NATIONAL INSTITUTE OF TECHNOLOGY

KURUKSHETRA
(Institute of National Importance)

Department of Mechanical Engineering

Report for Industrial Training
undergone at

MAHINDRA SWARAJ DIVISON

Plant 1,phase 4,mohali,Punjab-160055

From: 27-5-19 To: 12-7-19

Submitted by:
Name: Sumit Saini
Roll No.: 11610692
Branch: Mechanical Engineering
Batch: 2016-2020
 Contents
1. Acknowledgement
2. Introduction
3. Company Profile
 PTL`s birth
 Origin of SWARAJ
 SWARAJ in market
4.Light machine shop
5.Heavy machine shop
6.Heat Treatment Sho
7.Assembly Line
 Differential housing assembly
 Gear Box assembly
 Rear Cover assembly
 Engine Assembly
 Front Axle Assembly
 Final Assembly
8.QUALITY DEPARTMENT
9.PROJECT WORK
10.CONCLUSION
 ACKNOWLEDGEMENT:
Any endeavour cannot lead to success until and unless a proper
platform is provided for the same. This is the reason I find myself
very fortunate to have undergone industrial training of six weeks at
Mahindra swaraj division,mohali.
First of all I would like to thank Training and Placement Cell of NIT
Kurukshetra. I am very thankful to Mr. Bob Vashisth (Head of
dismounting line), Mr. Abhishek wadhawa(shift incharge) for their
valuable support and guidance.
I am extremely grateful to the all the supervisors and workers who
offered the valuable guidance, assistance, cooperation and
suggestions.
In the last I express my thanks to all, who directly or indirectly
encouraged me to work at shop floor and helped me to sharpen my
skills.

Sumit Saini
 Company Profile

PTL`S birth

Keeping in mind Punjab`s agrarian economy it was decided

by Punjab govt. To encourage the growth of industries, which
complement Punjab`s agriculture growth.
This task was entrusted to Punjab state industrial
development corporation(PSIDC), which has played a major role in
bringing Punjab to the threshold of industrial revolution.
With the dual objective of industrial and agricultural
growth,Punjab Tractors Limited was established on 27 june 1970.

Introduction:
Punjab Tractors Limited, a public limited company, is India's first
large—scale project based company with e totally indigenous
design, know—how and technology. Punjab State Industrial
Development Corporation {PSIDC},which was a major player,
prompted it; the government of India and financial institutes like
Punjab Financial Corporation {PFC} provided significant support. The
public subscribed the remainder.
The factory is located at s.a.s.nagar which is important township of
Punjab. A board of directors manages the company with the
secretary,industrial department,Punjab being the ex-offical
chairman. The vice-chairman and managing director manages the
day to day affairs.
Growth of PTL:
Punjab Tractors limited started with an annual tractors of 5000 units
and with an inventory of rs.3.7 crores. It went into commercial
production in the year 1974; its first production of 26.6 BHP tractors
was given the name SWARAJ-720, ever since the PTL has not look
back. In first 20 years of its existence its capacity has increased to
24000 tractors annually, which is a considerable achievement.
In all, SWARAJ provides a variety of products, which includes:
 Tractors
 Harvesting Combine
 Fork Lifters
 Agriculture Implements
 Automotive Castings
 Light Commercial Vehicles
 Shelter
 Engines
 Castings
 Rough
 Terrain
 Origin of SWARAJ
The word `SWARAJ` means Bondage from Freedom.
Since PTL was the first largest tractor project in India, moreover fully
based upon Indian technology. So `SWARAJ` was appropriately
choosen as its brand name.
SWARAJ GROUP sells its products under this brand name.

SWARAJ in Market
With more than 2 lacs tractors and harvesters combines operating in
Indian farms , SWARAJ is now a well established brand name in
Indian market and also a well recognized international name in
developing countries.
The products of SWARAJ are not only restricted to Indian
market , but they had entered into the international market.
SWARAJ tractors find an important place in developing countries like
Ghana , Tanzania , Zambia , Kenya , Sudan , Uganda , Indonesia ,
Mayamar etc.
They also send harvesting combines to South Korea having first A.C.
cabin hsrvesting combines in India.
They also send various machined parts to Japan worth millions of
dollars.
INDIAN TRACTOR MARTKET SALES SCENARIO

COMPANY WISE GROWTH PROJECTION

SWARAJ Tractors Division (Mohali)
SWARAJ Tractors divison is situated in phase IV,S.A.S. Nagar, a
important township some 5 kms from Chandigarh in Mohali,Punjab.
It was set up on may 27, 1970 with the dual objective of industrial
and agricultural growth.It was the first SWARAJ divison to set up.
This was INDIA`s first large scale project totally based upon
indigenous design and technology.
It manufactures different models of tractors i.e. of different HPs
,different other specifications
Presently around 250 tractors are produced in a single day of three
shifts.

RATED CAPACITY 65200 Tractors per year

EMPLOYEE STRENGTH Around 3000
ANNUAL TURNOVER Rs. 1300 crores apprx.
VARIOUS DEPARTMENT IN SWARAJ TACTORS
DIVISION
CONSTRUCTIONAL PARTS OF TRACTOR:
 LIGHT MACHINE SHOP
INTRODUCTION:

LMS is the largest section in the company. All transmission

components like Shafts and Gears used in tractors are manufactured
here. It has nearly 117 machines; facilities of this shop includes
equipment for blank operation, boring , drilling etc.

FUNCTION OF THE DEPARTMENT:

 Gear manufacturing
 Machining of Bull Gears
 Bevel Gears cutting of all rounds on power hacksaws
 Facing and Centering
 All type of grinding i.e. inner and outer gears both
 Hobbing and Broaching
 Gears shaving

TYPES OF MACHINES:

 Universal milling machine

 Internal grinding machine
 External grinding machine
 Bevel Gear generator
 Broaching machine
 Shaper machine
 Multipurpose CNC machine
 Hydraulic presses

MANUFACTURING OPERATIONS:

 Facing
 Undercutting
  Chamfering
 Finish turning
 Grooving
 Knurling
 Broaching
 Drilling
 Boring
 Grinding
 Hobbing
 Shaping

COMPONENTS MACHINED IN SHOP:

1. Bull Pinion Shaft(L&R)

2. Bull Pinion(L&R)
3. Gears
4. Idler Cluster
5. Input Shaft
6. Intermediate Shaft
7. Lay Shaft
8. Internal Gears
9. Bushes
10. Cage ass.
 HEAVY MACHINE SHOP
INTRODUCTION:

All heavy castings of tractors are machined in this shop with help of
variety of special machines(SPM).
Facilities of this shop includes general purpose turning, boring,
drilling and milling machines.
About 20 SPM and 30 GPM are installed in a covered area of about
47,000 sq.ft.

FUNCTIONS OF THE DEPARTMENT:

 Machining of heavy castings like differential housing ,gear box

housing , rear cover, trumpet housing etc.
 Machining of Steering housing
 Machining of some parts for SWARAJ mazda ltd.

TYPES OF MACHINES USED:

 Radial drilling machines

 Vertical and horizontal milling machines
 Hergebret machine
 Automated laths
 SPM(Special Purpose Machines)

COMPONENTS MACHINED IN THIS SHOP:

 Differential housing
 Gear box housing
 Rear cover
 Trumpet housing
 HEAT TREATMENT SHOP
INTRODUCTION:

In the automobile industry, all the gears and shafts must be

heat treated in order to impart desired strength to the
component as well as the increased life of the component.
The H.T. shop at SWARAJ is equipped with several gas
carbonizing furnaces, pit furnaces, quenching tanks as well as
various hardness testing machines and shot blast furnaces.

WHY?
 Improve mach inability
 Relieve internal stresses
 Improve mechanical properties such as ductility, strength,
hardness, toughness etc.
 Change in grain size
 Increase resistance to Heat and Corrosion

OPERATIONS PERFORMED IN H.T. SHOP:

 Carbonizing
 Quenching
 Tempering
 Hardness testing
 Shot blasting
 Penning
 ASSEMBLY LINE
In this shop, the different machined parts, housing and other
components which are finished or machined in other departments of
industry and other components which are purchased from the
vendors are assembled here. The different parts are assembled in
different shops and joined to each other. The heavy parts are lifted
by overhead chain rotating conveyor. It is supported from ceiling and
has a fixed path to travel which saves valuable floor space
Following are the main phases of assembly line:

DIFFERENTIAL HOUSING ASSEMBLY

Differential is the rear part of tractor chassis. The main function of
differential in tractor is to supply the power from gearbox to the
wheels, it also helps the tractor to turn with different speeds of
wheels.
First stage is tail pinion and crown wheel meshing and second stage
reduction in bull gear meshing with left and right B.P. shaft. It also
consists of the P.T.O. shaft (Power take off shaft), which is used to
run the threshers, pumps and other necessary with the help of pulley
attached on it.

Crown wheel and Tail pinion Sun and planet gear

Following are the main parts of differential housing:
 Crown wheel
 Tail pinion
 Cage assembly (With sun, planet gears and cross)
 P.T.O shaft
 B.P. shaft left
 B.P. shaft right
 Bull gear
 Bevel gear
 Bearings
 Bearing cones
 Brakes housing assembly (with disc etc.)
 Shims
 Gaskets
 Fasteners

ASSEMBLY OF DIFFERENTIAL CASING:

First of all differential casing is placed over trolley continuously
moving over metal conveyor belts. Then,cage assembly
containing sun gear, planet gears is placed inside it & as well as
crown wheel gear set & pinion gear . The splines of wheel gear
helps to rotate both left&right side B.P. Shafts via bull gear
attached some time after on main back end line. after that, we
move to attach brake housing assembly. Brake housing is
attached directly with gear that rotates bull gear.In this
housing,we fit first an actuator plate having rolling balls three
asbestos discs and between these three discs,two cast iron
sheem plate fitted.on braking, pressure wedge at actuator tries
to expand, giving balls ramp action &thus braking is achieved as
these plates pressed.the PTO shaft which extends from gear
box passes through this just below the differential gear.
GEAR BOX ASSEMBLY:
In these tractors the sliding mesh type gear box are used for
transmission of power at various speeds from engine to differential.
It is the main assembly between the engine and differential housing.

Following are the main components of Gear box:

 Input shaft assembly
 Output shaft assembly
 Lay shaft assembly
 Intermediate shaft assembly
 Actuator shaft assembly
 Gears
 Gear box housing
 Shifter rods
 Shifter forks
 Bearings
 Fasteners, gaskets and spacers
 Clutch actuator assembly

ASSEMBLY OF GEAR BOX:

First of all gear box is placed over the trolley which is continuously
moving with the help of the chain system. The idler gear is placed
with idler gear shaft in in gear box in their respective place. Then
the lay shaft is placed in its respective hole and tightened from
front with hexagonal nut. After this input shaft is placed from the
front side of the gear box housing. Its Z-19 is meshed with C.M. Z-
45 of lay shaft. Then the output shaft is placed into gear box
where one side is inserted into the input shaft hole. For dual
clutch models the intermediate shaft which is hollow, placed over
the input shaft and its Z-21 gear is meshed with Z-43 of connecting
shaft, which placed through the hollow lay shaft. The internal gear
assembly is tightened on the outside of gear box with output
shaft. The four selector rods are placed in the holes with spring
loaded ball. The gear selector forks are installed in to the groove
of sliding gears and then tightened to the gear shifter rods with
the help of bolts. The forth selector is meant for low and high
speed selection. This rod is connected to drive the shaft, which is
placed into the internal gear. Then cover bracket is placed over
the upper side of the gear box. The cover plate consists of steering
mechanism and high, low speed shifter assembly.
 The different views of gear box are:

The basic diagram of gearbox with attachment with the

differential is shown below:
 REAR COVER ASSEMBLY:
Rear cover assembly is used to cover the differential housing. It
contains lift controlled system, which is hydraulically operated.
Driver seat is fitted on the upper side of rear cover. The response
valve housing (R.V.) control valve, cylinder and other components
assembly fitted inner and outer side of rear cover assembly.

The main components in rear cover assembly are:

 Control valve assembly
 R.V. housing assembly
 Hydraulic cylinder and piston assembly with lift arm
 Operating sector assembly
 Sensor tube assembly
 Gaskets, bolts and nuts

ASSEMBLY OF REAR COVER PARTS:

First of all control sector assembly is attached with rear cover casing
through its housing bolts . After that, we fit coupler assembly inside
it & the springs of coupler are then tighted according to
requirement.Then we attach control valve assembly with coupler . it
also has a draft sensing tube attached with it which is useful for
preventing ploughing very deep when it effects tractor speed. Then
we fit Ram cylinder assembly consisting cylinder, ram arm as well as
ram shaft. To Ram shaft we attach lift arms. In case of wet braking
tractors the piping for wet braking also goes through this section
from control valve. then after reversing it, we attach response valve
assembly with it through which oil enters in Ram cylinder. response
valve has various valve sections having one response valve, a check
valve and a release valve. a knob is also attached on top to control
r.v. according to requirements.
After all this, it undergoes a hydraulic test to measure the required
capacity & then we send it to main back end line.

The top view of rear cover assembly:

ENGINE ASSEMBLY:
Engine is the most important part of tractor. This is the very part
which produces the power to run the tractor and other electronic
functions in the tractor. It is placed on the front side of tractor. In
it, the 4-stroke diesel engines are used.

Following are the main components of engine

assembly:
 Crank case
 Cam shaft
 Crank shaft
 Connecting rod
 Piston
 Cylinder
 Cylinder head
 Hydraulic pump
 Fuel injector pump
 Flywheel
 Gasket, bolts, nuts and other parts
 Oil filter
FRONT AXLE ASSEMBLY:
Front Axle carries the front end load of the tractor fully. It withstands
shocks while running on the field. Field is not a plain surface and is
totally uneven. Due to this property, axle beams are very sturdy in
nature.Front wheels steer the tractor in the left or right side
manually or hydraulically. For hydraulic, the front axle is connected
to rear cover by pipes.

Major components of front axle assembly:

 Front axle beam

 Hub

 Stub-axle
 Pivot pin
 Hydraulic cylinder
 Steering arms
Hub is the part of assembly that holds the wheel. It is fitted in stub
axle by hydraulic machine. This is then fitted to front beam axle.
There is a hole for putting pivot pin in front axle. It is a hole to put
hydraulic cylinder also. Hydraulic cylinders are absent in manual
steering. Left and right steering arms are put on lower side on both
sides. The steering arms are joined by a rod, called tie rod so that
both the wheels can turn in same side. In power steering, oil is given
by pump at engine to hydraulic cylinder by pipes. The flow is
channelized and controlled by steering wheel.
 Front wheel axle

Detailed hub and stub axle arrangement

Tie rod
FINAL ASSEMBLY (DISMOUNTING STAGE):
Before sending to pre-delivery inspection, the tractor goes through
final assembly. Here some important parts like fender, installing fuel
tank, electrical assembly, radiator assembly, and other parts.

The major parts are following:

 Fender
 Fuel tank
 Battery
  Radiator and other cooling system
 Bonnet, steering wheel and other parts
Before coming to final assembly the tractor is painted. Firstly driver
seat is attached and fenders are attached on both sides. Then fuel
tank is attached and dashboard is placed over fuel tank. Fuel cork is
inserted in tank to filter oil. For installing light lamps, speedometer
(analogue and digital), metre to check fuel. These all are connected
to battery and the battery is charged by alternator. The alternator is
rotated by belt going over pulley and is run by crank shaft. Battery is
earthed by connecting to chassis. Radiator is very important part
which circulates the water in engine to keep it cool. Radiator pipe is
installed to join radiator and water pump. No loss tank is installed to
avoid shortage of water. When temperature in engine rises above a
certain temperature, the valve is opened and water circulates in the
engine. Fan is installed on the front side for keeping the engine cool.
Further bonnet, steering wheel, tyres are attached.
Then the tractor is sent for Pre-Delivery Inspection.

Radiator
Fuel tank
 QUALITY DEPARTMENT
There are 5 quality assurances at Swaraj division in the quality
department which manage the overall product and service quality.

These are classified as follows:

SQA:

Supplier quality assurance.

It works with the quality of the material coming from the venders.

Here the vender’s service and his quality is assured and inspected.

RQA:

Receiver quality assurance.

Here quality of received product or material from the venders is

assured whether they are stored properly or how the defects are
coming in them in any case.

PQA:

Product quality assurance.

It is related to the quality of processes of product manufacturing.

MQA:

Machining quality assurance.

In the MQA the quality assurance of LMS and HMS is seen.

CQA:

Customer quality assurance.

In CQA tasks like checking and solving customer complaints are done.

Quality post inspections (QP)

There are 4 QP’s at the swaraj division plant 1 at the different stages
of the product manufacturing.

QP1: this comes before the all assembled chassis is sent to the paint
shop. A person inspects the chassis overall to see if any of the bolts
are loose or any of the holes are kept open before the paint job and
all this. After the chassis is marked pass at the QP1 it is headed to the
paint shop for paint job.
 (QUALITY POST-1)

QP2: this quality post is situated at the last station of the

dismounting line. Here the worker checks all the nut bolts whether
they are tight or not with a torque wrench. Also, the radiator caps
and any other parts like bonnet are inspected. At QP2 the tractor is
started for the first time and all the fluids are filled.

QP3: at this quality post the road and roller test of the tractor is
done.

Also, the testing of hydraulic lift takes place here. They check all the
functions of the lift mechanism correctly and then the product is
headed to the final inspection.
QP4: this is the final inspection of the product.

The various tasks done here are –

1. Ensure same make front and rear tyres

2. Ensure same make rear rims

3. Ensure correct engine and chassis no. on data plate.

4. Ensure all the defects mentioned on travel card are rectified.

5. Ensure absence of aesthetical defects (paint flow, paint

damage, dust in paint, shade variation, improper decal
application.)

6. Ensure proper pasting of stickers as per tractor model

7. Check leakage if any

8. Pasting final ok sticker on tractor

9. Tractor held up reason

10. Ensure tightening of radiator cap

11. Ensure touch up on tackle points

AUDITS-

There are various audits which are done here at Swaraj

division-
CTQ (critical to quality)-

In this checking of bolt or mountings that are if loose can cause

high amount of damage or harm to the product or even the
customer like the bolts of trumpet, engine and transmission.
They are very important for safety reasons also.

TORQUE AUDIT-

here checking whether the bolts are being tightened at the

given standard of torque or not.

Poka-yoke AUDIT-

Poka-yoke is Japanese word used for mistake proofing.

Its main function at the plant is reduce the mistakes done by

the operator or workers at the assembly line.

For example using same bearing for various different models so

as to reduce the mistake of fitting wrong size bearing is the
work of this system.

SOP AUDIT (standard operating procedure)-

In this how a fitment should be done and how the parts should
be handled and carried comes. For every part there are some
standards that how it should be carried to the assembly line
and how it should be fitted. The worker has to follow this
standard made for every product.

MILIPORE AUDIT-

In this the impurities in the oil are checked. The standard

bearable amount of impurities is 160mg in oil.

YARD AUDIT (yard PDI)- pre-delivery inspection.

After the tractor is passed from QP4 it is headed to the yard,

where yard PDI is done. Here any kind of leakage or other
defects are inspected, pictures are clicked of the seen defects
and RPH (repair per hundred tractors) and LPH (leak per
hundred)are studied.

And from the yard tractor is supplied to the dealers.

PROJECT WORK-

- MINIMIZING THE DEFECTS IN THE PAINT JOB-

I was given the task to analyse the defects occurring in the

paint job of the tractor and find the top occurring defect and
suggest a useful solution for minimizing it.

PROBLEM STATEMENT-

It is impossible to achieve zero defects in the whole painting

processes. The problems come from the 4M, which are men,
machines, methods and materials. Therefore, to improve the
process is by reducing the defects or problems as lower as
possible. The tasks are to study the method that use in the
process and propose a new method that can overcome the
defects or problems.

AIM AND OBJECTIVES-

To reduce the problems and defects that occur at painting

processes. In order to achieve the aim, the following objectives
are required
- To identify the defects that occurs in paint job and improving
the paint processes.

IDENTIFYING THE DEFECTS THAT OCCUR IN PAINT

JOB-

During my training period working for the project first of all I

had to identify all the defects related to the paint job that occur
in the company product.

So the paint related defects that can be seen mostly at the

quality post 4 are as follows-

PAINT FLOW-

It is the defect in which a flow of paint occurs on the surface.

This defect can occur when a excess of paint is sprayed on a
surface which maybe a round or vertical surface due to which
the excess paint starts to flow on the surface and create a
flowing appearance on the surface when it dries.
 (PAINT FLOW)

LESS PAINT-

This defect occurs when any area of the surface is not painted
properly.

Its cause can be that the defected area maybe hard to reach or
a blind spot that do not come under the eye of the painter. Also
there are some tackle points on the tractor chassis on which
less paint defect can be seen because at the tackle point the
paint cannot be applied properly.

(LESS PAINT AT TACKLE POINT)

ORANGE PEEL-
 The term orange peel refers to a bumpy coating surface that
resembles the surface of an orange. Orange peel normally is due to
poor flow-out and leveling of spray droplets, but occasionally is
caused by surface tension driven flow (sometimes called sinks and
bumps) in the oven. Orange peel rarely affects gloss, but the bumpy
surface really reduces the quality and finish of the paint job.

(ORANGE PEEL)

PAINT CHIP OFF-

In this defect the paint on the surface starts chipping off. It can be
very small but it can not be ignored because it can damage the whole
paint job. This defect occurs mainly because of poor paint job done
at the surface or maybe any kind of rusting or dusting on the surface.

PAINT DUST-

this defect occurs because the surface was not properly cleaned
before the painting process, the dust particle on the surface are
responsible for this defects as they create small edgy bumps on the
surface on a quite large scale so this defect damages the paint job.

(PAINT DUST)

PIN HOLES-

In this defect small holes takes place on the surface they are very
small in size but can be large in number. These can be caused by
moisture in the spray guns or unclean surfaces.

(pin hole defect)

PAINT SCRATCHES-

It can occur anywhere at the dismounting line where something can

strike the painted surface and scratch the painted surface it can be
overcame by using coverings for the body parts like used for the
fenders.

 So during my training period I collected the data of paint

defects occurring and being caught at the quality post 4 in the
month of June and start of July. I made a list of all the defects
that I caught at the QP4 and made a list of them. Out of which
the top occurring defects in this time period are as following-
Defect with part on which it No. of times occurrence during
occurred time period of one month.

1. Trailer hook paint flow 13

2. Silencer paint damage 8

3. Draw bar paint damage 12

4. Paint dust CRE plate 12

5. Fender edge paint damage 22

6. Battery cover paint dust 7

7. Levelling rod less paint 6

8. Tie rod paint flow 5

9. Battery cover paint flow 10

So here from the list of defects occurred in the month of June we can
see that the most occurring defects were the fender edge paint
damage, trailer hook paint flow and draw bar paint damage and
paint dust on CRE plate.

Solutions for the paint defects-

As we know that it is quite hard to get almost zero percent defects in

the paint job but still we can find ways to minimize the defects
occurring related to the painting processes.
Some solutions are:

I suggested some solutions at the plant which I hope are going to be

implemented or given attention in the upcoming time.

1. The spray guns should be in proper working condition.

2. The workers in paint shop should ensure the use of proper

amount of thinners and hardeners.

3. Temperature conditions should also be maintained in the

oven area.

4. For the defect of less paint if the workers can give a little bit
more attention at the rear side of chassis while
painting(without taking much time) in paint shop then we
can minimize the less paint and some other defects on parts
like trailer hook, angle brackets and rocker link which are
mostly seen at the QP-4 and the time taken to fix them is
more at the quality post as compared to if we already
correctly spray paint on them in the paint shop.

5. And for the fender edge paint damage, we should ensure the
proper cleaning of fenders before painting also the paint
booth, because most of the time the paint damage at the
edges was due to dusting and in some cases it was paint
flow, so we suggested our ideas to the paint shop and they
accepted them. Also for the better protection of the fender
 edges the coverings used for the fenders can be a little large
in size. Because they only cover the upper part of the fender
but if they also covers the edges it would be much better.

PROJECT WORK-

-Minimization of jamming of FCO valve rod-

i was given the task how to minimize the stickiness or jamming of
fuel cut off valve rod.

Problem Statement:
In case of tractors,its engine is stopped with help of fuel cut off valve
which is controlled by help of a rod connected to it & extended
towards operator position.
Sometimes, when we pull this rod it gets very sticky & jammed
abruptly , so therefore it took some time to off the engine and in
rare cases we are no longer be able to switch of the engine.
So, our task is how to overcome this problem.
I do received previous 6 month data about this problem, which is as
follow:-
Month & Year No. of tractors having this defect
per 1000 tractors
December 2018 42
January 2019 41
February 2019 39
March 2019 41
April 2019 41
May 2019 39

Aim & Objectives:

-To overcome the problem of fuel cut off valve rod
stickiness/jamming.
-to identify the reasons of jamming of fuel cut off valve rod & find
solutions to overcome this.
WHAT IS FUEL CUT OFF VALVE ?
It is a valve located inside fuel injector assembly, it oversees the flow
of fuel after fuel injector feed pump. When we pull it,it controls flow
of fuel & in extreme case block flow of fuel completely.
So, due to this reason, it is used to stop the engine in our vehicles.
In case of tractors, this fuel cut off valve is connected with a long rod
& this rod extends to near the operator seat in dashboard and this
enables operator to off the tractor engine smoothly and easily.

/IDENTIFYING REASONS FOR PROBLEM/

1) The material used for rod is very light weight,very less diameter
(5mm) ,but very long in length (apprx. 75-80cm). Due to
this,along with due to large clearance allowance for smooth
movement, with continuous jerks and vibrations ,it gets
somewhat bend & with this shortened length more force is
required.

2) Due to jerks it gets wrapped with other accessories , thus

preventing motion of rod.These accessories are as follow:-
 Throttle rod: Sometimes it gets trapped between
clearance of throttle rod & chasis casings due to jerks .

 Pipings: sometimes this FCOV rod gets wrapped up with

various piping arrangements such as for oil water
separator and power steering oil pipings which are for oil
input as well as for oil output and after trapping in
between them, it is very difficult to get free again and so
we feel excessive jamming.
  Wirings: various wiring arrangements such as all kinds of
dashboard wiring , it gets wrapped with FCOV rod and
therefore it becomes sticky.

3) A bracket is attached with dashboard which helps to maintain

fuel cut off rod in position and keeps it fitted in position near
operator. After a long time , friction between bracket and rod
increases greatly and results in jamming . But its extent is very
less.
SOME SOLUTIONS ARE:
I suggested various solutions by my own observations during
my training period , which my mentors said they would think
of,while applying implementations to this problem.
Some of these are as follow-
 To overcome this, instead of a rod , we can use a cable
wire as most of the problem is due to the wrapping and
 bending of rod and cable wires have no effect on of either
bending or wrapping.
 All of the piping cables must be completely below the
level of rod with some pre decided clearance.(as currently
there is not exactly specified position of these piping
cables, you would find these at different positions in
every tractors)
 For all of the wirings , we must attach them with atleast 1
or 2 brackets . This would help them to remain in at a
fixed position and they are very cheap in cost and also
thereafter these wirings would no longer be able to wrap
up with rod.
 We can also have an use of extra bracket to set the rod in
more guided, less freely position and also due to reduced
length it opposes wrapping.This may increase bracket
friction but as we know bracket friction comes into
picture only after a long time with very less extent. So,
this method is most suitable, as it comes with least cost
among all the methods discussed.
 CONCLUSION

My training was the most versatile experience , i ever been able to

have. I had the pleasure to do the work with most reputed company
in this field- PUNJAB TRACTORS LIMITED. I received a blend of
experience in this field.
Definitely , my training has given me a lot of exposure to undergo
various tasks , projects, jobs in manufacturing field as well as help me
a lot to understand about the company work environment , working
with teams and many more.
In the end , i would like to thanks all the persons who helped me
endorse various operations and helped me throughout my training
duration to enhance my experience.

SUMIT SAINI