rp project report sonalika

ACKNOACKNOACKNOACKNOWWWWLEDGLEDGLEDGLEDGEEEEMENTMENTMENTMENT

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. Mr. Mr. Mr. Gurvinder SinghGurvinder SinghGurvinder SinghGurvinder Singh (Training-In-charge) for his inputs &

guidance throughout the training. I also express my thanks to Mr. ManojMr. ManojMr. ManojMr. 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 ARupinderpal Singh ARupinderpal Singh ARupinderpal Singh Aulakhulakhulakhulakh

DECLARATIONDECLARATIONDECLARATIONDECLARATION

I, Rupinder pal SRupinder pal SRupinder pal SRupinder pal Singhinghinghingh AulakhAulakhAulakhAulakh , bearing Roll no. 09109073. 09109073. 09109073. 09109073 , , , , Mechanical EMechanical EMechanical EMechanical Engineeringngineeringngineeringngineering

student (Final YearFinal YearFinal YearFinal Year) of Dr. B. R. Ambedkar National Institute of Technology, Jalandhar

hereby declares that this Project Report entitled “ International Tractors Ltd. ““ International Tractors Ltd. ““ International Tractors Ltd. ““ 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 Signature of Student Signature of Student Signature of Student

CONTENTCONTENTCONTENTCONTENT

Serial no.Serial no.Serial no.Serial no. TitleTitleTitleTitle Page no. 1 Company profile 5-6 2 Introduction to Tractors 7-9 3 Basic Terminologies used 10-12 4 Working of an Engine 13 5 Main Parts of an Engine 14 6 Engine Performance 15 7 Fuel System 16 8 Engine Cooling 17-18 9 Process of Engine Assembly 19 10 Engine Trouble and Remedy 20-21 11 Decodification 22 12 Electrical Trouble and Remedies 22-23 13 Braking System 24-25 14 Lubrication 26-27 15 Transmission 28-30 16 5S Formula 31 17 Procedure of Final Assembly 32 18 Practical Work During Training 33-37 19 Bibliography 38

COMPANY PROFILECOMPANY PROFILECOMPANY PROFILECOMPANY PROFILE

We are pleased to introduce ourselves as one of the largest Manufacturer and Exporters of

agricultural Tractors, implements and equipments in India.

SSSSONALIKAONALIKAONALIKAONALIKA has a current turnover of approx. SSSSix hundred million USDix hundred million USDix hundred million USDix 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 SonalikaSonalikaSonalikaSonalika 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 RangeProduct RangeProduct RangeProduct 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.

SONALIKA | HIGHLIGHTSSONALIKA | HIGHLIGHTSSONALIKA | HIGHLIGHTSSONALIKA | HIGHLIGHTS 2010201020102010

• 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$.

2009200920092009

• Grand Launch of technical advanced WWWWorldtracorldtracorldtracorldtrac 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.

2008200820082008

• Launch of RX Series of Tractors. Aesthetically appealing designs and shape accepted

across the world & started Export of Tractors to USA.

2007200720072007

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

2006200620062006

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

Yanmar.

2005200520052005

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

2001200120012001

• Started in house manufacturing of engines for tractor application.

INTRODUCTION TO TRACTORINTRODUCTION TO TRACTORINTRODUCTION TO TRACTORINTRODUCTION TO TRACTOR

TRACTOR: TRACTOR: TRACTOR: TRACTOR: 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 TRACTORCLASSIFICATION OF TRACTORCLASSIFICATION OF TRACTORCLASSIFICATION OF TRACTORSSSS::::

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

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 TRACTORREQUIREMENTS OF A FARM TRACTORREQUIREMENTS OF A FARM TRACTORREQUIREMENTS 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.

CONSTRUCTION OF A TRACTORCONSTRUCTION OF A TRACTORCONSTRUCTION OF A TRACTORCONSTRUCTION OF A TRACTOR

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

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

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

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

BASIC PARTS OF TRACTORBASIC PARTS OF TRACTORBASIC PARTS OF TRACTORBASIC PARTS OF TRACTOR

1. Radiator

2. Water pump and fan

3. Front axle

4. Front and Rear tires.

5. Engine and Engine sump

6. Clutch and Gear Box

7. P.T.O. shaft

8. Differential

9. Lift lower link

10. Sensing spring

11. Gear lever

12. Steering box

13. Diesel tank

BASIC TERMINOLOGIES USEDBASIC TERMINOLOGIES USEDBASIC TERMINOLOGIES USEDBASIC TERMINOLOGIES USED::::

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

energy (chemical energy) & transforms into mechanical energy.

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

3. STROKE:STROKE:STROKE: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):STROKE BORE RATIO (L/D):STROKE BORE RATIO (L/D):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:SWEPT VOLUME:SWEPT VOLUME:SWEPT VOLUME: It is a volume displaced by one stroke of the piston.

6. COMPRESSION RATIO:COMPRESSION RATIO:COMPRESSION RATIO: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:CLEARANCE VOLUME:CLEARANCE VOLUME:CLEARANCE VOLUME: Total cylinder volume-swept volume.

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

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

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

as indicated horse power.

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

brake horse power.

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

known as brake horse power.

13. MECHANICAL EFFICIENCY OF IC ENGINE:MECHANICAL EFFICIENCY OF IC ENGINE:MECHANICAL EFFICIENCY OF IC ENGINE: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 EFFITHERMAL EFFITHERMAL EFFITHERMAL EFFICIENCY:CIENCY:CIENCY:CIENCY: It determines how efficiently fuel is utilized in the engine.

15. INDICATED THERMAL EFFICIENCY:INDICATED THERMAL EFFICIENCY:INDICATED THERMAL EFFICIENCY: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 BRAKE BRAKE BRAKE THERMAL EFFICIENCY:THERMAL EFFICIENCY:THERMAL EFFICIENCY: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:CRANK THROW:CRANK THROW: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:IDLE RPM:IDLE RPM:IDLE RPM: Revolution per minute at no load and no acceleration.

19. MAXIMUM RPM:MAXIMUM RPM:MAXIMUM RPM: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.

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

a) 1 inch = 1000 thou = 25 mm.

b) 1 mm = 40 thou

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

remains 1.9 to 2.1 mm.

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

case breather.

24. LIVE HYDRAULIC: LIVE HYDRAULIC: LIVE HYDRAULIC: 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:TRACTION:TRACTION:TRACTION: Force developed by wheels in the direction of motion.

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

27. RPM:RPM:RPM:RPM: Revolution per minute.

28. VTU:VTU:VTU:VTU: Vary touch unit.

29. HSU:HSU:HSU:HSU: Hydro static steering unit.

30. CRDI:CRDI:CRDI:CRDI: Common rail direct injection.

31. EGR:EGR:EGR:EGR: Exhaust gas recirculation.

32. TAPPET CLEARANCE:TAPPET CLEARANCE:TAPPET CLEARANCE:TAPPET CLEARANCE:

a)a)a)a) Exhaust: Exhaust: Exhaust: Exhaust: 0.4 mm

b)b)b)b) Inlet:Inlet:Inlet:Inlet: 0.3 mm

WORKING OF FOUR WORKING OF FOUR WORKING OF FOUR WORKING OF FOUR STROKE DIESEL ENGINESTROKE DIESEL ENGINESTROKE DIESEL ENGINESTROKE 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:The four strokes of piston are:The four strokes of piston are:The four strokes of piston are:

1. SUCTION STROKESUCTION STROKESUCTION STROKESUCTION 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 STROKECOMPRESSION STROKECOMPRESSION STROKECOMPRESSION 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 STROKEPOWER STROKEPOWER STROKEPOWER 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 EXHAUST EXHAUST EXHAUST STROKE:STROKE:STROKE: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.

MAIN PARTS OF IC ENGINE AND MATERIAL USEDMAIN PARTS OF IC ENGINE AND MATERIAL USEDMAIN PARTS OF IC ENGINE AND MATERIAL USEDMAIN 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.

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

ENGINE PERFORMANCEENGINE PERFORMANCEENGINE PERFORMANCEENGINE PERFORMANCE ::::

INTRODUCTIONINTRODUCTIONINTRODUCTIONINTRODUCTION: 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. WORKWORKWORKWORK: 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. ENERGYENERGYENERGYENERGY: Energy is the ability or capacity to do work. When the work is done on object, energy is stored in that object. POWER:POWER:POWER: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 POWERHORSE POWERHORSE POWERHORSE POWER: A horse power is the power of horse, or a measure of the rate at which horse can work. TORQUE:TORQUE:TORQUE: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 RATIOCOMPRESSION RATIOCOMPRESSION RATIOCOMPRESSION 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 POWERSAE HORSE POWERSAE HORSE POWERSAE 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 = D2N 2.5 D = diameter of cylinder in inch N = number of cylinders

FUEL SYSTEM IN DIESEL ENGINEFUEL SYSTEM IN DIESEL ENGINEFUEL SYSTEM IN DIESEL ENGINEFUEL 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:MAIN COMPONENT OF FUEL SYSTEM:MAIN COMPONENT OF FUEL SYSTEM:MAIN COMPONENT OF FUEL SYSTEM:

1. Fuel feed pump 2. Fuel filter 3. 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.

ENGINE COOLING:ENGINE COOLING:ENGINE COOLING: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:Method of cooling:Method of cooling:Method of cooling:

(1) Air cooling (2) Water cooling

1) WaterWaterWaterWater coolingcoolingcoolingcooling: 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 coolingAir coolingAir coolingAir cooling: In this method of cooling, the heat is decreased directly to the air after being conducted through the cylinder wall.

Main component of coolingMain component of coolingMain component of coolingMain component of cooling:

1) RadiatorRadiatorRadiatorRadiator: The radiator is the flat type with the core and water tanks combined in one integral unit. It is enclosed with the grill and fan housing which are removable for cleaning.

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

3) ThermostatThermostatThermostatThermostat: 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 engine part during the different operating condition.

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

4) Water pumpWater pumpWater pumpWater 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 jacketWater jacketWater jacketWater 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 capRadiator pressure capRadiator pressure capRadiator 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) CoolinCoolinCoolinCooling Fang Fang Fang Fan: Cooling fan sucks in fresh cool air through the radiator, thus cooling the hot water.

Process of engine assembly in plantProcess of engine assembly in plantProcess of engine assembly in plantProcess of engine assembly in plant

Crankcase washing

Oil Pump & Suction tube fitment

Cylinder head assembly & engine belt pulley fitment

Alternator & valve cover fitment

Oil filter & fuel filter fitment

Process of engine assembly in plantProcess of engine assembly in plantProcess of engine assembly in plantProcess of engine assembly in plant::::

Crankcase loading & plugs fitment Crankshaft assembly

Camshaft & timing gear fitment

Piston & connecting rod fitment

Flywheel & oil pan fitment

Rocker arm assembly, push rod

fitment

Water pump, side cover & Thermostat

fitment

Inlet & exhaust manifold fitment

Breather assembly & starter motor

fitment Engine testing

Dispatch

Page

19

Crankshaft assembly

Camshaft & timing gear fitment

Rocker arm assembly, push rod

Water pump, side cover & Thermostat

Engine testing

ENGINE TROUBLE AND REMEDY :ENGINE TROUBLE AND REMEDY :ENGINE TROUBLE AND REMEDY :ENGINE TROUBLE AND REMEDY :

Probable causesProbable causesProbable causesProbable causes RemedyRemedyRemedyRemedy

Fuel line clogged. Flush and blow out with compressed air.

Air in fuel system. Remove air with help of feed pump. Fuel filters clogged. Wash coarse filter element. Change

fine filter element. Incorrect injection timing. Adjust injection timing Engine sluggish. Check injectors, rectify spray.

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

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

Injector needle stuck or nozzle holes clogged

Wash nozzles, clean out holes (use 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 adjusted Valve stuck Remove cylinder head and valve

decarbonizes Fuel filter clogged Wash coarse filter element or change

fine filter element Fuel line clogged Flush and blow out Air cleaner clogged Wash out and refill with clean oil Cylinders, piston and pins worn Replace Engine overload Reduce load Engine cold Warm up Lack of compression Adjust valve clearance Crank case oil level high Check drain to dipstick upper mark Piston rings worn or stuck, cylinders or piston worn

Replace or wash rings, if necessary replace cylinders and piston

Trouble: Knocking noise :Trouble: Knocking noise :Trouble: Knocking noise :Trouble: Knocking noise :

Probable cause Probable cause Probable cause Probable cause RemedyRemedyRemedyRemedy Injection too early Check and set time Valve clearance large Adjust Valve striking piston Investigate cause and correct Piston slap(wall hard throughout cylinder, disappears when throttling up)

Cylinder and piston worn, replace on earliest opportunity

Pounding from excessive crankshaft bearing clearance

Regrind journals, fit replacements shells

Trouble: Engine overheatsTrouble: Engine overheatsTrouble: Engine overheatsTrouble: Engine overheats ::::

Probable causeProbable causeProbable causeProbable cause RemedyRemedyRemedyRemedy Dirt on cooling fins Stop engine and allow cooling off,

remove dirt Fan screen clogged Clean Fan belt worn or broken Replace Undue use of fan throttle plates Remove throttle plate Engine overload Reduce load

Trouble: Engine racing awayTrouble: Engine racing awayTrouble: Engine racing awayTrouble: Engine racing away ::::

Probable causeProbable causeProbable causeProbable cause RemedyRemedyRemedyRemedy Air cleaner oil bowel overfilled Remove bowl and empty excess Injection pump faulty Replace pump and have it repaired

DECODIFICATION of Engine Model :DECODIFICATION of Engine Model :DECODIFICATION of Engine Model :DECODIFICATION of Engine Model :

Ø Simpson Engine S-325 • S - Simpson Engine • 3 - Three Cylinder • 25 - 25 X 100 cc

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

Trouble: Ammeter needle dancingTrouble: Ammeter needle dancingTrouble: Ammeter needle dancingTrouble: Ammeter needle dancing::::

Probable causesProbable causesProbable causesProbable causes RemedyRemedyRemedyRemedy Fault in alternator to battery circuit Find fault and correct Field coil open or short circuited Have coil replaced Voltage regulator fault Correct fault

Probable causes Probable causes Probable causes Probable causes RemedyRemedyRemedyRemedy Rectifier faulty Replace alternator

Trouble: Alternator noisyTrouble: Alternator noisyTrouble: Alternator noisyTrouble: Alternator noisy::::

Probable causes Probable causes Probable causes Probable causes RemedyRemedyRemedyRemedy Pulley loose Tighten pulley nut Ball bearing worn(excessive play or damaged rolling contact surface)

Have bearing replaced

Trouble: Starter will not run when switched onTrouble: Starter will not run when switched onTrouble: Starter will not run when switched onTrouble: Starter will not run when switched on::::

Trouble: Starter will not stop after engineTrouble: Starter will not stop after engineTrouble: Starter will not stop after engineTrouble: Starter will not stop after engine ::::

Probable causes Probable causes Probable causes Probable causes RemedyRemedyRemedyRemedy Solenoid contacts stuck closed Stop engine and immediately open

earth switch (or disconnect wire from battery terminals) correct fault

Trouble: STrouble: STrouble: STrouble: Starter fails to crank enginetarter fails to crank enginetarter fails to crank enginetarter fails to crank engine ::::

Probable causes Probable causes Probable causes Probable causes RemedyRemedyRemedyRemedy Engine at fault Find fault and correct Battery low Charge the battery Commutator or brushes dirty Clean thoroughly Poor connection in starter circuit Check and tighten Solenoid contacts burnt Clean

Probable causesProbable causesProbable causesProbable causes RemedyRemedyRemedyRemedy Heavily oxidized battery wire terminals

Clean

BRAKING SYSTEMBRAKING SYSTEMBRAKING SYSTEMBRAKING 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:FUNCIONS OF BRAKE:FUNCIONS OF BRAKE: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.

TYTYTYTYPES OF BRAKES:PES OF BRAKES:PES OF BRAKES:PES OF BRAKES:

1) Mechanical brake

2) Hydraulic brake

3) Disk brake

Mechanical brake: Mechanical brake: Mechanical 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 brakeImportant parts in mechanical brakeImportant parts in mechanical brakeImportant parts in mechanical brake

1) Brake paddle

2) Brake shoe

3) Brake shoe lining

4) Brake drum

5) Brake paddle

HydrHydrHydrHydraulic brakeaulic brakeaulic brakeaulic 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 brakeDisk brakeDisk brakeDisk 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.

http://en.wikipedia.org/wiki/Brake

http://en.wikipedia.org/wiki/Brake_fluid

http://en.wikipedia.org/wiki/Ethylene_glycol

http://en.wikipedia.org/wiki/Disk_brake#Brake_pads

http://en.wikipedia.org/wiki/Disk_brake#Brake_disc

http://en.wikipedia.org/wiki/Disk_brake#Calipers

http://en.wikipedia.org/wiki/Cast_iron

http://en.wikipedia.org/wiki/Reinforced_carbon%E2%80%93carbon

http://en.wikipedia.org/wiki/Ceramic_matrix_composite

http://en.wikipedia.org/wiki/Axle

http://en.wikipedia.org/wiki/Hydraulics

http://en.wikipedia.org/wiki/Pneumatics

http://en.wikipedia.org/wiki/Electromagnet

http://en.wikipedia.org/wiki/Friction

http://en.wikipedia.org/wiki/Brake_fade

LUBRICATIONLUBRICATIONLUBRICATIONLUBRICATION ::::

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.

PropertiesPropertiesPropertiesProperties of lubricants:of lubricants:of lubricants:of lubricants:

1) Viscosity

2) Flash points

3) Fire point

4) Cloud point

Ø ViscosityViscosityViscosityViscosity: Viscosity is a measure of the resistance to flow or the internal friction of

oil.

Ø Flash pointsFlash pointsFlash pointsFlash 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.

Ø Fire pointFire pointFire pointFire 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.

Ø Cloud pointCloud pointCloud pointCloud 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.

TYPE OF LUBRICANTSTYPE OF LUBRICANTSTYPE OF LUBRICANTSTYPE OF LUBRICANTS::::

There are three types of lubricants:

1) Solid: Graphite, mica, soap stone, or steatite.

2) Semi solid: Grease

3) Liquid: Mineral oil, vegetable oil, animal oil etc.

LUBRICATION SYSTEM FAULTSLUBRICATION SYSTEM FAULTSLUBRICATION SYSTEM FAULTSLUBRICATION SYSTEM FAULTS :::: Trouble: Low oil pressureTrouble: Low oil pressureTrouble: Low oil pressureTrouble: Low oil pressure ::::

Probable causeProbable causeProbable causeProbable cause RemedyRemedyRemedyRemedy Oil 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 replacements

shells Trouble: Excessive oil consumptionTrouble: Excessive oil consumptionTrouble: Excessive oil consumptionTrouble: Excessive oil consumption ::::

Probable causeProbable causeProbable causeProbable cause RemedyRemedyRemedyRemedy Piston rings worn out or stuck Replace Piston rings side clearance large Replace or piston if necessary Large intake valve stem clearance in guide

Replace worn parts

TRANSMISSIONTRANSMISSIONTRANSMISSIONTRANSMISSION::::

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:TYPE OF GEAR BOXES:TYPE OF GEAR BOXES:TYPE OF GEAR BOXES:

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

Ø Sliding mesh gear box: In this type of gear box one moving gear is pulled out and

pushed to mesh another gear.

Ø 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.

Ø 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.

PARTS OF GEAR BOX AND THEIR FUNCTIONSPARTS OF GEAR BOX AND THEIR FUNCTIONSPARTS OF GEAR BOX AND THEIR FUNCTIONSPARTS OF GEAR BOX AND THEIR FUNCTIONS: : : : Input shaft: Input shaft: Input shaft: Input shaft: It transmits power from clutch plate to gear box Lay shaft: Lay shaft: Lay shaft: 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:Intermediate shaft:Intermediate shaft:Intermediate shaft: Take power from lay shaft gears, in this shaft, gears remains sliding. Output shaft:Output shaft:Output shaft:Output shaft: Take power from immediate shaft and transmit to the tail pinion. Idler cluster:Idler cluster:Idler cluster:Idler cluster: It gives reverse motion. Internal gear:Internal gear:Internal gear:Internal gear: It remains fixed on gear box housing and support the motion of planetary gear. Planetary assembly:Planetary assembly:Planetary assembly:Planetary assembly: It reduces the speed of working at heavy loads. HighHighHighHigh----low sleeve:low sleeve:low sleeve:low sleeve: It connects the output shaft to intermediate shaft and planetary assembly for high and low speed resp. Gear shifting lever: Gear shifting lever: Gear shifting lever: Gear shifting lever: Shift the gears

Locking wire: Locking wire: Locking wire: Locking wire: Lock the fork on shifter fork.

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

CLUTCHCLUTCHCLUTCHCLUTCH ::::

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.

There are following types of clutch :

1) Single plate clutch:Single plate clutch:Single plate clutch: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 parts

i) Flywheel

ii) Clutch plate

iii) Pressure plate

iv) Clutch spring

v) Clutch release bearing

vi) Clutch fork

vii) Clutch fork ball

2) MultiMultiMultiMulti----plate clutchplate clutchplate clutchplate 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 ASSEMBLYCLUTCH ASSEMBLYCLUTCH ASSEMBLYCLUTCH ASSEMBLY::::

There are following parts in clutch assembly

1) Clutch lining

2) Cushion spring

3) Torsion spring

4) Rivet

5) Hub flange

5 5 5 5 S FORMULAS:S FORMULAS:S FORMULAS:S FORMULAS:----

1. Seiri 1. Seiri 1. Seiri 1. Seiri

2. Seiton 2. Seiton 2. Seiton 2. Seiton

3. Seiso3. Seiso3. Seiso3. Seiso

4. Seiketsu 4. Seiketsu 4. Seiketsu 4. Seiketsu

5. Shitsuke 5. Shitsuke 5. Shitsuke 5. Shitsuke

S. No. JAPANESE WORD

MEANING

1s SEIRI Sorting out, clearing, segregation, proper selection and remove the waste

2s SEITON Systematic arrangement, keeping things at proper place. A place for 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 the rules.

Procedure for Tractor final AProcedure for Tractor final AProcedure for Tractor final AProcedure for Tractor final Assemblyssemblyssemblyssemblyssemblyssemblyssemblyssembly::::

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32

PRACTICAL WORK DURING TRAININGPRACTICAL WORK DURING TRAININGPRACTICAL WORK DURING TRAININGPRACTICAL WORK DURING TRAINING

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

Ø Time Study:Time Study:Time Study: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.

Ø Average Cycle TimeAverage Cycle TimeAverage Cycle TimeAverage Cycle Time::::

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

one cycle of an operation.

Part 1Part 1Part 1Part 1–––– Differential Time StudyDifferential Time StudyDifferential Time StudyDifferential Time Study

Ø Function of differential:Function of differential:Function of differential: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.

Ø Various parts Various parts Various parts Various parts used in differential assembly areused in differential assembly areused in differential assembly areused in differential assembly are::::----

� Trumpet

� Spur ,helical gears

� Break

� Gasket

� Cage

Differential Assembly Loop:Differential Assembly Loop:Differential Assembly Loop:Differential Assembly Loop:

Testing Done at Differential AssemblyTesting Done at Differential AssemblyTesting Done at Differential AssemblyTesting Done at Differential Assembly

v Pattern or %age Contact Test:

%age contact required is 60%

v Pre-Loading Test:

Cage assembly bearing

v Backlash Testing: .2 -

Dropping the housing on

trolley

B.P Shaft fitment (crown

gear)

Punching Chasis

Bull gear placing

Trumpet Fitment

Trumpet & bull gear Fitment

Differential Assembly Loop:Differential Assembly Loop:Differential Assembly Loop:Differential Assembly Loop:

Testing Done at Differential AssemblyTesting Done at Differential AssemblyTesting Done at Differential AssemblyTesting Done at Differential Assembly ::::

Pattern or %age Contact Test:

%age contact required is 60% - 70%

Cage assembly bearing – 12 kg T.P. Shaft – 6 kg

- .3 mm

B.P Shaft fitment (crown

gear)

P.T.O Shaft fitment

OIB drum fitment on both sides

Crown Gear preloading

checkPinion FitmentPunching

Chasis No.

Trumpet & bull gear Fitment

P.T.O Shifter Fitment

Brake Lever fitment

Suction pipe fitment

Lifted by overhead

crane

Page

34

OIB drum fitment on both sides

Crown Gear preloading

check

Brake Lever fitment

Suction pipe fitment

Total Cycle Time:Total Cycle Time:Total Cycle Time:Total Cycle Time:

Total cycle time taken by the process at differential loop = 637 sec637 sec637 sec637 sec or 10.61 minutes10.61 minutes10.61 minutes10.61 minutes

RecommendationRecommendationRecommendationRecommendations:s:s:s:

v Dial gauge place needs to be changed.

v More workers are required.

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

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

v Mismanagement among the workers.

Part 2 Part 2 Part 2 Part 2 –––– Gear Box Time StudyGear Box Time StudyGear Box Time StudyGear Box Time Study

Ø Function of a Gear Box:Function of a Gear Box:Function of a Gear Box:Function of a Gear Box:

As per application/condition, different speeds and torque combination are required which

can be achieved by a GEAR BOX.

Ø Various parts of a Gear box:Various parts of a Gear box:Various parts of a Gear box:Various parts of a Gear box:

v Gear Box Housing

v Cover Plates

v High & Low Gears

v Shifter Rod & fork

v Input , Intermediate and Output Shafts

v Idler Cluster

v Planetary Assembly

v Locking Wire

Ø Total Cycle Time:Total Cycle Time:Total Cycle Time:Total Cycle Time:

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

single unit= 448.25448.25448.25448.25 secondssecondssecondsseconds or 7.477.477.477.47 minutes.minutes.minutes.minutes.

Gear Box Assembly loop:Gear Box Assembly loop:Gear Box Assembly loop:Gear Box Assembly loop:

Recommendations:Recommendations:Recommendations:Recommendations:

v Mismanagement among workers.

v Mandrel tools are not placed at right place

v More involvement of man then machine.

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

Gearbox housing on trolley

Cover plate fitmentBottom plate fitment

C.A. guide & Bell housing fitment accelerator fitment

Mismanagement among workers.

Mandrel tools are not placed at right place

More involvement of man then machine.

Torquing of nuts should be divided at different sub stations.

Lay Shaft fitment Intermediate Shaft fitment

Shifter Rod & fork fitmentCover plate fitment

Steering & accelerator fitment

Lay & Intermediate Shaft plate fitment

Page

37

High Low gear fitment

Input shaft fitment

Lifted by overhead crane

BIBLIOGRAPHYBIBLIOGRAPHYBIBLIOGRAPHYBIBLIOGRAPHY

1.1.1.1. www.sonalika .comwww.sonalika .comwww.sonalika .comwww.sonalika .com

2.2.2.2. Search EngineSearch EngineSearch EngineSearch Enginessss (Google an(Google an(Google an(Google andddd Yahoo)Yahoo)Yahoo)Yahoo)

3.3.3.3. Sonalika Library material.Sonalika Library material.Sonalika Library material.Sonalika Library material.

4.4.4.4. “ “ “ “ I. C. Engines” book by V. GanesI. C. Engines” book by V. GanesI. C. Engines” book by V. GanesI. C. Engines” book by V. Ganesanananan

5.5.5.5. “ Production Management” book“ Production Management” book“ Production Management” book“ Production Management” bookssss

THANK YOUTHANK YOUTHANK YOUTHANK YOU

rp project report sonalika

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