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ACKNOW
ACKNOWLEDGE
LEDGEMENT
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.

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Rupinderpal Singh Aulakh

Aulakh

DECLARATION

I, Rupinder pal Singh

Singh Aulakh , bearing Roll no.. 09109073 , Mechanical Engineering
Engineering
student (Final
Final Year)
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.

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Signature of Student

Title

Page no.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

Company profile
Introduction to Tractors
Basic Terminologies used
Working of an Engine
Main Parts of an Engine
Engine Performance
Fuel System
Engine Cooling
Process of Engine Assembly
Engine Trouble and Remedy
Decodification
Electrical Trouble and Remedies
Braking System
Lubrication
Transmission
5S Formula
Procedure of Final Assembly
Practical Work During Training
Bibliography

5-6
7-9
10-12
13
14
15
16
17-18
19
20-21
22
22-23
24-25
26-27
28-30
31
32
33-37
38
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Serial no.

CONTENT

COMPANY PROFILE
We 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 Groups flagship company International Tractors Ltd is one of the
largest tractor manufacturing companies in India manufacturing tractors in the range of 2090Hp.

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. Ploughs,

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Harrows, Rotavators, Trolleys, Crop Reapers, Potato Planters.

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.

Started in house manufacturing of engines for tractor application.

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2001

INTRODUCTION TO 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 TRACTORS
TRACTORS:

We can classify tractors according to the following scale:

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

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

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

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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 TRACTOR

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

1. Power Unit:
Unit: Engine and all accessories necessary for its operation such as ignition, fuel
supply, cooling, lubrication, governing , starting and lightning system.
2. Transmission System:
System: Clutch, gear box, differential, drive mechanism, belt pulley,
power take off, power lift and control.
3. Chassis:
Chassis: Frame, wheel and steering mechanism. It does not have body.

BASIC 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
12. Steering box

13. Diesel tank

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11. Gear lever

BASIC TERMINOLOGIES USED:

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

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10

as indicated horse power.

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:
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

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11

gives its maximum power.

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

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b) Inlet: 0.3 mm

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:
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:
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:
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.

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13

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.

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.

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

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18. Governor: Cast iron.

14

17. Gaskets: Copper and asbestos.

ENGINE PERFORMANCE :
INTRODUCTION:
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:
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 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:
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:
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

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SAE Horse power = D2N

2.5
D = diameter of cylinder in inch
N = number of cylinders

15

SAE HORSE POWER:

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.

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 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.

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16

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:
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:
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:
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:

cooling
1) Radiator:
Radiator 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.

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

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2) Fan and fan belt:

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.

Valve open start = 70*-80*C

Full open = 100*-110*C
4) Water pump:
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:
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:
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.

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18

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

Process of engine assembly in plant

plant::

Crankcase washing

Crankcase loading &

plugs fitment

Crankshaft assembly

Oil Pump & Suction

tube fitment

Piston & connecting

rod fitment

Camshaft & timing

gear fitment

Cylinder head
assembly & engine
belt pulley fitment

Flywheel & oil pan

fitment

Rocker arm
assembly, push rod
fitment

Alternator & valve

cover fitment

Inlet & exhaust

manifold fitment

Water pump, side

cover & Thermostat
fitment

Oil filter & fuel filter

fitment

Breather assembly &

starter motor
fitment

Engine testing

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19

Dispatch

ENGINE TROUBLE AND REMEDY :

Probable causes

Remedy

Fuel line clogged.

Flush and blow out with compressed

air.
Remove air with help of feed pump.
Wash coarse filter element. Change
fine filter element.
Adjust injection timing
Check injectors, rectify spray.

Air in fuel system.

Fuel filters clogged.
Incorrect injection timing.
Engine sluggish.

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

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Remove air, prime with clean settled

fuel
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 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 Replace or wash rings, if necessary
piston worn
replace cylinders and piston

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Air or water in fuel

Trouble: Knocking noise :

Probable cause
Injection too early
Valve clearance large
Valve striking piston
Piston slap(wall hard throughout
cylinder, disappears when throttling
up)
Pounding from excessive crankshaft
bearing clearance

Remedy
Check and set time
Adjust
Investigate cause and correct
Cylinder and piston worn, replace on
earliest opportunity
Regrind journals, fit replacements
shells

Trouble: Engine overheats :

Probable cause
Dirt on cooling fins
Fan screen clogged
Fan belt worn or broken
Undue use of fan throttle plates
Engine overload

Remedy
Stop engine and allow cooling off,
remove dirt
Clean
Replace
Remove throttle plate
Reduce load

Trouble: Engine racing away :

21

Remedy
Remove bowl and empty excess
Replace pump and have it repaired

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Probable cause
Air cleaner oil bowel overfilled
Injection pump faulty

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:remedies:Trouble: Alternator (low or no charge) :

Probable causes
Fault in alternator to battery circuit
Field coil open or short circuited
Voltage regulator fault

Remedy
Find fault and correct
Have coil replaced
Correct fault

Remedy
Replace alternator

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Probable causes
Rectifier faulty

22

Trouble: Ammeter needle dancing:

dancing:

Trouble: Alternator noisy:

noisy:
Probable causes
Pulley loose
Ball bearing worn(excessive play or
damaged rolling contact surface)

Remedy
Tighten pulley nut
Have bearing replaced

Trouble: Starter will not run when switched on:

on:
Probable causes
Heavily
oxidized
terminals

battery

wire

Remedy
Clean

Trouble: Starter will not stop after engine :

Probable causes
Solenoid contacts stuck closed

Remedy
Stop engine and immediately open
earth switch (or disconnect wire from
battery terminals) correct fault

Trouble: Starter
Starter fails to crank engine :

23

Remedy
Find fault and correct
Charge the battery
Clean thoroughly
Check and tighten
Clean

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Probable causes
Engine at fault
Battery low
Commutator or brushes dirty
Poor connection in starter circuit
Solenoid contacts burnt

BRAKING SYSTEM:
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
TYPES OF BRAKES:
1) Mechanical brake
2) Hydraulic brake
3) 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 brake
1) Brake paddle

4) Brake drum
5) Brake paddle

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3) Brake shoe lining

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2) Brake shoe

Hydraulic
Hydraulic brake:
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:
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 carboncarbon 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

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25

as brake fade.

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) Viscosity
2) Flash points
3) Fire point
4) Cloud point
Viscosity:
Viscosity Viscosity is a measure of the resistance to flow or the internal friction of
oil.
Flash points:
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:
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:
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

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26

appear cloudily. The temperature at which this take place is called cloud point.

TYPE OF LUBRICANTS:
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 FAULTS :
Trouble: Low oil pressure :
Probable cause
Oil pressure gauge faulty
Oil pump intake strainer clogged
Oil pressure relief valve clogged
Unauthorized grade of engine oil
Crank shaft bearing worn

Remedy
Check gauge, replace if necessary.
Look for oil leaks, stop if any.
Wash
Wash
Change to authorized oil
Required journals fit replacements
shells

Trouble: Excessive oil consumption :

27

Remedy
Replace
Replace or piston if necessary
Replace worn parts

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Probable cause
Piston rings worn out or stuck
Piston rings side clearance large
Large intake valve stem clearance in
guide

TRANSMISSION:
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,

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28

wear/breakage & hard gear shifting problems.

PARTS OF GEAR BOX AND THEIR FUNCTIONS:

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.
HighHigh-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 :

located between engine and gearbox.

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other components. The main motive of clutch is to make gearing easily and quick. It is

29

The clutch is fitted in engine to connect and disconnect power stream in gear box and

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 parts
i) Flywheel
ii) Clutch plate
iii) Pressure plate
iv) Clutch spring
v) Clutch release bearing
vi) Clutch fork
vii) Clutch fork ball
2) MultiMulti-plate clutch:
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:
ASSEMBLY:
There are following parts in clutch assembly
1) Clutch lining
2) Cushion spring

5) Hub flange

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4) Rivet

30

3) Torsion spring

5 S FORMULAS:FORMULAS:1. Seiri
2. Seiton
3. Seiso
4. Seiketsu
5. Shitsuke

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.

31

1s

JAPANESE MEANING
WORD
SEIRI
Sorting out, clearing, segregation, proper selection and remove the
waste

Page

S. No.

Page

32

Procedure for Tractor final Assembly

ssembly::
Assembly

PRACTICAL WORK DURING TRAINING

Project:
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:
Time:
Average Cycle Time is defined as the mean of the different durations taken to complete
one cycle of an operation.

Part 1
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:
are:
Trumpet

Spur ,helical gears

Cage

Page

Gasket

33

Break

Differential Assembly Loop:

Dropping the
housing on
trolley

B.P Shaft
fitment (crown
gear)

P.T.O Shaft
fitment

OIB drum
fitment on
both sides

Bull gear
placing

Punching
Chasis No.

Pinion Fitment

Crown Gear
preloading
check

Trumpet
Fitment

Trumpet & bull

gear Fitment

P.T.O Shifter
Fitment

Brake Lever
fitment

Lifted by
overhead
crane

Suction pipe
fitment

Testing Done at Differential Assembly :

v Pattern or %age Contact Test:
%age contact required is 60% - 70%
v Pre-Loading Test:

.2 - .3 mm

Page

v Backlash Testing:

34

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

Total Cycle Time:

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

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35

v Mismanagement among the workers.

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:
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

Total Cycle Time:

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

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36

single unit= 448.25 seconds or 7.47 minutes.

Gear Box Assembly loop:

Gearbox housing
on trolley

Lay Shaft fitment

Intermediate Shaft
fitment

High Low gear

fitment

Bottom plate
fitment

Cover plate fitment

Shifter Rod & fork

fitment

Input shaft fitment

C.A. guide & Bell

housing fitment

Steering &
accelerator fitment

Lay & Intermediate

Shaft plate fitment

Lifted by overhead
crane

Recommendations:
v Mismanagement among workers.
v Mandrel tools are not placed at right place
v More involvement of man then machine.

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37

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

BIBLIOGRAPHY

1. www.sonalika .com
2. Search Engines
Engines (Google and
and Yahoo)
3. Sonalika Library material.
4. I. C. Engines book by V. Ganesan
Ganesan

Page

38

5. Production Management books

books

Page

39

THANK YOU