into te turbine eel by te ousin( Te enery in te e)aust as

turns te turbine( One te as as passed trou te blades o te eel

it leaves te turbine ousin via te e)aust outlet area(

Te speed o te enine determines o ast te turbine eel spins( I te

enine is in idle mode te eel ill be spinnin at a minimal speed( gts

more as passes trou te turbine ousin te aster te turbine eel

rotates(

Compressors are te opposite o turbines( Tey omprise o to setions

te impeller or ompressor eel and te ompressor ousin ( Te

ompressor eel is onneted to te turbine by a ored steel sat( gts te

ompressor eel spins air is dran in and is ompressed as te blades

spin at a i veloity( Te ousin is desined to onvert te i veloity

lo pressure air stream into a i pressure lo veloity air stream trou

a proess alled diusion(

gtir enters te ompressor at a temperature e0uivalent to atmospere8

oever it leaves te ompressor over at a temperature up to 433 de

Celsius( =eause te density o te air dereases as it is eated up even

more air an be ored into te enine i te air is ooled ater te

ompressor( Tis is alled inter oolin or ater oolin and is aieved by

oolin te are air eiter it ater air(

Te turboarer bearin system is lubriated by oil rom te enine( Te

oil is ed under pressure into te bearin ousin trou to te ournal

bearins and trust system( Te oil also ats as a oolant ta$in aay eat

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1859

enerated by te turbine(

Te ournal =earins are a reeampoatin rotational type( To perorm orretly

te ournal bearins sould ampoat beteen a 9lm o oil i(e( beteen bearin sat and bearin and bearin ousin-( Te bearin learanes are very

small less tan te idt o a uman air( +irty oil or blo$aes in te oil

supply oles an ause serious damae to te turboarer(

In simple terms a turboarer omprises o a turbine and a ompressor

onneted by a ommon sat supported on a bearin system( Te

turboarer onverts aste enery rom te e)aust maniold into

ompressed air i it puses into te enine( Tis allos te enine to

produe more poer and tor0ue and improves te overall e6ieny o te

ombustion proess(

Detaile amporking o7 turbocharger ampith iagram

bull Te turbine ousin is bolted to te e)aust maniold o te enine(

bull Te aste e)aust asses are used to rotate a turbine eel i

is oused in te turbine asin(

bull Te turbine eel is onneted to a ommon sat i in turn

rotates a ompressor eel(

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1959

Fi(1

bull otatin te turbine eel is te only use or te aste e)aust as(

bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(

Fi(4

bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(

bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$in proess and pulls air into teompressor over rom te atmospere9ltered-(

Te aster te eel spin te more air is su$ed in(

Fi(

bull gts te air is su$ed into te ompressor overit is ored trou a

diuser area(

bull Tis ompressors te air and ores it into te enine(

27

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2059

bull Tis proess auses te air to inrease in temperaturesometimes

upto 433 derees C(

Fi(2

bull Te oil used in a turboarer is te same as tat used or your

turboarer(

bull Te oil is used as bot a lubriant and a oolant(

bull It is ed under pressure into te bearin ousintrou to te

ournal bearins and trust system(

01

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 12: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1259

leay and eritae ave e0uipped us ell or te allenes aead as e

enter a ne deade o aelerated lobal rot( ile e ontinue to

partner it our ustomers to deliver te best produts and tenoloies

our ommitment to te environment and te ommunities itin ie live remains at te eart o our business(

CTT as not only ron its business but as also played a sini9ant role

in orporate responsibility(

Re are very ommitted to our vision o a$in peopleQs lives better by

unleasin te 7oer o CumminsQ( e ave been and aim to be a ood

itien o India( e loo$ orard to strentenin our partners and

ommunities and ontinue to ro rom strent to strent ile stayin

rooted to te CompanyQs vision mission and si) ore values o interity

innovation deliverin superior results diversity lobal involvement and

orporate responsibility( added gtrun amaandran India =usiness

Country Leader or Cummins Turbo Tenoloies(

ourne6 o7 Cummins Turbo Technologies in )nia

1882 Sined te oint venture areement to operate as Tata

Holset Limited in India(

1889 anuaturin operations started at te 9rst plant in India(

Te e)istin Tata plant as upraded to te turboarer plant at

+eas(

4552 +eas plant e)pansion( Te plant as built to orld lass

standards to aieve ero deets( To support te e)pandin

business a bran o6e as set up in 7une(

455 Tata Holset Limited beame a olly oned subsidiary o

Cummins( Holset as renamed as Cummins Turbo Tenoloies(

20

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1359

gtnoter important landmar$ as layin te oundation stone o te

7itampur plant(

455 Te 7itampur plant bean its operations( Te 7itampurplant is one o te best manuaturin ailities anyere in te

orld(

4558 To support te roin domesti business Cummins Turbo

Tenoloies started its operations in udrapur(

4515 it inreased business and enineerin ous omin toIndia te India Tenial Center as establised in 7une( Currently

te tenial entre as over 13 speialised desin enineers o

atively support domesti as ell international proets(

AOT CMM)NS T(O TECltNOLOG)ES DEWAS

2=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1459

In India CTT bean as a A it Tata otors in Deampas in 188=( In 433

te oint venture Tata Holset Limited beame a olly oned subsidiary

o Cummins and as renamed as Cummins Turbo Tenoloies

Te CTT plant at +eas ommened operations in 155B it merely 1B

employees( In line it Cummins pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at +eas is no bein pratied by over 533

employees o CTT aross te plant (

Te plant as a apaity o 2B333 it 442 employees( CTT is supported

by sales and tenial o6e in 7une( It produes midrane and lit duty

apaity produts li$e ltgt2 ltgt2W3 lt=53 ltEgt21W3 Clt(A core$3

haing caacit6 o7 4K an 1K

Te manuaturin system as Gaues it Online S7C and data

entralied Server( CTT ouses on improvin proess apability rater

tan inspetion( 7roess and produts are reularly audited by 0uality

team(

Environment System is erti9ed it ISO 12331 and Healt and saety

System by OHSgtS 1lt331( CTT alays $eeps Heat and Saety as its top

priority( It as a team based or$ ulture it sel manaed team at sop

26

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1559

ampoor(

Te gtssembly ell as ommissioned in 155 it te initial setup o

benes 9)ture as data plate m rom HUD( Te urrent SetU7 as

Failsae Conveyor gtssembly Line( Tree sit run in a day it Bassoiates( ore tan 433 parts are assembled in te plant(

23

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1659

ltEALTlt SA-ET AND EN)(ONMENTAL +OL)C

Cummins is ommitted to osterin a leaner ealtier and saer

environment in every ommunity in i our people live and or$( gtllour ailities ill employ te Cummins Saety and Environmental

anaement Systems i are desined to protet our personnel and

te environment to preserve natural resoures and to prevent arm to

loal ommunities( Our approa in tis endeavor is multi aeted( e ill

systemially and aressively assess operations tat ave te potential to

arm individuals or impat te environment( e ill also set substantial

and measurable obetives in manain saety and te environment(

Finally e ill periodially revie our proress aainst our obetives(

Sustainable improvement is an essential element o bot systems and is

aimed at ontributin positively to personal saety environmental ell

bein and onservation o natural resoures(

Cummins ill ontinue to implement manaement prorams developed to

ensure tat our produts servies and ativities alays omply it loal

las and ompany standards establised to protet ealt saety and te

environment( e are ommitted to minimiin

potentially armul eets resultin rom our operations and to

implementin improvements assoiated it te prevention o pollution

inury and illness(

tis Healt Saety and Environmental 7oliy ill be applied trouout

Cummins via a set o doumented ompanyide and loal poliies and

proedures( It ill be ommuniated to all employees at least annually(

Upon re0uest te poliy ill be made available to te publi(

Tim Solso

Cairman CEO

November 15 4331

2gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1759

WO(K)NG O- T(OCltA(GE(

Te turbine omprises o to omponents8 te turbine ee l and te

olletor ommonly reerred to as te turbine ousin ( Te e)aust as is

uided into te turbine eel by te ousin( Te enery in te e)aust as

turns te turbine( One te as as passed trou te blades o te eel

it leaves te turbine ousin via te e)aust outlet area(

Te speed o te enine determines o ast te turbine eel spins( I te

enine is in idle mode te eel ill be spinnin at a minimal speed( gts

more as passes trou te turbine ousin te aster te turbine eel

rotates(

Compressors are te opposite o turbines( Tey omprise o to setions

te impeller or ompressor eel and te ompressor ousin ( Te

ompressor eel is onneted to te turbine by a ored steel sat( gts te

ompressor eel spins air is dran in and is ompressed as te blades

spin at a i veloity( Te ousin is desined to onvert te i veloity

lo pressure air stream into a i pressure lo veloity air stream trou

a proess alled diusion(

gtir enters te ompressor at a temperature e0uivalent to atmospere8

oever it leaves te ompressor over at a temperature up to 433 de

Celsius( =eause te density o te air dereases as it is eated up even

more air an be ored into te enine i te air is ooled ater te

ompressor( Tis is alled inter oolin or ater oolin and is aieved by

oolin te are air eiter it ater air(

Te turboarer bearin system is lubriated by oil rom te enine( Te

oil is ed under pressure into te bearin ousin trou to te ournal

bearins and trust system( Te oil also ats as a oolant ta$in aay eat

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1859

enerated by te turbine(

Te ournal =earins are a reeampoatin rotational type( To perorm orretly

te ournal bearins sould ampoat beteen a 9lm o oil i(e( beteen bearin sat and bearin and bearin ousin-( Te bearin learanes are very

small less tan te idt o a uman air( +irty oil or blo$aes in te oil

supply oles an ause serious damae to te turboarer(

In simple terms a turboarer omprises o a turbine and a ompressor

onneted by a ommon sat supported on a bearin system( Te

turboarer onverts aste enery rom te e)aust maniold into

ompressed air i it puses into te enine( Tis allos te enine to

produe more poer and tor0ue and improves te overall e6ieny o te

ombustion proess(

Detaile amporking o7 turbocharger ampith iagram

bull Te turbine ousin is bolted to te e)aust maniold o te enine(

bull Te aste e)aust asses are used to rotate a turbine eel i

is oused in te turbine asin(

bull Te turbine eel is onneted to a ommon sat i in turn

rotates a ompressor eel(

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1959

Fi(1

bull otatin te turbine eel is te only use or te aste e)aust as(

bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(

Fi(4

bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(

bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$in proess and pulls air into teompressor over rom te atmospere9ltered-(

Te aster te eel spin te more air is su$ed in(

Fi(

bull gts te air is su$ed into te ompressor overit is ored trou a

diuser area(

bull Tis ompressors te air and ores it into te enine(

27

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2059

bull Tis proess auses te air to inrease in temperaturesometimes

upto 433 derees C(

Fi(2

bull Te oil used in a turboarer is te same as tat used or your

turboarer(

bull Te oil is used as bot a lubriant and a oolant(

bull It is ed under pressure into te bearin ousintrou to te

ournal bearins and trust system(

01

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 13: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1359

gtnoter important landmar$ as layin te oundation stone o te

7itampur plant(

455 Te 7itampur plant bean its operations( Te 7itampurplant is one o te best manuaturin ailities anyere in te

orld(

4558 To support te roin domesti business Cummins Turbo

Tenoloies started its operations in udrapur(

4515 it inreased business and enineerin ous omin toIndia te India Tenial Center as establised in 7une( Currently

te tenial entre as over 13 speialised desin enineers o

atively support domesti as ell international proets(

AOT CMM)NS T(O TECltNOLOG)ES DEWAS

2=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1459

In India CTT bean as a A it Tata otors in Deampas in 188=( In 433

te oint venture Tata Holset Limited beame a olly oned subsidiary

o Cummins and as renamed as Cummins Turbo Tenoloies

Te CTT plant at +eas ommened operations in 155B it merely 1B

employees( In line it Cummins pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at +eas is no bein pratied by over 533

employees o CTT aross te plant (

Te plant as a apaity o 2B333 it 442 employees( CTT is supported

by sales and tenial o6e in 7une( It produes midrane and lit duty

apaity produts li$e ltgt2 ltgt2W3 lt=53 ltEgt21W3 Clt(A core$3

haing caacit6 o7 4K an 1K

Te manuaturin system as Gaues it Online S7C and data

entralied Server( CTT ouses on improvin proess apability rater

tan inspetion( 7roess and produts are reularly audited by 0uality

team(

Environment System is erti9ed it ISO 12331 and Healt and saety

System by OHSgtS 1lt331( CTT alays $eeps Heat and Saety as its top

priority( It as a team based or$ ulture it sel manaed team at sop

26

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1559

ampoor(

Te gtssembly ell as ommissioned in 155 it te initial setup o

benes 9)ture as data plate m rom HUD( Te urrent SetU7 as

Failsae Conveyor gtssembly Line( Tree sit run in a day it Bassoiates( ore tan 433 parts are assembled in te plant(

23

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1659

ltEALTlt SA-ET AND EN)(ONMENTAL +OL)C

Cummins is ommitted to osterin a leaner ealtier and saer

environment in every ommunity in i our people live and or$( gtllour ailities ill employ te Cummins Saety and Environmental

anaement Systems i are desined to protet our personnel and

te environment to preserve natural resoures and to prevent arm to

loal ommunities( Our approa in tis endeavor is multi aeted( e ill

systemially and aressively assess operations tat ave te potential to

arm individuals or impat te environment( e ill also set substantial

and measurable obetives in manain saety and te environment(

Finally e ill periodially revie our proress aainst our obetives(

Sustainable improvement is an essential element o bot systems and is

aimed at ontributin positively to personal saety environmental ell

bein and onservation o natural resoures(

Cummins ill ontinue to implement manaement prorams developed to

ensure tat our produts servies and ativities alays omply it loal

las and ompany standards establised to protet ealt saety and te

environment( e are ommitted to minimiin

potentially armul eets resultin rom our operations and to

implementin improvements assoiated it te prevention o pollution

inury and illness(

tis Healt Saety and Environmental 7oliy ill be applied trouout

Cummins via a set o doumented ompanyide and loal poliies and

proedures( It ill be ommuniated to all employees at least annually(

Upon re0uest te poliy ill be made available to te publi(

Tim Solso

Cairman CEO

November 15 4331

2gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1759

WO(K)NG O- T(OCltA(GE(

Te turbine omprises o to omponents8 te turbine ee l and te

olletor ommonly reerred to as te turbine ousin ( Te e)aust as is

uided into te turbine eel by te ousin( Te enery in te e)aust as

turns te turbine( One te as as passed trou te blades o te eel

it leaves te turbine ousin via te e)aust outlet area(

Te speed o te enine determines o ast te turbine eel spins( I te

enine is in idle mode te eel ill be spinnin at a minimal speed( gts

more as passes trou te turbine ousin te aster te turbine eel

rotates(

Compressors are te opposite o turbines( Tey omprise o to setions

te impeller or ompressor eel and te ompressor ousin ( Te

ompressor eel is onneted to te turbine by a ored steel sat( gts te

ompressor eel spins air is dran in and is ompressed as te blades

spin at a i veloity( Te ousin is desined to onvert te i veloity

lo pressure air stream into a i pressure lo veloity air stream trou

a proess alled diusion(

gtir enters te ompressor at a temperature e0uivalent to atmospere8

oever it leaves te ompressor over at a temperature up to 433 de

Celsius( =eause te density o te air dereases as it is eated up even

more air an be ored into te enine i te air is ooled ater te

ompressor( Tis is alled inter oolin or ater oolin and is aieved by

oolin te are air eiter it ater air(

Te turboarer bearin system is lubriated by oil rom te enine( Te

oil is ed under pressure into te bearin ousin trou to te ournal

bearins and trust system( Te oil also ats as a oolant ta$in aay eat

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1859

enerated by te turbine(

Te ournal =earins are a reeampoatin rotational type( To perorm orretly

te ournal bearins sould ampoat beteen a 9lm o oil i(e( beteen bearin sat and bearin and bearin ousin-( Te bearin learanes are very

small less tan te idt o a uman air( +irty oil or blo$aes in te oil

supply oles an ause serious damae to te turboarer(

In simple terms a turboarer omprises o a turbine and a ompressor

onneted by a ommon sat supported on a bearin system( Te

turboarer onverts aste enery rom te e)aust maniold into

ompressed air i it puses into te enine( Tis allos te enine to

produe more poer and tor0ue and improves te overall e6ieny o te

ombustion proess(

Detaile amporking o7 turbocharger ampith iagram

bull Te turbine ousin is bolted to te e)aust maniold o te enine(

bull Te aste e)aust asses are used to rotate a turbine eel i

is oused in te turbine asin(

bull Te turbine eel is onneted to a ommon sat i in turn

rotates a ompressor eel(

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1959

Fi(1

bull otatin te turbine eel is te only use or te aste e)aust as(

bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(

Fi(4

bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(

bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$in proess and pulls air into teompressor over rom te atmospere9ltered-(

Te aster te eel spin te more air is su$ed in(

Fi(

bull gts te air is su$ed into te ompressor overit is ored trou a

diuser area(

bull Tis ompressors te air and ores it into te enine(

27

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2059

bull Tis proess auses te air to inrease in temperaturesometimes

upto 433 derees C(

Fi(2

bull Te oil used in a turboarer is te same as tat used or your

turboarer(

bull Te oil is used as bot a lubriant and a oolant(

bull It is ed under pressure into te bearin ousintrou to te

ournal bearins and trust system(

01

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 14: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1459

In India CTT bean as a A it Tata otors in Deampas in 188=( In 433

te oint venture Tata Holset Limited beame a olly oned subsidiary

o Cummins and as renamed as Cummins Turbo Tenoloies

Te CTT plant at +eas ommened operations in 155B it merely 1B

employees( In line it Cummins pilosopy te oraniation as alays

oused on developin its people and teir s$ills( Te team based or$

ulture pioneered at +eas is no bein pratied by over 533

employees o CTT aross te plant (

Te plant as a apaity o 2B333 it 442 employees( CTT is supported

by sales and tenial o6e in 7une( It produes midrane and lit duty

apaity produts li$e ltgt2 ltgt2W3 lt=53 ltEgt21W3 Clt(A core$3

haing caacit6 o7 4K an 1K

Te manuaturin system as Gaues it Online S7C and data

entralied Server( CTT ouses on improvin proess apability rater

tan inspetion( 7roess and produts are reularly audited by 0uality

team(

Environment System is erti9ed it ISO 12331 and Healt and saety

System by OHSgtS 1lt331( CTT alays $eeps Heat and Saety as its top

priority( It as a team based or$ ulture it sel manaed team at sop

26

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1559

ampoor(

Te gtssembly ell as ommissioned in 155 it te initial setup o

benes 9)ture as data plate m rom HUD( Te urrent SetU7 as

Failsae Conveyor gtssembly Line( Tree sit run in a day it Bassoiates( ore tan 433 parts are assembled in te plant(

23

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1659

ltEALTlt SA-ET AND EN)(ONMENTAL +OL)C

Cummins is ommitted to osterin a leaner ealtier and saer

environment in every ommunity in i our people live and or$( gtllour ailities ill employ te Cummins Saety and Environmental

anaement Systems i are desined to protet our personnel and

te environment to preserve natural resoures and to prevent arm to

loal ommunities( Our approa in tis endeavor is multi aeted( e ill

systemially and aressively assess operations tat ave te potential to

arm individuals or impat te environment( e ill also set substantial

and measurable obetives in manain saety and te environment(

Finally e ill periodially revie our proress aainst our obetives(

Sustainable improvement is an essential element o bot systems and is

aimed at ontributin positively to personal saety environmental ell

bein and onservation o natural resoures(

Cummins ill ontinue to implement manaement prorams developed to

ensure tat our produts servies and ativities alays omply it loal

las and ompany standards establised to protet ealt saety and te

environment( e are ommitted to minimiin

potentially armul eets resultin rom our operations and to

implementin improvements assoiated it te prevention o pollution

inury and illness(

tis Healt Saety and Environmental 7oliy ill be applied trouout

Cummins via a set o doumented ompanyide and loal poliies and

proedures( It ill be ommuniated to all employees at least annually(

Upon re0uest te poliy ill be made available to te publi(

Tim Solso

Cairman CEO

November 15 4331

2gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1759

WO(K)NG O- T(OCltA(GE(

Te turbine omprises o to omponents8 te turbine ee l and te

olletor ommonly reerred to as te turbine ousin ( Te e)aust as is

uided into te turbine eel by te ousin( Te enery in te e)aust as

turns te turbine( One te as as passed trou te blades o te eel

it leaves te turbine ousin via te e)aust outlet area(

Te speed o te enine determines o ast te turbine eel spins( I te

enine is in idle mode te eel ill be spinnin at a minimal speed( gts

more as passes trou te turbine ousin te aster te turbine eel

rotates(

Compressors are te opposite o turbines( Tey omprise o to setions

te impeller or ompressor eel and te ompressor ousin ( Te

ompressor eel is onneted to te turbine by a ored steel sat( gts te

ompressor eel spins air is dran in and is ompressed as te blades

spin at a i veloity( Te ousin is desined to onvert te i veloity

lo pressure air stream into a i pressure lo veloity air stream trou

a proess alled diusion(

gtir enters te ompressor at a temperature e0uivalent to atmospere8

oever it leaves te ompressor over at a temperature up to 433 de

Celsius( =eause te density o te air dereases as it is eated up even

more air an be ored into te enine i te air is ooled ater te

ompressor( Tis is alled inter oolin or ater oolin and is aieved by

oolin te are air eiter it ater air(

Te turboarer bearin system is lubriated by oil rom te enine( Te

oil is ed under pressure into te bearin ousin trou to te ournal

bearins and trust system( Te oil also ats as a oolant ta$in aay eat

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1859

enerated by te turbine(

Te ournal =earins are a reeampoatin rotational type( To perorm orretly

te ournal bearins sould ampoat beteen a 9lm o oil i(e( beteen bearin sat and bearin and bearin ousin-( Te bearin learanes are very

small less tan te idt o a uman air( +irty oil or blo$aes in te oil

supply oles an ause serious damae to te turboarer(

In simple terms a turboarer omprises o a turbine and a ompressor

onneted by a ommon sat supported on a bearin system( Te

turboarer onverts aste enery rom te e)aust maniold into

ompressed air i it puses into te enine( Tis allos te enine to

produe more poer and tor0ue and improves te overall e6ieny o te

ombustion proess(

Detaile amporking o7 turbocharger ampith iagram

bull Te turbine ousin is bolted to te e)aust maniold o te enine(

bull Te aste e)aust asses are used to rotate a turbine eel i

is oused in te turbine asin(

bull Te turbine eel is onneted to a ommon sat i in turn

rotates a ompressor eel(

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1959

Fi(1

bull otatin te turbine eel is te only use or te aste e)aust as(

bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(

Fi(4

bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(

bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$in proess and pulls air into teompressor over rom te atmospere9ltered-(

Te aster te eel spin te more air is su$ed in(

Fi(

bull gts te air is su$ed into te ompressor overit is ored trou a

diuser area(

bull Tis ompressors te air and ores it into te enine(

27

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2059

bull Tis proess auses te air to inrease in temperaturesometimes

upto 433 derees C(

Fi(2

bull Te oil used in a turboarer is te same as tat used or your

turboarer(

bull Te oil is used as bot a lubriant and a oolant(

bull It is ed under pressure into te bearin ousintrou to te

ournal bearins and trust system(

01

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 15: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1559

ampoor(

Te gtssembly ell as ommissioned in 155 it te initial setup o

benes 9)ture as data plate m rom HUD( Te urrent SetU7 as

Failsae Conveyor gtssembly Line( Tree sit run in a day it Bassoiates( ore tan 433 parts are assembled in te plant(

23

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1659

ltEALTlt SA-ET AND EN)(ONMENTAL +OL)C

Cummins is ommitted to osterin a leaner ealtier and saer

environment in every ommunity in i our people live and or$( gtllour ailities ill employ te Cummins Saety and Environmental

anaement Systems i are desined to protet our personnel and

te environment to preserve natural resoures and to prevent arm to

loal ommunities( Our approa in tis endeavor is multi aeted( e ill

systemially and aressively assess operations tat ave te potential to

arm individuals or impat te environment( e ill also set substantial

and measurable obetives in manain saety and te environment(

Finally e ill periodially revie our proress aainst our obetives(

Sustainable improvement is an essential element o bot systems and is

aimed at ontributin positively to personal saety environmental ell

bein and onservation o natural resoures(

Cummins ill ontinue to implement manaement prorams developed to

ensure tat our produts servies and ativities alays omply it loal

las and ompany standards establised to protet ealt saety and te

environment( e are ommitted to minimiin

potentially armul eets resultin rom our operations and to

implementin improvements assoiated it te prevention o pollution

inury and illness(

tis Healt Saety and Environmental 7oliy ill be applied trouout

Cummins via a set o doumented ompanyide and loal poliies and

proedures( It ill be ommuniated to all employees at least annually(

Upon re0uest te poliy ill be made available to te publi(

Tim Solso

Cairman CEO

November 15 4331

2gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1759

WO(K)NG O- T(OCltA(GE(

Te turbine omprises o to omponents8 te turbine ee l and te

olletor ommonly reerred to as te turbine ousin ( Te e)aust as is

uided into te turbine eel by te ousin( Te enery in te e)aust as

turns te turbine( One te as as passed trou te blades o te eel

it leaves te turbine ousin via te e)aust outlet area(

Te speed o te enine determines o ast te turbine eel spins( I te

enine is in idle mode te eel ill be spinnin at a minimal speed( gts

more as passes trou te turbine ousin te aster te turbine eel

rotates(

Compressors are te opposite o turbines( Tey omprise o to setions

te impeller or ompressor eel and te ompressor ousin ( Te

ompressor eel is onneted to te turbine by a ored steel sat( gts te

ompressor eel spins air is dran in and is ompressed as te blades

spin at a i veloity( Te ousin is desined to onvert te i veloity

lo pressure air stream into a i pressure lo veloity air stream trou

a proess alled diusion(

gtir enters te ompressor at a temperature e0uivalent to atmospere8

oever it leaves te ompressor over at a temperature up to 433 de

Celsius( =eause te density o te air dereases as it is eated up even

more air an be ored into te enine i te air is ooled ater te

ompressor( Tis is alled inter oolin or ater oolin and is aieved by

oolin te are air eiter it ater air(

Te turboarer bearin system is lubriated by oil rom te enine( Te

oil is ed under pressure into te bearin ousin trou to te ournal

bearins and trust system( Te oil also ats as a oolant ta$in aay eat

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1859

enerated by te turbine(

Te ournal =earins are a reeampoatin rotational type( To perorm orretly

te ournal bearins sould ampoat beteen a 9lm o oil i(e( beteen bearin sat and bearin and bearin ousin-( Te bearin learanes are very

small less tan te idt o a uman air( +irty oil or blo$aes in te oil

supply oles an ause serious damae to te turboarer(

In simple terms a turboarer omprises o a turbine and a ompressor

onneted by a ommon sat supported on a bearin system( Te

turboarer onverts aste enery rom te e)aust maniold into

ompressed air i it puses into te enine( Tis allos te enine to

produe more poer and tor0ue and improves te overall e6ieny o te

ombustion proess(

Detaile amporking o7 turbocharger ampith iagram

bull Te turbine ousin is bolted to te e)aust maniold o te enine(

bull Te aste e)aust asses are used to rotate a turbine eel i

is oused in te turbine asin(

bull Te turbine eel is onneted to a ommon sat i in turn

rotates a ompressor eel(

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1959

Fi(1

bull otatin te turbine eel is te only use or te aste e)aust as(

bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(

Fi(4

bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(

bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$in proess and pulls air into teompressor over rom te atmospere9ltered-(

Te aster te eel spin te more air is su$ed in(

Fi(

bull gts te air is su$ed into te ompressor overit is ored trou a

diuser area(

bull Tis ompressors te air and ores it into te enine(

27

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2059

bull Tis proess auses te air to inrease in temperaturesometimes

upto 433 derees C(

Fi(2

bull Te oil used in a turboarer is te same as tat used or your

turboarer(

bull Te oil is used as bot a lubriant and a oolant(

bull It is ed under pressure into te bearin ousintrou to te

ournal bearins and trust system(

01

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 16: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1659

ltEALTlt SA-ET AND EN)(ONMENTAL +OL)C

Cummins is ommitted to osterin a leaner ealtier and saer

environment in every ommunity in i our people live and or$( gtllour ailities ill employ te Cummins Saety and Environmental

anaement Systems i are desined to protet our personnel and

te environment to preserve natural resoures and to prevent arm to

loal ommunities( Our approa in tis endeavor is multi aeted( e ill

systemially and aressively assess operations tat ave te potential to

arm individuals or impat te environment( e ill also set substantial

and measurable obetives in manain saety and te environment(

Finally e ill periodially revie our proress aainst our obetives(

Sustainable improvement is an essential element o bot systems and is

aimed at ontributin positively to personal saety environmental ell

bein and onservation o natural resoures(

Cummins ill ontinue to implement manaement prorams developed to

ensure tat our produts servies and ativities alays omply it loal

las and ompany standards establised to protet ealt saety and te

environment( e are ommitted to minimiin

potentially armul eets resultin rom our operations and to

implementin improvements assoiated it te prevention o pollution

inury and illness(

tis Healt Saety and Environmental 7oliy ill be applied trouout

Cummins via a set o doumented ompanyide and loal poliies and

proedures( It ill be ommuniated to all employees at least annually(

Upon re0uest te poliy ill be made available to te publi(

Tim Solso

Cairman CEO

November 15 4331

2gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1759

WO(K)NG O- T(OCltA(GE(

Te turbine omprises o to omponents8 te turbine ee l and te

olletor ommonly reerred to as te turbine ousin ( Te e)aust as is

uided into te turbine eel by te ousin( Te enery in te e)aust as

turns te turbine( One te as as passed trou te blades o te eel

it leaves te turbine ousin via te e)aust outlet area(

Te speed o te enine determines o ast te turbine eel spins( I te

enine is in idle mode te eel ill be spinnin at a minimal speed( gts

more as passes trou te turbine ousin te aster te turbine eel

rotates(

Compressors are te opposite o turbines( Tey omprise o to setions

te impeller or ompressor eel and te ompressor ousin ( Te

ompressor eel is onneted to te turbine by a ored steel sat( gts te

ompressor eel spins air is dran in and is ompressed as te blades

spin at a i veloity( Te ousin is desined to onvert te i veloity

lo pressure air stream into a i pressure lo veloity air stream trou

a proess alled diusion(

gtir enters te ompressor at a temperature e0uivalent to atmospere8

oever it leaves te ompressor over at a temperature up to 433 de

Celsius( =eause te density o te air dereases as it is eated up even

more air an be ored into te enine i te air is ooled ater te

ompressor( Tis is alled inter oolin or ater oolin and is aieved by

oolin te are air eiter it ater air(

Te turboarer bearin system is lubriated by oil rom te enine( Te

oil is ed under pressure into te bearin ousin trou to te ournal

bearins and trust system( Te oil also ats as a oolant ta$in aay eat

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1859

enerated by te turbine(

Te ournal =earins are a reeampoatin rotational type( To perorm orretly

te ournal bearins sould ampoat beteen a 9lm o oil i(e( beteen bearin sat and bearin and bearin ousin-( Te bearin learanes are very

small less tan te idt o a uman air( +irty oil or blo$aes in te oil

supply oles an ause serious damae to te turboarer(

In simple terms a turboarer omprises o a turbine and a ompressor

onneted by a ommon sat supported on a bearin system( Te

turboarer onverts aste enery rom te e)aust maniold into

ompressed air i it puses into te enine( Tis allos te enine to

produe more poer and tor0ue and improves te overall e6ieny o te

ombustion proess(

Detaile amporking o7 turbocharger ampith iagram

bull Te turbine ousin is bolted to te e)aust maniold o te enine(

bull Te aste e)aust asses are used to rotate a turbine eel i

is oused in te turbine asin(

bull Te turbine eel is onneted to a ommon sat i in turn

rotates a ompressor eel(

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1959

Fi(1

bull otatin te turbine eel is te only use or te aste e)aust as(

bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(

Fi(4

bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(

bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$in proess and pulls air into teompressor over rom te atmospere9ltered-(

Te aster te eel spin te more air is su$ed in(

Fi(

bull gts te air is su$ed into te ompressor overit is ored trou a

diuser area(

bull Tis ompressors te air and ores it into te enine(

27

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2059

bull Tis proess auses te air to inrease in temperaturesometimes

upto 433 derees C(

Fi(2

bull Te oil used in a turboarer is te same as tat used or your

turboarer(

bull Te oil is used as bot a lubriant and a oolant(

bull It is ed under pressure into te bearin ousintrou to te

ournal bearins and trust system(

01

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 17: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1759

WO(K)NG O- T(OCltA(GE(

Te turbine omprises o to omponents8 te turbine ee l and te

olletor ommonly reerred to as te turbine ousin ( Te e)aust as is

uided into te turbine eel by te ousin( Te enery in te e)aust as

turns te turbine( One te as as passed trou te blades o te eel

it leaves te turbine ousin via te e)aust outlet area(

Te speed o te enine determines o ast te turbine eel spins( I te

enine is in idle mode te eel ill be spinnin at a minimal speed( gts

more as passes trou te turbine ousin te aster te turbine eel

rotates(

Compressors are te opposite o turbines( Tey omprise o to setions

te impeller or ompressor eel and te ompressor ousin ( Te

ompressor eel is onneted to te turbine by a ored steel sat( gts te

ompressor eel spins air is dran in and is ompressed as te blades

spin at a i veloity( Te ousin is desined to onvert te i veloity

lo pressure air stream into a i pressure lo veloity air stream trou

a proess alled diusion(

gtir enters te ompressor at a temperature e0uivalent to atmospere8

oever it leaves te ompressor over at a temperature up to 433 de

Celsius( =eause te density o te air dereases as it is eated up even

more air an be ored into te enine i te air is ooled ater te

ompressor( Tis is alled inter oolin or ater oolin and is aieved by

oolin te are air eiter it ater air(

Te turboarer bearin system is lubriated by oil rom te enine( Te

oil is ed under pressure into te bearin ousin trou to te ournal

bearins and trust system( Te oil also ats as a oolant ta$in aay eat

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1859

enerated by te turbine(

Te ournal =earins are a reeampoatin rotational type( To perorm orretly

te ournal bearins sould ampoat beteen a 9lm o oil i(e( beteen bearin sat and bearin and bearin ousin-( Te bearin learanes are very

small less tan te idt o a uman air( +irty oil or blo$aes in te oil

supply oles an ause serious damae to te turboarer(

In simple terms a turboarer omprises o a turbine and a ompressor

onneted by a ommon sat supported on a bearin system( Te

turboarer onverts aste enery rom te e)aust maniold into

ompressed air i it puses into te enine( Tis allos te enine to

produe more poer and tor0ue and improves te overall e6ieny o te

ombustion proess(

Detaile amporking o7 turbocharger ampith iagram

bull Te turbine ousin is bolted to te e)aust maniold o te enine(

bull Te aste e)aust asses are used to rotate a turbine eel i

is oused in te turbine asin(

bull Te turbine eel is onneted to a ommon sat i in turn

rotates a ompressor eel(

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1959

Fi(1

bull otatin te turbine eel is te only use or te aste e)aust as(

bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(

Fi(4

bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(

bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$in proess and pulls air into teompressor over rom te atmospere9ltered-(

Te aster te eel spin te more air is su$ed in(

Fi(

bull gts te air is su$ed into te ompressor overit is ored trou a

diuser area(

bull Tis ompressors te air and ores it into te enine(

27

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2059

bull Tis proess auses te air to inrease in temperaturesometimes

upto 433 derees C(

Fi(2

bull Te oil used in a turboarer is te same as tat used or your

turboarer(

bull Te oil is used as bot a lubriant and a oolant(

bull It is ed under pressure into te bearin ousintrou to te

ournal bearins and trust system(

01

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 18: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1859

enerated by te turbine(

Te ournal =earins are a reeampoatin rotational type( To perorm orretly

te ournal bearins sould ampoat beteen a 9lm o oil i(e( beteen bearin sat and bearin and bearin ousin-( Te bearin learanes are very

small less tan te idt o a uman air( +irty oil or blo$aes in te oil

supply oles an ause serious damae to te turboarer(

In simple terms a turboarer omprises o a turbine and a ompressor

onneted by a ommon sat supported on a bearin system( Te

turboarer onverts aste enery rom te e)aust maniold into

ompressed air i it puses into te enine( Tis allos te enine to

produe more poer and tor0ue and improves te overall e6ieny o te

ombustion proess(

Detaile amporking o7 turbocharger ampith iagram

bull Te turbine ousin is bolted to te e)aust maniold o te enine(

bull Te aste e)aust asses are used to rotate a turbine eel i

is oused in te turbine asin(

bull Te turbine eel is onneted to a ommon sat i in turn

rotates a ompressor eel(

2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1959

Fi(1

bull otatin te turbine eel is te only use or te aste e)aust as(

bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(

Fi(4

bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(

bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$in proess and pulls air into teompressor over rom te atmospere9ltered-(

Te aster te eel spin te more air is su$ed in(

Fi(

bull gts te air is su$ed into te ompressor overit is ored trou a

diuser area(

bull Tis ompressors te air and ores it into te enine(

27

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2059

bull Tis proess auses te air to inrease in temperaturesometimes

upto 433 derees C(

Fi(2

bull Te oil used in a turboarer is te same as tat used or your

turboarer(

bull Te oil is used as bot a lubriant and a oolant(

bull It is ed under pressure into te bearin ousintrou to te

ournal bearins and trust system(

01

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 19: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 1959

Fi(1

bull otatin te turbine eel is te only use or te aste e)aust as(

bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(

Fi(4

bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(

bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$in proess and pulls air into teompressor over rom te atmospere9ltered-(

Te aster te eel spin te more air is su$ed in(

Fi(

bull gts te air is su$ed into te ompressor overit is ored trou a

diuser area(

bull Tis ompressors te air and ores it into te enine(

27

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2059

bull Tis proess auses te air to inrease in temperaturesometimes

upto 433 derees C(

Fi(2

bull Te oil used in a turboarer is te same as tat used or your

turboarer(

bull Te oil is used as bot a lubriant and a oolant(

bull It is ed under pressure into te bearin ousintrou to te

ournal bearins and trust system(

01

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 20: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2059

bull Tis proess auses te air to inrease in temperaturesometimes

upto 433 derees C(

Fi(2

bull Te oil used in a turboarer is te same as tat used or your

turboarer(

bull Te oil is used as bot a lubriant and a oolant(

bull It is ed under pressure into te bearin ousintrou to te

ournal bearins and trust system(

01

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 21: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2159

Fi(B

bull Te ournal =earins are a ree ampoatin rotational type(

bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm

o oil i(e( beteen bearin sat bearin bearin ousin(-

bull +irty oilor blo$aes in te oil supply oles an ause serious

damae to te turboarer(

Fi(

bull 7iston in Sealsan be ound at bot ends o te turboarer(

bull Tey are desined to $eep te e)aust pressure out o te bearin

ousinand te air pressure out o te bearin ousin(

bull Te surae 9nis on bot turbine ompressor end bore must be

smoot and sore ree(

02

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 22: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2259

Fi(

Fi(lt

MAClt)N)NG O+E(AT)ONS

For ritial omponents ompary arry out te in ouse mainin o te

parts( Folloin turboarer parts bein mained at CTT +eas(

Impeller Sat eel

00

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 23: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2359

=earin Housin

Folloin mainin ells are establised or mainin o ea o te

above omponent(

)meller cell maines impellerSha7t Wheel Cell maines sat eel

earing ltousing Cell maines bearin ousin

7rodution Time study is important or understandin te i lead time

operations in all te tree prodution ells(

4(7roet Obetives

bull Identiy te i loadin unloadin operations o all te tree

prodution ells(

bull Identiy te i yle time operations o all te tree prodution

ells (

bull Identiy te lo apaity operations o all te tree prodution ells (

(+ata easurement gtnalysis Interpretation

)meller Machining Cell

gtll te impellers are mained in te impeller ell( ainin set up is

establised or mainin te impellers appliable to CTT +eas plant(

=elo is te piture o Impeller part bein used in turboarer(

Fi(5

Impeller astins are mained or ma$in te 9nised part( Impeller ell

is oranied it olloin operations(

)meller Impeller is a eel made up o aluminum alloy used in

0=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 24: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2459

turboarer or su$in te air rom atmospere( Tis eel runs at very

i speed 123333 rpm( Te mainin preiseness balanin o

tis part is very important( So tis part is mained it ade0uate

ontrols surin te mainin proess(gt mainin ell is desin to do te mainin o impeller eel astin(

gt ell setup o CNC maines is establised to arry out te mainin o

impellers

Tere are various operation ours in te manuaturin o impeller eel

in te impeller ell

Tey are ell desribed as belo

ainin Operations in Impeller 7rodution Cell

O+E(AT)ON 15 A$

In tis operation CNC maine as 9ve tool or perormin dierent

operation on impeller eel(

bull ouin operation

bull Centre +rillin

bull Center Hole +rill +iameter (lt mm-

bull

emer o (554 diameterbull oller =urniser o diameter (332 it tolerane V 3(2

O+E(AT)ON 45 A

In tis CNC operation our main tools are used or perormin te re0uired

mainin on te impeller eel( Tey are

bull ouin o impeller eel

bull Camerin o impeller eel

bull Finisin o impeller eel

bull +eburrin o impeller eel

06

S( NO( O7EgtTION aine Type1 O7(13 gt =- Turnin aine4 O7( 43 gt =- Turnin aine O7( 3 gt =- =alanin aine2 O7( 23 Wylo Inspetion

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 25: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2559

O+E(AT)ON gt5 A

=alanin aine It is te operation in i balanin o impeller eel

is e$ed by balanin maine and ater tat operator send impellereel to automati orretion maine or proper balanin o impeller

eel(

Tere are to plane are used or e$in te balanin o impeller eel(

S( No( 7lane 7osition or ass

Unbalane

in anles-

Unbalane ass

Spei9ation

1( 7lane 1 33 deree 1B m

4( 7lane 4 33 deree lt3 m Te set up ti$ness o impeller eel sould be in beteen 1(13 to 1(43

only(

O+E(AT)ON =5

Tis is te main operation perormed in impeller ell or e$in te

ear tear =lo ole in te impeller (It is also alled ylo inspetion o

impeller in impeller ell( In tis operation various test are perormed on

impeller i are listed belo(

ater asin o impeller

Hot air bloin to impeller

Aarious emial test

Usin ultra violet rays in te impeller

gtter tis operation 9nal 9nised impeller are made an be used or

turbo assembly(

)meller Cell Time Stu6

Time study o impeller ell is arried out in tree ateory i(e loadin time

yle time unloadin time( Stop at is used or measurin Time at te

mainin ell(

03

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 26: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2659

Te impeller ell loadin time or ea operation is measured trou stop

at te observations reorded as belo( a)imum loadin time is

observed at Op 43( minimum loadin time is observed at operation 13(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

(33

(B3

2(33

2(B3

448

gt8

48

)meller Loaing Time

in Sec$

Fi(13

Te impeller ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 3( minimum un

loadin time is at operation 43(

O 15 O 45 O gt5

3(33

3(B3

1(33

1(B3

4(33

4(B3

12

111

4gt

)meller nloaing Time

in Sec$

Fi(11

0gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 27: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2759

Te impeller ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

13( minimum yle time is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33

lt1(33

255

gt95

)meller Machine C6cle Time

in Sec$

Fi(14

Te impeller ell RTotal Cyle Time or mainin one omponent on ea

operation is measured reorded as belo( a)imum Total Cyle Time

observed at Op 13( minimum is at Op 3(

O 15 O 45 O gt5

3(33

13(33

43(33

3(33

23(33

B3(33

3(33

3(33

lt3(33

53(33 lt2(lt

(33

2(lt

)meller Total C6cle Time

in Sec$

Fi(1

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 28: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2859

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 3(

minimum sit output is rom operation 13(

O 15 O 45 O gt5

3

B3

133

1B3433

4B3

33

B3

233

2B3

B33

423

42

2B

)meller Cell 0 Shi7t Caacit6

in Nos$

Fi(12

0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 29: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 2959

Sha7t Wheel Machining Cell

gtll te Sat eel are mained in tis ell( ainin set up isestablised or mainin te Sat eel(

Sha7t Wheel Sat eel is a rition elded sat eel made

up o SS Sat- inonel alloy eel- used in turboarer i is

rotatin under te enery o e)aust ases under operatin temp 33

de C( Tis eel runs at very i speed 123333 rpm( Te mainin

preiseness balanin o tis part is very important( So tis part is

mained it ade0uate ontrols in te mainin proess(

Fi(1B

07

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 30: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3059

ainin Operations in Sat eel 7rodution Cell

S( NO( O7EgtTION TY7E

1 O7( 34 ass enterin maine

4 O7( 3B Frition eldin maine

O7( 13 gt = +rillin maine

2 O7( 43 gt = C Turnin maine

B O7( 3 gt = Indution ardenin and temperin

O7( 23 gt = C Grindin maine

O7( B3 gt = Groove rindin maine

lt O7( 3 gt = C 7ro9le rindin

5 O7( lt3 gt = Treads rollin maine

13 O7( 53 gt = ou balanin maine

11 O7( 53 HUD anual orretion maine

14 O7( 133 gt = Final orretion maine

1 O7( 113 Super 9nisin maine

12 O7( 143 7art punin maine

ainin details o ea operations is as belo

O+E(AT)ON 54

Tis operation is a mass enterin maine operation in i drillin o

=S2 ours on te ba$ ae o eel( Tis maine is very useul or

mass drillin o =S2 in te Sat eel ell(

e also e$ balanin o eel ater drill on it in a mass enterin

maine(

O+E(AT)ON 52

=1

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 31: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3159

Tis is a rition eldin operation Frition eldin o sat and eel or

ma$in Sat eel 7ermanent gtssembly( For rition eldin pressure

maintained is 5 bar temp maintained is ltltltde C(

O+E(AT)ON 15 A

+rillin operation is arried out at bot te maine 13 gt =(Tese

maine drills =S4 and =S2 drills on te omponent( To maines are

installed to inrease te apaity(

S( No( Name o drillin Sie o drillin ere drill ours1 =S4 3(B eel Turbine4 =S2 3( Sat

e drill only or te purpose o oldin te ob sat eel - durinne)t operation o turnin and rindin(

O+E(AT)ON 45 A 3 C

Tis operation is used or turnin te diameters o Sat eel

Component( aintainin te dierent diameters o te omponent(

Te olloin tools are used or perormin te operation on sat eel

omponents(

Tool or eld star remove

Tool or adius

ouin tool or te sat eel

ournal bearin diameter 9nisin tool

Impeller diameter ouin o te omponent

Impeller diameter 9nisin o te omponent

Tese all tool perormed teir untion on te sat eel

omponents(

O+E(AT)ON gt5 A

In tis operation temperin and ardenin proess o sat ours o sat

eel gtssembly(

Te purpose o tis operation is mainly tat in te assembly bearin

rotate on te sat at 1(2La r(p(m( Tereore ardenin is done on sat in

tis operation( Hardness maintained at tis operation rom B3 to B2

HC(In operation 3 = to omponents an be loaded simultaneously(

=2

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 32: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3259

O+E(AT)ON =5 A 3 C

Tis operation perormed or te maintainin te dierent diameter o

sat eel omponents( ouin proess is also ours in tis

operation( Tis operation maintained olloin diameter o sat eelomponent(

S( No( +iameter Nominal mm- Tolerane V mm-1 7eroll diameter (2 3(3B4 Impeller diameter (4B 3(3B = diameter

ompressor side-

11(4B 3(3B

2 = diameter Turbine

side-

11(4B 3(3B

B Hub diameter 1lt(lt 3(3B Hub distane B4(B2 3(3B Trust ore distane 114(ltlt 3(3B

O+E(AT)ON 25 A

Operation B3 is used or te roove rindin operation or te omponent

sat eel(

O+E(AT)ON 95 A 3 C

Operation 3 is used or pro9le rindin( In tis operation e maintained

same diameter o pro9le o sat eel omponents and e also

maintained same lent o sat eel omponents(

O+E(AT)ON 5 A

Tis operation is used or Treads manuaturin in te ell o Sat

eel( Tis Operation is done by usin CNC maine( Operation lt3 as

larest prodution apaity in te ell as ompared to all oter CNC

maine o te ell o Sat eel Cell(

O+E(AT)ON 85 A 3 C

Tis operation is ou balanin operation( e maintained balanin o

133m at te operation 53 o ell o Sat eel(

Here e balane trou roller tereore it is alled rou balanin(

=0

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 33: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3359

In tis operation 9rst e e$ omponent at te balanin maine and

ten send tat omponent to te automati orretion maine(

O+E(AT)ON 155

Tis operation is also used or te balanin purpose (Tis balanin is

alled ain balanin beause in tis operation e maintained lo level o

amount at dierent plane li$e at plane 1 and plane 4(

e maintained balanin at operation 133 o te ell o Sat ell are

listed belo(

S( No( 7lane 1 7lane 41 B3 m 1B m

O+E(AT)ON 115 145

=ot operation are or$s as a output operation( Op(113 is super 9nisin

maine and Op(143 is 4d matris maine o te ell Sat eel( In

super 9nisin operation omponent is ased learly and 9nisin by

CNC maine( 4+matri) maine is used or te printin te =arode

7art No( and date o manuaturin o te omponents(

Sha7t Wheel Cell Time Stu6

Time study o sat eel ell is arried out in tree ateory i(e loadin

time yle time unloadin time( Stop at is used or measurin Time

at te mainin ell(

Te sat eel ell loadin time or ea operation is measuredtrou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 13( minimum loadin time is observed at

operation 113(eer te belo rap(

==

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 34: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3459

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115O+ 145

555

155

455

gt55

=55

255

955

55

gtgt=55

(B3

2gt9

gt4

=4

2gt5

=25

gt98

1

gt=

SW 0 Loaing Time

in Sec$

Fi(1

Te sat eel ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op B3 minimum un

loadin time is at operation 113(

eer te belo rap(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

42

(33 (3

=2

=1gt=91

2gt1

=45

4gt=

149192

SW 0 n loaing Timein Sec$

Fi(1

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or Sat

eel ell( Te maor dierene observed beteen loadin unloadin

time is or Op13(

=6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 35: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3559

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

555

155

455

gt55

=55

255

955

55

(lt

=55

925

2gt9

gt4

=4

2gt5

=25

gt98

1

(lt2

4(ltB (33(3

2(B

=1gt2(1

B(1

2(43

4(2

1(41(B

SW 0 Loaing s n loaing Time

in Sec$

Fi(1lt

Te sat eel ell yle time or mainin one omponent on ea

operation is measured reorded as belo( a)imum yle time is at Op

113( minimum yle time is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

45

=5

95

5

155

145

=2

44 B2

8gt

42

115

99 1

8

4

=2

SW 0 C6cle Time

in Sec$

Fi(15

Te sat eel ell RTotal Cyle Time or mainin one omponent on

ea operation is measured reorded as belo( a)imum Total Cyle

=3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 36: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3659

Time observed at Op 23( minimum is at Op 3B(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 1455

45

=5

95

5

155

145

1=5

21

45 2

15gt

gt4

118

5

82

gt5

25

SW 0 Total C6cle Time

in Sec$

Fi(43

Te impeller ell sit apaity is alulated based total yle time te

duration available or prodution( a)imum sit output is rom Op 53(

minimum sit output is rom operation 34(

O+ 54 O+ 52 O+ 15 O+ 45 O+ gt5 O+ =5 O+ 25 O+ 95 O+ 85 O+115 O+ 145

5

155455

gt55

=55

255

955

55

55

855

gt8

3

528= 9gt5

212 2gtgt

9

229

=5=

SW 0 Shi7t Caacit6in Nos$

Fi(41

=gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 37: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3759

earing ltousing Machining Cell

earing ltousing

=earin Housin is rey ast iron made material( Tis is te enter

ousin i stores all te bearins o turboarer is a lubriation

system or Turboarer( Tis lubriation bearin system is re0uired to

support te very i operatin speed 123333 rpm- o otor gtssembly

o turboarer mainly sateel impeller-(

Fi(44

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 38: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3859

ainin Operations in =earin Housin 7rodution Cell

S( NO( O7EgtTION TY7E1 O7( 13 Turnin maine4 O7( 1B 7art punin maine

O7( 43 Turnin maine2 O7(3 gt = illin drillin and tapinB O7( 23 7re asin maine O7( B3 +eburrin ampe) onin- O7( 3 ou onin mainelt O7( 3 Finis onin maine5 O7( lt3 Fine asin maine13 O7(53 Lea$ testin maine11 O7(133 Aisual inspetion maine

Te olloin operation areperormed in te ell o bearin ousin ormanuaturin te omponent(

O+E(AT)ON 15 A Turning Machine

Folloin operations ours at tis turnin operation

Turnin ear ae

Turnin I+ 9nisin

Turnin I+ Groovin

Turnin O+ Finisin

Turnin O+ Groovin 4+ matri) is used or punin te part number bar ode date on

te omponent on bearin ousin(

O+E(AT)ON 45 A Turning Machine

Folloin operations ours at tis operation

ear ain

I+ 9nisin

O+ Finisin

gtir aue measures olloin diameters

Outer dia lt1

=ore dia 1B(lt

Seal =ore Finis 15(3Blt

+ial Gaue bein used or e$in run out ae run out bottom

run out- ulti Gaue used or measurin olloins

Outer dia 1B4(32B

+istane 1(5

Ti$ness B(34 +iameter 4(3

=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 39: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 3959

+iameter o bearin ousin 2(2

gtll te distanes dimensions o Op 43(

Impeller restin diameter e$ed by vernier alipers 5(B Impeller

restin diameter varies aordin to part to part( Operation 13gt

43gt are turnin maines(

O+E(AT)ON gt5 A $ Milling Drilling Machine

Folloin operations arried out at op 3gt

=earin ousin Input output ole drillin

=earin ousin gtnular drill upper side bottom side-

GO NOGO aues are used or e$in omponents or treads

dept dimensions( =ot operation 3 gt 3 = an be perormed at B omponents

simultaneously(

O+E(AT)ON =5 +re0Washing Machine

7reasin o bearin ousin is arried out at tis operation( Four

omponents an be ased in one yle(

O+E(AT)ON 25 -le ltoning Machine

Cleanin te bearin ousin bores by brus beore onin operation(e

perormed tis operation beause in te ou onin operation pressure

remain i at te bores diameter(

O+E(AT)ON 95 5 (ough an Bne honing Tere are to operation ours on =earin Housin omponents ou

onin and Fine onin(First e perormed rou onin operation on

bearin ousin bore diameter(gtter rou onin 9ne onin operation

ours at te omponent o =earin Housin(Te purpose o onin is to

solidiy te bore diameter o =earin Housin(In assembly =earin

Housin rotates at very i r(p(m appro) 1(B la$s r(p(m

O+E(AT)ON 5 -inal Washing

=7

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 40: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4059

In tis operation e perormed asin o =earin Housin omponent(In

tis e use oolant and tenially SF at te ratio o 1J43(In tis operation

to omponents an be loaded simultaneously(Tis operation aine

only is te maine in i e use ba$ as o CNC maine or properleanin o internal portion o maine(In tis operation e an loaded

to omponents simultaneously(

O+E(AT)ON 85 leak testing oeration

In tis operation Lea$ is e$ed o =earin Housin(e put te very i

pressure on bearin ousin omponents or e$in it aainst lea$(

O+E(AT)ON 155 isual )nsection

Tis is te last operation o te bearin ousin ell (In tis operation

operator e$ed totally bearin ousin by visual inspetion(I any ault

is seen ten operator mar$ and send to te inspetion trolley(

earing ltousing Cell Time Stu6

Time study o =earin Housin ell is arried out in tree ateory i(e

loadin time yle time unloadin time( Stop at is used or

measurin Time at te mainin ell(

Te =earin Housin ell loadin time or ea operation is measured

trou stop at te observations reorded as belo( a)imum

loadin time is observed at Op 3( minimum loadin time is observed at

operation 23(

61

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 41: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4159

555

155

455

gt55

=55

255

955

gt84

488

(2

14419

==gt

244

44

gt= gt=

earing ltousing 0 Loaing Time

in Sec$

Fi(4

Te =earin Housin ell unloadin time or ea operation is measured

reorded as belo( a)imum unloadin time is at Op 43( minimum

unloadin time is at operation lt3(

62

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 42: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4259

555

525

155

125

455

425

gt55

gt25

=55

=25

424

gt

4(31

14= 145

455

4

52

14 14

earing ltousing 0 nloaing Time

in Sec$

Fi(42

Comparison beteen loadin time unloadin time eer te belo

rap or omparison beteen loadin time unloadin time or bearin

ousin ell( Te maor dierene observed beteen loadin unloadintime is or Op 3 Op(3(

555

155

455gt55

=55

255

955

(54

4(55gtgt=

14 419

==gt

244

44

gt= gt=

4(B4

(lt

4(311(42 1(43

4(33

4(

3(ltB

1(lt4 1(lt4

earing ltousing 0 Loaing s n loaing Time

in Sec$

Fi(4B

Te bearin ousin ell yle time or mainin one omponent on ea

60

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 43: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4359

operation is measured reorded as belo( a)imum yle time is at Op

lt3( minimum yle time is at Op B3(

51545gt5=525955585

9

2

gt2

12

2

gt4

5

=4 =4

earing ltousing 0 C6cle Time

in Sec$

Fi(4

Te bearin ousin ell RTotal Cyle Time or mainin one omponent

on ea operation is measured reorded as belo( a)imum Total Cyle

Time observed at Op 13( minimum is at Op B3(

55515554555gt555

=555255595555555558555 ===

=9

5(B

=529

1gt9

9==gt

gt888

lt(14

=gt5 =gt5

earing ltousing 0 Total C6cle Time

in Sec$

Fi(4

Te bearin ousin ell sit apaity is alulated based on total yle

time te duration available or prodution( a)imum sit output is rom

6=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 44: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4459

Op B3( minimum sit output is rom operation 13(

5

455

=55

955

55

1555

1455

4=4 4gt

452

25gt

1111

gt1

215

42B

=gt1 =gt1

earing ltousing 0 Shi7t Caacit6

in Nos$

Fi(4lt

Technical Details o7 SGM CGM CNC

Drie Mechanism Table is driven on turitelined KA ampat uide ays by gtC

servomotor trou a preision ball sre( Te ball sre ends are

supported on bearin blo$( One bearin blo$ ontains to pairs o

preision lass anular ontat ball bearins it 3 deree o

66

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 45: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4559

ontat and te oter blo$ ontains a needle bearin( gt ampe)ible

ouplin is used beteen te motor sat and ball sre(Limit sampitchesCams are mounted on te ront o table slide to operate over travels

and ome limit o table travel( Te position o tis limit sites and

am sould not be disturbed(

1 Work ltea0C Ais$

Te or$ ead is used to lamp te omponent and or ob rotation

te ob is eld in te ollet and lamped tou a built in ydrauli

ylinder mounted at ba$ side o or$ ead( gt servomotor via

timin pulleys and belt radially osillates te omponent te or$

ead an be sited a)ially on te table or proper rindin position(

Work ltea Sinle SeeSine te spindle is ontrolled trou a servomotor ene its

speed is prorammable(elt Tension AustmentLoosen te our bolt gtdust te tension o te spindle belt by te

sre and titen te our bolt(

Changing the Work ltea elt Timing$bull Loosen te belt tensionin bolt(

bull Open te dra bar rom te ollet(

bull emove te rear over by loosenin te bolts(

bull emove te belt and put a ne belt(

bull gtssemble te rear over(

bull Titen te dra bar(

bull Titen te belt tensionin bolt(

4 Tail Stock

Te tailsto$ is mounted on te top table by bolts( =y sla$en te bolt it

an be sited aordin to te lent o or$ piee( Te enter is pressed

aainst te or$ piee by te adustable sprin( Titenin te nut on

enter itsel an eet enter(

gt Wheel ltea0oss

63

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 46: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4659

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speedOter inormation reardin eel speedotor speed X4lt33 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X121 rpmgtt ne eel 233 spindle speed at H X41B3 rpmgtt disard eel 33 spindle speed at B3H X4ltB3 rpm

= Wheel ltea0(ear

eel ead is te most preision part o te maine( It onsist o a

ardened round spindle i runs on 72 lass anular ontat ball

bearin( +iretion o te spindle L(H( i(e( antilo$ise viein rom pulley

side( Te spindle desined or eel periperal speed o 2B mse(

Sinle Lubrication

Te eel spindle bearin are rease lubriated it i speed o

$luber imported- ma$e( Te rease last or appro)imately B333 rs(

o runnin o te spindle(

Sinle See =2 msec$ Te spindle speed an be alulated as per te olloin ormulaJ

πDN X2Bmse(

3)1333+X diameter o rindin eel in mmNXrindin eel speed

6gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 47: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4759

Oter inormation reardin eel speedotor speed X4533 rpmotor pulley diameter X1B3 rpmSpindle pulley diameter X2 rpm

gtt ne eel 133 spindle speed at 2H Xlt33 rpmgtt disard eel ltB spindle speed at B3H X13333 rpm

2 Carriage an ais$

Drie Mechanismeel arriae moves on te ardened round linear uide ays

driven by gt(C( Servomotor trou a preision ball sre and nut

assembly( Te ball sre ends are supported on to bearin blo$s(

Ea bearin blo$ ontains a set o preision lass bearins( gt

ouplin is used beteen motor sat and ball sre( Carriae slide

or boss side nominated as Y a)is(Lubrication Te oil lubriation unit arries out antirition uide ays and ball

sre lubriation(Te lubriation arranement or$s on pulse type

lubriation system(

Limit SampitchCams are mounted on te rit side o te arriae to operate te

over travel and ome limit sit( Te position o tis limit sited

and ams sould not be disturbed(

MA)NTENANCEaintenanerepair and operationsO- or

maintenanerepairand overaul involves 9)in any sort o

meanialplumbin or eletrial devie sould it beomeOut o order or bro$en $non as repairunseduled or asualty

maintenane(It also inludes perormin routine ations i $eep te devie in

or$in order $non as seduled maintenane or prevent trouble

rom arisin preventive maintenane(O may be de9ned as gtll

ations i ave te obetive o retainin or restorin an item in

or to a state in i it an perorm its re0uired untion(Te ations

inlude te ombination o all tenial and orrespondin

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 48: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4859

administrativemanaerialand supervision ations(

Tere are our types o maintenaneJ

+reentie Maintenance0ere e0uipment is maintained beore

brea$don ours(Tis type o maintenane as many dierent

variations and is subet o various to determine best and most

e6ient ay to maintain e0uipment(

Correctie Maintenanceere e0uipment is maintained ater

brea$don(Tis maintenane is oten e)pensive beause orn

e0uipment an damae oter parts and ause multiple damae(

(eliabilit6 Centere MaintenanceOten $non as Cis a

proess to ensure tat assests ontinue to do at teir users

re0uire in teir present operatin onte)t(

+lan +reentie MaintenanceIt is neessary to run te plant

ontinuously itout any brea$don(7reventive maintenane is

eetive in preventin ae related ailures o te e0uipment( For

random ailure patterns i amount to lt3Z o te ailure

patternsondition monitorin proves to be eetive(

CltECK SltEET

6

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 49: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 4959

67

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 50: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5059

31

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 51: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159

32

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 52: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259

30

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 53: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5359

3=

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 54: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5459

Lockout0tag out LOTO$

Lo$outta out LOTO- or lo$ and ta is a saety proedure i is used

in industry and resear settins to ensure tat danerous maines are

properly sut o and not started up aain prior to te ompletion o

maintenane or serviin or$( It re0uires tat aardous poer soures

be [isolated and rendered inoperative[ beore any repair proedure is

started( [Lo$ and ta[ or$s in onuntion it a lo$ usually lo$in te

devie or te poer soure it te asp and plain it in su a position

tat no aardous poer soures an be turned on( Te proedure

re0uires tat a ta be a6)ed to te lo$ed devie indiatin tat it sould

not be turned on(

Grou lockout

en to or more subontrators are or$in on dierent parts o a

larer overall system te lo$edout devie is 9rst seured it a oldin

sissors lamp tat as many padlo$ oles apable o oldin it losed(

Ea subontrator applies teir on padlo$ to te lamp( Te lo$edout

devie annot be ativated until all or$ers ave sined o on teir

portion o te proet and removed teir padlo$ rom te lamp(

ltaFarous energ6 an its isolation

36

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 55: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5559

Tas let in plae in a poerplant ater it as sut don deommissioned

and abandoned

odern mainery an ontain many aards to or$ers rom tins li$e

eletrial meanial pneumati or ydrauli soures( For e)ample atypial industrial maine may ontain tins li$e ot ampuids movin

presses blades propellers eletrial eaters onveyor belts it pin

points movin ains ultraviolet lit et(

+isonnetin or ma$in sae te e0uipment involves te removal o all

enery soures and is $non as isolation( Te isolation proedure

enerally inludes te olloin tas$sJ

1( Identiy te enery soures-

4( Isolate te enery soures-

( Lo$ and Ta te enery soures-

2( 7rove tat te e0uipment isolation is eetive

Site olicies regaring lockouttag out

any sites ave te o6ially stated poliy tat only te person o

taed te devie an unta it( Tis means tat i a or$er oes ome

ater teir sit itout removin te ta rom a devie i is ready or

servie ten tey ill ave to travel ba$ to te site to unta it( Givin

approval or te removal o a ta over te pone is proibited(

ilst tis poliy mit ma$e it seem as i it is enourain or$ers to

ta$e te ris$ o not tain out in te 9rst plae it is usually aompanied

by a poliy statin tat operatin on a devie itout tain it out ill

result in instant dismissal(

)entiBcation

Te ta must ave an identi9ation soin te name o te person doin

33

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 56: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5659

te lo$ and ta( CF 1513(12 - B- ii- - 1- ile tis may be true

or te United states it is not mandatory in Europe( Te lo$out an also

be done by a [role[ e(( te sit leader( Usin a [lo$bo)[ te sit leader

is alays te last one to remove is lo$ e as to veriy it is sae to startup e0uipment(

General Sa7et6

7rotet your eyes by earin saety lasses(

ear soes it oil resistant soles(

+o not ear lon sleeves loose lotin or ne$ ties(

a$e sure tat your area is ree rom ips oil and oolant

spills air oses or anytin tat may et in your ay and

ma$e you to all or slip(

a$e sure tat all uttin tools and or$ oldin e0uipment

are tit beore runnin te spindle or movin te slides(

gtll maintenane and repair or$ sould be done it tepoer o( I any or$ re0uires poer ON e)treme are sould

be ta$en(

Deep te maine alays lean and $eep aay te tools and

aues rom ettin damaed

Mechanical Sa7et6 Care sould be ta$en en removin a part or replaement or

repair( a$e sure tat any onneted or supported part an be

saety let in te maine( I not tey sould be removed also(

ere orientation o adaent parts may be important mat

mar$ parts beore removin tem(

en perormin poer ON maintenane or e$in o

movin parts e)treme aution sould be ta$en( Tese parts

3gt

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 57: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5759

an ause serious inury(

Te maine sould be lubriated aordin to te maine

lubriation inormation iven in tis manual(

en perormin maintenane o te ydrauli systems te

poer must be OFF and tere sould be no pressure in te

lines(

I you ave removed any overuard or some reason dont

oret to re9t tem beore you start te maine(

Sa7et6 check on the machine =eore start

Ce$ te voltae and urrent(

Ce$ te lubriant tan$ oil level(

Ce$ te ydrauli tan$ oil level(

Ce$ te lampin devies(

Ce$ and lean te maine(

Ce$ te lampin sto$(

Maintenance Oerations +er7orme )n +lant0

(eairing O7 Cone6or0

gtt operation 3= Sat Turnin- in sat and eel ell te onveyor as

not or$in( Te entire srape is olleted inside te maine( e Aiay

Sarma +evra 7armar and e- e$ te panel 9rst tan rom te

ommand bo)( Tan e notie tat te onveyors side plates ere ully

damaed by tis te onveyor is ammed inside te over(

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 58: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5859

First o all e ere ta$in out te onveyor rom te maine or tat e

disonnet te onveyor rom te maine( Ten ta$e out te motor rom

te onveyors i rotate te onveyors ain( Tan open te over o

onveyor and e$ te ain( Te ain side plates ere damaed ias observed by us( Te old plates ere replaed by te ne plates i

as available in te spare parts( Te sat as also banned or tat e

ave to replae it too( gtter repairin it e 9) te motor aain on its plae

and bolted all te overs( Tan ere onnet it to te maine and ten it

or$s properly(

Leakage o7 Lubrication0

gtt te operation 13gt Turnin- in te bearin ousie te lea$ae o

lubriation as ours rom te lubriation pipe( =y tis te oil as one

astae( So e ave to identiy te lea$ae in te pipe and seal it(

Initially e lean te maine area ere te oil is olleted( gtter tat e

Lo$es ain and e- run te lubriation motor by i te oil ampos in te

maine( Tere e at te oil lea$ae rom te lubriation pipe( Tan

te maine as lo$out by Lo$es ain( e ta$e out te pipe rom te

maine and ut te area ere te lea$ae as ours( Ten aain 9)

tat pipe properly in te motor( Open te lo$out and start te maine(

e ait or some time ater tat no any oil is ound tan e and over

te maine to te operator(

-itting o7 -(L -loamp (egulation o7 Lubrication$0

Te FL is 9tted or ere te air pressure as to be ontrol( Te air as

ampos it i pressure in te maine and te air un( For ontrollin

tat pressure e ere 9t te devie alled FL( In tat devie te

pressure aue as 9)ed and te valve as tere or ontrollin te

pressure(

First e e$ te maine ere te FL as not 9tted note don te

maine and ten 9) te FL on te maine( For tat e ere drill te

3

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(

Page 59: cummins

7182019 cummins

httpslidepdfcomreaderfullcummins-5697a4f70e68e 5959

oles on te maines and an te devie trou te bolts( Ten ut

te pipe and onnet one end at te inlet o te FL i as rom main

line o te air( gtnd anoter as outlet i oes in te maine( Connet

bot te pipe and ampos te air rom te FL( Te pressure as tied at (Bbars at ea maine(

(eairing o7 Door0

gtt te L r( 7in Hole- te door as not or$in properly( Te slider as

not slide on its prede9ned pat( Te door as ame out rom te slider

due to te opposite ore( Te ore as atin opposite at te slider

i auses out te door rom te te slider(

First e open te over o te door ten disonnet te door rom te

slider i as bolted by LN bolts( e alin te slider and te door and

aain bolted it properly( Ten e ave te air pressure to tat trou

tat e sa tat it slides properly( Close te over o te door and ten

andover te maine to te operation(

Changing o7 elt0

gtt operation 3gt 7ro9le Grindin- te belt as damaed( i also

damae te arpose o te maine( +ue to tat te pulley as ammed

and te maine as one to brea$don time( e ave to ane te

belt(

First e lo$ out te maine and open te over o te maine( Te belt

as bro$e and ammed te pulley( Tan e lean te maine and ta$e

out te damaed belt rom te maine( Fi) te ne belt in beteen te

pulleys( Te ne belt as available in te spare parts room(