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ACKNOWLEDGEMENT

I take this opportunity to express my gratitude to the person, who has directly & indirectly helped to complete this training with a positive note.

I am greatly indebted to Mr. Gurvinder Singh (Training-In-charge) for his inputs & guidance throughout the training. I also express my thanks to Mr. Manoj for his timely inputs on the scope & presentation of the study. I am also thankful to the Training Department of International Tractors Limited, Hoshiarpur.

Last but not the least, I would like to thank all my friends who have helped me in the study by providing critical examination of the training & very co-operative behaviour.

Rupinderpal Singh Aulakh

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DECLARATION

I, Rupinder pal Singh Aulakh , bearing Roll no. 09109073 , Mechanical Engineering student (Final Year) of Dr. B. R. Ambedkar National Institute of Technology, Jalandhar hereby declares that this Project Report entitled “ International Tractors Ltd. “ is an original work and the same has not been submitted to any other institute for the award of any other degree. The suggestions as approved by the faculty were duly incorporated.

Signature of Student

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CONTENT

Serial no.

Title Page no.1 Company profile 5-62 Introduction to Tractors 7-93 Basic Terminologies used 10-124 Working of an Engine 135 Main Parts of an Engine 146 Engine Performance 157 Fuel System 168 Engine Cooling 17-189 Process of Engine Assembly 1910 Engine Trouble and Remedy 20-2111 Decodification 2212 Electrical Trouble and Remedies 22-2313 Braking System 24-2514 Lubrication 26-2715 Transmission 28-3016 5S Formula 3117 Procedure of Final Assembly 3218 Practical Work During Training 33-3719 Bibliography 38

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COMPANY PROFILEWe are pleased to introduce ourselves as one of the largest Manufacturer and Exporters of agricultural Tractors, implements and equipments in India.

SONALIKA has a current turnover of approx. Six hundred million USD with activities spread in various fields including Tractors and Automobiles; Hydraulic Systems; Engines; Forgings; Brake Systems; Component Manufacturing, etc.

Established 1969, Sonalika Group has been contributing towards green revolution since its inception. Sonalika Group’s flagship company International Tractors Ltd is one of the largest tractor manufacturing companies in India manufacturing tractors in the range of 20-90Hp.

International Tractors Limited with brand name Sonalika ventured into production of tractors in 1995 and has emerged as the fastest growing Tractors Company having sold more than 32,000 Tractors last year and counted among the Top Three-Tractor Manufacturers in India.

Product Range – Tractors – ranging from 30HP to 90HP in 2WD and 4WD, Tractor Mounted Combine Harvesters, Multi Crop Threshers,

Harvesting Attachments. Plough’s, Harrows, Rotavators, Trolleys, Crop Reapers, Potato Planters.

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SONALIKA | HIGHLIGHTS

2010

• Sonalika Tractors are now EURO –III A Norms Compliant.• Started Export of Tractors to Argentina & Serbia.• Executed the export order to Cameroon worth 40 Million US$.

2009

• Grand Launch of technical advanced Worldtrac series of tractors. The series comprises of tractors with advanced features.

• Developed in-house unique DIESEL SAVER UNIT FOR SONALIKA Tractors.

• Became only Company in India To Produce 90 Hp Tractors.

2008

• Launch of RX Series of Tractors. Aesthetically appealing designs and shape accepted across the world & started Export of Tractors to USA.

2007

• Joint Venture between International Tractors Ltd. and Magma Shrachi Finance.

2006

• Successfully Developed Four Wheel Drive front axles and Transmission of tractor for Yanmar.

2005

• Achieved turnover of USD 235 Million.• Joint venture with Yanmar of Japan for manufacturing of

Tractors in India.

2001

• Started in house manufacturing of engines for tractor application. Pa

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INTRODUCTION TO TRACTORTRACTOR: The word ‘TRACTOR’ has been derived from traction which means pulling. A tractor is required to pull or haul an equipment, implement or trolley, which are coupled to the tractor chassis through suitable linkage. A tractor can also be used as a prime mover as it has a power outlet source which is also called Power Take Off or P.T.O. shaft.

The use of tractor in India was established with the help of Czechoslovakia. Then tractors were imported from European countries.

But after knowing the use of it, the demand increased dynamically. So many industries started its production in India to compel with demand.

CLASSIFICATION OF TRACTORS:

We can classify tractors according to the following scale:

1. According to wheels:(a) Three wheeler(b) Four wheeler(c) Chain wheel(track type)

2. According to capacity:(a) Light tractor(b) Medium tractor(c) Heavy tractor

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3. According to engine fitting:(a) Front engine which pull the implement(b) Rear engine which pull the implement

4. According to drive:(a) Two wheel drive(b) Four wheel drive

5. According to use:(a) Utility tractor(b) Row crop tractor(c) Orchard type tractor(d) Industrial type tractors(e) Garden tractor(f)Rotary tiller(g) Implement carrier(h) Earth moving tractor

REQUIREMENTS OF A FARM TRACTOR

1. Greater clearance both vertical and horizontal.2. Adaptation to the usual row width.3. Quick and short turning ability.4. Convenient and easy handling.5. Quick and easy attachment and removal of field equipments.6. Essential accessories such as hydraulic control and power take off.7. More Front weight.8. Larger Wheel Base.9. High Torque Backup.10. Aerodynamic Shape body for higher speed.

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CONSTRUCTION OF A TRACTOR

The tractor is made up of three distinct parts or assemblies as follows:

1. Power Unit: Engine and all accessories necessary for its operation such as ignition, fuel supply, cooling, lubrication, governing , starting and lightning system.

2. Transmission System: Clutch, gear box, differential, drive mechanism, belt pulley, power take off, power lift and control.

3. Chassis: Frame, wheel and steering mechanism. It does not have body.

BASIC PARTS OF TRACTOR

1. Radiator2. Water pump and

fan3. Front axle4. Front and Rear

tires.5. Engine and Engine

sump6. Clutch and Gear

Box7. P.T.O. shaft8. Differential9. Lift lower link10. Sensing spring11. Gear lever12. Steering box13. Diesel tank

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BASIC TERMINOLOGIES USED:

1. ENGINE: Heat engine is a machine for converting heat developed

by burning fuel energy (chemical energy) & transforms into

mechanical energy.

2. BORE: It is inside diameter of engine cylinder.

3. STROKE: It is a linear distance traveled by the piston top dead

centre (TDC) to bottom dead centre (BDC).

4. STROKE BORE RATIO (L/D): It is a ratio of length of the stroke and

the diameter of the cylinder. For tractor engine this ratio is 1:25.

5. SWEPT VOLUME: It is a volume displaced by one stroke of the piston.

6. COMPRESSION RATIO: It is the ratio of the volume of charge at

the beginning of the compression stroke to that at the end of

compression stroke.

a) Diesel engine 14:1 to 22:1

b) Petrol engine 4:1 to 8:1

7. CLEARANCE VOLUME: Total cylinder volume-swept volume.

8. POWER: It is the rate of doing work & expressed in watt.

9. BLOW BY: It is the escaping of gases vapours.

10. INDICATED HORSE POWER: Power produced inside the engine cylinder is known

as indicated horse power.

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11. BRAKE HORSE POWER: Actual horse power produced on fly wheel is known as

brake horse power.

12. FRICTIONAL HORSE POWER: Actual horse power produced on fly wheel is

known as brake horse power.

13. MECHANICAL EFFICIENCY OF IC ENGINE: It is the ratio of brake horse power

to indicated horse power. It varies from 65 to 90 percent.

14. THERMAL EFFICIENCY: It determines how efficiently fuel is utilized in the engine.

15. INDICATED THERMAL EFFICIENCY: It is the ratio of heat to work done by the

gases in the cylinder to the total heat energy supplied by the

combustion of fuel in the same time.

16. BRAKE THERMAL EFFICIENCY: It is the ratio of heat to work done by the gases in

the cylinder to the total heat supplied by the fuel in the same time.

17. CRANK THROW: This is the distance between the center of crank pin and main

bearing of the crank shaft. This distance is equal to the

stroke length. 18. IDLE RPM: Revolution per minute at no

load and no acceleration.

19. MAXIMUM RPM: Revolution per minute at no load and full accelerator.

20. RATED RPM: Revolution per minute at full load and full accelerator,

where engine gives its maximum power.

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21. THOU: It is the thousand part of the inch

a) 1 inch = 1000 thou = 25 mm.

b) 1 mm = 40 thou

22. BUMPING CLEARANCE: Clearance between the top of piston and cylinder head, it

remains 1.9 to 2.1 mm.

23. BACK COMPRESSION: Leakage of compression through the piston ring via. Crank

case breather.

24. LIVE HYDRAULIC: The hydraulic system taking power directly from the engine i.e.

hydraulic working is not affected by the position of clutch.

25. TRACTION: Force developed by wheels in the direction of motion.

26. SPEED DROP: Speed at no load-Speed at on load.

27. RPM: Revolution per minute.

28. VTU: Vary touch unit.

29. HSU: Hydro static steering unit.

30. CRDI: Common rail direct injection.

31. EGR: Exhaust gas recirculation.

32. TAPPET CLEARANCE:

a)Exhaust: 0.4 mm

b)Inlet: 0.3 mm

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WORKING OF FOUR STROKE DIESEL ENGINE

In four stroke diesel engine all events taking place inside the cylinder completed with four stroke of piston. Each cylinder has two valves for inlet and outlet. The opening and closing of valves are controlling by cam shaft. It is driven by crank shaft with the help of suitable gears. The cam shaft runs at half speed of crank shaft.

The four strokes of piston are:

1. SUCTION STROKE: During suction stroke air or mixture of air and fuel are drawn inside the cylinder. The air enters the cylinder through inlet valve and exhaust valve remains closed during this stroke. The pressure in the cylinder is less than the atmosphere pressure.

2. COMPRESSION STROKE: The air taken in the cylinder is compressed by the piston to a small volume of cylinder. The fuel is injected at the end of the compression stroke. The ignition takes place due to high pressure and temperature. After ignition a large amount of heat is generated in the cylinder which pushes the piston backward for useful work. Both valves remains closed during this stroke.

3. POWER STROKE: During power stroke the high pressure is developed due to combustion of fuel causing the piston to move forward or backward at regular intervals. Both valves remains closed during the stroke.

4. EXHAUST STROKE: During exhaust stroke the exhaust gases go out to exhaust and valve and the cylinder becomes ready to receive fresh air. The inlet valve is closed and exhaust valve remains open during this stroke.

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MAIN PARTS OF IC ENGINE AND MATERIAL USED

1. Engine cylinder: Aluminum, grey cast iron (with a cast iron linear or sleeve).

2. Cylinder head: Grey cast iron, aluminum alloy, cast iron.

3. Piston: Aluminum alloy, cast steel, cast iron, chrome nickel.

4. Connecting rod: Alloy of medium carbon steel.

5. Crank shaft: Forged steel.

6. Main bearing: These are made of white metal or leads to phosphorus bronze.

7. Fuel injectors: Steel.

8. Piston rings: Aluminum alloy.

9. Valve (Intake and Exhaust): Nickel chromium.

10. Cam shaft: Forged steel.

11. Crank case and Cylinder block: Aluminum with linear ferrous alloy , Semi steel.

12. Fly wheel: Cast iron.

13. Bed plate: Cast iron.14. Cooling water jackets: Masonry foundation.

15. Spark plug: Electrode of nickel chromium steel & body is made of heat resisting material.16. Fuel pump: Aluminum alloy.

17. Gaskets: Copper and asbestos.

18. Governor: Cast iron.

1419. Exhaust manifold and inlet manifold: Cast iron and aluminum alloy.

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ENGINE PERFORMANCE :

INTRODUCTION: This topic describes different terms relating to engine measurement and performance such as cylinder diameter, length of piston stroke, cylinder volume and so on but also the engine rating, efficiency, head balance etc.

WORK: When an object is moved by the application of force, work is set to be done. It is measured by the product of the distance. The body moves and the force applied on it.

ENERGY: Energy is the ability or capacity to do work. When the work is done on object, energy is stored in that object.

POWER: Power is the rate of doing work. The work can be done slowly or rapidly. The rate at which work is done is measured in term of power.

HORSE POWER: A horse power is the power of horse, or a measure of the rate at which horse can work.

TORQUE: Torque is twisting or turning effort. The torque is equal to the product of the force and its perpendicular distance to the point of rotation.

COMPRESSION RATIO: It is the ratio of the volume of the charge in the cylinder above the piston at Bottom Dead Center and the volume of charge when the piston is at Top Dead Center.

r = clearance volume + displacement volume clearance volume

SAE HORSE POWER: The SAE (Society of Automotive Engineers) horse power rating of engine is used to compare engine on the basis of number and diameter of cylinder.

SAE Horse power = D 2 N

2.5D = diameter of cylinder in inc

h N = number of cylinders

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FUEL SYSTEM IN DIESEL ENGINE :

• During engine operation, the fuel is supplied by gravity from the fuel tank to the primary filter.

• Where coarse impurity is removed, the fuel is drawn by fuel transfer pump and is delivered to fuel injection pump through second filter.

• The fuel injection pump supplies fuel under high pressure to the injectors through high pressure pipe.

• The injectors atomize the fuel and inject it into the combustion chamber of the engine.

• The fuel injection pump is fed with fuel in abundance. The excess fuel is by passed to the intake side of the fuel transfer pump through a relief valve.

MAIN COMPONENT OF FUEL SYSTEM:

1. Fuel feed pump2. Fuel filter3. Fuel injection pump

1 FUEL FEED PUMP: It is a pump which transfers fuel from the fuel line to the fuel injection pump. It is mounted on the body of fuel injection pump.

2 FUEL INJECTION PUMP: It is a pump which delivers metered quantity of fuel to each cylinder at appropriate time under high pressure.

3 FUEL FILTER: It is device to remove dirt from fuel. Usually two filter primary and secondary filter are used in diesel engine.

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ENGINE COOLING:

Properties of an efficient cooling system: An efficient cooling system removes 30 to 35% of the heat generated in the combustion chamber. Too much removed of the heat decrease thermal efficiency of the engine.

Method of cooling:(1) Air cooling(2) Water cooling

1) Water cooling: In this method of cooling, the water is circulated though water jackets around each of the combustion chamber and cylinder valve stem. The circulating water when passes through the engine jacket in the block it takes heat. When it passes through the radiator, it is cooled by air drawn through the radiator.

2) Air cooling: In this method of cooling, the heat is decreased directly to the air after being conducted through the cylinder wall.

Main component of cooling:

1) Radiator: The radiator is the flat type with the core and water tanks combined in oneintegral unit. It is enclosed with the grill and fan housing which are removable forcleaning.

2) Fan and fan belt: A fan is mounted behind the radiator on the water pump shaft. It isdriven by the same belt that drives the pump and generator. The purpose of the fanis to draw air through the radiator.

3) Thermostat: A thermostat valve is used in water cooling system to regulate the

circulation of water in system to maintain the normal working temperature of the

17engine part during the different operating condition.

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Valve open start = 70*-80*CFull open = 100*-110*C

4) Water pump: A pump is used in the water cooling system to increase the velocity of the circulating water. Impeller type pump is mounted at the front end of the cylinder block and the radiator.

5) Water jacket: Water jacket is cast into the cylinder block and head. Jacket is simply the passage through which water circulated around the cylinder, valve port and seats.

6) Radiator pressure cap: Water normally starts boiling at 100 degree Celsius. In order to increase the boiling temperature of water, the cooling system is pressurized. The Radiator pressure cap is set at 0.9 bar so that the cooling system operates under a pressure of 1.9 bar. When the pressure exceeds 1.9 bar, the pressure valve opens and let out the excessive pressure along with some coolant. When the engine cools down, the vacuum valve opens and let in air so that the radiator does not collapse inwards due to vacuum.

7) Cooling Fan: Cooling fan sucks in fresh cool air through the radiator, thus cooling the hot water.

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Process of engine assembly in plant:

Crankcase washing Crankcase loading & Crankshaft assemblyplugs fitment

Oil Pump & Suctiontube fitment

Cylinder head assembly & engine belt pulley fitment

Alternator & valve cover fitment

Oil filter & fuel filter fitment

Piston & connecting rod fitment

Flywheel & oil pan fitment

Inlet & exhaust manifold fitment

Breather assembly & starter motor

fitment

Camshaft & tim ing gear fitment

Rocker arm assembly, push

rod fitment

Water pump, s ide cover & Therm ostat fitment

Engine testin g

Dispatch

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ENGINE TROUBLE AND REMEDY :

Probable causes Remedy

Fuel line clogged. Flush and blow out with compressedair.

Air in fuel system. Remove air with help of feed pump.

Fuel filters clogged. Wash coarse filter element. Changefine filter element.

Incorrect injection timing. Adjust injection timingEngine sluggish. Check injectors, rectify spray.

Trouble: Irregular engine running, Smoking, Loss of power.

Air or water in fuel Remove air, prime with clean settledfuel

Injector needle stuck or nozzle holes

Wash nozzles, clean out holes (use

clogged cleanout tool 0.25-0.28mm dia.)

Incorrect injector operating pressure

Adjust injector operating pressure

Injector pump faulty Replace pump and have it repaired

Pump delivery out of adjusting Have pump adjustedValve stuck Remove cylinder head and

valvedecarbonizes

Fuel filter clogged Wash coarse filter element or changefine filter element

Fuel line clogged Flush and blow out

Air cleaner clogged Wash out and refill with clean oil

Cylinders, piston and pins worn ReplaceEngine overload Reduce loadEngine cold Warm upLack of compression Adjust valve clearanceCrank case oil level high Check drain to dipstick upper

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Piston rings worn or stuck, cylinders or

Replace or wash rings, if necessary

piston worn replace cylinders and piston

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Trouble: Knocking noise :

Probable cause

Remedy

Injection too early

Check and set time

Valve clearance large AdjustValve striking piston Investigate cause and correctPiston slap(w

allhard througho

utCylinder and piston worn, replace on

cylinder,

disappears when throttling

earliest opportunity

up)Pounding from

excessive

crankshaft

Regrind journals, fit replacements

bearing clearance

shells

Trouble: Engine overheats :

Probable cause

Remedy

Dirt on cooling fins Stop engine and allow cooling off,remove dirt

Fan screen clogged CleanFan belt worn or broken

Replace

Undue use of fan throttle plates Remove throttle plateEngine overload

Reduce load

Trouble: Engine racing away :

Probable Remedy

causeAir cleaner oil bowel overfilled Remove bowl and empty

excessInjection pump faulty Replace pump and have it

repaired

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DECODIFICATION of Engine Model :

¬ Simpson Engine S-325

• S - Simpson Engine• 3 - Three Cylinder• 25 - 25 X 100 cc

¬ ITL Engine 3100FL

• 3 – Three Cylinder• 100 – Bore diameter in mm• F – Fuel Efficient Engine• L – Extra Length of Stroke (118 mm)

Electrical trouble and remedies:-Trouble: Alternator (low or no charge) :

Probable causes RemedyFault in alternator to battery circuit

Find fault and correct

Field coil open or short circuited

Have coil replaced

Voltage regulator fault Correct faultTrouble: Ammeter needle dancing:

Probable causes Remedy

Rectifier faulty Replace alternator

Trouble: Alternator noisy:

Probable causes RemedyPulley loose Tighten pulley nutBall bearing worn(excessive play or

Have bearing replaced

damaged rolling contact surface)

Trouble: Starter will not run when switched on:

Probable causes

Remedy

Heavily oxidized

battery

wire

Clean

terminals

Trouble: Starter will not stop after engine :

Probable causes

Remedy

Solenoid contacts stuck closed

Stop engine and immediately openearth switch (or disconnect wire frombattery terminals) correct fault

Trouble: Starter fails to crank engine :

Probable causes RemedyEngine at fault Find fault and correctBattery low Charge the battery

Commutator or brushes dirty Clean thoroughlyPoor connection in starter circuit

Check and tighten

Solenoid contacts burnt Clean

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BRAKING SYSTEM:

Brakes are used to stop, stand or to turn tractor. There is different brake for every wheel. It is known as a mechanism to stop the moving vehicle in shortest time and in shortest distance.

FUNCIONS OF BRAKE:1) It helps operator to decrease the speed of machine.2) It also helps during turn.3) It helps in control in heavy traffic.4) To stop a machine.

TYPES OF BRAKES:1) Mechanical brake2) Hydraulic brake3) Disk brake

Mechanical brake: This is an internal expanding brake when the brake paddle is pressed the cam revolves with help of cable and link. It force the brake shoe, because of this force they expand and start to friction with brake drum, makes them slow and ultimately stop them with braking power. When the force is removed from paddle it is reset.

Important parts in mechanical brake1) Brake paddle2) Brake shoe3) Brake shoe lining

4) Brake drum

5) Brake paddle

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Hydraulic brake: The hydraulic brake is an arrangement of braking mechanism which uses brake fluid, typically containing ethylene glycol, to transfer pressure from the controlling unit, which is usually near the operator of the vehicle, to the actual brake mechanism, which is usually at or near the wheel of the vehicle.

Disk brake: The disc brake is a wheel brake which slows rotation of the wheel by the friction caused by pushing brake pads against a brake disc with a set of calipers. The brake disc (or rotor in American English) is usually made of cast iron, but may in some cases be made of composites such as reinforced carbon–carbon or ceramic matrix composites. This is connected to the wheel and/or the axle. To stop the wheel, friction material in the form of brake pads, mounted on a device called a brake caliper, is forced mechanically, hydraulically, pneumatically or electromagnetically against both sides of the disc. Friction causes the disc and attached wheel to slow or stop. Brakes convert motion to heat, and if the brakes get too hot, they become less effective, a phenomenon known as brake fade.

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LUBRICATION :

Lubrication is essentially, required in tractor maintenance. To supply the lubricating oil between the moving parts is simply termed as lubricating. Lubrication of all moving parts is essential to reduce friction, wear and to prevent seizure.

Properties of lubricants:

1) Viscosity2) Flash points3) Fire point4) Cloud point

¬ Viscosity: Viscosity is a measure of the resistance to flow or the internal friction of oil.

¬ Flash points: The flash point has been defined as the lowest temperature at which the lubricating oil will flash when a small flame is passed across its surface.

¬ Fire point: If the oil is heated further after flash point has been reached. The lowest temperature at which the oil will burn continuously is called fire point.

¬ Cloud point: The oil changes from liquid state to a plastic or solid state when subjected to low temperature. In some cases

the oil solidifying which makes it to appear cloudily. The temperature at which this take place is called cloud point.

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TYPE OF LUBRICANTS:

There are three types of lubricants:1) Solid: Graphite, mica, soap stone, or steatite.2) Semi solid: Grease3) Liquid: Mineral oil, vegetable oil, animal oil etc.

LUBRICATION SYSTEM FAULTS :

Trouble: Low oil pressure :

Probable cause RemedyOil pressure gauge faulty Check gauge, replace if

necessary.Look for oil leaks, stop if any.

Oil pump intake strainer clogged

Wash

Oil pressure relief valve clogged

Wash

Unauthorized grade of engine oil

Change to authorized oil

Crank shaft bearing worn Required journals fit replacementsshells

Trouble: Excessive oil consumption :

Probable cause RemedyPiston rings worn out or stuck ReplacePiston rings side clearance large

Replace or piston if necessary

Large intake valve stem Replace worn parts

clearance inguide

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TRANSMISSION:

We know that the horse power, the rear wheel depends upon the turning effort and the speed of rotation. We need different torque and speed for different application at the rear wheel but engine speed and torque are between engine and rear wheel, which gives variable torque and speed. This mechanism is known gear box. Any combination of gear wheels by which power is transmitted one shaft to another shaft is called gear train. The direction of rotation of driver gear will be opposite to that of driving gear.

TYPE OF GEAR BOXES:

There are mainly two types of gear boxes. These are as under:

¬ Sliding mesh gear box: In this type of gear box one moving gear is pulled out and pushed to mesh another gear.

¬ Constant mesh gear box: In constant mesh gear box, the gears on main and counter shaft are always in engaged position. In this the splined sleeve is made to shift to mesh with the gear to right and left or kept in neutral position.

¬ Synchromesh: It is similar to constant mesh gear box except synchronizing cones which are provided on its hub sleeves for equalizing the speeds of gears. This type of gear box is being

used in Worldtrac range. It overcomes noise, wear/breakage & hard gear shifting problems.

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PARTS OF GEAR BOX AND THEIR FUNCTIONS:

Input shaft: It transmits power from clutch plate to gear box

Lay shaft: For maintaining the made of rotation of gears and changing the speed of gears on this shaft the gear remains fixed to prevent the gear slippage

Intermediate shaft: Take power from lay shaft gears, in this shaft, gears remains sliding.

Output shaft: Take power from immediate shaft and transmit to the tail pinion.

Idler cluster: It gives reverse motion.

Internal gear: It remains fixed on gear box housing and support the motion of planetary gear.

Planetary assembly: It reduces the speed of working at heavy loads.

High-low sleeve: It connects the output shaft to intermediate shaft and planetary assembly for high and low speed resp.

Gear shifting lever: Shift the gears

Locking wire: Lock the fork on shifter fork.

Gear shifter rod: Given movement to the shifter fork and then gear while shifting them

CLUTCH :The clutch is fitted in engine to connect and disconnect power stream in gear box and other components. The main motive of clutch is to make gearing easily and quick. It is located between engine and gearbox.

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There are following types of clutch :

1) Single plate clutch: This type is mostly used in motor cars, it is also known as with the name of DISC CLUTCH AND SOLID CLUTCH. It has following partsi) Flywheelii) Clutch plateiii)Pressure plateiv)Clutch springv) Clutch release bearingvi)Clutch forkvii) Clutch fork ball

2) Multi-plate clutch: As per name, this type of clutch uses multiple clutch and pressure plates. It also works as single plate clutch and all parts are usually similar. This type of clutch is used in light weight motors like bike, scooter etc. In it all clutch plates have lining in their radius and same numbers of pressure plates are fitted in it.

CLUTCH ASSEMBLY:

There are following parts in clutch assembly

1) Clutch lining

2) Cushion spring

3) Torsion spring

4) Rivet

5) Hub flange Page

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5 S FORMULAS:-

1.

Seiri

2.

Seiton

3.

Seiso

4.

Seiketsu

5.

Shitsuke

S. NO. JAPANESE MEANINGWORD

1S SEIRI Sorting out, clearing, segregation, proper selection and remove thewaste

2S SEITON Systematic arrangement, keeping things at proper place. A placefor everything and everything in its place.

3S SEISO Cleaning. Keep all the work place area, equipment clean

4S SEIKETSU Standardizing, environment, cleanliness. Light, noise, punctuality.(Order and save time)

5S SHITSUKE Maintain discipline and standards To maintain above 4s,respect therules.

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Procedure for Tractor final Assembly:

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PRACTICAL WORK DURING TRAINING

Project: Time Study at Differential Loop assembly and Gear box Assembly

¬ Time Study:

Time study is the process to establish a time for a qualified worker to perform specified

work under stated conditions and at a defined rate of working.

¬ Average Cycle Time:

Average Cycle Time is defined as the mean of the different durations taken to complete

one cycle of an operation.

Part 1– Differential Time Study

¬ Function of differential:A differential is used between the back tyres of the tractor.Its basic function is to provide different rotation to both the back gears during turning.

¬ Various parts used in differential assembly are:-Trumpet

Spur ,helical gears BreakGasket Cage

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Differential Assembly Loop:

Dropping the B.P Shaft P.T.O Shaft OIB drumhousing on fitment (crown fitm ent onfitmenttrolley ge ar) both sides

Bull gear Punching Cro wn GearPinion Fitment preloadingplacing Chasis No. check

Trumpet Trumpet & bull P.T.O Shifter Brake LeverFitment gear Fitment Fitment fitment

Lifted by Suct ion pipe overhead

fitmentcrane

Testing Done at Differential As sembly :

ϖ Pattern or %age Contact Test:

%age contact required is 60% - 70%

ϖ Pre-Loading Test:

Cage ass embly bearing – 12 kg T.P. Shaft – 6 kg

ϖ Backlash Testing: .2 - .3 mm Page

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Total Cycle Time:

Total cycle time taken by the process at differential loop = 637 sec or 10.61 minutes

Recommendations:

ϖ Dial gauge place needs to be changed.

ϖ More workers are required.

ϖ No place for stocking of PTO shaft in on-hold inventory.

ϖ On-hold inventory racks were not placed at right place.

ϖ Mismanagement among the workers.

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Part 2 – Gear Box Time Study

¬ Function of a Gear Box:

As per application/condition, different speeds and torque combination

are required which can be achieved by a GEAR BOX.

¬ Various parts of a Gear box:

ϖ Gear Box Housing

ϖ Cover Plates

ϖ High & Low Gears

ϖ Shifter Rod & fork

ϖ Input , Intermediate and Output Shafts

ϖ Idler Cluster

ϖ Planetary Assembly

ϖ Locking Wire

¬ Total Cycle Time:

Total cycle time taken by the process at gear box assembly loop for manufacturing of

single unit= 448.25 seconds or 7.47 minutes.

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Gear Box Assembly loop:

Gearbox housing Lay Shaft fitment Intermediate Shaft High Low gearon trolley fitment fitment

Bottom plate Cover plate fitment Shifter Rod & fork Input shaft fitmentfitment fitment

C.A. guide & Bell Steering & Lay & Intermediate Lifted by overheadhousing fitment accelerator fitment Shaft plate fitment crane

Recommendations:

ϖ Mismanagement among workers.

ϖ Mandrel tools are not plac ed at right place

ϖ More involvement of man then machine.

ϖ Torquing of nuts should be divided at different sub stations.

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37

BIBLIOGRAPHY

1. www.sonalika .com 2. Search Engines (Google and Yahoo)3. Sonalika Library material.4. “ I. C. Engines” book by V. Ganesan5. “ Production Management” booksPa

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THANK YOUPa

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