Garav

1
ACKNOWLEGMENT
I attribute my Honours’ in showing my feelings of indebtedness and

thankful to Mr. B.S. Bhullar(Head of Training and Placement cell at Baba
Banda Singh Bahadur Engineering college,FatehGarh Sahib(Punjab), S. Hari
Singh (M.D.) and Mr. Rajiv Kaushal (Head of Training and accounts manager of
Preet tractors Industries Pvt. Ltd. )
I am extremely grateful to Er. Gurpreet Singh (Head of Assembly
Department), all the supervisors and workers who offered the valuable guidance,
assistance, cooperation, and suggestion.
In the last but not the least I express my thanks to all, who directly or indirectly
encourage me to work at shop floor and discussed with me the trick’s to achieve the
goal.
So I thanks to all mighty God who gave me chance to work with such nice
personalities.
GAURAVJIT SINGH
Mechanical Engineering
2
CONTENTS
S. No. Text Page No

1. Certificate -
2. Acknowledgement 1
3. Declaration 3
4. Company Profile 4
5. Quality Department 18
6. Differential 40
7. Brakes 47
8. Rear Axle 51
9. Gear Box Assembly 57
10. Rear Cover Assembly 67
11. Engine 73
12. Other Departments 77
13. PROJECTS: 86
13.1 To make Hardness chart of various parts of tractor 87
so that ease in checking the incoming quality
of various components
13.2 To implement power steering on the tractor to 93
make the steering simpler and easier.
3
Declaration
I, Gauravjit Singh do hereby solemnly affirm that the project work has been
undertaken by me at the” Preet Tractor Pvt. Ltd.", is an original work and that it is not a
duplicate or a copy of any other work. I was guided in this project by Gurpreet Singh,
and have performed all the required tasks on my own.
Date: January 5, 2009 Gauravjit Singh

4
5
Introduction to company
History of the firm:
In 1980, when the nation needed one type of machine which could harvest
and thresh the crop simultaneously, to reduce the losses beared by the farmers, S. Hari
Singh (M.D. of Preet Agro Pvt. Ltd.) was working on the project in his tractor repair
workshop. After three years of hardship, he was able to establish a small scale unit for
manufacturing harvesting reapers, Threshers, Agriculture parts. Later, his brother
S.Gurcharan Singh (Director) joined him in 1985 and they were able to make a tractor
driven combine in 1986.
The name Preet was established in 1987. The Project for manufacturing
agricultural Tractors was the farmer’s agricultural requirement. Now the M.D of Preet
Tractor is “S.Gurpreet Singh” s/o S. Hari Singh. The development of tractors which
started in house in 2001 was materialized in launching manufacturing activities of
tractors have started in early 2003. A batch of 21 tractors have been tested (On all the
farming operation) through farmers who had the vast experience in agriculture.
6
Products
Today, Preet Agro Industries is the largest manufacturer of self propelled combines,
tractors and harvesters in India. The company produces a wide range of tractors and
combines which are given below: -
1. Tractors
a) Preet 6049
b) Preet 5049
c) Preet 4549
d) Preet 4049
e) Preet 3549
f) Preet 3049
7
1.PRODUCT RANGE FOR TRACTORS

8
9
INFRASTRUCTURE:
PREET is one of the India's leading manufacturers of agricultural tractors and combine
harvesters. PREET is market leader in self propelled combine harvesters in India. We
are controlling 35% market share of self-propelled combine harvesters.
• Present scenario of plant: -
1. Our company is ISO 9001: 2000 certified company.
2. Combine harvesters are manufactured on organized assembly

production line.
3. Plant is equipped with latest CNC turning machines for machining of

components and others computerized machines i.e. shearing
machines, bending press, power press, lathe, shapers and radial drill
machines etc.
4. Company is having one another fully computerized Turret punching

machine to enhance production capacity and to maintain the quality of
product.
• Future Plans: -
1. Company has installed Laser oscillator machine from MAZAK Japan.
2. We will be first to install Robots for all type of welding jobs in our plant
in next financial year.
3. Dip Painting of sheet metal will be install soon.

10
AWARDS / ACHIEVEMENTS:
 The company participated in KISSAN MELA organized by Punjab Agricultural

University Ludhiana in September 2003 and September 2005 with exhibition our
tractors and harvester combine. In the fair all the established manufacturers and
international giants participated we were adjudged the best performer and awarded
the first prize by the organizing authorities.
 The company has participated in International Farm Equipment Show held in
Toronto Canada in Feb’06.
 Mr. Ron Bollman from Government of Canada Invites “Preet Agro Industries” to
setup their plant in Ontario Canada.
 The company has also participated in international trade exhibitions held in Sri
Lanka & South Africa.
 The company has also attended the multi-trade visit, in different companies of
United States of America & Canada.
 Participated, adjudged the best performer and awarded the first prize in Krishi
Mela 2006 held in University of Agricultural Sciences, Dharwad Karnataka.
11
OBJECTIVES:
PRIMARY OBJECTIVES:
The company has laid down for itself goal of improving the value to the customers
through maintaining leadership in following categories.
• Market share: To maintain its status as brand leaders in the country

for combines and tractors.
• Product Development: To develop tractors and combines for all new applications as
identified.
• Technology modernization and up gradation of technology to the latest
improvements to meet customers requirements.
• Customer satisfaction it shall strive to achieve customer satisfaction rating more than
90%.
• Quality: To improve quality consistently through quality assurance and process
control.
• Delivery to strive to achieve 100% on time.
SECONDARY OBJECTIVES:
• To create and distribute a product.
• To profit earning.
• Protection & security to its workers.
• Safety for its workers.
• To meet social obligation.
• Economy of operation by lowering cost.
• Ensure a good quality system.
• Training & development of existing work force.
• To satisfy customer.
12
• Better management
• Better human relation.
FLOW CHART OF MANUFACTURING PROCESS
Production Planning & Control (PPC)
Purchase Department
Quality Control Department
Stores
Machine Shop
Assembly Shop
Paint Shop
Pre Delivery Inspection (PDI)
Sales Department
13
Process of Manufacturing
The process of manufacturing is rather a complex one though it seems to be simple.

Every part to be manufactured undergoes through tests and is used only after the
approval of quality department. The entire manufacturing process is pre decided and is
guided by the recommendations and suggestions of Production Planning & Control
Department (PPC). During manufacturing process, the manufacturer has to follow the
industry standards being established by the industry. After quality control department
o.k. & rejected component send to store. From store o.k. component are send to the
assembly line no.1 and after assembling, the tractors are send to paint shop for
painting. After paint shop all the electrical work is done in the assembly line no.2. Thus,
the manufacturing process is complete after assembly line no.2. Then tractor is send to
PDI (Pre Delivery Inspection) where they are checked for the faults if any. Now, the
tractors are ready to be send to the sales department for sale
14
Technical Specifications of Tractors
DESCRIPTIO PREET 3549-

PREET 4049-I PREET 4549-I PREET 5049-I PREET 6049-I
N I
ENGINE
Model / Make PREET 3549 PREET 4049 PREET 4549 PREET 5049 PREET 6049
Power (PS) 34 39 45 47 57
Type Four Stroke DI Four Stroke DI Four Stroke DI Four Stroke DI Four Stroke DI
No. of
3. Vertical Inline 3. Vertical Inline 3. Vertical Inline 4. Vertical Inline 4. Vertical Inline
Cylinders
136Nm @ 1300 150Nm @ 1300 175.5%Nm @ 136Nm @ 1300

Max. Torque 183Nm @ 1300 rpm
rpm rpm 1300 rpm rpm
Bore / Stroke
95/110 97/110 102/110 95/110 100/110
(mm)
Rated Engine
2100 2100 2100 2100 2200
rpm
Displacement
2340 2438 2697 3119 3456
(cc)
Inline Plunger Inline Plunger Inline Plunger Inline Plunger Inline Plunger
Fuel Pump
(MICO Bush) (MICO Bush) (MICO Bush) (MICO Bush) (MICO Bush)
15
Oil Bath with Oil Bath with pre Oil Bath with pre Oil Bath with pre Oil Bath with pre
Air Cleaner
pre cleaner cleaner cleaner cleaner cleaner
Cooling
Water Cooled Water Cooled Water Cooled Water Cooled Water Cooled
System
TRANSMISSION
8 + 2 Sliding 8 + 2 Sliding 8 + 2 Sliding 8 + 2 Sliding

Gear Box 8 + 2 Sliding Mesh
Mesh Mesh Mesh Mesh
Heavy Duty Dry Heavy Duty Dry Heavy Duty Dry Heavy Duty Dry Heavy Duty Dry
Clutch
Single 280 mm Single 280 mm Single 280 mm Single 280 mm Single 280 mm
Multi Disc Dry Multi Disc Dry Multi Disc Dry Multi Disc Dry Multi Disc Dry Type
Breaks
Type Mech. Type Mech. Type Mech. Type Mech. Mech.
ROAD SPEED Km/Hr
Gear LOW HIGH LOW HIGH LOW HIGH LOW HIGH LOW HIGH
1 2.51 9.87 2.51 9.87 2.51 9.87 2.57 10.1 2.37 10.88
2 3.30 12.98 3.30 12.98 3.30 12.98 3.38 13.28 3.64 14.30
3 5.12 20.13 5.12 20.13 5.12 20.13 5.24 20.6 5.64 22.18
4 8.08 31.8 8.08 31.8 8.08 31.8 8.27 32.54 8.90 35.04
Reverse 3.51 13.8 3.51 13.8 3.51 13.8 3.59 14.12 3.87 15.21
STEERING
Type 2 Lever, ADDC 2 Lever, ADDC 2 Lever, ADDC 2 Lever, ADDC 2 Lever, ADDC
Hydraulic
Gear Type Gear Type Gear Type Gear Type Gear Type
Pump
3 Point Linkage 3 Point 3 Point 3 Point 3 Point

Linkage
- II Linkage - II Linkage - II Linkage - II Linkage - II
POWER TAKE OFF

16
Splines 21 21 21 21 21
P.T.O. Speed 1000 1000 1000 1000 1000
CAPACITIES (Liters)
Fuel Tank 48 48 56 56 56
Engine Sump 8 8 8 10 10
Cooling
8.5 8.5 8.5 9.5 9.5
Systems
Air Cleaner 0.75 0.75 0.75 1 1
Transmission
55 55 55 55 55
& Hydraulic
Steering 0.5 0.5 0.5 0.5 0.5
TYRE SIZE
Front 6.00x16 6.00x16 6.00x16 6.00x16 7.50x16
Rear 13.6x28 13.6x28 13.6x28 14.9x28 16.9x28
Weight (Kgs) 1945 1945 1945 1945 2170

17
Definition of Tractor
A tractor is a vehicle specifically designed to deliver a high tractive effort at slow

speeds, for the purposes of hauling a trailer or machinery used in agriculture or
construction. Most commonly, the term is used to describe the distinctive farm vehicle:
agricultural implements may be towed behind or mounted on the tractor, and the tractor
may also provide a source of power if the implement is mechanized. Another common
use of the term is for the power unit of a semi-trailer truck.
The word tractor was taken from Latin, being the agent noun of trahere "to pull". The
first recorded use of the word meaning "an engine or vehicle for pulling wagons or
ploughs" occurred in 1901, from the earlier term traction engine (1859).
The first tractors were steam-powered ploughing engines. They were used in pairs
either side of a field to haul a plough back and forth between them using a wire cable.
History of Tractor
In 1889 first time a tractor manufactured by a company in which internal

combustion engine was used. The first demonstration of tractor was shown in 1910-
1914. In 1915-1919 first time P.T.O added into the tractor. In 1930-1937 all electricity
works tyres and diesel engine used in the tractor. In 1937-1941 three point hitch system
18
attached with tractor. In 1950-1960 so many tractor manufactured which was have
higher horse power as compared to previous tractors.
19
INTRODUCTION
TO
INCOMING QUALITY CONTROL DEPARTMENT
(IQC)
Preet Tractor Ltd. Is making a wide variety of tractors which is being sent to
National & International market .Quality is the main & important thing of this industry to
sell there tractors.
Incoming Quality Control is a department at preet tractor ltd. which checks

the quality of the components being purchased from the different vendors, which are
used in the assembly of the tractors. These components are checked with very close
quality control on every parameter with the help of state-of-the-art quality control and
inspection equipments.
MEANING AND NEED OF QUALITY AND QUALITY CONTROL

Quality is one of the important factors which influences the purchaser of product
and helps to capture market. It plays an important role in customer‘s decision and
which is why control of quality during manufacture of a product is very necessary.
20
Quality in simple words is defined as the fitness for use. An equally good
definition is conformance to requirements. In both the above definitions, quality is
defined relative to use, rather than as a general characteristic that may be
intangible. By this simple, yet practical definition, if a product or service lives up
to expectations, it is of high quality. On the other hand, extra fine finish or using
materials that are far stronger than required does NOT add quality to an item
unless it somehow causes the item to conform to its requirement better.
Quality of product depends upon the application of materials, men, machines
and manufacturing conditions. The systematic control of these factors is the quality
control. The quality of a product differs greatly due to these factors. For example, a
skilled worker will produce products of better quality and a less skilled worker will
produce poor quality products. Similarly better machines and better materials with
satisfactory manufacturing conditions produce a better quality product. Thus it is
clear that to control the quality of product; the various factors which are
responsible for quality are required to be controlled properly.
It may also be defined as “Quality control is an effecting system for
integrating the quality development, quality maintenance and quality
improvement efforts of various groups in an organization so as to enable
production and service, at the most economic levels which allow for full
customer satisfaction”. In other words, quality is everybody’s business and not
only the duty of the persons in the Inspection Department.
NEED: The quality control is needed due to the following reasons:

a) Customer’s Satisfaction
b) Economy
c) Reduction in Scrap
21
BENEFITS OF QUALITY CONTROL

There are many advantages by controlling the product quality. Some of them are
listed below:
a) Improvement in quality.
b) Increased production under same set up.
c) Reduction in cost due to lower rejection and reworking.
d) Reduction in scrap.
e) Reduction in production bottlenecks.
f) Reduction in inspection in terms manpower and equipment cost.
g) Evaluation of quality tolerance with an idea of avoiding uncalled for quality
build-up.
h) Maintenance of operating efficiency.
i) Less customer complaints.
j) Quality consciousness.
In IQC Department Incoming Raw Material are inspected in order to:
 Eliminate those material which do not meet specification and likely to cause
trouble during processing.
 Evaluate vendor’s quality and ability to supply acceptable materials.
22
• Inspection of raw material may involve a visuals check up only, a

dimensional check, a test of physical properties and chemicals
composition, etc.
• Raw materials depending upon their characteristics and may require a
sampling inspection
• After inspection, the right quality parts are sent either to stock room or
Assembly lines.
Hence Incoming Quality Control department helps to maintain the standard of the
tractors being assembled in International tractor Ltd.
QUALITY RESPONSIBILITIES:-
AS A USER:-
 Transmit needs to supplier.
 Provide feed back to supplier
 Obtain feed back from supplier
AS A PROCESSOR:-
 Plan process to meet customers need.
 Control process to meet customers need.
 Improve process based on customers feed back.

23
AS A SUPPLIER:-
 Know who are customers
 Understand the needs of customers.
 Avoid creating problems for customers
 Obtain feed back from customers.
TESTING PROCEDURE OF THE COMPONENTS
The components are tested by the following procedure:-

1) APPEARANCE
2) DIMENSIONS
3) WEIGHT
4) FITMENT
5) FUNCTION/PERFORMANCE
6) MATERIAL
7) PROCESS
8) WELDING CHECKING
1) APPERANCE: -
It is the first step to checking appearance of the components means how the
component looks like. Whether its surface is smooth or not? Whether its sharp edges
are chamfered or not? In this step component welding, surface treatment and machining
is also checked.
24
2) DIMENSIONS: -
It is the most important step of the quality testing of the various components. The
dimensioning means the checking of the dimensions of the component, whether these
are correct or not? The dimensioning is done by certain instruments like the VERNIER
CALLIPER, MICROMETER, BEVEL PROTECTOR, HEIGHT GAUGE, etc. By these
measuring instruments the measurement of the dimensions of the component become
very easy. These dimensions are checked with respect to the dimensions given in the
drawing i.e. the required dimensions.
3) WEIGHT: -
The material of component is also necessary because it gives idea of the material
required for manufacture the component. The weight of the component is measured by
weighing machine. This machine can measure the weight from 500gram to 50000gram.
There is scale on the measuring machine, which shows the reading of the weight.
4) FITMENT: -
Fitment means fitting of the component actually in the vehicle. The component is
then checked whether it fit properly in the relevant position or not. If the component is
fitted properly and then component get accepted otherwise it rejected. So the
acceptation or rejection of the component is also based upon the fitment of the
component.
5) FUNCTIONAL PERFORMANCE: -
The functional performance of the component is measured after the fitment of the
component. Functional performance means how well the component is functioning in
the vehicle.
6) MATERIAL: -
The material of the component should be able to absorb the stresses produced in
that component. The material may be brittle, hard or tensile as per requirement.
25
Hardness of the material is generally checked by Rockwell hardness testing machine,

poldi hardness tester and shore hardness tester.
7) PROCESS: -
In this step of the quality control of the components the processes of the
components are checked. For making a certain component there are certain processes
by which a component should go through. These processes are made in serial wise and
the component should follow these processes in serial wise. If the processes are serial
wise then component is made exactly according to our requirement. These processes
can be checked only at the production site i.e. where the component is manufactured.
So in case of our industry the processes can only be checked on the vendor side where
the component is manufactured. The processes can be drilling, punching, tapering,
lathing, heat treatment, machining etc.
8) WELDING CHECKING: -
Welding checking is also an important process in the quality testing of the different
components. It is mean that checking of strength of welding portion. The components
are made of different parts, which are welded with each other to make the suitable and
complete component. So it is very necessary to check the strength of the welding, in
order to maintain strength and quality of the component. Here mainly blow holes,
porosity; welding appearance etc of the welded component is checked.
26
QUALITY IMPROVEMENT SYSTEMS
1. COMPONENT DRAWINGS.
2. PROCESS SHEET WITH SUMMERY SHEET. (REF. SCD PROCESS SHEETS).
3. FIRST PC. SETTING OK RECORD
4. RUN CHART FILLING BY OPERATOR & AUDIT BY QE ON RUN CHART.
5. CHECKLIST ON FRONT SIDE & PDI ON THE BACKSIDE OF THE SHEET.
6. IN PLANT REJECTION & THERE DEFECT ANALYSIS.
7. PERIODIC INSPECTION AND MAINTENANCE OF TOOLS/GAUGES &
MACHINES.
8. MASTER SAMPLE SHOULD BE AVAILABLE FOR EACH SHEET.
9. MATERIAL SHOULD BE PROPERLY STACKED IN BINS .(NO MATERIAL
SHOULD BE ON SHOP FLOOR)
10. TOOLS & GAUGES SHOULD BE KEPT PROPERLY AT THEIR ENMARKED
PLACE.
11. WORKSTATION SHOULD BE ACCORDING TO LAYOUT PLAN.
12. MATERIAL SHOULD BE TRANSPORTED TO PTL IN BINS & ARRANGEMENT
SHOULD BE AVAILABLE FOR LODING BINS INTO LCVs.
13. THE RESPONSIBILITY OF IMPLEMENTING AND MAINTAINING THE
VERIOUS RECORDS SHOULD BE CLEARLY DEFINED AND THE NAME OF
THE PERSON TO BE INTIMATED TO VDC AND BUY.
14. SUBMISSION OF SELF-APPRAISAL FORM.
27
HARDWARE SECTION
Hardware is one of the main sections of the Incoming Quality Control Department.
All the hardware items which are used in the tractor assembly are checked
thoroughly in this section of IQC department. There are more than 900 different
components which are checked on regular basis, for this purpose Quality Inspectors
are provided with the entire measuring Instrument required by them.
For the convenience these components are further categorized under different
groups .Name of such groups is as follows:-
 WASHERS:-There are 96 types of different WASHERS which are

checked under this group. All these are used in different tractor
assemblies.
 SHIMS: - There are 75 types of different SHIMS which are checked under this
group. All these are used in different tractor assemblies
 BOLTS & SCREWS: - There are 60 types of different BOLTS & SCREWS
which are checked under this group. All these are used in different tractor
assemblies
28
 RUBBER ITEMS: - There are 80 types of different RUBBER ITEMS which

are checked under this group. All these are used in different tractor
assemblies.
 SPRINGS: - There are 50 types of different SPRINGS which are checked

under this group. All these are used in different tractor assemblies.
 DELIVERY & FUEL PIPES: - There are 54 types of different DELIVERY &
FUEL PIPES which are checked under this group. All these are used in
different tractor assemblies.
 SUCTION PIPES: - There are 54 types of different SUCTION PIPES

assemblies.
 KNOBS: - There are 21 types of different KNOBS which are checked

 PLUGS: - There are 21 types of different PLUGS which are checked

 O-RINGS &SEALING RINGS: - There are 20types of different O-RINGS

&SEALING RINGS which are checked under this group. All these are
used in different tractor assemblies.
 CLAMPS: - There are 23 types of different CLAMPS which are checked

29
 HOSE PIPES: - There are 18 types of different HOSE PIPES which are
assemblies.
 DUST CAP PTO COVER: - There are20 types of different DUST CAP
PTO COVER which are checked under this group. All these are used in
different tractor assemblies.
 BUSHES: - There are58 types of different BUSHES which are checked

 WIRE & CABLES: - There are 23 types of different WIRE & CABLES
assemblies.
 PINS: - There are 120types of different PINS WASHERS which are

assemblies.
 NUTS: - There are 14 types of different NUTS which are checked under
this group. All these are used in different tractor assemblies.
 ADOPTERS: - There are 13 types of different ADOPTERS which are

assemblies.
 SPACERS: - There are 65 types of different SPACERS which are

assemblies.
30
 GASKETS: - There are 66 types of different GASKETS which are

assemblies.
 FUEL CUT OFF RODS: - There are 6 types of different FUEL CUT OFF
ROD which are checked under this group. All these are used in different
tractor assemblies.
Flow chart for quality process
Material receiving report
Sampling as per IS 2500
Checking as per quality plan
O.K. Result not ok
Send to store passes under deviation

In process rejection
Quality rating
31
Monthly rejection report information sends to purchase department
Analysis of rejections
Monthly performance trends
List of instruments used into IQC department

S.NO. NAME OF INSTRUMENT RANGE MAKE QTY.
1 VERNIER CALLIPER 0 - 600mm MITUTOYO 1
4 DIAL INDICATOR 0 - 11mm MITUTOYO 3
5 DIAL INDICATOR - MITUTOYO 1
6 MICROMETER 0 - 25mm MITUTOYO 1
13 FLANGE MICROMETER 0 - 25mm MITUTOYO 1
19 SLIP GAUGE BOX 83PC. PECOCK 1
20 RADIUS GAUGE 1 - 7mm MITUTOYO 1
21 RADIUS GAUGE 7.5 - 15mm MITUTOYO 1
22 RADIUS GAUGE 15 - 25mm MITUTOYO 1
23 FEELER GAUGE 0.05 - 1.00 ATUL 1
24 HEIGHT GAUGE(DIGITAL) 0 - 600 MITUTOYO 1
25 ROCKWELL HARDNES - FINE 1
32
TESTER
SHORE HARDNESS
26 TESTER 0 - 100 MITUTOYO 1
27 DIAL BORE GAUGE 10 - 18.5 MITUTOYO 1
28 DIAL BORE GAUGE 18 - 35 MITUTOYO 1
31 MEGNETIC STAND - - 1
32 MICROMETER STAND MS - 1 - 1
33 MAGNETIC V - BLOCK 102X96X72 SAMRT 1
34 MAGNETIC V - BLOCK 152X98X74 SAMRT 1
35 THREAD PITCH GAUGE B.S.W. MITUTOYO 1
BHAL
36 SPECIAL DEAD CENTRE - ENGG. 1
37 SCREW JACK (BIG) - - 4
38 SCREW JACK (SMALL) - - 4
39 BED CENTRE 1000X260 LUTHRA 1
SURFACE PLATE
40 (GRANITE) 1000X1000 LUTHRA 1
41 CYLINDRICAL PINS ø 3.1 - 5
50 THREAD RING GAUGE M24X1.5 HIP 1
55 THREAD RING GAUGE M16X2 HIP 1
62 THREAD PLUG GAUGE M24X1.5 HIP 1
33

67 THREAD PLUG GAUGE M16X2 HIP 1
74 CALCULTOR SCIENTIFIC - CASIO 1
75 GEAR PROFILE TEATER MITUTOYO 1
Poldi hardness tester
Direction of use
This poldi hardness tester is use to find out the brinell number of the
component. First of all insert the tapered end of the standard test bar after cleaning into
the space provided between the ball and plunger and slide it further beyond the tapered
portion. The test bar will thus firmly grip between the ball and plunger pressed by the
spring. The specimen to be tested should be properly ground or filed and polished at the
surface where it is to be tested to ensure accurate reading. With standard test bar
inserted place the tester vertically or the specimen such that the ball touches the
polished surface. Give a blow on the top of the plunger, with a hammer. The blow
should not be very hard and should be as vertical as possible.
The blow will cause two indentations one on the standard test bar and the
other on the specimen. The diameters of these two indentations should be measured
accurately with magnifier having least count of 0.1 mm provided with the machine. If the
indentation so obtained is slightly elliptical, average diameter should found out. The
distance between the centres of any two indentations on the standard test bar should be
less then 1.5 mm. If the bar is fully utilized it has to be replaced. The limiting indentation
diameter on the standard test bar is 4.2 mm.
34
The tensile strength and brinell hardness number of various metals can be
found as under.
Steel: - the booklet contains two tables one for steel in natural or annealed state and
the other for steel in hardened or tempered state. It is necessary to know the condition
of specimen before and if however it is not know or cannot be determined than first the
table is for natural or annealed steel be used for specimen having Brinell hardness
number up to 360. When the hardness of the specimen exceed 360 the other are to be
used.
Other metals: - separate tables have been provided for other metals example brass,
copper, bronze and cast iron. These tables do not show the tensile strength of these
metals but only the Brinell hardness number because the relation between the Brinell
hardness and the corresponding tensile strength has not yet been established with as
much reliability as in the case of steels.
Procedure
After measuring the actual diameter of indentation on standard test bar the
column diameter of indentation on standard bar should be referred for the same value
and for the actual diameter of indentation on work piece the row diameter of indentation.
On work piece should be referred where the horizontal and vertical columns intersects
the tensile strength in tonnes per square in and the Brinell hardness number can be
read. To convert the tensile strength from tonne/sq. In to kg. /sq. mm uses a multiplying
factor of 1.575.
To take core of the variations in the tensile strength and the hardness of
standard test bar is properly tested and a multiplying factor is inscribed on it, at the end.
For determine the exact tensile strength and hardness of specimen,
multiply the reading found from the table by this multiply factor.
Example: - diameter of ball indentation
1 on the test bar 1.8mm
2 on the specimen 1.7mm
Tensile strength found from table after conversion 80kg/sq. mm. Brinell hardness
number found from table is 223 BHN. Multiplying factor inscribed on standard test bar
35
1.03. Therefore, the tensile strength of specimen is 80*1.03 = 82.4 kg/sq. mm in and the
Brinell hardness 225*1.03 = 235.8 BHN. When after some use the protruding end of the
plunger gets deformed by blows it may be reconditioned and rounded off or simply
replaced.
Poldi type impact hardness tester is not designed to replace the tensile
strength hardness machine and standard hardness tester. The accuracy of this
hardness tester may be very times to the extent of 10% as against the more accurate
table type standard hardness tester. However the poldi impact hardness tester has the
advantage of easy handling and greater flexibility. This is very important, specially for
testing heavy specimen which cannot be taken to a table type hardness tester are
extremely costly compared to poldi tester and require greater skill to operated properly.
Gear Roll Tester
It is hand operated bell crank lever type. First of all we will study about introduction.
Introduction
1 Gear roll tester is a simple workshop gear rolling facility, designed to
measure double flank error of smaller component gear meshing with its master.
2 The result indicated size, hence backlash, run out, tooth damage and
some, ensure of individual tooth quality.
3 The tester is robust intended for workshop use where it may be placed
next to gear generating machine or on the production line.
Principle of operation
1. Component gear is rolled against its master gear of suitable quality,
under positive spring load ensuring (zero backlash double flank contact).
2. Master gear mounted on spring loaded bell crank lever and component
gear is mounted on fixer saddle clamped at designed centre distance.
3 Change in centre distance as gear is rolled together cause bell crank to
respond, which is registered on suitable dial indicator. The element measured or which
can be deduced from the results are as follows.
36
Size and backlash

If component gear is oversize, its close mesh centre distance will be
greater than designed and will be reflected in dial indicator readings. An oversize gear
will have a reduced backlash, resulting in tightly running, overheating excessive noise
and possible physical damage. An under size component gear will recorded lower than
desired dial indicator readings, will have more than desired backlash, which in turn may
cause loss of tooth strength excessive noise on reversed and changed pressure angle
reducing transmission efficiency.
Eccentricity
Continuous measure of effective centre distance during rolling is indicated
as geared rotated. Run out is TIR (excluding localized defects registered as sudden
flicks or kicks) on dial indicator. Run out will cause transmission errors and noise, and
may cause harmful backlash either two great or two small.
Composite errors
Centre distance between gear under roll change as each pair of teeth
move into and out of contact. The change is registered on dial indicator. This is known
as “tooth to tooth composite error”. Total composite error is difference between
minimum and maximum reading on dial indicator.
Damage
Sharp flicker on dial indicator is generally caused by some localized
defects viz. bruising, raised burn or dent on tooth profile. Zero backlash double flank roll
test between component gear and its master is the quickest and satisfactory method to
determine all the above 4 parameters, in a single pass having tome and cost.
Advantage of the test
The rolling testing offers considered technical advantage mainly.
1 Composite error is often specified by national and international standard
and therefore often common base for comparison.
2 The test is very simple and does not require skilled operated.
3 It is very fast, required negligible setting time, therefore very economical.
37
4 The test covers both the flank of every tooth and detects damage; even
through tooth from cannot be directly measured. It is therefore very through.
5 It is most convenient and effective way of measuring size and backlash.
Construction features
Bell crank lever mechanism is essentially a mechanism having a bell
crank with fully protected pivot and it is placed inside the gear roll tester. Harder block is
on one arm of the bell crank and dial actuating pin is on the other arm. On the harder
block provision is made for the mounting mandrel for master gear. Distance of master
gear and dial actuating pin from pivoted centre line are exactly some and hence it
indicates exact deviation of the gear. A tension spring is used to maintain correct load
for component and master gear engagement. This spring force is calibrated before the
dispatch of the gear roll tester. Fixed saddle provided on the other side of bell crank
lever the main body. Component gear mandrel is mounted on the ground pad on this,
which is made flat and parallel to master gear mandrel mounting face on bell crank
mechanism. This fixed slide on the scraped bed of main body has two tendon slots
which have four holes to clamp fixed saddle in requisite position by tighten four dome
nuts.
The fixed saddle is to be moved only during setting of specified centre
distance for different gears. During test fixed saddle must be properly clamped by
tightening four dome nuts.
Method of operation
1 This merely involves adjusting vertical level of both gear and setting
centre distance to the required datum using gauge block or special setting discs.
2 Bell crank lever is with drawn to disengage position. Component gear is
mounted and engaged with its master.
3 It is usual to load component gear on fixed saddle, as it is clamped on
the main body. If heavy component gear is mounted on sensitive bell crank lever it may
damper free sensitive movement.
4 Component gear is located on suitable mandrel if necessary, on fixed
saddle in fixed position and in then rotated until component gear completes one
38
complete rotation. During this time, TTCE and maximum and minimum dial indicator
readings are observed; with special attention to sudden flickers.
Capacity
1 Maximum centre distance between mandrel is 260 mm.
2 Standard equipments: - gear roll tester with fixed saddle with bell crank
mechanism, having master mandrel faces fitted with dial indicator having least count .01
mm capacity 10 mm.
Accessories
1 Sliding bracket with vertical column to accommodate mandrel/ gear of
length 100 to 500 mm provided.
2 Baker make dial gauge 0 to 10 mm provided.
Operating Instructions
1 Using engagement/disengagement lever confirms bell crank lever
movement is free and smooth.
2 Mount master and component gear mandrel on their respective
mounting faces after cleaning the mating faces properly. Tommy is provided to tighten
the mandrel.
3 Place PCD discs of master and component on respective mandrels
4 Loosen 4 nos. dome nuts on fixed saddle and move it gently to fro, as
required, till both PCD discs touch each other when bell crank lever is in engaged
position.
5 Reposition fixed saddle to adjust required pre load on dial indicator.
Clamp the four dome nuts on fixed saddle to fix position and desired meshing centre
distance. Set zero on dial indicator. Repeats engage disengage movement to ensure
that set zero is repeated.
6 Retract engagement lever to disengagement position remove PCD
disks. In obscene of PCD links, requisite desired centre distance can be set by means
of suitably slip gauge blocks.
39
7 Locate master and component gear on their locating mandrels. Now the
tester is ready for checking component gears. Put engagement lever to engage
position, thereby meshing component and master gear with a positive and constant
spring load pressure, to give double flank contact.
8 Rotate the component gear manually. A minimum of one revolution of
the component gear has to be completed observe dial indicator reading, which can be
interpreted for PCD variation, PCD run out, high spots caused by dent burr etc.
9 Disengage master gear by retracting bell crank lever. Remove
component gear under test.
10 For checking similar component gears repeat the above steps.
40
41
Differential
If a tractor travels in a straight line, the two rear wheels turn on the road
exactly at the same speed. There is no relative movement between the rear wheels. But
when the tractor takes a turn, the outer wheel travels on a longer radius than the inner
wheel. The outer wheel turns faster than the inner wheel, that is, there is a relative
movement b/w the two rear wheels. If the two rear wheels are rigidly fixed to a rear axle
the inner wheel will slip which will cause rapid tyre wear, steering difficulties and poor
road holding. Therefore, there must be some devices to provide relative movement to
the two rear wheels when the tractor is taking a turn. The differential serves this
purpose.
Differential is a part of the inner rear axle housing assy., which includes the
differential, rear axles, wheels and bearings. The differential consists of a system of
gears arranged in such a way that connects the intermittent shaft with the rear axles.
The purpose of the differential is to provide the relative movement to the two rear
wheels when the tractor is taking a turn. The torque transmitted to each wheel is,
however, always equal.
42
Construction: - Fig. shows the construction of a simple differential. In this

case cage assembly is made by four bevel gears. On the cage assembly crown wheel is
mounted. This crown wheel is attached with the tail pinion gear. Cage assembly is
hollow from both sides. In this space two bull pinion shafts are attached. These shafts
help to transmit relative motion when tractor takes turn. This bull shaft further attached
with bull gear which is mounted on the rear axles. Now we learn about how power is
transmitted from when tractor moves in straight position and when it takes turn. When
tractor moves in straight position then power transmitted from tail pinion to crown wheel.
When crown wheel rotates then whole cage assembly rotates but its internal gears of
cage assembly remains constant. From crown wheel power transmits to bull pinion shaft
and further to bull shaft. But when tractor takes turn then relative motion produces
between the tyres due to these internal gears of cage assembly rotates. This relative
cause is to give the different speed ratio to the rear wheels. This way it works.
Scoop lock set is also mounted on the cage assembly. It plays a great roll
in cage assembly. Every body knows very well that every gear needs lubrication for long
life. Scoop lock is doing same work here. When cage assembly rotates with high speed
then one layer is become on the outer surface of the cage assembly. Due to that
lubricant does not enter into the cage assembly. Scoop lock destroys this outer layer of
lubricant means this scoop help to lubricant to reach into the cage assembly.
43
Cage assembly
1 Bevel gear
2 Thrust roller bearings
3 Cross
4 Thrust washers
5 Spider kit
6 Scoop lock
7 B.P. shafts
44
CAGE ASSEMBLY
Technical condition for differential
Pre loading of tail pinion

Pre loading means load required to rotate tail pinion with easy way. It is very
necessary part when we assemble the tractor. It we did not check this then some
problem would create. If pre load is less then it may rotate at a high speed which will
cause of damage of teeth’s. If pre load is greater then required then more wear will
occurs. Generally pre load for tail pinion is 6 kg to 8 kg.
Pre loading of crown wheel
For crown wheel it is generally 10 kg to 12 kg.
Backlash
It is the difference between the tooth space and the tooth thickness space, as
measured on the pitch circle. It is also very important term. If we did not check the
backlash during assembly of differential than it may cause of some damages.
Between the tail pinion and crown wheel it is generally .25 to .35 mm.
If backlash is less or greater than required then it makes correct with the help of
packing material or shims. If backlash is less then range than packing material or shims
45
transfer from left to right. If backlash is greater then range than packing material or
shims transfer from right to left.
Pattern
It is percentage of surface area which come contact between the two
meetings tooths. It should be more then 50%.
Lapping
It is a process in which one pair of tail pinion and crown wheel prepared.
In this process pinion teeth’s makes mark on the crown wheel teeth’s. This way one set
is prepared. If we use two different pair in one assembly than it would creates some
problems.
Differential Trouble Shooting
1. Noisy Differential :
(a) Less lubricating oil in the differential housing.
(b) Low viscosity oil or use of quality oil.
(c) Wrong adjustment of crown wheel and pinion teeth.
(d) Wrong out hub bearing.
(e) Worn out or broken teeth of crown wheel or pinion.
(f) Less in backlash in crown wheel and pinion teeth.
(g) Worn out bearing of crown wheel or pinion.
(h) Crown wheel misaligned on cage.
(i) Loose star pinion.
(j) Broken or worn out thrust washers of pinion or sun pinion.
2. Vehicle does not move when put in gear :

(a) Broken propeller shaft.
46
(b) Broken axle shaft.

(c) Broken pinion flange key.
(d) Broken teeth of crown wheel and pinion.
(e) Broken cross or star pinion.
47
48
Introduction
The vehicle had been started, accelerated and was running on the road. It
is now to be stopped. Stopping of the vehicle is as necessary as it starting. Once the
vehicle is started, it must be stopped somewhere. Brakes are applied on the wheels to
stop the vehicle. Before applying the brakes , the acceleration is released to stop the
fuel supply thus the engine develops no more power to run the vehicle, and then the
brake are applied which stop the rolling of the wheels on the road and hence the vehicle
is stopped.
Functions of the brakes

There are two distinct functions of the brakes.
1 To stop or slow down the vehicle in the shortest possible distance in
emergencies.
2 To control the vehicle to be retained when descending a hill.
The first function calls for the brakes which can apply large braking
torques to the brake drum, while the second calls for brakes that can dissipate large
quantities of heat without large temperature rises.
Brake assembly parts
1 Brake disk
2 Brake link
3 Brake actuator fork
4 Brake boot
5 Brake lever
6 Brake tie road
7 Brake liner having diameter 7.5 inches
8 vent breather
49
Construction and working of the brake
Brakes used into the tractor are Mechanical brakes. First of all in the brake
housing put one ne brake liner and than on that brake disc put into. This brake disc
make with five springs which help it to remain its position when brake foot lever
released. On the other face of brake disc also one brake liner attached. When brake
actuate than one brake liner produce friction with the differential face and second brake
liner produce friction with brake housing face. Assemble two brake links with the brake
disc. After that brake fork attached with the brake links and than brake lever and tie road
assembled. This tie road is used to adjust the length. When we press the brake foot
50
lever than through the attached link power transmitted to tie road. This tie road pulls the
fork and lever. Then power transmitted to brakes links. These brake links pull both ends
of the brake disk. When both ends of brake links pulls into each other than balls which
are adjust into the gap of brake disc moves from lower portion to upper portion. Due to
that movement they put the force on the disc. Then space between the brake disc
increases. On both side of the brake disc brake liner are attached. Due to increase in
gap these liner get attached with differential housing face and brake housing with a
great force. Due to friction between the brake liners and faces speed of tractor slow
down or stopped. Speed change into and to remove this heat from the inner space to
atmosphere vent breather situated into the assembly of brake. This way brake works
into the tractor.
For parking brakes one lever attached right hand side of the driver. This
lever entrapped the brake foot lever. This way parking brakes do his work. This lever is
attached on the gear box housing. One side of this lever teeth’s are manufactured.
These teeth are attached with the brake foot lever when we required. Releasing of this
brake is also very easy.
Lining wear
Lining wear is most important topic in the brakes. Because if brake liner
wears more rapidly than it is very bad for a tractor as well as for a manufacture. That is
why lining wear is important during designing. Wear of the liner is more at near about
centre and continues decreases towards the outer ward face. That is why liner are
make is such a way they thicker at the centre and less thick at the outer surface.
Brake clearance
` At the time of operation of brakes, wear and rear of the lining takes place.
Hence, clearance provided between the lining and brake housing in the initial stage thus
necessitating adjustment. The adjustment made by the help of nut. The clearance
provided in the brake is mostly 1 to 2 mm.
51
52
In between the differential and the driving wheels is the rear axle to transmit
power from the differential to the driving wheels. It is clear from the construction of the
differential, that the rear axle is not a single piece, but it is in two halves connected by
the differential, one part is known as half shaft. Inner end of the half shaft is connected
to the bull gear of the differential. And the other end to the driving wheel. Almost all rear
axles are live axle, that is, they revolve with the wheels. Dead axle simply remains
stationary; do not move with the wheels. Housing of rear axle is protecting from the
water, dust and injury, in addition their inner bearings and providing a container for the
lubricants.
Load on the rear axle
1 Total rear weight of the vehicle

2 Side thrust on the wheel
3 Driving torque
Types of Rear Axle
1 Semi-floating
2 Full floating axle
3 Three quarter floating axle
53
Construction and working of the Rear Axle
In the construction, first of all housing of the rear axle is attached with the
differential housing with the help of studs. Half portion of stud is inside the differential
housing and other one in the rear axle housing. Between these parts seal or gasket is
adjusted to prevent the leakage of lubricant oil. Now axle put inside the housing. This
housing is hollow. One part of axle enters into the differential housing and other one out
from the rear axle housing. On the inner end of the axle bull gear is attached. Now with
the help of locking nut, it is locked.
First of all, power from the tail pinion is transfer to the crown wheel. Here whole
assembly of the cage revolves. Here power is transfer to the bull pinion shaft. Bull
pinion shaft is assembled with the bull gear. So power from the bull pinion shaft is
transfer to the bull gear. This gear is attached with rear axle. So from bull gear it is
transfer to the rear axle. This rear axle is attached with wheels. So this way power is
transferred from tail pinion to wheels through differential and rear axle.
Rear Axle Assembly

54
Axle housing
On account of appearance, one piece of housing is called a banjo type. In this
design, the complete differential unit is carried in a separate casing which is bolted to
the axle casing. The two half shafts are put from the sides. In this design, if there is any
fault, the whole of the rear axle has to be removed as a unit and then disassembled.
Rear Axle Noises

Noise is a usual indication of trouble in the rear axle assembly. The causes of
noise should be carefully noted:
1 Noise occurs when the vehicle is pulling- the cause is probably insufficient clearance
between the gears.
a. Too much clearance between the gears
b. End play in the pinion assembly.
2 Noise occurs when vehicle is cornering- the cause may be faulty differential gears,
either damaged teeth or excessive wear
3 Noise occurs due to the shortage of oil or incorrect viscosity of oil.
The noise sometimes appears coming from the rear axle, but actually may come
from the transmission, front wheel bearing or engine. The types also making a humming
sound on certain types of the road surface. Sometimes muffler noise may be considered
as coming from the rear axle. Therefore, it is important to check these conditions before
beginning to work on rear axle assembly.
Axle Breather
The heat generated by the gears causes to expand the air in the rear axle. It will
increase oil pressure also. To maintain oil pressure in the rear axle within limits so that
the oil is not pas the oil seal, an axle breather is provided on the axle casing.
55
Flow chart for Differential assembly

Visual inspection
Drain plug assembly
All stud fastening
Trumpt housing assembly
Bull gear assembly
PTO shaft, End cover, Cap assembly
Angle bracket assembly
Brake pedal assembly
Cage assembly
Bull pinion shaft assembly
Seal carrier assembly
Tail pinion assembly
Brake housing assembly
PTO lever assembly

56
Suction strainer assembly
Rear axle assembly
Code punching and final inspection
Plan for gear assembly backlash checking
Serial no. Gear type Specification Instrument Frequency Sample size

used
1 Front .2 to .35 mm Dial Gauge 100% 100%
transmission
gear
2 Bevel gear .2 to .35 mm Dial Gauge 100% 100%
(spider kit)
3 Bull pinion .3 to .5 mm Dial Gauge 100% 100%
shaft
4 crown to .25 to .35 mm Dial Gauge 100% 100%
pinion
57
58
GEAR BOX ASSEMBLY
In Preet Tractors Pvt. Ltd the 2nd stage in the assembly shop is gearbox assembly. The
function of gearbox, its parts and working is explained as below: -
FUNCTION OF GEARBOX
The main functions which are performed by the gearbox are: -

a) The torque or the tractive effort produced by the engine varies with speed only
within narrow limits. But the practical consideration for the running of tractor
under different conditions demands a large variation of torque available at the
wheels. The main purpose of the gearbox is to provide a means to vary the
leverage or torque ratio between the engine and the road wheels as required.
b) Gearbox also provides a neutral position so that the engine and the road wheels
are disconnected even with the clutch in the engaged position.
c) The third function of the gearbox is to reverse the rotation of the outgoing shaft
so as to drive the tractor in reverse direction.
TYPES OF GEARBOXES
 Sliding mesh gearbox

 Constant mesh gearbox
 Synchromesh gearbox
59
Sliding Mesh Gearbox

1. Engine Shaft
2. Lay Shaft
3. Main Shaft
4. First Gear
5. Second Gear
6. Third Gear
7. Fourth Gear
PARTS USED IN GEARBOX ASSEMBLY
 Gearbox housing
 Lay shaft
 Four gears on lay shaft (Z-45, Z-36, Z-30 & Z-25)
 Intermediate shaft
 Three gears on intermediate shaft (Z-24, Z-31 & Z-34)
 Input shaft
 Four bearing 6209
 Circlip
 Spacers
60
 Four shifter rods & forks (Hi-Low, 1st-Rev, 2nd & 3rd -4th )
 Springs
 Gaskets
 C.A. Guide & C.A. Bush
 Bottom cover plate
 Drain plug
 Greasing nipple
 Idler gear
 Idler gear pin
 Washers
 Hexagonal nut
 Z-F bracket
 Steering assembly
 Shifter lever housing
 Levers
 Planet gears
61
GEAR BOX HOUSING

LAY SHAFT ASSEMBLY
The lay shaft is hollow shaft with splines on outer surface. The one end of the lay shaft
is threaded (in case of single clutch) and tightened from front side of gearbox with
hexagonal nut. The whole assembly consists of gear Z-45(i.e. constant mesh gear with
input shaft gear), spacer 15mm, gear Z-36, gear Z-30, spacer 30.5mm, gear Z-25,
spacer 30.5mm, 3mm washer and bearing 6209 with Circlip. In case of dual clutch
tractor model the drive shaft is placed through the hollow lay shaft. The drive shaft
consists of splines on one end and a gear (Z-45) on the other end. The gear constantly
meshed with the gear of intermediate shaft.
62
INPUT SHAFT ASSEMBLY
Input shaft consists of spiral gear on one end and splines on other end. Splined part is
attached to clutch and geared part (Z-19) is constantly meshed with gear of lay shaft i.e.
Z-45. Input shaft is put into the gearbox with the bearing 6209, which is locked by
Circlip.
OUTPUT SHAFT ASSEMBLY
Output shaft is solid shaft with splines on outer surface. The shaft is placed into gearbox
with both ends supported by bearing and locked by Circlip. The one end of shaft is
projected out side of gearbox from which drive is given to differential. The assembly of
shaft consists of gears Z-24, Z-31, Z-34. The sliding gear Z-34 is used for first and
reverse gear, sliding gear Z-31 is used for second gear and sliding gear Z-24 is used for
third and fourth gear. These gears are provided with grooves on one side to attach gear
shifter fork.
ASSEMBLY OF GEARBOX
First of all the gearbox housing is placed over the assembly stand with the help of
overhead crane. The idler gear is placed with the idler gear pin in the gearbox at its
respective place. Then lay shaft assembly is inserted into the respective hole and
tightened from front side by hexagonal nut. After this, input shaft is placed in gearbox
housing. Its Z-19 is constantly meshed with Z-45 of lay shaft. Then the output shaft
assembly is placed into the gearbox housing where its one side is inserted into the input
shaft hole. For dual clutch models the intermediate shaft is hollow and placed over the
input shaft. Then Z-21 gear is meshed with Z-43 gear of connecting shaft, which is
63
placed through the hollow lay shaft. The internal gear assembly is tightened on the
outside of gear box with output shaft. The four shifter rods are placed in their respective
hole with spring loaded ball. The gear shifter forks are inserted into the groove of sliding
gears and then tightened to the gear shifter rods with the help of bolts. The fourth shifter
rod is meant for high and low-speed selection. This shifter rod is connected to the drive
shaft, which is placed into the internal gear. Then bottom cover plate is attached to the
bottom of gearbox housing with the help of gasket and four bolts. After this drain plug is
tightened. Now Z-F bracket is placed over the upper side of the gearbox. Z-F bracket
assembly is consists of steering assembly and shifter lever housing. Then whole
assembled gearbox is send to the main line assembly.
Gear Box Troubles
The most common trouble of the gear box and their causes are as follows:
1 Grinding noise in neutral- a grinding noise occurs when the engine is running and
tractor is in neutral. It is causes are:
a. Gear box is not properly aligned with the engine casing the shaft from the
flywheel to the gear box to bind
2 Noise in gear- when the tractor is being driven or rear wheels turning off the ground,
noise is heard in gear. Its causes are:
 Dry rear bearing on the main shaft
 Damaged drive gear
 The noise heard in the neutral will also be heard in the gear but will be more
pronounced.
 Noise occurring in the rear end and in the clutch may be also seem to come from
the gear box
3 A hum or blow in neutral- when the engine is running, it occurs due to following
reasons
64
a. Lack of lubricants
b. Damaged shaft
c. Too much backlash between the gears
d. Gear chipped, burred, improperly matching and badly machined
e. Too much end play between the gears and counter shaft
f. Worn bearing
4 Hard shifting, sticking in gear- it occurs due to following reasons:
a. Distorted splines of the main shaft
b. Too strong shifter lock spring
c. Improper clutch adjustment
d. Battered gear tooth
5 Oil Leakage- oil leaks from the gear box due to following reasons:
a. Too high level in case
b. Damaged or improperly installed gasket or oil seal
c. Loose cover bolts
d. Cracked case or cover
e. Loose brain or filler plug
6 Slipping out of gear:
a. Too much clearance between the teeth in mesh
b. Insufficient mesh or gears
c. Worn gear of meshing teeth
d. Weak or broken shifter lock spring
65
Assembly plan for Gear Box
Visual inspection
Drain plug assembly
Input shaft
Lay shaft
C.A guide, C.A bush, C.A shaft cover plate
Idealer gear
Main shaft
Shifter rod, fork, locking pins
Steering mounting bracket assembly
Steering assembly
Gear shifter housing
Plant gear assembly

66
Work Instructions
1. First of all check the housing of gear box properly.

2. Fastening the stud with the help of stud fastener.
3. Fasten the drain plug when threads are cover with thread seal tape.
4. Fasten all nut, screw and bolt as according to given torque.
5. Use proper tool during assembly of oil seal and bearing.
6. Clean the shaft and gear with the help of diesel before fitting.
7. Check the backlash between the gears according to the given standards.
8. Check the pattern with the help of gauge.
9. Use lubricant up to proper level.
10. To lift the heavy parts always use Hoistus Crane.
11. Cover the washed parts properly.
12. Note all record in your register of sub assembly.
13. Attach the history card with the sub assembly.
67
68
Hitch system
Introduction to Hitch system

We know very well that tractor is use for make the level of land, transportation,
cultivation of seeds. Pesticides etc. To do these types of work some implements
attached with the tractor at the behind portion. These implements are seed cum fertilizer
drill, leveller etc. Through which system these implements are attached is called hitch
system or linkage system.
Properties of a rood hitch and linkage system

1. First of all hitch system should be like that in which installation and reinstallation
of the implements are very easy.
2. It must help to implement to go in the deep point of the hard land.
3. It must help to the implement to stable at the same level in the land if level of
land are not stable.
4. Implement should move up and down very easily during transportation.
5. Side thrust should not affect the tools of field.
69
Type’s of hitch system
Hitch system mainly divided into two types.
 Single point hitch system:

It is also called integral hitch system. In this only draw bar is used
to attach various implements with the tractor. Draw bar is made by mild steel and
many holes drilled in this. In this holes with the help of pin tools are attached. That is
why it is called single point hitch system. In this system we are not able to pull the
tools but we are not able to lift the tools up and down. Also we are not able to control
the depth of tool in the field. This system is used only to attach trailing type harrow.
 Three point linkage system:
This system mostly used into the tractors. We are able to use this system
as a single point linkage system. Main parts of this system follow:
a. Two lower links:

These links are assembled in tractor on the back side of the system. These are
attached on the right and left side. These links are made by the help of iron. This is a
piece of pressed iron. On both sides flexible ball socket are attached with them. With
the help of these tools are attached with tractor. Between these links right side link is
adjustable.
b. Top link or upper link:

On this link also adjustable ball sockets attached. This link is adjustable
into length. End of draw bar is attached with this system. This draw bar also able to
attached with socket. This way it becomes single point hitch system. With this
system we are able to lift the implements of the tractor for example tiller, mounted
harrow. Seed cum fertilizer drill, leveller etc.
70
Lift and Hydraulic System
The system which help to move up and down to the cultivate tools and also
control the depth of the tool is called lift or hydraulic system.
During doing work on the field, we have to move up and down our cultivate tools
during cultivating and also we have to control the depth of tools, we have to do it
because structure, quantity and level of the soil is differ at every point. So if tools do his
work on the same level or on the same setting. Then sometimes tractor gets slipped
and sometimes engine has to do more work or we can say that 0verloading of engine.
So to over come on these problems hydraulic system is attached with tractor. Without
this system tractor are not able to complete his main motive.
Functions of Hydraulic system
1. With the help of two lower links tractor is able to move the cultivation tools up and
down.
2. This help to make a constant level of the tools as according to the structure or
level of the field.
71
Main parts of Hydraulic System and working of these parts
This rear cover attached on the housing of differential and rear axle. Between
these housings lubricant oil is filled which help to do two works. One is that it helps
to lubricate parts of the differential and other it helps into the hydraulic system.
1. Filter
To remove the impurities from the lubrication this filter is used. Filter first
removes the impurities and then it delivers to the next part. Please check the
filter after some times otherwise it may be choke the hydraulic system.
2. Pump
This is a main part of this system. After removing of impurities oil reaches
into the pump. This pump is fitted front of the tractor. Drive is given to the pump
with the help of timing gears. It is the main function to increase the pressure of
the oil and deliver to next part. This is a gear type pump which converts
mechanical power to the hydraulic power. First oil reaches at the inlet port of the
pump and entrapped between the gears of the pump. This way its pressure
increases. This pump increases the oil pressure up to 135 kg/ square centimetre.
3. Ram and Power cylinder
In this part, one part is cylinder in which piston moves. This piston is
attached with rod. Second end of this rod is attached with two lower links. Oil
entre with pressure into the cylinder and put a pressure on the piston. This piston
is attached with lower links which help to move up and down. By controlling the
oil pressure we can control the depth of the tools.
4. Distributor
In this system control valves and safety valves are attached. With the help
of this system we are able to control the oil pressure. If we want to give less or
more oil to the cylinder then this system works. If lift system feels load then it
72
works automatically and transfer oil to the tank. This system is made by the help
of three sliding valves and one by-pass valve and one safety valve.
73
74
Engine
In this tractor internal combustion diesel engine is used to produce the power.
Internal combustion engine mean that in these engine fuel is burned inside the engine
cylinder. Power is produced during the power stroke. This power helps to move the
tractor or for do work. In Preet tractor 2 cylinder, 3 cylinder and 4 cylinder engines are
used. By using number of cylinders and by using differ pistons differ horse power
produced. From this company we are able to purchase different kind of tractor which
has different horse power. Parts of engine are follows:
1. Cylinder block
2. Cylinder head
3. Crankcase
4. Piston
5. Piston rings
6. Connecting rod
7. Crankshaft
8. Flywheel
9. Valve and valve mechanism
10. Camshaft
75
Cylinder Block
Cylinder block, cylinder head and crankcase- these three parts form the
foundation and main stationary body in the tractor. They serve as support and enclosure
for moving parts. The cylinder block and crankcase is manufactured together as a single
piece. This gives a rigid structure. Ribs are cast to give extra strength to the structure.
A cylinder block consists if mainly three parts:
1. The cylinder in which the piston slides up and down.
2. The ports or opening of the valves.
3. The passage for the flow of cooling water.
The round cylinder surface is given precision mirror finish by accurate grinding and
honing process. Cylinder head is made by cast iron and some quantity of nickel and
chromium is added in the cast iron. Cylinder walls are plated by chromium very hard
metal, to reduce the wall wear and to increase the service life.
Cylinder Head
The top of the cylinder is covered by a separate cast piece known as the cylinder
head. The cylinder head is bolted to the cylinder block. It contains combustion
chamber. It incorporates passages for the flow of cooling water. The cylinder usually
made of gray iron. It is separate from the cylinder block so that it mat be removed for
cleaning carbons and grinding valves.
Care should be taken to the following points when detachable heads are made:
1. The bore of the cylinder or liner should not be destroyed by the pull of the holding
of down studs.
2. The circulation of the coolant in the cylinder head should be carried as nearly as
possible to the top end.
76
3. To ensure a sound gas tight joint, the holding down stud must be distributed as
uniformly as possible around the circumference of the cylinder.
Engine Assy.
Cleaning of Crank
Crank Shaft assembly In to Crank
Cam Shaft
Assembly of timing gears
Piston assembly
Oil pump
Suction strainer assembly
Front and rear cover
Oil pan assembly
Flywheel assembly
Cylinder head assembly
Fitment of all
Tappet assembly
Rocker arm assembly
Belt pulley assembly

77
78
Stores
The necessity of storing the material is to maintain a reserve of goods that will ensure
manufacturing according to the production plan based on sales requirements and the
lowest possible ultimate cost. Losses from improper inventory control include
purchase in excess then what needed, the cost of slowed up production resulting
from material not been available when wanted. Each time a machine is shut down for
lack of materials, or each time, sale is postponed or cancelled for lack of finished
goods a factory looses money.
Machine shop
In general, a machine is made up of many individual parts. For example a tractor is

made up of engine, gear box, electrical, suspension etc. The machine shop is
assigned the task of manufacturing individual parts or units of machine which are
assembled together to make the machine.
The machine shop includes following units:-
1. CNC – Computer Numeric Control.
2. Horizontal milling machine.
3. Vertical milling machine.
4. Radial machine (drilling).
5. SPM boring machine.
79
Paint shop
The job assigned to paint shop is to paint the finalized machine. Here, the
concern is given on the outer appearance and to make the product look good and
attractive. After painting the machine, manufacturer logos are affixed and electrical
are also fitted. Then, final assembly is performed and machine is fitted with
electrical wirings and installations. The machine is ready for the pre delivery
inspection.
Pre delivery inspection
PDI means Pre delivery Inspection. When a vehicle comes from the
assembly shop after final assembly, they are first inspected after complete washing
and greasing.
The PDI is performed by two electricians, a mechanic and a helper for
each.
Following operations are performed here:-
1. Washing
2. Greasing
3. Engine oil check
4. Rear axle oil check
5. gear box oil check
6. Test drive.
80
MAINTENANCE
In the modern industry, equipment and machinery are very important part of the total
productive effort. Lot of capital is invested in plant equipment and machinery. These
are deteriorated by their exposure to environmental and working conditions. If these
damages are not checked at proper time, these may make the equipment non-
usable. Thus it is very important to maintain, repair and recondition these to increase
their life and make them available for maximum number of operating hours. The
various objective of the maintenance department are:
• To achieve minimum breakdown.

• To keep the plant in good working condition at the lowest possible cost.
• To prevent loss in production time.
• To maintain the various plant services.
• To provide plant protection including fire protection.
• To establish and maintain a suitable store of maintenance materials.
• Insurance administration.
• Generation and distribution of power and other facilities.
• Overhauling of plant equipment and machinery.
• To carry out corrective repairs to alleviate unsatisfactory conditions found
during preventive maintenance inspection.
81
VARIOUS TYPES OF MAINTENANCE:
1. BREAK DOWN MAINTENANCE :

This maintenance is to deal with the problems in which the machine may be
running but the final product which we are supposed to get is not available
.Means the output is not of desired accuracy e.g. dimensions of the product are
not up to the mark or shape may be distorted .
2. PREVENTIVE MAINTENANCE :
In this the prevention of the machine is considered , time to time checking of the
machine is done so that they work properly & production is good .on Sundays
machines are checked , oil filters , electric wires, cables are checked .
3. INSTALLATION & COMISSIONING :

It includes installation of machines also includes loading & unloading of the
machines to place them at proper place. Inspection is done by some specialized
engineers.
4. SERVICES:
It includes various things which maintenance department has to look after, for the
proper running of the industry. Without this many problems may occur. Service
block consist of:
• Generator (2 in no)
• Compressor (3 in no)
• Compressed air drier
• Cooling tower
• Softening plant ETP( Effluent treatment plant)
• Air receiver
82
SERVICES
TELEPHONE WATER OIL ELECTRICITY COMPRESSED

AIR
To provide
compressed
From NAC air.Compressor
To repair all Supply of
(notified areas Generates air at
Telephone 11KV.transfor
committee. 7 kg/cm sq.
lines inside mers 2 each of
Takes care of 1500KVA
the plant 14 kg /cm sq
water supply capacity
18 kg/cm sq
Machine Fuel Engine

Oil Oil Oil
DG Set & Production

Engine Testing
Hydraulic oil Lubricating oil Cutting oil Washing M/C Diesel, (Engine oil)
INDUSTRIAL ENGINEERING
Industrial Engineering is the most important department in terms of production,

planning, designing and optimization of methods governing the factory operations. It
deals in utilization of resources i.e. manpower, machines, money etc. Hence it can
be considered as the backbone of production industries. For a new industry I.E
department plays an important role.
83
Its main functions involve the planning of layouts of all the shops to get the
maximum benefits of the available space, setting the time standards to perform
particular job by micro motion study, implementing the company standards. All type
of data collection and data analysis; setting the targets and try to achieve them etc.
the other function of this department may involve selection of cutting tools machine
tools, designing of jigs, fixtures and inspection of gauges etc.
In I.E there are following four sections:
• Machine Shop Processing:

This section controls processing of all components in machine shop and
make continues production and make C.N.C. machines program for new
components and improving exiting programmes. The new machines are setup
by this section and development of new comp. also done.
• Assembly and Projects:

This section controls the assembly shop and testing lab of plant. And ensure
assembly line goes smoothly and fulfil its targets. It also implements new
projects in the plant for increasing production and convenience of workers or
operators. It also done time study and work study.
• Tool Control Cell:

It controls tool crib of plant and assures proper supply of tools to various
machines and also store proper amount of tools for regular production of
components. It also reworks or re sharps the damaged tools.
• Tool Design Cell
This section designs new tools, jigs, fixtures etc. according to requirements of
various departments. It also improves exiting fixtures to achieve greater
accuracy.
84
The Functions of I.E. are following:
11
Plant layout:
The best optimum utilization of space can be achieved by optimum layouts. An
improper layout may result in wastage of manpower and hence production so the
most important and first task of I.E in setting up a new industry and expanding
the old is planning and making the layout according to the requirements of the
process .
22
Installation of new machines:

The function of I.E is to install the new machines acc. to proposed layout.
While installing the new machines and other systems, the I.E has to take
care of some precautions like ease of the worker to do his work easily, safety
measures etc.
22
Setting the standard timing of workers:
The next function of I.E is to set the worker to perform certain operations. This
is calculated by the micro motion study in which stop watch is used which
record all the minute time period spent by the worker in different steps of the
work and after that all the periods are added up thus giving the total time to
do a complete operation. With the help of that determined time by the
camera, the standard time of operation has been found out according to the
formula:-
Standard time =Normal time + Allowance
When the normal time is determined by the camera and allowances is that
time which the workers spends for his personal needs etc.
85
22
Appropriate selection of the m/c and cutting tool
22 Designing the jigs, fixtures and inspection gauges
22
Planning the manufacturing of new components
22
Receiving components and drawings from R&D
22 Prepare and release of process sheet.
22 Miscellaneous and advisory functions.

86
87
PROJECT NO.1
Aim: - Making hardness chart of various parts of tractor which are generally undergoing
to check in quality control for hardness purposes.
Requirement of Hardness Chart:-

 If any component which is come under line rejection in quality control for mainly
hardness then there is no need to open the control plan of that components,
simply see the hardness of that component from hardness chart and check it
again with suitable instrument.
 It is easy to locate the component control plan from the file by note the
component part no. from the hardness chart.
 It is beneficial for trainee students and for trainee engineers that they not know
hardness of various components of tractors.
Control Plans used for making Hardness chart:

88
 Rear Cover
 Front Axle
 Differential
 Gear and Shafts
 Gear Box
 Hardware
HARDNESS CHART INCLUDES FOLLOWING COMPONENTS
REAR COVER
S.NO. PART NO. DESCRIPTION HARDNESS
1 401004 POSITION ACTUATOR ASSY. 58-63HRC
2 401007 POSITION LINK ASSY. 30-35HRC
3 401010 DRAFT LINK ASSY. 35-40HRC
4 401011 SENSOR LEVER HINGE PIN 25-30HRC
5 401013 SENSOR (L-42) 40-45HRC
6 401017 SENSOR ROD 30-36HRC
7 401020 PIN ROCKER LINK 25-30HRC
8 402008 CONNECTING ROD 40-45HRC
9 402010 LIFT ARM ASSY. 58-62HRC
10 405009 POSITION CRANK ASSY. 20-24HRC
11 405016 RETAINING PIN (BIG) 20-25HRC
12 403007 RESPONE VALVE 25-30HRC
13 402018 LINEAR 50-60HRC
14 104005 LINK PIN 25-30HRC
15 403006 BALL SHEET 50-60HRC
16 104006 LINCH PIN 25-30HRC
17 403002 PLUG 20-25HRC
89
18 104004 PIN 25-30HRC

19 401023 PIN 25-30HRC
20 4010106 SWIVEL PIN 25-30HRC
21 402021 INSERT 40-45HRC
22 402016 ROCK SHAFT 50-55HRC
23 405023 DRAFT LEVER ASSY. 35-40HRC
24 405013 POSITION LEVER ASSY. 35-40HRC
25 405007 DRFT CRANK ASSY. 20-40HRC
DIFFERENTIAL
P010300
1 5 P.T.O. COVER PLATE ( L ) 180-230BHN
P040600
2 1 P.T.O. COVER PLATE ( R ) 180-230BHN
3 401019 ROCKER LINK ASSY. 40-45HRC
4 407023 DRAW BAR 25-30HRC
M080500
5 7 WITHDRAWL NUT (PINION42X1.5) 25-30HRC
6 301005 PLATE ASSY. ( L ) 25-28HRC
7 301006 PLATE ASSY. ( R ) 25-28HRC
8 407025 LOWER LINK BRACKET ( L ) 25-30HRC
9 407026 LOWER LINK BRACKET ( R ) 25-30HRC
FRONT AXLE
S.NO. PART NO. DECRIPTION HARDNESS
1 502013 STEERING ARM ( L ) 210-240BHN
2 502009 STEERING ARM ( R ) 210-240BHN
3 502007 HUB CAP 130-180BHN
4 501021 DOWEL LEEVE 20-25BHN
5 502008 O-RING HOLDER 20-25BHN
6 501003 PIN ( TOE HOOK ) 35-42BHN
7 502002 WEAR RING ( STUB AXLE ) 45-50BHN
8 502015 KING PIN 45-50HRC
9 501010 PIVOT PIN 25-35HRC
90
HARDWARE
1 P0609002 RUBBER PAD ( FLY WHEEL ) SH 65 ±5
2 301002 WHEEL BOLT ( REAR AXLE ) 20 - 25HRC
3 301003 WHEEL NUT ( REAR AXLE ) 20 - 25HRC
M080600
4 1 STUD ( M16X1.5 ) 20 - 25HRC
5 P0301007 RUBBER PAD ( FENDER ) SH 80 ±5
6 104007 DRAIN PLUG ( M24X1.5 ) 20 - 25HRC
7 1003009 HOSE PIPE SH 60 - 65
8 402025 O RING SH 65 ±5
M081100
9 0 COPPER WASHER 40 -45HRC
10 406034 SPECIAL STUD 20 - 25HRC
11 406031 SEALING WASHER SH 65 ±5
12 106020 O RING (B.P.S.) SH 65 ±5
13 401022 O RING (SENSOR) SH 65 ±5
15 406025 SEALING RING SH 65 ±5
16 402012 SEAL RING (ROCK SHAFT) SH 65 ±5
GEAR BOX
1 P0204009 INNER BUSH 180-230BHN
2 P0210004 SHIFTER LEVER 50-60HRC
3 P0210005 SHIFTER LEVER (HI - LOW) 55-60HRC
91
4 P0203017 BOTTOM COVER PLATE 180-230BHN

5 207024 IDLER CLUSTER PIN 58-63HRC
38-43 HRC
6 203010 LOCKING PIN
30-40 HRC
7 207015 WITHDRAWL NUT (C.S.) 25-30HRC
GEAR AND SHAFTS

S.
NO. PART NO. DESCRIPTION HARDNESS
58-63HRC
1 P0105001 BULL GEAR
2 P0105005 BULL PINION SHAFT ( L ) 58-63HRC
3 P0105016 BULL PINION SHAFT ( R ) 58-63HRC
4 P0207020 C. M. GEAR Z-43 DUAL 58-63HRC
5 P0102002 CONNECTING SHAFT SMALL 58-63HRC
6 P0207023 CONNECTING SHAFT BIG 58-63HRC
7 P0207005 CONSTNT MESH GEAR Z-45 58-62HRC
8 P0105009 CROWN WHEEL Z-42 58-62HRC
9 P0207019 DRIVE SHAFT Z-21 58-62HRC
10 P0207002 FIXED GEAR Z-25 58-62HRC
11 P0207003 FIXED GEAR Z-30 58-62HRC
12 P0207004 FIXED GEAR Z-36 58-62HRC
13 P0207015 IDLER CLUSTER GEAR Z-15, Z-21 58-63HRC
14 P0205001 INPUT SHAFT Z-19 58-60HRC
15 P0206001 INTERMEDIATE SHAFT 58-63HRC
16 P0206008 INTERNAL GEAR (4+1) 58-63HRC
92
17 P0206009 OUTPUT SHAFT 58-63HRC

18 208009 PLANET GEAR 60-62HRC
19 P0102006 PTO SHAFT (21 SPLINES) 52-60HRC
20 206020 SLEEVE HI/LOW 50-55HRC
21 P0206002 SLIDING GEAR 34/12 58-63HRC
22 P0206003 SLIDING GEAR Z-31 58-63HRC
23 P0206004 SLIDING GEAR Z-24 58-63HRC
24 101001 TAIL PINION 58-63HRC
25 105006 CROSS 58-63HRC
26 105007 BEVEL GEAR ( L ) 58-63HRC
27 105008 BEVEL GEAR ( R ) 58-63HRC
28 105011 BEVEL PINION 58-63HRC
93
Project No. 2
AIM: - To implement power steering on the tractor to make the steering simpler and
easier.
REQUIREMENT OF THIS PROJECT
 Larger amount of torque is required to be applied by the driver for steering of

medium and heavy vehicles
 Heavy vehicles such as Off-road trucks, fork lifts, earth moving machines, and
tractors demands high steering forces.
 Mechanical linkage between the steering wheel and the steered wheels would be
more difficult and expensive in compact design vehicles.
APPLICATIONS
• Agriculture
• Construction
• Forklift trucks
• Lawn and garden
• Mini tractors
94
• Municipal vehicles
COMPONENTS OF POWER STEERING
1. STEERING WHEEL: - its diameter is 350mm [14 inch.], 3 spoke steering wheel with
knob standard and optional horn button.
2. STEERING COLUMN
 Steering columns connect the steering wheel to the steering unit.

 The steering column must be supported when its length exceeds 150 mm.
 The mounting of the steering column must be properly aligned so that the
steering unit can return to neutral position automatically after a steering action
has been completed.
 The construction of the steering column must ensure that no axial or radial forces
are transferred to the steering unit input shaft.
95
3. STEERING UNIT
 It has four ports, one is connected to tank or reservoir, one is connected to pump,
and remaining two is connected to steering cylinder.
 It controls the flow of oil in different ports.
 It is rigidly fixed with steering column.
4. TANK
 It provides the oil to the pump.
 It has two ports one is connected to steering column and other is connected to
pump.
96
 The oil used must be filtered for better working of the system.
 A magnetic insert is recommended when using filters larger than 25 micron.
5. STEERING CYLINDERS:-
 The steering cylinder used in this power steering is double acting balanced
cylinder.
 Balanced cylinders are compact and eliminate differences between steering
wheel turns and steering forces because of equal volumes.
6. PUMP:-
 The hydraulic power for the steering is provided by a rotary-vane pump (see
diagram below).
97
 This pump is driven by the tractor's engine via a belt and pulley.
 Correct pump sizing is important in avoiding unnecessary energy consumption,
or slow response to steering demand.
 It supplies the required pressure to oil.
98
LAYOUT OF HYDROSTATIC
POWER STEERING
99
HOW TO SIZE THE CORRECT STEERING SYSTEM

STEP 1. TOTAL STEERING TORQUE:-
Total steering torque, T = C.f (√B2/8 + E2 ) kgmm
Where C = Load on the steered axle (in kgmm)
E = King pin offset (in mm)
B = Tyre breadth (in mm)
LOAD ON THE STEERED AXLE,
C = 1030 (LOAD ON FRONT STEERING)
+2000 (Load of the loader)
C = 3030 kg
100
E/B = 60/190 = .316

(WHERE B=190,E=60)
F = 0.4 (from above graph )

Where f = coefficient of friction(dimensionless).Based on 0.7
As maximum.
T = 3030X0.4 √(190)2/8+(60)2 kgmm
= 3030X0.4X90.07 kgmm
T = 109164.13 kgmm
STEP 2. FORCE REQUIRED FOR AXLE :-
F= Mr/Rmin.
Where F = Required piston rod force (in kg),
Rmin. = Minimum effective radius arm (mm)
F= 109164.13/100 kg
F = 1091.64 kg
101
A = F/P cm2
Where A = Pushing cylinder area (mm2),
P = Steering max. pressure in bar
A = 1091.64/90 = 12.13 cm2
A = 1213 mm2
STEP 3. SELECTING STEERING UNIT DISPLACEMENT :-
Before proceeding further, a decision must be made as to the number of steering wheel
revolutions desired for the application to steer the axle from full one side to the.
1/2 1/2
Depending on vehicle usage, this will vary, normally 2 to 5 with 4 being a good
typical value.
Area of cylinder, A = Π/4[(D)2-(d)2] = Π/4[(60)2-(36)2]
A= 1808 mm2
As 1808 > 1213
Therefore it is acceptable.
Stroke length, S = 175 mm
Volume, V = 1808X175mm3 = 316400mm3
V = 316.4 cm3 ,The volume of oil required to move cylinder rod(s) through the entire
stroke.
Total wheel turns, N = 3
Therefore, steering unit displacement, Cu = V/N = 316/3 cm3/rev.
Cu = 105 cm3/rev.
As the calculations are complete, we select the closest standard steering unit
displacement (i.e. 100 cc unit) from catalog information.
STEP 4. CALCULATING REQUIRED PUMP FLOW :-

We select Dowty pump IP 30 28,which has discharge of 12.7 liter at 1500 rpm.
At 1000 rpm its discharge will be = 12.7X1000/1500
= 8.5 liter/min.
102
Hence at 1000 engine rpm, we shall be able to get 8.5 liter./min. which means we can
steer wheel = 8.5X1000/100 = 85 rpm which is fairly ok and at 2000 rpm of engine
we shall be able to steer wheel by 170 rpm.
STEERING TROUBLE SHOOTING
1. EXCESSIVE BACKLASH IN STEERING:- The most probable cause of this

trouble is the slackness in the steering linkage due to wear of bell joints and
steering.
2. WANDER:- When the vehicle is being driven straight, it turns slightly to one side
and when the driver turns the steering to bring it back to the straight ahead, it
turns slightly to the other side, thus the driver has to adjust steering constantly to
keep the vehicle direction straight, the effect is called wander.
3. PULLING TO ONE SIDE:- Sometimes the vehicle constantly pulls towards one
side.
4. WHEEL WOBBLE(LOW SPEED SHIMMY):- The oscillation of the front wheels
at low speeds is called wobble.
5. HIGH SPEED SHIMMY:- The oscillation of the front wheels at high speed is
called high speed shimmy.
6. WHEEL TRAMP:- Sometimes the front wheels of vehicle at high speeds
vibrate so violently that an almost uncontrollable motion of the vehicle is
103
caused that is called wheel tramp.

7. EXCESSIVE TYRE WEAR:- This is normally due to incorrect tyre
pressure, excessive toe-in or toe-out.
8. HARD STEERING:- When the effort required for steering is more than the
normal steering force.
9. POOR RETURNABILITY:- Poor return of the steering wheel to centre may be
due incorrect tyre pressure, tight or frozen steering shaft bearing, and incorrect
front wheel alignment.
BENEFITS
 Minimizes steering linkage-reduces cost, provides flexibility in design.
 Provides complete isolation of load forces from control station-provides operator
comfort.
 Provides continuous, unlimited control action with very low input torque.

Garav

Hochgeladen von

Dokumentinformationen

Originalbeschreibung:

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Garav

Hochgeladen von

Copyright:

Verfügbare Formate

1

I attribute my Honours’ in showing my feelings of indebtedness and

S. No. Text Page No

9. Gear Box Assembly 57

10. Rear Cover Assembly 67

12. Other Departments 77

Date: January 5, 2009 Gauravjit Singh

History of the firm:

1.PRODUCT RANGE FOR TRACTORS

• Present scenario of plant: -

1. Our company is ISO 9001: 2000 certified company.

2. Combine harvesters are manufactured on organized assembly

3. Plant is equipped with latest CNC turning machines for machining of

4. Company is having one another fully computerized Turret punching

1. Company has installed Laser oscillator machine from MAZAK Japan.

3. Dip Painting of sheet metal will be install soon.

 The company participated in KISSAN MELA organized by Punjab Agricultural

• Market share: To maintain its status as brand leaders in the country

FLOW CHART OF MANUFACTURING PROCESS

Production Planning & Control (PPC)

Quality Control Department

Pre Delivery Inspection (PDI)

The process of manufacturing is rather a complex one though it seems to be simple.

Technical Specifications of Tractors

DESCRIPTIO PREET 3549-

136Nm @ 1300 150Nm @ 1300 175.5%Nm @ 136Nm @ 1300

8 + 2 Sliding 8 + 2 Sliding 8 + 2 Sliding 8 + 2 Sliding

ROAD SPEED Km/Hr

3 Point Linkage 3 Point 3 Point 3 Point 3 Point

POWER TAKE OFF

P.T.O. Speed 1000 1000 1000 1000 1000

Air Cleaner 0.75 0.75 0.75 1 1

Steering 0.5 0.5 0.5 0.5 0.5

Front 6.00x16 6.00x16 6.00x16 6.00x16 7.50x16

Rear 13.6x28 13.6x28 13.6x28 14.9x28 16.9x28

Weight (Kgs) 1945 1945 1945 1945 2170

A tractor is a vehicle specifically designed to deliver a high tractive effort at slow

In 1889 first time a tractor manufactured by a company in which internal

Incoming Quality Control is a department at preet tractor ltd. which checks

MEANING AND NEED OF QUALITY AND QUALITY CONTROL

NEED: The quality control is needed due to the following reasons:

BENEFITS OF QUALITY CONTROL

In IQC Department Incoming Raw Material are inspected in order to:

• Inspection of raw material may involve a visuals check up only, a

 Transmit needs to supplier.

 Provide feed back to supplier

 Obtain feed back from supplier

 Plan process to meet customers need.

 Control process to meet customers need.

 Improve process based on customers feed back.

 Know who are customers

 Understand the needs of customers.

 Avoid creating problems for customers

 Obtain feed back from customers.

TESTING PROCEDURE OF THE COMPONENTS

The components are tested by the following procedure:-

Hardness of the material is generally checked by Rockwell hardness testing machine,

QUALITY IMPROVEMENT SYSTEMS

 WASHERS:-There are 96 types of different WASHERS which are

 RUBBER ITEMS: - There are 80 types of different RUBBER ITEMS which

 SPRINGS: - There are 50 types of different SPRINGS which are checked

 SUCTION PIPES: - There are 54 types of different SUCTION PIPES