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INDUSTRIAL TRAINING REPORT
ON
ldquoManufacturing of Turbochargersrdquo
IN
CUMMINS TURBO TECHNOLOGIESDEWAS (MP)
For the parta $et o the amperee o
Baheor o Tehoo+
I
Mehaa Eeer
ECHELON INSTITUTE OF TECHNOLOGY
Maharh Daaaamp U-ertRohta
Seo(01220123)
UNDER THE GUIDANCE OF UMITTED
MR AMIT SHARMA SHI4AM SARASWAT
(DEPUT5 GENERAL MANAGER) (22ME6107)
2
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CERTIFICATE
It erteamp that the 8or otaeamp the the tteamp Manufacturing of Turbochargers+
9 hi$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
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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-
=
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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
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)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
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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
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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(
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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
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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
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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
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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(
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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=
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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
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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(
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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
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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
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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
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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(
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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
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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
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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
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=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=
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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
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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
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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
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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
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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
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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
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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
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3=
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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
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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
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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
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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(
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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
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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(
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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
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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$(
Shiam Sarasampat
11E2345-
=
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AST(ACT
Te trainin as arried out in Cummins Turbo Tenoloies at +eas in
te adya prades State o Central India in maintenane department(It
manaesdevelopsand leadste daily ativities o multiple prodution units or team ma$es
reommendations to improve produtivity 0ualitysaetyand e6ieny o
operations(
7rovides uidane and eedba$ or team members in aomplisin tas$s
and oals8sets e)petations and lari9es responsibilities(Coaes and
mentors team members (Identi9es trainin needs8develops and
implement trainin plans(
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)NDE
SNO CONTENTS +AGE NO
1 INTO+UCTION lt
4 CUINS TU=O TECHNOLOGY 7LgtNTS IN
IN+Igt
513
OUNEY OF CUINS TU=O
TECHNOLOGIES IN IN+Igt
11
2 HEgtLTH SgtFETY gtN+ ENAIONENT 7OLICIES 12
B TU=OCHgtGE ODING 1B15
gtCHINING O7EgtTION 4323
TECHNICgtL +ETgtILS OF SG CG CNC 212
lt gtINTENgtNCE 22
5 CHECD SHEET 2BB3
13 gtINTENgtNCE O7EgtTION 7EFOE+ IN7LgtNT
B1B4
11 CONCLUSION
COM+AN +(O-)LE
)NT(ODCT)ON
Cummins India Limited CIL- is a B1 perent subsidiary o Cummins In(
USgt te orlds larest independent diesel enine desiner and
gt
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manuaturer above 433 H7( Cummins In te maority sareolder
Cummins is te leadin orldide desiner and manuaturer o diesel
enines rom 1H7 to B33 H7( Cummins pioneer and mar$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$s and
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oter eavyduty veiles( It is primarily enaed in distribution o parts
omponents servie support and value added servies or Kbumper to
bumper support( Cummins India Limiteds Lo Horse 7oer =usiness
Unit i manuatures and mar$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(
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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
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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$eters and produer o 0uality branded automotiveindustrial
produts(
Cummins Turbo Technologies +lants in )nia
Cummins Turbo Tenoloies part o Cummins In(- ompletes 3 years
15B4 4314- o operations orldide( Cummins Turbo Tenoloies is a
leadin manuaturer o Turboarers it presene in most parts o te
orld(
In India Cummins Turbo Tenoloies as its plants and oies in
+eas 7itampur udrapur and 7une(
+ithamur 0 une 123 4514
Cummins Turbo Tenoloies CTT- is elebratin its 3t anniversary
year( it sales o over USP1 billion CTT as ron to be a lobalompany it operations in most parts o te orld( Tenial Centres in
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UD Cina USgt and India ontinue to develop air andlin tenoloies or
lobal ustomers in diverse mar$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
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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(
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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=
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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
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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(
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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
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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
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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
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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(
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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
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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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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3=
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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
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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
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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
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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(
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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
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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(
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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$(
Shiam Sarasampat
11E2345-
=
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AST(ACT
Te trainin as arried out in Cummins Turbo Tenoloies at +eas in
te adya prades State o Central India in maintenane department(It
manaesdevelopsand leadste daily ativities o multiple prodution units or team ma$es
reommendations to improve produtivity 0ualitysaetyand e6ieny o
operations(
7rovides uidane and eedba$ or team members in aomplisin tas$s
and oals8sets e)petations and lari9es responsibilities(Coaes and
mentors team members (Identi9es trainin needs8develops and
implement trainin plans(
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)NDE
SNO CONTENTS +AGE NO
1 INTO+UCTION lt
4 CUINS TU=O TECHNOLOGY 7LgtNTS IN
IN+Igt
513
OUNEY OF CUINS TU=O
TECHNOLOGIES IN IN+Igt
11
2 HEgtLTH SgtFETY gtN+ ENAIONENT 7OLICIES 12
B TU=OCHgtGE ODING 1B15
gtCHINING O7EgtTION 4323
TECHNICgtL +ETgtILS OF SG CG CNC 212
lt gtINTENgtNCE 22
5 CHECD SHEET 2BB3
13 gtINTENgtNCE O7EgtTION 7EFOE+ IN7LgtNT
B1B4
11 CONCLUSION
COM+AN +(O-)LE
)NT(ODCT)ON
Cummins India Limited CIL- is a B1 perent subsidiary o Cummins In(
USgt te orlds larest independent diesel enine desiner and
gt
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manuaturer above 433 H7( Cummins In te maority sareolder
Cummins is te leadin orldide desiner and manuaturer o diesel
enines rom 1H7 to B33 H7( Cummins pioneer and mar$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$s and
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oter eavyduty veiles( It is primarily enaed in distribution o parts
omponents servie support and value added servies or Kbumper to
bumper support( Cummins India Limiteds Lo Horse 7oer =usiness
Unit i manuatures and mar$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(
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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
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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$eters and produer o 0uality branded automotiveindustrial
produts(
Cummins Turbo Technologies +lants in )nia
Cummins Turbo Tenoloies part o Cummins In(- ompletes 3 years
15B4 4314- o operations orldide( Cummins Turbo Tenoloies is a
leadin manuaturer o Turboarers it presene in most parts o te
orld(
In India Cummins Turbo Tenoloies as its plants and oies in
+eas 7itampur udrapur and 7une(
+ithamur 0 une 123 4514
Cummins Turbo Tenoloies CTT- is elebratin its 3t anniversary
year( it sales o over USP1 billion CTT as ron to be a lobalompany it operations in most parts o te orld( Tenial Centres in
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UD Cina USgt and India ontinue to develop air andlin tenoloies or
lobal ustomers in diverse mar$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
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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(
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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=
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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
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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(
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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
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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
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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$aes in te oil
supply oles an ause serious damae to te turboarer(
In simple terms a turboarer omprises o a turbine and a ompressor
onneted by a ommon sat supported on a bearin system( Te
turboarer onverts aste enery rom te e)aust maniold into
ompressed air i it puses into te enine( Tis allos te enine to
produe more poer and tor0ue and improves te overall e6ieny o te
ombustion proess(
Detaile amporking o7 turbocharger ampith iagram
bull Te turbine ousin is bolted to te e)aust maniold o te enine(
bull Te aste e)aust asses are used to rotate a turbine eel i
is oused in te turbine asin(
bull Te turbine eel is onneted to a ommon sat i in turn
rotates a ompressor eel(
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Fi(1
bull otatin te turbine eel is te only use or te aste e)aust as(
bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(
Fi(4
bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(
bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$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(
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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
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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 $eep te e)aust pressure out o te bearin
ousinand te air pressure out o te bearin ousin(
bull Te surae 9nis on bot turbine ompressor end bore must be
smoot and sore ree(
02
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Fi(
Fi(lt
MAClt)N)NG O+E(AT)ONS
For ritial omponents ompary arry out te in ouse mainin o te
parts( Folloin turboarer parts bein mained at CTT +eas(
Impeller Sat eel
00
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=earin Housin
Folloin mainin ells are establised or mainin o ea o te
above omponent(
)meller cell maines impellerSha7t Wheel Cell maines sat eel
earing ltousing Cell maines bearin ousin
7rodution Time study is important or understandin te i lead time
operations in all te tree prodution ells(
4(7roet Obetives
bull Identiy te i loadin unloadin operations o all te tree
prodution ells(
bull Identiy te i yle time operations o all te tree prodution
ells (
bull Identiy te lo apaity operations o all te tree prodution ells (
(+ata easurement gtnalysis Interpretation
)meller Machining Cell
gtll te impellers are mained in te impeller ell( ainin set up is
establised or mainin te impellers appliable to CTT +eas plant(
=elo is te piture o Impeller part bein used in turboarer(
Fi(5
Impeller astins are mained or ma$in te 9nised part( Impeller ell
is oranied it olloin operations(
)meller Impeller is a eel made up o aluminum alloy used in
0=
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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(
==
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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
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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
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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
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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
=
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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
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+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
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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(
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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(
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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
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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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
6
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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67
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31
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32
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30
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3=
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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
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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
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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
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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(
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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
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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(
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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$s
and oals8sets e)petations and lari9es responsibilities(Coaes and
mentors team members (Identi9es trainin needs8develops and
implement trainin plans(
3
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)NDE
SNO CONTENTS +AGE NO
1 INTO+UCTION lt
4 CUINS TU=O TECHNOLOGY 7LgtNTS IN
IN+Igt
513
OUNEY OF CUINS TU=O
TECHNOLOGIES IN IN+Igt
11
2 HEgtLTH SgtFETY gtN+ ENAIONENT 7OLICIES 12
B TU=OCHgtGE ODING 1B15
gtCHINING O7EgtTION 4323
TECHNICgtL +ETgtILS OF SG CG CNC 212
lt gtINTENgtNCE 22
5 CHECD SHEET 2BB3
13 gtINTENgtNCE O7EgtTION 7EFOE+ IN7LgtNT
B1B4
11 CONCLUSION
COM+AN +(O-)LE
)NT(ODCT)ON
Cummins India Limited CIL- is a B1 perent subsidiary o Cummins In(
USgt te orlds larest independent diesel enine desiner and
gt
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manuaturer above 433 H7( Cummins In te maority sareolder
Cummins is te leadin orldide desiner and manuaturer o diesel
enines rom 1H7 to B33 H7( Cummins pioneer and mar$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$s and
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oter eavyduty veiles( It is primarily enaed in distribution o parts
omponents servie support and value added servies or Kbumper to
bumper support( Cummins India Limiteds Lo Horse 7oer =usiness
Unit i manuatures and mar$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(
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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
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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$eters and produer o 0uality branded automotiveindustrial
produts(
Cummins Turbo Technologies +lants in )nia
Cummins Turbo Tenoloies part o Cummins In(- ompletes 3 years
15B4 4314- o operations orldide( Cummins Turbo Tenoloies is a
leadin manuaturer o Turboarers it presene in most parts o te
orld(
In India Cummins Turbo Tenoloies as its plants and oies in
+eas 7itampur udrapur and 7une(
+ithamur 0 une 123 4514
Cummins Turbo Tenoloies CTT- is elebratin its 3t anniversary
year( it sales o over USP1 billion CTT as ron to be a lobalompany it operations in most parts o te orld( Tenial Centres in
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UD Cina USgt and India ontinue to develop air andlin tenoloies or
lobal ustomers in diverse mar$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
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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(
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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=
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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
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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(
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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
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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
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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$aes in te oil
supply oles an ause serious damae to te turboarer(
In simple terms a turboarer omprises o a turbine and a ompressor
onneted by a ommon sat supported on a bearin system( Te
turboarer onverts aste enery rom te e)aust maniold into
ompressed air i it puses into te enine( Tis allos te enine to
produe more poer and tor0ue and improves te overall e6ieny o te
ombustion proess(
Detaile amporking o7 turbocharger ampith iagram
bull Te turbine ousin is bolted to te e)aust maniold o te enine(
bull Te aste e)aust asses are used to rotate a turbine eel i
is oused in te turbine asin(
bull Te turbine eel is onneted to a ommon sat i in turn
rotates a ompressor eel(
2
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Fi(1
bull otatin te turbine eel is te only use or te aste e)aust as(
bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(
Fi(4
bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(
bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$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(
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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
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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 $eep te e)aust pressure out o te bearin
ousinand te air pressure out o te bearin ousin(
bull Te surae 9nis on bot turbine ompressor end bore must be
smoot and sore ree(
02
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Fi(
Fi(lt
MAClt)N)NG O+E(AT)ONS
For ritial omponents ompary arry out te in ouse mainin o te
parts( Folloin turboarer parts bein mained at CTT +eas(
Impeller Sat eel
00
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=earin Housin
Folloin mainin ells are establised or mainin o ea o te
above omponent(
)meller cell maines impellerSha7t Wheel Cell maines sat eel
earing ltousing Cell maines bearin ousin
7rodution Time study is important or understandin te i lead time
operations in all te tree prodution ells(
4(7roet Obetives
bull Identiy te i loadin unloadin operations o all te tree
prodution ells(
bull Identiy te i yle time operations o all te tree prodution
ells (
bull Identiy te lo apaity operations o all te tree prodution ells (
(+ata easurement gtnalysis Interpretation
)meller Machining Cell
gtll te impellers are mained in te impeller ell( ainin set up is
establised or mainin te impellers appliable to CTT +eas plant(
=elo is te piture o Impeller part bein used in turboarer(
Fi(5
Impeller astins are mained or ma$in te 9nised part( Impeller ell
is oranied it olloin operations(
)meller Impeller is a eel made up o aluminum alloy used in
0=
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
6
7182019 cummins
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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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
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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
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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(
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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
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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(
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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$s
and oals8sets e)petations and lari9es responsibilities(Coaes and
mentors team members (Identi9es trainin needs8develops and
implement trainin plans(
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)NDE
SNO CONTENTS +AGE NO
1 INTO+UCTION lt
4 CUINS TU=O TECHNOLOGY 7LgtNTS IN
IN+Igt
513
OUNEY OF CUINS TU=O
TECHNOLOGIES IN IN+Igt
11
2 HEgtLTH SgtFETY gtN+ ENAIONENT 7OLICIES 12
B TU=OCHgtGE ODING 1B15
gtCHINING O7EgtTION 4323
TECHNICgtL +ETgtILS OF SG CG CNC 212
lt gtINTENgtNCE 22
5 CHECD SHEET 2BB3
13 gtINTENgtNCE O7EgtTION 7EFOE+ IN7LgtNT
B1B4
11 CONCLUSION
COM+AN +(O-)LE
)NT(ODCT)ON
Cummins India Limited CIL- is a B1 perent subsidiary o Cummins In(
USgt te orlds larest independent diesel enine desiner and
gt
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manuaturer above 433 H7( Cummins In te maority sareolder
Cummins is te leadin orldide desiner and manuaturer o diesel
enines rom 1H7 to B33 H7( Cummins pioneer and mar$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$s and
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oter eavyduty veiles( It is primarily enaed in distribution o parts
omponents servie support and value added servies or Kbumper to
bumper support( Cummins India Limiteds Lo Horse 7oer =usiness
Unit i manuatures and mar$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(
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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
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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$eters and produer o 0uality branded automotiveindustrial
produts(
Cummins Turbo Technologies +lants in )nia
Cummins Turbo Tenoloies part o Cummins In(- ompletes 3 years
15B4 4314- o operations orldide( Cummins Turbo Tenoloies is a
leadin manuaturer o Turboarers it presene in most parts o te
orld(
In India Cummins Turbo Tenoloies as its plants and oies in
+eas 7itampur udrapur and 7une(
+ithamur 0 une 123 4514
Cummins Turbo Tenoloies CTT- is elebratin its 3t anniversary
year( it sales o over USP1 billion CTT as ron to be a lobalompany it operations in most parts o te orld( Tenial Centres in
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UD Cina USgt and India ontinue to develop air andlin tenoloies or
lobal ustomers in diverse mar$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
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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(
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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=
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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
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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(
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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
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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
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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$aes in te oil
supply oles an ause serious damae to te turboarer(
In simple terms a turboarer omprises o a turbine and a ompressor
onneted by a ommon sat supported on a bearin system( Te
turboarer onverts aste enery rom te e)aust maniold into
ompressed air i it puses into te enine( Tis allos te enine to
produe more poer and tor0ue and improves te overall e6ieny o te
ombustion proess(
Detaile amporking o7 turbocharger ampith iagram
bull Te turbine ousin is bolted to te e)aust maniold o te enine(
bull Te aste e)aust asses are used to rotate a turbine eel i
is oused in te turbine asin(
bull Te turbine eel is onneted to a ommon sat i in turn
rotates a ompressor eel(
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Fi(1
bull otatin te turbine eel is te only use or te aste e)aust as(
bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(
Fi(4
bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(
bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$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(
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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3=
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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
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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
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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
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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(
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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
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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(
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)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
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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
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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$Agt is partially enaed in te manuature o Telos
CNG enines Cummins SA as enines- urrently used to poer +elis
publi transport system( Te Cummins SA as enine as been desined
to ombine ompat sie lo emission levels and e)ellent perormane
arateristis o ispeed tenoloy it te medium speed bene9ts
or loest lieyle osts in terms o uel e6ieny reliability and
durability(
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Cummins Generator Technologies
Cummins Generator Tenoloies onentrates on enerators( ItMs not ust
te produts e ma$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
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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$eters and produer o 0uality branded automotiveindustrial
produts(
Cummins Turbo Technologies +lants in )nia
Cummins Turbo Tenoloies part o Cummins In(- ompletes 3 years
15B4 4314- o operations orldide( Cummins Turbo Tenoloies is a
leadin manuaturer o Turboarers it presene in most parts o te
orld(
In India Cummins Turbo Tenoloies as its plants and oies in
+eas 7itampur udrapur and 7une(
+ithamur 0 une 123 4514
Cummins Turbo Tenoloies CTT- is elebratin its 3t anniversary
year( it sales o over USP1 billion CTT as ron to be a lobalompany it operations in most parts o te orld( Tenial Centres in
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UD Cina USgt and India ontinue to develop air andlin tenoloies or
lobal ustomers in diverse mar$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
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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(
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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=
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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
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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
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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
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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
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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$aes in te oil
supply oles an ause serious damae to te turboarer(
In simple terms a turboarer omprises o a turbine and a ompressor
onneted by a ommon sat supported on a bearin system( Te
turboarer onverts aste enery rom te e)aust maniold into
ompressed air i it puses into te enine( Tis allos te enine to
produe more poer and tor0ue and improves te overall e6ieny o te
ombustion proess(
Detaile amporking o7 turbocharger ampith iagram
bull Te turbine ousin is bolted to te e)aust maniold o te enine(
bull Te aste e)aust asses are used to rotate a turbine eel i
is oused in te turbine asin(
bull Te turbine eel is onneted to a ommon sat i in turn
rotates a ompressor eel(
2
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Fi(1
bull otatin te turbine eel is te only use or te aste e)aust as(
bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(
Fi(4
bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(
bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$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
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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
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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 $eep te e)aust pressure out o te bearin
ousinand te air pressure out o te bearin ousin(
bull Te surae 9nis on bot turbine ompressor end bore must be
smoot and sore ree(
02
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Fi(
Fi(lt
MAClt)N)NG O+E(AT)ONS
For ritial omponents ompary arry out te in ouse mainin o te
parts( Folloin turboarer parts bein mained at CTT +eas(
Impeller Sat eel
00
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=earin Housin
Folloin mainin ells are establised or mainin o ea o te
above omponent(
)meller cell maines impellerSha7t Wheel Cell maines sat eel
earing ltousing Cell maines bearin ousin
7rodution Time study is important or understandin te i lead time
operations in all te tree prodution ells(
4(7roet Obetives
bull Identiy te i loadin unloadin operations o all te tree
prodution ells(
bull Identiy te i yle time operations o all te tree prodution
ells (
bull Identiy te lo apaity operations o all te tree prodution ells (
(+ata easurement gtnalysis Interpretation
)meller Machining Cell
gtll te impellers are mained in te impeller ell( ainin set up is
establised or mainin te impellers appliable to CTT +eas plant(
=elo is te piture o Impeller part bein used in turboarer(
Fi(5
Impeller astins are mained or ma$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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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(
==
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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
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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
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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
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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
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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
=
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+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
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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(
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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(
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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
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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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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3=
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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
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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
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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
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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(
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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
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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(
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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
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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$Agt is partially enaed in te manuature o Telos
CNG enines Cummins SA as enines- urrently used to poer +elis
publi transport system( Te Cummins SA as enine as been desined
to ombine ompat sie lo emission levels and e)ellent perormane
arateristis o ispeed tenoloy it te medium speed bene9ts
or loest lieyle osts in terms o uel e6ieny reliability and
durability(
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Cummins Generator Technologies
Cummins Generator Tenoloies onentrates on enerators( ItMs not ust
te produts e ma$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
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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$eters and produer o 0uality branded automotiveindustrial
produts(
Cummins Turbo Technologies +lants in )nia
Cummins Turbo Tenoloies part o Cummins In(- ompletes 3 years
15B4 4314- o operations orldide( Cummins Turbo Tenoloies is a
leadin manuaturer o Turboarers it presene in most parts o te
orld(
In India Cummins Turbo Tenoloies as its plants and oies in
+eas 7itampur udrapur and 7une(
+ithamur 0 une 123 4514
Cummins Turbo Tenoloies CTT- is elebratin its 3t anniversary
year( it sales o over USP1 billion CTT as ron to be a lobalompany it operations in most parts o te orld( Tenial Centres in
21
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UD Cina USgt and India ontinue to develop air andlin tenoloies or
lobal ustomers in diverse mar$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
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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(
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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=
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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
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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(
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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
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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
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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$aes in te oil
supply oles an ause serious damae to te turboarer(
In simple terms a turboarer omprises o a turbine and a ompressor
onneted by a ommon sat supported on a bearin system( Te
turboarer onverts aste enery rom te e)aust maniold into
ompressed air i it puses into te enine( Tis allos te enine to
produe more poer and tor0ue and improves te overall e6ieny o te
ombustion proess(
Detaile amporking o7 turbocharger ampith iagram
bull Te turbine ousin is bolted to te e)aust maniold o te enine(
bull Te aste e)aust asses are used to rotate a turbine eel i
is oused in te turbine asin(
bull Te turbine eel is onneted to a ommon sat i in turn
rotates a ompressor eel(
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Fi(1
bull otatin te turbine eel is te only use or te aste e)aust as(
bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(
Fi(4
bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(
bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$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(
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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(
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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 $eep te e)aust pressure out o te bearin
ousinand te air pressure out o te bearin ousin(
bull Te surae 9nis on bot turbine ompressor end bore must be
smoot and sore ree(
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Fi(
Fi(lt
MAClt)N)NG O+E(AT)ONS
For ritial omponents ompary arry out te in ouse mainin o te
parts( Folloin turboarer parts bein mained at CTT +eas(
Impeller Sat eel
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=earin Housin
Folloin mainin ells are establised or mainin o ea o te
above omponent(
)meller cell maines impellerSha7t Wheel Cell maines sat eel
earing ltousing Cell maines bearin ousin
7rodution Time study is important or understandin te i lead time
operations in all te tree prodution ells(
4(7roet Obetives
bull Identiy te i loadin unloadin operations o all te tree
prodution ells(
bull Identiy te i yle time operations o all te tree prodution
ells (
bull Identiy te lo apaity operations o all te tree prodution ells (
(+ata easurement gtnalysis Interpretation
)meller Machining Cell
gtll te impellers are mained in te impeller ell( ainin set up is
establised or mainin te impellers appliable to CTT +eas plant(
=elo is te piture o Impeller part bein used in turboarer(
Fi(5
Impeller astins are mained or ma$in te 9nised part( Impeller ell
is oranied it olloin operations(
)meller Impeller is a eel made up o aluminum alloy used in
0=
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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(
==
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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
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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
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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
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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
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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
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+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
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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
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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
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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
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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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
6
7182019 cummins
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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67
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31
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32
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30
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3=
7182019 cummins
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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
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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
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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
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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(
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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
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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(
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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$Agt is partially enaed in te manuature o Telos
CNG enines Cummins SA as enines- urrently used to poer +elis
publi transport system( Te Cummins SA as enine as been desined
to ombine ompat sie lo emission levels and e)ellent perormane
arateristis o ispeed tenoloy it te medium speed bene9ts
or loest lieyle osts in terms o uel e6ieny reliability and
durability(
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Cummins Generator Technologies
Cummins Generator Tenoloies onentrates on enerators( ItMs not ust
te produts e ma$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
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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$eters and produer o 0uality branded automotiveindustrial
produts(
Cummins Turbo Technologies +lants in )nia
Cummins Turbo Tenoloies part o Cummins In(- ompletes 3 years
15B4 4314- o operations orldide( Cummins Turbo Tenoloies is a
leadin manuaturer o Turboarers it presene in most parts o te
orld(
In India Cummins Turbo Tenoloies as its plants and oies in
+eas 7itampur udrapur and 7une(
+ithamur 0 une 123 4514
Cummins Turbo Tenoloies CTT- is elebratin its 3t anniversary
year( it sales o over USP1 billion CTT as ron to be a lobalompany it operations in most parts o te orld( Tenial Centres in
21
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UD Cina USgt and India ontinue to develop air andlin tenoloies or
lobal ustomers in diverse mar$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
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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(
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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=
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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
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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(
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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
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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
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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$aes in te oil
supply oles an ause serious damae to te turboarer(
In simple terms a turboarer omprises o a turbine and a ompressor
onneted by a ommon sat supported on a bearin system( Te
turboarer onverts aste enery rom te e)aust maniold into
ompressed air i it puses into te enine( Tis allos te enine to
produe more poer and tor0ue and improves te overall e6ieny o te
ombustion proess(
Detaile amporking o7 turbocharger ampith iagram
bull Te turbine ousin is bolted to te e)aust maniold o te enine(
bull Te aste e)aust asses are used to rotate a turbine eel i
is oused in te turbine asin(
bull Te turbine eel is onneted to a ommon sat i in turn
rotates a ompressor eel(
2
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Fi(1
bull otatin te turbine eel is te only use or te aste e)aust as(
bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(
Fi(4
bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(
bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$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(
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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
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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 $eep te e)aust pressure out o te bearin
ousinand te air pressure out o te bearin ousin(
bull Te surae 9nis on bot turbine ompressor end bore must be
smoot and sore ree(
02
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Fi(
Fi(lt
MAClt)N)NG O+E(AT)ONS
For ritial omponents ompary arry out te in ouse mainin o te
parts( Folloin turboarer parts bein mained at CTT +eas(
Impeller Sat eel
00
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=earin Housin
Folloin mainin ells are establised or mainin o ea o te
above omponent(
)meller cell maines impellerSha7t Wheel Cell maines sat eel
earing ltousing Cell maines bearin ousin
7rodution Time study is important or understandin te i lead time
operations in all te tree prodution ells(
4(7roet Obetives
bull Identiy te i loadin unloadin operations o all te tree
prodution ells(
bull Identiy te i yle time operations o all te tree prodution
ells (
bull Identiy te lo apaity operations o all te tree prodution ells (
(+ata easurement gtnalysis Interpretation
)meller Machining Cell
gtll te impellers are mained in te impeller ell( ainin set up is
establised or mainin te impellers appliable to CTT +eas plant(
=elo is te piture o Impeller part bein used in turboarer(
Fi(5
Impeller astins are mained or ma$in te 9nised part( Impeller ell
is oranied it olloin operations(
)meller Impeller is a eel made up o aluminum alloy used in
0=
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
6
7182019 cummins
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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67
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31
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32
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30
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3=
7182019 cummins
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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
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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
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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
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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(
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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
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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(
7182019 cummins
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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
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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$eters and produer o 0uality branded automotiveindustrial
produts(
Cummins Turbo Technologies +lants in )nia
Cummins Turbo Tenoloies part o Cummins In(- ompletes 3 years
15B4 4314- o operations orldide( Cummins Turbo Tenoloies is a
leadin manuaturer o Turboarers it presene in most parts o te
orld(
In India Cummins Turbo Tenoloies as its plants and oies in
+eas 7itampur udrapur and 7une(
+ithamur 0 une 123 4514
Cummins Turbo Tenoloies CTT- is elebratin its 3t anniversary
year( it sales o over USP1 billion CTT as ron to be a lobalompany it operations in most parts o te orld( Tenial Centres in
21
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UD Cina USgt and India ontinue to develop air andlin tenoloies or
lobal ustomers in diverse mar$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
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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(
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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=
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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
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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(
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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
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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
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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$aes in te oil
supply oles an ause serious damae to te turboarer(
In simple terms a turboarer omprises o a turbine and a ompressor
onneted by a ommon sat supported on a bearin system( Te
turboarer onverts aste enery rom te e)aust maniold into
ompressed air i it puses into te enine( Tis allos te enine to
produe more poer and tor0ue and improves te overall e6ieny o te
ombustion proess(
Detaile amporking o7 turbocharger ampith iagram
bull Te turbine ousin is bolted to te e)aust maniold o te enine(
bull Te aste e)aust asses are used to rotate a turbine eel i
is oused in te turbine asin(
bull Te turbine eel is onneted to a ommon sat i in turn
rotates a ompressor eel(
2
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Fi(1
bull otatin te turbine eel is te only use or te aste e)aust as(
bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(
Fi(4
bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(
bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$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(
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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
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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 $eep te e)aust pressure out o te bearin
ousinand te air pressure out o te bearin ousin(
bull Te surae 9nis on bot turbine ompressor end bore must be
smoot and sore ree(
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Fi(
Fi(lt
MAClt)N)NG O+E(AT)ONS
For ritial omponents ompary arry out te in ouse mainin o te
parts( Folloin turboarer parts bein mained at CTT +eas(
Impeller Sat eel
00
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=earin Housin
Folloin mainin ells are establised or mainin o ea o te
above omponent(
)meller cell maines impellerSha7t Wheel Cell maines sat eel
earing ltousing Cell maines bearin ousin
7rodution Time study is important or understandin te i lead time
operations in all te tree prodution ells(
4(7roet Obetives
bull Identiy te i loadin unloadin operations o all te tree
prodution ells(
bull Identiy te i yle time operations o all te tree prodution
ells (
bull Identiy te lo apaity operations o all te tree prodution ells (
(+ata easurement gtnalysis Interpretation
)meller Machining Cell
gtll te impellers are mained in te impeller ell( ainin set up is
establised or mainin te impellers appliable to CTT +eas plant(
=elo is te piture o Impeller part bein used in turboarer(
Fi(5
Impeller astins are mained or ma$in te 9nised part( Impeller ell
is oranied it olloin operations(
)meller Impeller is a eel made up o aluminum alloy used in
0=
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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
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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
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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
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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
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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
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
6
7182019 cummins
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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67
7182019 cummins
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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
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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
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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
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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(
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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
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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(
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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$eters and produer o 0uality branded automotiveindustrial
produts(
Cummins Turbo Technologies +lants in )nia
Cummins Turbo Tenoloies part o Cummins In(- ompletes 3 years
15B4 4314- o operations orldide( Cummins Turbo Tenoloies is a
leadin manuaturer o Turboarers it presene in most parts o te
orld(
In India Cummins Turbo Tenoloies as its plants and oies in
+eas 7itampur udrapur and 7une(
+ithamur 0 une 123 4514
Cummins Turbo Tenoloies CTT- is elebratin its 3t anniversary
year( it sales o over USP1 billion CTT as ron to be a lobalompany it operations in most parts o te orld( Tenial Centres in
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UD Cina USgt and India ontinue to develop air andlin tenoloies or
lobal ustomers in diverse mar$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
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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(
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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=
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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
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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(
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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
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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
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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$aes in te oil
supply oles an ause serious damae to te turboarer(
In simple terms a turboarer omprises o a turbine and a ompressor
onneted by a ommon sat supported on a bearin system( Te
turboarer onverts aste enery rom te e)aust maniold into
ompressed air i it puses into te enine( Tis allos te enine to
produe more poer and tor0ue and improves te overall e6ieny o te
ombustion proess(
Detaile amporking o7 turbocharger ampith iagram
bull Te turbine ousin is bolted to te e)aust maniold o te enine(
bull Te aste e)aust asses are used to rotate a turbine eel i
is oused in te turbine asin(
bull Te turbine eel is onneted to a ommon sat i in turn
rotates a ompressor eel(
2
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Fi(1
bull otatin te turbine eel is te only use or te aste e)aust as(
bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(
Fi(4
bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(
bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$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(
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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
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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 $eep te e)aust pressure out o te bearin
ousinand te air pressure out o te bearin ousin(
bull Te surae 9nis on bot turbine ompressor end bore must be
smoot and sore ree(
02
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Fi(
Fi(lt
MAClt)N)NG O+E(AT)ONS
For ritial omponents ompary arry out te in ouse mainin o te
parts( Folloin turboarer parts bein mained at CTT +eas(
Impeller Sat eel
00
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=earin Housin
Folloin mainin ells are establised or mainin o ea o te
above omponent(
)meller cell maines impellerSha7t Wheel Cell maines sat eel
earing ltousing Cell maines bearin ousin
7rodution Time study is important or understandin te i lead time
operations in all te tree prodution ells(
4(7roet Obetives
bull Identiy te i loadin unloadin operations o all te tree
prodution ells(
bull Identiy te i yle time operations o all te tree prodution
ells (
bull Identiy te lo apaity operations o all te tree prodution ells (
(+ata easurement gtnalysis Interpretation
)meller Machining Cell
gtll te impellers are mained in te impeller ell( ainin set up is
establised or mainin te impellers appliable to CTT +eas plant(
=elo is te piture o Impeller part bein used in turboarer(
Fi(5
Impeller astins are mained or ma$in te 9nised part( Impeller ell
is oranied it olloin operations(
)meller Impeller is a eel made up o aluminum alloy used in
0=
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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
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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
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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
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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
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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
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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
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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
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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
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3=
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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
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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
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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
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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(
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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
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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(
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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
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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(
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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=
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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
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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(
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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
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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
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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$aes in te oil
supply oles an ause serious damae to te turboarer(
In simple terms a turboarer omprises o a turbine and a ompressor
onneted by a ommon sat supported on a bearin system( Te
turboarer onverts aste enery rom te e)aust maniold into
ompressed air i it puses into te enine( Tis allos te enine to
produe more poer and tor0ue and improves te overall e6ieny o te
ombustion proess(
Detaile amporking o7 turbocharger ampith iagram
bull Te turbine ousin is bolted to te e)aust maniold o te enine(
bull Te aste e)aust asses are used to rotate a turbine eel i
is oused in te turbine asin(
bull Te turbine eel is onneted to a ommon sat i in turn
rotates a ompressor eel(
2
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Fi(1
bull otatin te turbine eel is te only use or te aste e)aust as(
bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(
Fi(4
bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(
bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$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(
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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
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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 $eep te e)aust pressure out o te bearin
ousinand te air pressure out o te bearin ousin(
bull Te surae 9nis on bot turbine ompressor end bore must be
smoot and sore ree(
02
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Fi(
Fi(lt
MAClt)N)NG O+E(AT)ONS
For ritial omponents ompary arry out te in ouse mainin o te
parts( Folloin turboarer parts bein mained at CTT +eas(
Impeller Sat eel
00
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=earin Housin
Folloin mainin ells are establised or mainin o ea o te
above omponent(
)meller cell maines impellerSha7t Wheel Cell maines sat eel
earing ltousing Cell maines bearin ousin
7rodution Time study is important or understandin te i lead time
operations in all te tree prodution ells(
4(7roet Obetives
bull Identiy te i loadin unloadin operations o all te tree
prodution ells(
bull Identiy te i yle time operations o all te tree prodution
ells (
bull Identiy te lo apaity operations o all te tree prodution ells (
(+ata easurement gtnalysis Interpretation
)meller Machining Cell
gtll te impellers are mained in te impeller ell( ainin set up is
establised or mainin te impellers appliable to CTT +eas plant(
=elo is te piture o Impeller part bein used in turboarer(
Fi(5
Impeller astins are mained or ma$in te 9nised part( Impeller ell
is oranied it olloin operations(
)meller Impeller is a eel made up o aluminum alloy used in
0=
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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
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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(
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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
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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
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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
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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
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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
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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
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3=
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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
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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
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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
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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(
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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
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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(
7182019 cummins
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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(
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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=
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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
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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(
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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
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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
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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$aes in te oil
supply oles an ause serious damae to te turboarer(
In simple terms a turboarer omprises o a turbine and a ompressor
onneted by a ommon sat supported on a bearin system( Te
turboarer onverts aste enery rom te e)aust maniold into
ompressed air i it puses into te enine( Tis allos te enine to
produe more poer and tor0ue and improves te overall e6ieny o te
ombustion proess(
Detaile amporking o7 turbocharger ampith iagram
bull Te turbine ousin is bolted to te e)aust maniold o te enine(
bull Te aste e)aust asses are used to rotate a turbine eel i
is oused in te turbine asin(
bull Te turbine eel is onneted to a ommon sat i in turn
rotates a ompressor eel(
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Fi(1
bull otatin te turbine eel is te only use or te aste e)aust as(
bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(
Fi(4
bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(
bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$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(
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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
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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 $eep te e)aust pressure out o te bearin
ousinand te air pressure out o te bearin ousin(
bull Te surae 9nis on bot turbine ompressor end bore must be
smoot and sore ree(
02
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Fi(
Fi(lt
MAClt)N)NG O+E(AT)ONS
For ritial omponents ompary arry out te in ouse mainin o te
parts( Folloin turboarer parts bein mained at CTT +eas(
Impeller Sat eel
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=earin Housin
Folloin mainin ells are establised or mainin o ea o te
above omponent(
)meller cell maines impellerSha7t Wheel Cell maines sat eel
earing ltousing Cell maines bearin ousin
7rodution Time study is important or understandin te i lead time
operations in all te tree prodution ells(
4(7roet Obetives
bull Identiy te i loadin unloadin operations o all te tree
prodution ells(
bull Identiy te i yle time operations o all te tree prodution
ells (
bull Identiy te lo apaity operations o all te tree prodution ells (
(+ata easurement gtnalysis Interpretation
)meller Machining Cell
gtll te impellers are mained in te impeller ell( ainin set up is
establised or mainin te impellers appliable to CTT +eas plant(
=elo is te piture o Impeller part bein used in turboarer(
Fi(5
Impeller astins are mained or ma$in te 9nised part( Impeller ell
is oranied it olloin operations(
)meller Impeller is a eel made up o aluminum alloy used in
0=
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
6
7182019 cummins
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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67
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31
7182019 cummins
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32
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30
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3=
7182019 cummins
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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
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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
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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
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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(
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7182019 cummins
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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
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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(
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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=
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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
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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
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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
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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
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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$aes in te oil
supply oles an ause serious damae to te turboarer(
In simple terms a turboarer omprises o a turbine and a ompressor
onneted by a ommon sat supported on a bearin system( Te
turboarer onverts aste enery rom te e)aust maniold into
ompressed air i it puses into te enine( Tis allos te enine to
produe more poer and tor0ue and improves te overall e6ieny o te
ombustion proess(
Detaile amporking o7 turbocharger ampith iagram
bull Te turbine ousin is bolted to te e)aust maniold o te enine(
bull Te aste e)aust asses are used to rotate a turbine eel i
is oused in te turbine asin(
bull Te turbine eel is onneted to a ommon sat i in turn
rotates a ompressor eel(
2
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Fi(1
bull otatin te turbine eel is te only use or te aste e)aust as(
bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(
Fi(4
bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(
bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$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(
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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
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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 $eep te e)aust pressure out o te bearin
ousinand te air pressure out o te bearin ousin(
bull Te surae 9nis on bot turbine ompressor end bore must be
smoot and sore ree(
02
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Fi(
Fi(lt
MAClt)N)NG O+E(AT)ONS
For ritial omponents ompary arry out te in ouse mainin o te
parts( Folloin turboarer parts bein mained at CTT +eas(
Impeller Sat eel
00
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=earin Housin
Folloin mainin ells are establised or mainin o ea o te
above omponent(
)meller cell maines impellerSha7t Wheel Cell maines sat eel
earing ltousing Cell maines bearin ousin
7rodution Time study is important or understandin te i lead time
operations in all te tree prodution ells(
4(7roet Obetives
bull Identiy te i loadin unloadin operations o all te tree
prodution ells(
bull Identiy te i yle time operations o all te tree prodution
ells (
bull Identiy te lo apaity operations o all te tree prodution ells (
(+ata easurement gtnalysis Interpretation
)meller Machining Cell
gtll te impellers are mained in te impeller ell( ainin set up is
establised or mainin te impellers appliable to CTT +eas plant(
=elo is te piture o Impeller part bein used in turboarer(
Fi(5
Impeller astins are mained or ma$in te 9nised part( Impeller ell
is oranied it olloin operations(
)meller Impeller is a eel made up o aluminum alloy used in
0=
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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(
==
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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
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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
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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
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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
=
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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
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+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
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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
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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
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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
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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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
6
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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31
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32
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3=
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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
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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
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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
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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
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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
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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(
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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
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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
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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
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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
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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$aes in te oil
supply oles an ause serious damae to te turboarer(
In simple terms a turboarer omprises o a turbine and a ompressor
onneted by a ommon sat supported on a bearin system( Te
turboarer onverts aste enery rom te e)aust maniold into
ompressed air i it puses into te enine( Tis allos te enine to
produe more poer and tor0ue and improves te overall e6ieny o te
ombustion proess(
Detaile amporking o7 turbocharger ampith iagram
bull Te turbine ousin is bolted to te e)aust maniold o te enine(
bull Te aste e)aust asses are used to rotate a turbine eel i
is oused in te turbine asin(
bull Te turbine eel is onneted to a ommon sat i in turn
rotates a ompressor eel(
2
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Fi(1
bull otatin te turbine eel is te only use or te aste e)aust as(
bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(
Fi(4
bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(
bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$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
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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
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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 $eep te e)aust pressure out o te bearin
ousinand te air pressure out o te bearin ousin(
bull Te surae 9nis on bot turbine ompressor end bore must be
smoot and sore ree(
02
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Fi(
Fi(lt
MAClt)N)NG O+E(AT)ONS
For ritial omponents ompary arry out te in ouse mainin o te
parts( Folloin turboarer parts bein mained at CTT +eas(
Impeller Sat eel
00
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=earin Housin
Folloin mainin ells are establised or mainin o ea o te
above omponent(
)meller cell maines impellerSha7t Wheel Cell maines sat eel
earing ltousing Cell maines bearin ousin
7rodution Time study is important or understandin te i lead time
operations in all te tree prodution ells(
4(7roet Obetives
bull Identiy te i loadin unloadin operations o all te tree
prodution ells(
bull Identiy te i yle time operations o all te tree prodution
ells (
bull Identiy te lo apaity operations o all te tree prodution ells (
(+ata easurement gtnalysis Interpretation
)meller Machining Cell
gtll te impellers are mained in te impeller ell( ainin set up is
establised or mainin te impellers appliable to CTT +eas plant(
=elo is te piture o Impeller part bein used in turboarer(
Fi(5
Impeller astins are mained or ma$in te 9nised part( Impeller ell
is oranied it olloin operations(
)meller Impeller is a eel made up o aluminum alloy used in
0=
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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(
==
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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
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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
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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
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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
=
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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
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+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
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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(
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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(
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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
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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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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67
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31
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32
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30
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3=
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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
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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
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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
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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(
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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
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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(
7182019 cummins
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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
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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
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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$aes in te oil
supply oles an ause serious damae to te turboarer(
In simple terms a turboarer omprises o a turbine and a ompressor
onneted by a ommon sat supported on a bearin system( Te
turboarer onverts aste enery rom te e)aust maniold into
ompressed air i it puses into te enine( Tis allos te enine to
produe more poer and tor0ue and improves te overall e6ieny o te
ombustion proess(
Detaile amporking o7 turbocharger ampith iagram
bull Te turbine ousin is bolted to te e)aust maniold o te enine(
bull Te aste e)aust asses are used to rotate a turbine eel i
is oused in te turbine asin(
bull Te turbine eel is onneted to a ommon sat i in turn
rotates a ompressor eel(
2
7182019 cummins
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Fi(1
bull otatin te turbine eel is te only use or te aste e)aust as(
bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(
Fi(4
bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(
bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$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
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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
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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 $eep te e)aust pressure out o te bearin
ousinand te air pressure out o te bearin ousin(
bull Te surae 9nis on bot turbine ompressor end bore must be
smoot and sore ree(
02
7182019 cummins
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Fi(
Fi(lt
MAClt)N)NG O+E(AT)ONS
For ritial omponents ompary arry out te in ouse mainin o te
parts( Folloin turboarer parts bein mained at CTT +eas(
Impeller Sat eel
00
7182019 cummins
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=earin Housin
Folloin mainin ells are establised or mainin o ea o te
above omponent(
)meller cell maines impellerSha7t Wheel Cell maines sat eel
earing ltousing Cell maines bearin ousin
7rodution Time study is important or understandin te i lead time
operations in all te tree prodution ells(
4(7roet Obetives
bull Identiy te i loadin unloadin operations o all te tree
prodution ells(
bull Identiy te i yle time operations o all te tree prodution
ells (
bull Identiy te lo apaity operations o all te tree prodution ells (
(+ata easurement gtnalysis Interpretation
)meller Machining Cell
gtll te impellers are mained in te impeller ell( ainin set up is
establised or mainin te impellers appliable to CTT +eas plant(
=elo is te piture o Impeller part bein used in turboarer(
Fi(5
Impeller astins are mained or ma$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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
=
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+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
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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(
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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(
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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
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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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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3=
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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
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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
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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
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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(
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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
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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(
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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
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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
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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$aes in te oil
supply oles an ause serious damae to te turboarer(
In simple terms a turboarer omprises o a turbine and a ompressor
onneted by a ommon sat supported on a bearin system( Te
turboarer onverts aste enery rom te e)aust maniold into
ompressed air i it puses into te enine( Tis allos te enine to
produe more poer and tor0ue and improves te overall e6ieny o te
ombustion proess(
Detaile amporking o7 turbocharger ampith iagram
bull Te turbine ousin is bolted to te e)aust maniold o te enine(
bull Te aste e)aust asses are used to rotate a turbine eel i
is oused in te turbine asin(
bull Te turbine eel is onneted to a ommon sat i in turn
rotates a ompressor eel(
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Fi(1
bull otatin te turbine eel is te only use or te aste e)aust as(
bull One te as as passed trou te blades o te eel it leaveste turbine ousin via te e)aust outlet area(
Fi(4
bull gts more as passed trou te turbine ousinte aster teturbine eel rotates(
bull gts te turbine eel inreases in speedso does te ompressoreel(Tis reates a su$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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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3=
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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
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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
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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
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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(
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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
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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(
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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$in aay eat
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enerated by te turbine(
Te ournal =earins are a reeampoatin rotational type( To perorm orretly
te ournal bearins sould ampoat beteen a 9lm o oil i(e( beteen bearin sat and bearin and bearin ousin-( Te bearin learanes are very
small less tan te idt o a uman air( +irty oil or blo$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(
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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$ed into te ompressor overit is ored trou a
diuser area(
bull Tis ompressors te air and ores it into te enine(
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bull Tis proess auses te air to inrease in temperaturesometimes
upto 433 derees C(
Fi(2
bull Te oil used in a turboarer is te same as tat used or your
turboarer(
bull Te oil is used as bot a lubriant and a oolant(
bull It is ed under pressure into te bearin ousintrou to te
ournal bearins and trust system(
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Fi(B
bull Te ournal =earins are a ree ampoatin rotational type(
bull To perorm orretlyte ournal bearins sould ampoat beteen a 9lm
o oil i(e( beteen bearin sat bearin bearin ousin(-
bull +irty oilor blo$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 $eep te e)aust pressure out o te bearin
ousinand te air pressure out o te bearin ousin(
bull Te surae 9nis on bot turbine ompressor end bore must be
smoot and sore ree(
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Fi(
Fi(lt
MAClt)N)NG O+E(AT)ONS
For ritial omponents ompary arry out te in ouse mainin o te
parts( Folloin turboarer parts bein mained at CTT +eas(
Impeller Sat eel
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=earin Housin
Folloin mainin ells are establised or mainin o ea o te
above omponent(
)meller cell maines impellerSha7t Wheel Cell maines sat eel
earing ltousing Cell maines bearin ousin
7rodution Time study is important or understandin te i lead time
operations in all te tree prodution ells(
4(7roet Obetives
bull Identiy te i loadin unloadin operations o all te tree
prodution ells(
bull Identiy te i yle time operations o all te tree prodution
ells (
bull Identiy te lo apaity operations o all te tree prodution ells (
(+ata easurement gtnalysis Interpretation
)meller Machining Cell
gtll te impellers are mained in te impeller ell( ainin set up is
establised or mainin te impellers appliable to CTT +eas plant(
=elo is te piture o Impeller part bein used in turboarer(
Fi(5
Impeller astins are mained or ma$in te 9nised part( Impeller ell
is oranied it olloin operations(
)meller Impeller is a eel made up o aluminum alloy used in
0=
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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
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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(
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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
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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
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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
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
6
7182019 cummins
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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67
7182019 cummins
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31
7182019 cummins
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32
7182019 cummins
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30
7182019 cummins
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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
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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
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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
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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
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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(
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(
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7182019 cummins
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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
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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 $eep te e)aust pressure out o te bearin
ousinand te air pressure out o te bearin ousin(
bull Te surae 9nis on bot turbine ompressor end bore must be
smoot and sore ree(
02
7182019 cummins
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Fi(
Fi(lt
MAClt)N)NG O+E(AT)ONS
For ritial omponents ompary arry out te in ouse mainin o te
parts( Folloin turboarer parts bein mained at CTT +eas(
Impeller Sat eel
00
7182019 cummins
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=earin Housin
Folloin mainin ells are establised or mainin o ea o te
above omponent(
)meller cell maines impellerSha7t Wheel Cell maines sat eel
earing ltousing Cell maines bearin ousin
7rodution Time study is important or understandin te i lead time
operations in all te tree prodution ells(
4(7roet Obetives
bull Identiy te i loadin unloadin operations o all te tree
prodution ells(
bull Identiy te i yle time operations o all te tree prodution
ells (
bull Identiy te lo apaity operations o all te tree prodution ells (
(+ata easurement gtnalysis Interpretation
)meller Machining Cell
gtll te impellers are mained in te impeller ell( ainin set up is
establised or mainin te impellers appliable to CTT +eas plant(
=elo is te piture o Impeller part bein used in turboarer(
Fi(5
Impeller astins are mained or ma$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
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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
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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
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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
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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
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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
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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
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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
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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(
==
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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
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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
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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
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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
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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
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+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
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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(
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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
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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
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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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
6
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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67
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31
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32
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30
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3=
7182019 cummins
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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
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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
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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
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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(
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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
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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(
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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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3=
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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
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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
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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
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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(
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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
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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(
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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(
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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 $eep te e)aust pressure out o te bearin
ousinand te air pressure out o te bearin ousin(
bull Te surae 9nis on bot turbine ompressor end bore must be
smoot and sore ree(
02
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Fi(
Fi(lt
MAClt)N)NG O+E(AT)ONS
For ritial omponents ompary arry out te in ouse mainin o te
parts( Folloin turboarer parts bein mained at CTT +eas(
Impeller Sat eel
00
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=earin Housin
Folloin mainin ells are establised or mainin o ea o te
above omponent(
)meller cell maines impellerSha7t Wheel Cell maines sat eel
earing ltousing Cell maines bearin ousin
7rodution Time study is important or understandin te i lead time
operations in all te tree prodution ells(
4(7roet Obetives
bull Identiy te i loadin unloadin operations o all te tree
prodution ells(
bull Identiy te i yle time operations o all te tree prodution
ells (
bull Identiy te lo apaity operations o all te tree prodution ells (
(+ata easurement gtnalysis Interpretation
)meller Machining Cell
gtll te impellers are mained in te impeller ell( ainin set up is
establised or mainin te impellers appliable to CTT +eas plant(
=elo is te piture o Impeller part bein used in turboarer(
Fi(5
Impeller astins are mained or ma$in te 9nised part( Impeller ell
is oranied it olloin operations(
)meller Impeller is a eel made up o aluminum alloy used in
0=
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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
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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(
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
6
7182019 cummins
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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67
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31
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32
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30
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3=
7182019 cummins
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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
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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
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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(
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
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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(
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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
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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
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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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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3=
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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
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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
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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
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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(
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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
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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(
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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
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=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$in te 9nised part( Impeller ell
is oranied it olloin operations(
)meller Impeller is a eel made up o aluminum alloy used in
0=
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turboarer or su$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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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(
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
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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
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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
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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
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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
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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
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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
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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
=
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+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
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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(
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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(
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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
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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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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3=
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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
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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
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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
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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(
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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
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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(
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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
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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(
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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
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31
7182019 cummins
httpslidepdfcomreaderfullcummins-5697a4f70e68e 5159
32
7182019 cummins
httpslidepdfcomreaderfullcummins-5697a4f70e68e 5259
30
7182019 cummins
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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
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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(
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
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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
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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
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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
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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(
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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
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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
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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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
6
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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67
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31
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32
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30
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3=
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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
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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
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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
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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
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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
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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(
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
=
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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
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+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
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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
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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
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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
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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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
6
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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31
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32
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3=
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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
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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
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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(
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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
6
7182019 cummins
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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67
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31
7182019 cummins
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32
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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
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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
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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
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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
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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
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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(
7182019 cummins
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
=
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+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
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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(
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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
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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
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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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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31
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32
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30
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3=
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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
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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
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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
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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(
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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
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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(
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
6
7182019 cummins
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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67
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31
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32
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30
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3=
7182019 cummins
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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
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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
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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
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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(
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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
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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(
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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
6
7182019 cummins
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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67
7182019 cummins
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31
7182019 cummins
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32
7182019 cummins
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30
7182019 cummins
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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
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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
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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
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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(
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
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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
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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
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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
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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
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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3=
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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
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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
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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
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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(
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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
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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(
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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
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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(
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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
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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
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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
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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
=
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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
=
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+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
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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
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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
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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
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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
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
6
7182019 cummins
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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67
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31
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32
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30
7182019 cummins
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3=
7182019 cummins
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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
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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
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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
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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
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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
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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(
7182019 cummins
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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
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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
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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
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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
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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
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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
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+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
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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
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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
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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
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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
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
6
7182019 cummins
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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67
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31
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32
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30
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3=
7182019 cummins
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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
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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
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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
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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
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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
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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(
7182019 cummins
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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
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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
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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
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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
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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
=
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+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
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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(
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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
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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
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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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
6
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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67
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31
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32
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30
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3=
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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
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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
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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
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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
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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
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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(
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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
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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
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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
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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
=
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+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
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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(
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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(
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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
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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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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67
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31
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32
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30
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3=
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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
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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
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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
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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(
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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
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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(
7182019 cummins
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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
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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
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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
=
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+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
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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(
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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(
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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
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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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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3=
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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
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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
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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
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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(
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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
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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(
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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
=
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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
=
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+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
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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(
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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
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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
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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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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67
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31
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32
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30
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3=
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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
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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
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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
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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
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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
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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(
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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
=
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+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
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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(
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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
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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
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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=
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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3=
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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
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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
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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
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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(
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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
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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(
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+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
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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(
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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(
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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
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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=
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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
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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
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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
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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
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67
7182019 cummins
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31
7182019 cummins
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32
7182019 cummins
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30
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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
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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(
7182019 cummins
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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(
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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
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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
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7182019 cummins
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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
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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
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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
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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
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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(
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
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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
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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
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31
7182019 cummins
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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(
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
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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
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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
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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
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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
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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
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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(
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
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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
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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
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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
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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(
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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
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7182019 cummins
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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(
7182019 cummins
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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
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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
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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
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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 $non as seduled maintenane or prevent trouble
rom arisin preventive maintenane(O may be de9ned as gtll
ations i ave te obetive o retainin or restorin an item in
or to a state in i it an perorm its re0uired untion(Te ations
inlude te ombination o all tenial and orrespondin
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administrativemanaerialand supervision ations(
Tere are our types o maintenaneJ
+reentie Maintenance0ere e0uipment is maintained beore
brea$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
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3=
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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
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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
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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
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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
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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(
7182019 cummins
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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
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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(
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(
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(
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(
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(
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(
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(
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(
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(
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(
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(
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(
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(
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(
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(