This document summarizes a student's internship project on the layout of an ACE Group plant. It provides background on ACE Group, which is a leading manufacturer of material handling and construction equipment in India. It then describes the assembly process for ACE's hydraulic cranes in 5 stages, covering the assembly of various parts like the transmission, engine, hydraulics, boom, and wheels. It also explains key concepts like Pascal's law that are relevant to hydraulic systems. Finally, it outlines the quality inspection process to check cranes, including incoming, in-line, testing, rework, pre-dispatch, and auditing.

1. SUBMITTED BY:
PUSHPENDRA SINGH
14EAXME055
SUBMITTED TO:
SAURABH KHANDELWAL
ASSISTANT PROFESSOR
AIET, JAIPUR
APEX INSTITUTE OF ENGINEERING & TECHNOLOGY, JAIPUR
18/05/2017 to 17/07/2017

2. PLANT LAYOUT

3. CONTENTS
• INTRODUCTION
• PASCAL’S LAW
• HYDRAASSEMBLY
• QUALITY
INSPECTION

4. ACE GROUPS
• India’s leading material handling and
construction equipment manufacturing
company with a majority market share
in mobile cranes and tower cranes
segment.
• Headquartered in Palwal, Haryana, the
company was established in 1995 and
has marketing operations in many
countries.
• One of the leading mobile crane
manufacturers of the country, ACE
offers a comprehensive range of
hydraulic cranes, more than 20 variants
starting from 9 to 25 ton.
• A leading material handling and
construction equipment manufacturer,
they manufacture and market a diverse

5. ACHIEVEMENTS OF ACE
• The company has the following
achievements to its credit. These
achievements have acted as a
motivation in the company’s growth.
• CNBC-TV18, EMERGING INDIA
AWARD-2006.
• BUILDING INDIA LEADERSHIP
AWARD-2006.
• Awarded with CW-NICMAR
AWARD for three years
consecutively (2006-2008).
• ACE has been awarded the
prestigious “ EQUIPMENT INDIA
AWARD ” for being the “ BEST
SELLER – MOBILE CRANES " at
the 3rd Annual Equipment India
Awards held on 16th March 2016 at
New Delhi.

6. ACE PRODUCT RANGES
1. ACE MOBILE CRANES
2. ACE BACKHOES AND
LOADERS
3. FORKLIFT TRUCKS
4. ROAD EQUIPMENT'S
5. AGRI MACHINES

7. ACE PRODUCTS
HYDRA NEW GEN. CRANES
BACKHOES LOADERS

8. ACE PRODUCTS
TRACTORS FORKLIFT TRUCKS
MOTOR GRADERS ROAD LEVELLING
EQUIPMENTS

9. ACE PRODUCTS
CONCRETE PLACING
BOOM
HARVESTER COMBINES

10. ON LINE WORKING IN PLANT

11. PASCAL’S LAW
Pascal's law is defined as “A change in pressure at any
point in an enclosed fluid at rest is transmitted
undiminished to all points in the fluid.”

12. PRATS OF HYDRA
1. Weight box
2. Chaise
3. Gear box
4. Yoke
5. Cradel
6. Engine
7. Radiator
8. Air tank
9. Air cleaner
10.Oil filter
11.Fuel filter
12.A-Frame
13.Fuel tank
14.Hydraulic oil tank
15.Main frame
16.Braking system
17.Cabin
18.Hydraulic pump
19.Stearing cylinder
20.Lifting cylinder
21.Rear wheel
22.Front wheel
23.Boom
24.Lifting hook
25.Snatch block
26.Winch
27.Rope
28.Control valve
29.OC valve
30.Electric system

13. PARTS OF HYDRA

14. ASSEMBLY PROCESS

15. ASSEMBLY STAGE
ASSEMBLY STAGE-1 OF TRANSMISSION & CHASSIS
sr. no. DESCRIPTION SPECIFICATIONS
1 Transmission &Chassis Assembly
Fitment of transmission &Chassis
Fitment of Slave cylinder brackets with
bolt 4 nos of M10x35
Mounting of Axle housing with axle
mounting plate 10 nos bolts(M16x220)
Mounting of gear box housing with
bracket bolt (M16x35)
2 A-Frame assembly
Fitment of A-frame with pivoting
ofcradle frame.
Tightening of check nut with splitPin

16. Ass.
ASSEMBLY STAGE-2 OF ENGINE ASSEMBLY
3 Engine assemblywith Back-End
Placing of Engine – Subassembly with
chassis
Fitment of Engine with backend12 nos
bolt with M10x35
Fitment of Engine mounting bracket
with 5/8” BSFx2 bolts
Fitment of rubber pads M12x80 &
locking of bolts
4 Assembly of Aircleaner
Fitment of air cleaner clamp with
M8x50 bolt
Air cleaner mounting with M8x25Bolt
5 Assembly of Fueltank Fitment of fuel tank with chassis with 4
nos of Bolts M12x50 & locking nuts.

17. Ass.
6 Assembly of Hydraulic tank Fitment of Hydraulic tank with chassis 4 nos of
Bolts M12x40 & locking nuts.
7 Assembly of Airtank Fitment of air tank with chassis with 4 nos of
Bolts M8x35 & nuts.
8 Assembly of Gearlever Fitment of Gear lever with gasketand 4 nos bolts
M8x20.
ASSEMBLY STAGE-3 OF RADIATOR, HYDRAULIC PUMP, HOSES, BRAKE
SYSTEM, STEERING CYLINDER & CAB-BASE
9 Assembly of Radiator
Fitment of radiator with chassis with rubber pads
& mounting with M10x50 bolts with locking
nuts.
10 Assembly of Hydraulic system
Fitment of pump mounting plate with M12x45
bolts (6 nos) and locking nuts
Fitment of hydraulic pump with M12x50 bolt and
locking nuts
Fitment of propeller shaft with engine with 4 nos
M8x30 bolts.
Fitment of 'O' Ring & dowty sealin pump Elbow
and flange
Fitment of suction tube with 'O'Ring & clamping
of suction hose.
Fitment of delivery tube with 'O'Ring & clamping
of delivery tube.

18. Ass.
11 Assembly of HP hoses
Fitment of Hose assembly
Fitment & tightening of HP Hoses with
'O' rings.
12 Brake circuit assembly
Fitment of un-loader valve, air tank,
master cylinder & tubes.Clamping of
parking cables & fork.
13 Steering cylinder fitment (Eye end)
Fitment of steering cylinder pin with
thrust washer & locking bolts M10x60
(Small cylinder) M12x20(Big cylinder)
14 Cabin assembly mounting
Fitment of cabin assembly
Fitment of 4 nos M12x40 bolts at rear
side & 4 nos M12x50 bolts at front side
15 Linkage assembly
Fitment of Accelerator pedal & Clutch
pedal linkage assembly
Fitment & locking of adjusting rods.
Adjustment of clutch rod

19. Ass.
ASSEMBLY STAGE-4 OF MAINFRAME ASSEMBLY & WHEELASSEMBLY
16 Mounting of Mainframe with yoke
Fitment of tie bolt, thrust bearing,
bearing cup, spring & Washer
Locking of tie bolt with M10x50Bolt
Fitment of castle nuts with splitPins
17 Mounting of frontaxle with A-
frame
Fitment of Pin for A frame leg Mounting
Fitment of castle nuts with split Pins
Fitment of Locking bolt with tightening
of M16x50 bolts
18 Steering cylinderfitment (Rod end)
Fitment of steering cylinder & proper
locking of steering jack pin with
M10x60bolts
Fitment of steering hoses & connection
of hoses assembly and fitment with 'O'
rings

20. Ass.
19 Front wheels assembly
Fitment of front wheel assembly
Tightening of wheel mounting nuts16
nos M20
Tightening of wheel mounting nuts16
nos M22
20 Rear wheels assembly Fitment of rear wheel assembly
Tightening of wheel mounting nuts16
nos M22
ASSEMBLY STAGE-5 OF BOOM ASSLY, WIRE ROPE, HOOK BLOCK
ASSEMBL & OIL / WATER FILLING
21 Mounting of Boom Assembly
Fitment of boom assembly with boom
pin
Fitment of castle nuts with split Pins
Fitment of Locking bolt for boom pin
with bolt M12x100 (12T/14T)
Fitment of lift cylinder with pin with
bolt of M12x80 for 9T/11T
Fitment of Locking bolt for lift cylinder
pin with M12x80 bolt.

21. Ass.
22 HydraulicConnections Fitment of U Tubes, hoses & lockValve
23 Silencer assembly Fitment of silencer pipe with engine intake
mani fold.
Fitment of silencer clamp with rubber pads
24 Oil levels
Filling of Engine oil (Gr- 15W40) Engine oil
Qty should be 8 Ltrs.
Filling of transmission oil EP90 Trans. Oil
Qty should be 55 Ltrs.
Filling of Hydraulic oil (Gr- EP68) Hyd. oil
Qty should be 125 Ltrs.
Filling of Air cleaner oil 15W40AC Oil Qty
should be 1.5 Ltrs.
Filling of Brake oil (Gr- Dot3) Brake oil Qty
should be 0.8 Ltrs.
Filling of water in radiator Coolant should be
filled in coolant bottle Qty 1.75 Ltrs.

22. Ass.
25 Wire rope, hook &Hook
blockassembly
Fitment of wire rope on guide pulleys,
hook block & on winch
Fitment of hooks & hook pins.
Tightening of hook pin locking bolt.

23. CONTROL VALVE AND JACK
The spool slides to different positions in the housing, and
intersecting grooves and channels route the fluid based on
the spool's position.

24. HOW THE WORK CONTROL VALVE
The spool has a central (neutral)
position maintained with springs;
in this position the supply fluid is
blocked, or returned to tank.
Sliding the spool to one side
routes the hydraulic fluid to an
actuator and provides a return
path from the actuator to tank.
When the spool is moved to the
opposite direction the supply and
return paths are switched. When
the spool is allowed to return to
neutral (center) position the
actuator fluid paths are blocked,
locking it in position

25. WORKING OF CONTROL VALVE AND JACK

26. QUALITY INSPECTION
INCOMING INSPECTION:-
Garbage in, garbage out‖: a factory usually cannot turn defective inputs
(components, or raw materials) into good products. And the problems are much
harder to detect once the materials are embedded in the final product.
ON LINE INSPECTION:-
Typically, in an in-line inspection, the first products that got out of the line are
inspected for conformity. If issues are raised at this stage, the factory can
immediately take some corrective actions and avoid delays.
TESTING:-
An inspection performed on the cranes in which they have to go through
various load and road test, as per the specifications to ensure their effective
working on the fields.

27. QUALITY INSPECTION
REWORK:-
A stage which comes after testing, where every minute parts of the crane are
observed carefully to check whether there is any defect that has been raised
after testing the crane at its full capacity. It also includes observing any leakage
and re-torqueing all the hardware components to ensure safety.
PDI (PRE-DISPATCH INSPECTION):-
This is the most popular type of QC inspection for importers. It takes place
once all the products are finished and ready for shipment.
AUDIT:-
The final stage after dispatch where from ‗N‘ no of cranes randomly few
cranes are selected and then these machines are inspected as per the pre-
defined check points.

28. THANK YOU…