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512 ARMY BASE WORKSHOP REPORT

DOJ:-11 JUNE PURPOSE :- VOCATIONAL TRAINING

SUBMITTED TO :- AIT

SUBMITED BY:MANOJ KUMAR

(sign and stamp)

1st WEEK TASK ALLOTED :- TO STUDY ABOUT RECLAMATION OF TANK & PERFORM IT PRACTICALLY TANK TYPE BMP-II (BIO MACHINE PICATIA) DATA OF BMP-II TANK:WEIGHT FUEL CAPACITY (DIESEL) WATER CAPACITY LUBRICATING OIL GRADE OF OIL POWER RPM GEAR 20W50 300HP 2600 RPM 5 FORWARD, 1 REVERSE 14.2 TON 462 L 52 L 58 L

OVERHAULING :- OVERHAULING MEANS TO RESTORE TO LIKE NEW CONDITIONS

OVERHAULING PROCESS: STRIPPING -> WASHING -> RECLAMATION -> PAINTING -> ASSEMBLY -> TESTING ->TRIAL

ASSEMBLY PROCESS :SUSPENSION LINKAGES -> HULL WIRING STAGE GEARBOX -> &PIPES (ELECTRICAL EQUIPMENT) TURRET ASSEMBLY -> FINAL ASSEMBLY -> ENGINE ASSEMBLY

VARIOUS PROCESS IN OVERHAULING:STRIPPING :It is the disassembly of a tank . Different parts of a tank ( electrical, metallic & non metallic etc.) are removed and sent to their respective sections It is of two types;1.Hull Stripping 2.Turret Stripping After stripping, the tank body is sent for washing WASHING:Washing is done to remove the paing frtom the tank body. It is done by spraying caustic soda and hot water. Wire brush are used for removing coated paint.Similarly compressed air is also used i.e after washing tank body with caustic soda & hot water, compressed air is blown over the tank body which now easily removes the paint. After washing tank body is sent for reclamation. RECLAMATION:Reclamation of a tank body is to restore the body to its original shape (like when it was all new) i.e to remove mistakes from the body. Ex:- Problems of a tank bought in for reclamation -Head light BKT Dent -Towing Hook Dent -Front Mudguard Hinges new welt (qty 6) -Flash deflector new weld -Splash deflector (gives new weld) -Spare track mounting post new weld -Rear door rebound pud BKT dent. -Bulk head plate repair -Clamping post 2 new weld -Blench pipe new weld -Deflection in turret compt. -Bullet hits on outer hull wall. -Deflection in engine compt.

Reclamation is to remove the above listed problems. Hence generally reclamation is :-To remove bends like in pipes. -To remove any dent present in the body -To cut access material (scrap) or to remove extra welding -To remove any deflection if present in any part -Welding of different parts -To change nuts, bolts, bushes -To check bending & breakage of shock absorber pin -Tapping of thread holes -To check if any post is broken -To change mudguard if its not working -To change various door hinges & to change them -To check for cracks in parts & weld seams -Grinding & wire brushing How reclamation is done:-> Bends & dents are removed by simply hammering or first heating the material to red hot & then hammering -> Threads are broken & hence tapping is done. -> Pipes are heated using oxy acetylene torch to remove all the dirt & block present in the pipes & also to remove bushes present inside. -> Excess material -> cutting -> grinding ->wire brushing Cutting is a very precise process since if extra material get cut then grinding is done followed by welding & again grinding hence it consumes time and extra hard work. ->grinding & wire brushin is to be done after every cutting process to make the surface smooth & clean. Wire brushing removes black spots. ->Cutting is done by electrode arc method operated in between 230 amps to 280 amps Depending on the thickness of material or type of material to be cut. -> Welding of various parts and Joints have to be done, similarly if extra material gets cut then welding is to be done. -> Welding is done by same electrode are method used for cutting but the current value set for the welding is between 80 amps to 90 amps & also fillers are used. ->Grinding & wire brushing is done after welding process.. -> Electrode used : Lotherme -802 AC-DC electode for cutting, welding of various metals with electric arc. -> To change mudguard, various posts, nuts bolts, springs, levers, if they are not working. ->if bolt holes broken then that parts is first cut them new part is welded.

VARIOUS PRECAUTION NEEDED TO BE TAKEN DURING CUTTING ,WELDING,HEATING. -> Avoid touching the metal just cut or welded it burns your hand hence proper gloves are to be worn. ->Proper helmets need to be provided to the workers during welding & cutting because if welding & cutting or helmets not used burning of eyes takes place & workers get various eye problem. Nowadays use electronic helmets instead of welding glares. -> Always check the current value set for a process acc to process is welding or cutting because if you go for welding & by mistake you set the value of current for cutting process 250amps then the material gets cut instead of being welded.

MODIFICATION OR CHANGES THAT CAN BE BOUGHTIN RECLAMATION :TOOLS OR EQUIPMENTS:Instead of welding glasses provide the workers with electronic helmets as you can always see through them and can adjust screen or glass darkness acc to process. This gives better welding or cutting. Workers should be provided with proper gloves for safety of hands during cutting or welding or preheating. Instead of metal arc welding, gas shielded welding or metal arc gas shielded welding should be used as they have various advantages over metal arc welding like :No slag is produced hence slag chipping operation is avoided . A clean weld is produced with little or no spatter . Heat is concentrated in a small area , minimizes stress and distortion Lack of smoke and fumes make process visible.

PAINTING:Spray painting is used for painting various parts of the tank. DIPPING:After painting the body is sent for dipping test to check for any leakages present. ASSEMBLY:Assembly takes place in various steps and these are :1. Suspensions, linkages and pipes mounting all suspensions, the axles, wheels etc 2. Hull wiring stage All electrical wiring and equipments such as cooling system , air compressor fire fighting equipments, various sensors, pipelines are mounted. 3. Engine gear box assembly (in this the engine, the clutch , gearbox assembly is done and various accessories are mounted such as radiator cooling pipes etc. 4. Turret assembly.

TESTING:After whole assembly again dipping test is performed to check if any leakage is present and then various other tests are performed in the static testing room. TRIAL:-Finally trial is performed by running the tank engine for 3- 4 hours continuously. ENGINE OVERHAUL DEPARTMENT EOD) STRIPPING :- DISSEMBLY Stage 1: Removal of stator Dynamo, oil pump and water pump Stage 2: Removal of inlet manifold, exhaust manifold, flywheel, inlet and exhaust cam shaft, air distributor unit, inlet and exhaust valve , oil filter, diesel filter, inspection plate, main oil seal, dynamo transmission, ATD (advance timer device), air valve , high pressure pipeline, tappet cover, lubrication pipelines , air breather. Stage 3: Head removal, connecting rod , piston, balancing shaft Stage 4: Camshaft removal stage, gear accessories, removing liner, strainer in oil sump, water jacket inspection plate. After this removal body part is sent for -Washing -Then engine block cleaning, denting, finishing, and painting.

OVERALL EXPERIENCE Over all experience working at 512 ABW was really great. I got a lot of practical knowledge about engines, gear boxes , etc. At 512 ABW I worked in the following sections. -Reclamation section - Engine overhauling department - Gear box assembly - Heat treatment section - Rubber component manufacturing section etc. -Pneumatic and hydraulic department.