112537953-hmt-report of training and development

8/12/2019 112537953-hmt-report of training and development

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REPORT

On

6 Weeks Industrial Training

At

HMT Ltd. Pinjore

(From ! ma" #! $ % june #!&

'umitted To.

Mr. ). *. +ro,er

'umitted "-

Rakes *ausik

MMU

A/*0OWLE1+EME0T

Firstly, I wish to express my deep gratitude to all the concernedpersons without whose generous cooperation and coordination, it would

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have been very difficult for me to have a successful training experience in

the organization.

It would like to thank Mr. ). *. +ro,erfor giving me a golden

opportunity of industrial training, which would help me to enhance my

technical skill and helps me a lot besides some technical skills.

I am extremely grateful to the management of HM, !in"ore for

giving me an opportunity to pursue four months training in their reputed

organization. his provides me a wonderful and learning experience for

me to go through this training.

Finally, I would like to thanks all those colleagues who help me out

of intensifying my technical knowledge and provide satisfactory solutions

to my all #ueries.

Inde2

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'r. no. Parti3ulars Page no.

I. $ection %

&. Introduction '

(. )ompany profile *+

-. raining centre '. Foundry Mechanism &/+&'

*. Heavy Machine $hop &*+&0

1. 2ight Machine $hop &+(/

0. Heat reatment (&+((

. 3ngine %ssembly and esting (-+(

. ractor %ssembly (+-'

I. I0TRO14/TIO0

he country, India, is basically an agricultural country where more

than 1* 4 of population population, enough food has to be produced.

his cannot be produced with our conventional bullock drawn

implements. $o there was need felt to invent such machine which speeds

up the agricultural production. 5ue to this reason the tractor wasinvented.

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6efore we start, it is necessary to know how the word 7tractor8 is

derived. !rior to &//, the machine i. e. tractor is known as traction

machine 9pulling machine:. %fter &//, both the words "oined by taking

7tract8 from traction and 7tor8 from motor calling 7tractor8. he tractor is

the machine which is used for applying high traction.

In our country, tractors were started manufacturing in real sense

after independence and at present, we are self sufficient in meeting

demand of country8s re#uirements for tractors. %t present in India, there

are different tractor producing factories present like Hindustan machine

tools, !un"ab tractors, ;irloskar tractors, etc is directly or indirectly

connected to agriculture. Moreover for increasing

.

II. /OMPA05 PROFILE.! irt o7 HMT

In &' the idea of public sector tools was commissioned to be a corner stone

for the government8s industrial development plans. his led to the birth of

HI2$ at 6angalore in &*- which started a single

machine tools factory to produce lathes at 6angalore, in collaboration with M?s

>erlikon of $witzerland.

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he main products produced by HM ltd are D

Machine tools,

@atches,

ractors,

6earings,

!rinting Machinery,

5ie )asting Machinery.

he divisions of HM are described below D

..! angalore

It produces lathes 9both )


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.. H"deraad

It produces the machining centers, )


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he retrofitting includes center less grinders and double disc grinders.

%fter establishing two machine factories and a watch factory in 6angalore, the

!in"ore unit was established as the third machine tool factory. 6reaking the ground on

(ndmay, &1(, this factory

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III. TRAI0I0+ /E0TRE

In training centre, the basic machines are studied such as 2athe Machine,

Milling machine, 5rilling Machine, etc.

9.! 'tru3ture o7 Training /entre

raining center is divided into four sections,

&. urning section,

(. Fitting section,

-. Milling section,

'. ractor training section.

9. Turning 'e3tion

In turning section, we have learnt about the lathe machine which is mother of

all machines and play a basic role in mechanical line.

9..! Late Ma3ine

2athe is probably the oldest machine tools. he basic idea about turning or

lathe machine came out in &0 century. =ntil &00/, lathes were useless metal cutting

because they lacked power and holding device, were not strong enough and accurate

enough to guide the tools. For its development to the form in which we know it now,

we owe much to Henry Muldsley, who developed the sliding carriage and in &/

built a screw cutting lathe.

9.. /lassi7i3ation o7 Late Ma3ine

&. 3ngine 2athe,

(. $peed 2athe,

-. urret 2athe,

'. oll Eoom 2athe,

*. Hollow $pindle 2athe,1. )apstan 2athe,

0. 6ench 2athe.

2athe is also called )omplete Machine. his single machine can do number of

operation.

9..9 Fa3ing

his operation is carried out to produce flat surface at the end of part, which is

useful for parts that are attached to other components, or face grooving to produce

grooves for >+ring seals.

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9..: 1rilling

In this process a drilling of desire diameter is held in the tail stock and the

operation of drill is carried out.

9..; oring

In this enlargement of hole or cylinder cavity made by previous process is

done. It improves accuracy and surface finish.

9..6 Treading

In this operation internal and external threads on the surface are prepared.

9..< *nurling

In this operation a regularly shaped roughness is prepared on the cylindrical

surface for fascinating easy gripping.

9.9 Fitting 'e3tion

Fitting work is very important work in engineering. In fitting shop unwanted

material is removed with the help of hand tools. It is done for mating, repair and

manufacturing purpose. he person working in fitting shop is called as fitter.

)ommonly used tools are hacksaw, files, chisels etc.

9.9.! Tools 4sed in Fitting 'o=

&. )lamping ools

(. Measuring and Marking ools

-. )utting ools

'. $triking ools

*. 5rilling ools

9.: Milling 'e3tion

Milling machine were basically developed to machine flat surface. 6ut, the

present machine can machine flat, countered and helical surfaces, cut gears and do

various other "obs. 5ue to this all milling machine is one of the most useful and

necessary machine tools found in the shop and it rank next to the lathe in importance.

Milling machine are designed to hold and rotate milling cutter or cutters, hold

the work piece and feed the work piece to the milling cutter in one several directions.

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I). FO401R5 ME/HA0I'M'

$ince there are certain basic steps in the metal casting process, these may be

used as unit of mechanism.

!rocessing steps which lead them to the mechanism are,

1. $and preparation,

2. )ore making,

3. Moulding, pouring and shakeouts,

'. Melting,

*. )leaning.

Foundry is divided into following section,

&. $and plant system,2. $and handling system,

3. )ore making and baking system,

'. Moulding making and handling,

*. )ore setting system,

1. Melting system,

7. Metal pouring system,

8. esting lab,9. Fettling section,

10. !ainting and printing section.

:.! 'and =lant s"stem

he main ob"ective of it is to reuse the used lad to the installation of sand plant

system. he vital task of sand plant system is to deliver well prepared sand at re#uired

place that will determine the efficient working of the foundry. %fter casing are

knocked out of moulding box on a vibratory shakeout box that the used sand is

returned to the fixed amount of new sand, binders, catalysts and hardeners to get to

the re#uired composition of the sand. Areen sand, dry sand and oil sand are being

prepared in the sand plant. hese constitutes are added in Muller in which all contents

are mixed thoroughly and then supplied via belt conveyor system to working stations.

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+reen sand 3om=osition>

Muller batch capacity 0// kg


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%s patterns are made to get to outer shape of the casting, the inner shapes are

used to for whole generation core placed in the moulds. %s the core comes in contact

of molten metal that must possess following characteristics

&. )ore sand must have high strength to bear the pressure of metal when poured.

(. he sand must have high refractory characteristics so that it may not fuse due

to high temperature being in contact with molten metal.

-. It must have high cohesive property so as to get good finish castings.

Gircon paint 9alcohol base: dried "ust by lightning it up. 2arge and heavy cores

are baked along with the dry sand moulds in oven.

)ore drying cycles for oven

-///) D & hrs.

(/// ) + ( hrs.

)ooling time in oven - hrs.

%fter baking, the hardness is tested by using hardness meter

:.: Mould making se3tion

Moulds are being made on moulding machine pedantically powered rammers.

Metallic patterns are being used. %fter mould being made on moulding machine, it

goes to sand cutter which removes extra sand present and level the mould base, from

on to the power operated roller conveyor, the mould is handled using the swing type

crane. )ore setting is done in drag part of mould. Gircon painting is sprayed on to the

mould 9as paint is alcohol based hence get dry up by lighting fire:.

:.:.! Mould aking

5ry sand moulds are to bake to ac#uire hardness to with sand the pressure

produced by the flow of molten metal. hese are baked in ovens. Mould baking cycles

for ovens -//) for ( hrs. and )ooling time in oven - hrs.

:.:. Melting se3tion

It is having two types of furnace.

&. 3lectric induction furnace,

(. )opula furnace.

:.; Fettling

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%fter they are knocked out on vibrator shake, the casting head to be finished

by the removal of pro"ections whether they are gets riser or runner that where there as

a part of design aspect or the pro"ection which has appeared as a defect like fins or

blow holes. he process that involves all these procedure of casting finish is termed as

fettling.

Fettling operation is divided into following stages

&. ;nocking out of dry sand cores,

(. Eemoval of gates and risers,

-. 3xtraction of fins and other pro"ections,

'. )leaning and smoothing of the surface,

*. Eepair casting by filling of the blow holes, straightening the wrap or deformed

casting.

:.6 Priming and =ainting

%fter all the cleaning process has been performed then the final step is priming

and the painting casting. he machine tool castings are generally big and are handled

with crane during painting. !ainting is done by brushes only.

). HEA5 MA/HI0E 'HOP

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;.! Introdu3tion

In heavy machine shop all the heavy part of tractor are machined like gear box

housing, Main transmission housing, Front cover etc. all the parts undergoes different

operations like milling, boring, drilling, tapping, slotting etc. in HM$ section.he entire machines in this section are special purpose machine it means the

machine doing special or specific operation on a "ob.

he advantage of special purpose machine is that it increases the rate of

production. he machines are capable of machining any number of identical parts in a

very less time.

;. Parts Ma3ined in HM'

&. Aear box housing(. Main transmission housing

;..! +ear o2 Housing

Aear box housing is used for fitment of gears and shafts. he material used for

Aear box housing is cast iron.

*.(.&.& !rocess of Aear 6ox Housing

'r. no. O=eration

&. Marking the gear box housing

@ith help of crane, we put the housing on the surface plate and after thiswith the help of vernier height gigue we mark the gear box housing.

Marking is done of the gearbox is done for remove the all allowances

material.

(. 6ottom Milling

@ith help of crane we put the work piece on the milling machine 9$!M:.

6ottom milling is done for removing the extra material on the gear box

housing.

-. 5rill the location hole on the gear box housing. 2ocation holes are made

for fix the housing on the different machine.'. op Milling

!ut the housing on milling machine according to location holes. op

milling done for removing the extra material on the housing.

*. Front and Eear )over

%ccording to their location of hole we fix the work piece on the milling

machine. For removing the all allowance on to the housing.

1. 2eft %nd Eight Milling

For removing the all allowance on to the housing.

0. $lot milling

In this milling we made the slots for gear forks which used for change the

gears. 5imension of slot is &1mm.

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. 6oring

6oring is done for removing extra material from bores to make the bore

according to their dimensions.

. !re 6oring of $teering 6ore

!re boring is done for removing the allowance from steering bore.

&/. Heavy 5uty 5rillingIt is done for making the drilling in to the housing for "oining purpose.

&&. 6ottom Milling Housing

(/ drills simultaneous.

&(. apping

apping is for making the internal thread in to the drilled holes and for

"oining purpose.

&-. 5rill for )lutch and !edal

For "oining the clutch and pedal drilling is done on both faces right and

left on the gear box housing.

&'. Final bores on the all bores i. e. steering bore, reverse gear and shaft

boring on the boring machine.

&*. @ashing for the gear box housing in the washing machine.

&1. Inspection of the Aear box housing according to design.

;.. Main Transmission Housing

Main ransmission Housing is manufacturing in heavy machine shop. M..

Housing is used for setup the differential and axle assembly. Material used for M.

Housing is cast iron.

*.(.(.& Manufacturing procedure of M. Housing

'r. no. O=erations&. Marking M. Housing

@ith help of crane we put the housing on the surface plate and after this

with the help of vernier height gauge we mark the M.. Housing according

to their dimension. @hite paint is used foe marking.

(. Horizontal Milling.

Horizontal milling is done for removing the extra material or allowances

according to their drawing

-. Eadial 5rilling

Eadial drills are used for the made the location holes in the housing and

these locations are used for seat the "ob on the different type of machine.

'. Milling of M.. Housing

In this operation milling of four faces is done front, rear, left and right. In

operation we fix the "ob on their location and holes and after we do milling

*. 6oring

In this boring operation we do rough boring of front, left right bores.

1. 5imensions of bores

2eft hand bore (/mm.

Eight hand bore ( front hand bore /mm

0. Horizontal milling on front

Horizontal milling is done for remove the extra material or allowances

according to their drawing. Horizontal milling is done on $!M milling

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machine.

. 6oring finish

%fter horizontal milling we put the housing on the boring machine on their

location holes. it is done for finishing purpose.

. @ashing

@ashing is done to remove chips and oil. this is done after all the

operation.

&/ Inspection

Inspection of work piece according to their drawing.

)I. LI+HT MA/HI0E 'HOP

6.! Introdu3tion%s the name suggests that in this section light parts or small parts of tractors

are machined such as speed gears of tractor, sun planet gears crown wheel, !>

shaft, clutch shaft, spline shaft, front and rear axle.

6. '=line sa7t

% shaft with longitudinal gear like ridges along its interior or exterior surface

is called spline shaft. the function of spline shaft is to transmit the power from

flywheel to lay shaft. Material used for spline shaft is low carbon steel.

6..! Pro3ess 7or s=line sa7t

&. Eaw material from vendors.

(. )utting of shaft.

-. Facing and centering.

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. Fitting.

. @ashing.

10. Inspection.

&&. Aear shaving.

&(. 6ench drilling.

%fter these process spline shaft send to heat treatment plant for hardening

process.

&. Aas carburizing hardening.

(. empering

-. $hot blasting.

'. $traightening.

*. )entre grinding.

1. Internal grinding.

0. Fitting.

. Inspection

6.9 e,el Pinion 'a7t

6evel pinion shaft is used for transmit the power from gear box to differential.

he material used for it is low carbon steel.

6.9.! Pro3ess 7or e,el Pinion 'a7t

&. Eaw material from vender.

(. Material cutting.

-. Facing and centering

'. urning on s+pilot machine.

*. Inspection according to drawing.

1. Aear hobbing.

0. Fitting.

. @ashing and inspection work piece.

. Aas carburizing hardening.

&/. %nnealing.

&&. urning.

&(. )ylindrical grinding.

&-. hread rolling.

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&'. 5rilling.

&*. empering.

&1. $hot blasting.

&0. $traightening.

18. @ashing inspection of the bevel pinion shaft.

6.: Weel 'a7t

@heel shaft is assembled in axle housing and its transmit tor#ue to wheels.

6.:.! Pro3ess 7or Weel 'a7t

&. Eaw material from vender.

(. Facing and centering on lathe machine.

-. 5rilling.'. Eadial drilling.

*. Aear hobbing.

1. Inspection according to drawing.

0. Induction hardening.

. empering.

. )ylindrical grinding.

&/. hreading.

&&. Fitting.

&(. Horizontal milling.

&-. Fitting

&'. Inspection according to drawing.

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)II. HEAT TREATME0T%ll components 9manufactured in 2M$: after undergoing machining operation

are sub"ected to heat treatment. It is done so as to improve hardness and strength of

these components viz. gears and shafts.

6asic operations performed during heat treatment

&. Hardening,

(. Juenching,

-. %nnealing,'. empering,

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Hardening is performed on the various metals and its alloys to provide them

with strength and wear resistance. It is accomplished by heating the component above

its hardening temperature and #uenching it in water.


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(. !ut the "ob in the H solution for &/ to (/ min. for de+greasing or

decomposition.

-. @ash it with warm water.

'. 5e+rust the "ob in the rust solution.

*. @ash it with water.

6. $hift it to blackening furnace at &(// ) for &/ D (/ min. according to sectional

area

)III. E0+I0E A''EML5 A01 TE'TI0+

he engines of different models are assembled and tested in this shop as per

standard procedures.

.! Engine Asseml"

In this shop, whole of the engine is completed and ready for the tractor

assembly. he various parts of engine from manufacturing section are brought in this

section and they are assembled to prepare the whole engine. he engine assembly can

be divided into following steps.

&. @ashing of crank case with a special soap solution and drying it by means

of air "ets.

(. Fitting of cylinder sleeve.

-. Fixing of studs and fitment of crank shaft in crank case.

'. Inserting pistons in cylinder sleeve.

*. %ssembling the lubrication pump and fitment of cam shaft.

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1. Mounting of flywheel with clutch assembly.

0. Fixing of cylinder head on the top of the cylinder sleeve.

. !utting tappets, push rods and rocker arm for opening and closing the

valves.

. %ttaching the fuel filters and oil filter.

&/. Mounting the fuel in"ection pump and in"ection lines.

&&. Fitting the self starter and alternator.


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control rack is in its opposite position he pump deliver the maximum amount of fuel.

%t the side fuel gallery into intake parts a relief valve is mounted which maintains a

constant pressure of & kg?cm(on the intake port and the excessive amount of fuel is

returned by this valve back to the tank. @hen starting the engine, by making the use

of excess fuel, starting spring is fitted in governor which returns the control rack is

obtained for the purpose of maximum delivery of fuel at maximum in"ection delay. %t

the opposite side of drive, the output governor is mounted which serves for regulating

the engine output at higher performance revolutions. he range of governing is given

by variable speed of engine.

he governor controls the amount of in"ected fuel into the engine, with set up

revolutions, in accordance with the taken of power. 5ecrease or increase of

revolutions at a higher or lower load of engine is called unevenness of output

governor. If the governing spring is set up from operator place to certain revolutions,

the governor shift the link member of pump into such position which at a certain

instantaneous load of engine corresponds to these selected revolutions.

Terminolog" /onne3ted Bit Engine PoBer

1. 6ore 6ore is the diameter of the engine cylinder.

(. $troke It is the linear distance traveled by the piston from top dead center to

bottom dead center.

-. $troke bore ratio the ratio of length of stroke and diameter of bore of the

cylinder is called stroke bore ratio this ratio vary between &

to&.'* and for tractor engine and this ratio is about &.(*.

4. $wept volume It is the volume 9% L 2: displaced by one stroke of the piston.

@here % is the cross sectional area of the piston and 2 is the

length of stroke.

*. )ompression ratio it is the ratio of the volume of the charge at beginning of

the compression stroke to that at the end of compression stroke

that8s mean ratio of total cylinder volume to clearance volume.

6. !ower It is the rate of doing work. It is expressed in watt in $I unit.

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7. Indicated power it is the power generated in the engine cylinder and received

by the piston. It is the power developed in the cylinder without

friction or auxiliary unit.

. 6reak power It is the powered delivered by the engine and is available at end

of the crankshaft.

9. 6elt power It is the power of the engine measured at the end of a suitable belt

receiving drive from the !> shaft.

&/. 5rawbar power It is the power of a tractor, measured at the end of the

drawbar. It is the power, which is available for pulling loads at

the drawbar.

11. !ower take off power it is the power delivered by a tractor through its !>

shaft.

12. Frictional power It is the power re#uired to the engine at a given speed

without producing any useful power. It represents the friction

and pumping losses of an engine.

13. Mean effective pressure it is the average pressure during the power stroke

minus the average pressure during other strokes. his pressure

actually forces the piston down during the power stroke.

14. Columetric efficiency It is the ratio of actual weight of air introduced by the

engine on the suction stroke to the theoretical weight of air that

should have been introduced by filling the piston displacement

volume with air at atm. !ressure and temp.

15. or#ue % turning effect due to force applied on some point is called tor#ue.

16. $pecific fuel consumption It is the #uantity of fuel consumed per k@+hr. in an

engine.

17. 6rake mean effective pressure It is the average pressure acting throughout the

entire power strokes, which are necessary to produce brake

power of the engine.

18. Mechanical efficiency It is the ratio of brake power to indicated power.

19. hermal efficiency It is the ratio of output in the form of useful mechanical

power to the power value of the fuel consumed.

Engine 3om=onents

Internal combustion engine consists of number of parts which are given as below

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1. )ylinder It is part of the engine which confines of the expanding gases and

forms the combustion space. It provides space in which piston operates to suck

the air or air fuel mixture. )ylinders are usually made of high grade cast iron.

2. )ylinder block It is the solid casting which includes the cylinder and water

"ackets.

3. )ylinder head It is detachable portion of an engine which covers the cylinder

and includes the combustion chamber, spark plug and valves.

4. )ylinder liner or sleeve

It is cylindrical lining either wet or dry which is inserted in the cylinder

block in which the piston slides. )ylinder liners are fitted in the cylinder bore

and they are easily replaceable. he overhauling and repairing of the engines,

fitted with liners is easy and economical. 2iners are classified as

a. 5ry liner and

b. @et liner

A) 5ry liners make meal to metal contact with the cylinder

block casting.

6: @et liners are come in contact with the cooling water,

where as dry liners do not come in contact with the cooling

water

5. !iston it is cylinder part closed at one end which maintains a close sliding fit

in the engine cylinder. It is connected to the connecting rod by a piston pin.

he force of the expanding gases against the closed end of the piston , forces

the piston down in the cylinder. his causes the connecting rod to rotate the

crankshaft. %luminum and its alloy are preferred to made piston.

Head 9)rown: of piston it is the top of the piston.

$kirt it is that portion of the piston below the piston pin which is designed to

absorb the side movements of the piston.

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6. !iston rings it is split expansion ring, placed in the groove of the piston. hey

are usually made of cast iron or pressed steel alloy. the functions of the rings

are

%: It forms a gas tight combustion chamber for all positions of

piston.

6: It reduces contact area between cylinder wall and piston

wall for preventing friction losses and excessive wear.

): It controls the cylinder lubrication.

5: It transmits the heat away from the piston to the cylinder

wall.

!iston rings are of two types

%: )ompression ring and

6: >il ring

7. !iston pin it is also called wrist pin or gudgeon pin . it is used to "oin the

connecting rods to the piston.. it provides a flexible or hinge like connection

between the piston and the connecting rod. It is usually made of case hardened

alloy steel.

8. )onnecting rod it is special type of rod. >ne end of which is connected to

piston and the other to the crankshaft. It transmits the power of combustion to

the crankshaft and makes it rotate continuously. It is usually made of drop

forged steel.

. )rankshaft

It is the main shaft of an engine which converts the reciprocating

motion of the piston in to rotary motion of the flywheel. =sually the

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crankshaft made of drop forged steel or cast steel. )rankshaft is provided with

counter weights throughout its length to have counter balance of the unit.

&/. Flywheel Fly wheel is made of cast iron. It stores energy during power stroke

and returns back the same energy during the idle strokes .engine timing marks

are usually stamped on the flywheel which helps in the ad"usting the timing of

engine.

11. )rankcase the crankcase is that part of the engine supports and encloses the

crankshaft and camshaft it provides the reservoir for the lubricating oil of the

engine. It also serves as a mounting unit for such accessories as the oil pump ,

oil filter, generator, starting motor and ignition components.

&(. )amshaft

It is shaft that raises and lowers the inlet and exhaust valves at propertime. he speed of the camshaft is exactly half the speed of crankshaft in four

stroke engine. It is mounted in the crankcase parallel to the crankshaft.

13. iming gear timing is a combination of gears one gear of which mounted at

one end of camshaft and other gear on the end of crankshaft. iming gear

controls the timing of ignition, timing of opening and closing of valves as well

as fuel in"ection timing.

14. Inlet manifold it is that part of engine through which air or air fuel mixture

enters into the engine cylinder. It is fitted by the side of the cylinder head.

15. 3xhaust manifold it is that part of engine through which exhaust gases go out

from engine cylinder. It is fitted by the side of the cylinder head.

. Engine testing

%fter assembly, engine is brought to engine testing section. In this section,

practical checking of engine is done on engine. Firstly the water supply is given to the

engine and then started it with external 5) supply. 5uring running the engine, the

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load is varied and various terms are checked such as lubricating oil pressure, load

capacity, fuel consumption, tor#ue, operating temperature, etc. hen proper operating

of valves is checked.

..! Pro3edure 7or Engine Testing

1.


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&&.


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0. 6umping clearance 9mm: /.0* K /.'

. In"ection tip 9mm: (.( D (.*. In"ection pressure 9bar: &/ K

&/. !iston ring end gap 9mm: +

First ring /.( D /.'

$econd ring /.' D /.1hird ring /.(* + /.*

&&.


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.9.: Model :%

'r. no. Parti3ulars '=e3i7i3ations

&. 6ore L $troke 9mm: &/( L &&/

(. 3ngine rated speed 9rpm: ((//

-. 3ngine fly up rpm ('// K 1/

'. $tatic in"ection timing 9/65): &'

*. appet clearance +

Inlet valve 9mm: /.-

3xhaust valve 9mm: /.'

1. Height of cylinder liner above cylinder block 9mm: /./1 + /.&(


. In"ection tip 9mm: (.( D (.*

. In"ection pressure 9bar: &/ K -&/. !iston ring end gap 9mm: +


$econd ring /.' D /.1

hird ring /.(* + /.*

&&.


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'r. no. Parti3ulars '=e3i7i3ations

&. 6ore L $troke 9mm: &/( L &&/

(. 3ngine rated speed 9rpm: (((/

-. 3ngine fly up rpm ('// K 1/'. $tatic in"ection timing 9/65): &'

*. appet clearance +

Inlet valve 9mm: /.-

3xhaust valve 9mm: /.'

1. Height of cylinder liner above cylinder block 9mm: /./1 + /.&(


. In"ection tip 9mm: (.( D (.*. In"ection pressure 9bar: &/ K

&/. !iston ring end gap 9mm: +


$econd ring /.' D /.1hird ring /.(* + /.*

&&. D

%.! +ear o2 'u Asseml">D

First gear box housing is put on the trolley and different type of the shaft and the gear

assemble in the gear box.

%. /lut3 Asseml">D

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)lutch is device used to connect and disconnect the tractor engine from the

transmission gears and the drive wheels. )lutch transmits power by mean of friction

between driving members and driven members. Aenerally dual clutch is used in the

HM ractors.

%.9 MT Housing Asseml">D

In this housing the differential unit and the hydraulic pump is fitted also it provide the

special arrangement of gears.

%.: Rear A2le Mounting>D

Mount brake shoes, brake shoes holder, expander unit, retractor spring wheel shaft

along with flange, tapered roller bearing, a bull gear along with spring and locked

device to prevent axial movement off bull gear, on the porter housing.

%ssemble rear axle housing on the portal and then assemble the crown on the

differential shaft around the brake shoes.

%.; Li7t Mounting>D

%fter mounting of axle on the differential lift is mounted on the main transmission

housing which is used for the load up to &(// kg and &'// kg.

%.6 Engine Mounting>D

%fter then engine is mounted on gear box and M housing and portal assembly with

the help of bolts.

%.< Front A2le Mounting>D

%ssembly front axle wheel hub, pivot, king pin, track record on the extension along

with locking devices, bush and bearings.

)onnect these two extensions with each other by the extension tube.

%. 'teering Asseml">D

'teering>D the system governing the angular movement of front wheel of tractor is

called steering system. his system minimizes the efforts of the operator in turning

the front wheel with the application of leverages.

%.% rake '"stem Asseml">D

6rake is used to stop or slow down the motion of tractor. It is mounted on the driving

axle and operated by two independent pedals. 3ach pedal can be operated

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independently to assist the turning of tractor during the field work or locked together

by means of a lock.

%.!# Wasing one- 1r"ing O,en and Painting>D

%fter mounting all the parts on the body it sends to washing zone for remove the

unwanted material like dust and machining material.

%fter washing of the body, it sends to oven for drying the body where we dry

it. %fter drying the body painting is done on the body. Arey paint is used for painting

the body and the chassis.

%.!! +reasing one

Areasing is done all the greasing points with the help of pneumatic gun.

he following are the grease points

&. Front wheel hub

(. Front axle extension

-. Front axle pin

'. )lutch shaft

*. Eight hand stud

1. hree point linkage

0. ie rod end

hree free play of foot brake is maintained (mm.

%.! Air /leaner- Radiator and Fuel Tank

%fter washing and painting air cleaner and radiator mount on the tractor body.

Heavy duty type of air cleaner is used in the tractors.

his is of oil bath type cleaner. It consists of a filter element saturated with oil.

%t the bottom there is separate oil pun. he air from atmosphere enter in to the gap

and when air takes turn it leaves the impurities there and after it impinging on the

surface of oil and leaves the impurities there and at last air pass through the filter and

cleaning of air is done.

%.!9 Air /leaner

%fter fitting the air cleaner radiator is attached with engine. he main purpose

of radiator is providing the cooling to the engine i.e. the remove the heat from engine.

@ater and alcohol is used as coolant in the radiator.

%.!: T"re Mounting

%fter attached all parts tyre is attached with tractors. %fter assembly the tyre

alignment of wheel is done.

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%.!; FolloBing ele3tri3al items are mounted-

&. Horn

(. Head 2ight

-. 6rake 2ight

'. !arking 2ight

*. !lough 2amp

1. 5irection Indicator

'E/TIO0

PROE/T WOR*

Oje3ti,es>

&.$tudy and documentation of stage wise assembly procedures in assembling

tractors of different models

.

(.ime and work force re#uirement study for assembling &// units of (*((, -1//

unit of -*((, &// unit of '/((, // unit of */((, // unit of 1*(( totaling ///

unit per annually.

.

-.%ction re#uired to be taken for increasing productivity and reduce in rework ?

re"ection at final ? different stages.

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TRA/TOR A''EML5

Introdu3tion

. %ll the tractors (*((, -*((, '/((, '*((, */(( and 1*(( are assembled here.

Tra3tor Asseml" Pro3edure

he detailed procedure of tractor assembly is given below.

+ear o2 'u Asseml"

First gear box housing is put on the trolley and different type of the shaft andgear assembled in the gear box.

Following parts are assembled in the gear box housing

&. 2ay shaft.

(. Eeverse gear.

-. Eeduction shaft.

'. )lutch.

*. 6ended gear.

1. Front cover.

0. !> $pline.

In HM tractors sliding mesh type gear box is used. It contains

&. $plined shaft.

(. 2ay shaft.

-. $peed gears.

'. Eeduction gears.

*. !> shaft.

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1. )lutch shaft.

0. )lutch.

. 6ended gear.

i. Main drive gear

ii. )ounter shaft

iii. Main shaft

iv. I gear

v. II gear

vi. III gear

vii. op speed engaging dogs

I0P4T 'HAFT A''EML5>

Input shaft consist of spiral gear on one end splines on the other end.

$plined part is attached to the clutch and geared part 9G+&: is attachNd the constant

mesh gear of lay shaft i. e. G+'*. Input is put in to the gearbox with the bearing, which

is locked by circlip.

MAI0 'HAFT A''EML5>

Main shaft assembly is solid shaft with splines on outer surface. he shaft

is placed in to gearbox with both end supporter by bearing and locked by circlip. he

back part of shaft is pro"ected outside the gearbox to get drive from it. he assembly

of shaft consist of gears (', -& and -' gear. he sliding gear -' is used for first and

reverse gear, sliding gear -& is used for second gear and sliding gear (' used for third

and fourth gear. hese gears are provided with grooves on one side to attached gear

shifter fork.

Intermediate shaft assembly.

>utput shaft assembly.

2ay shaft and connecting shaft assembly 9 along with power

transmission gears:.

LA5 'HAFT A''EML5>

he lay shaft is hollow shaft with spling on outer surface. he one end of

the lay shaft is threaded 9 in case of single clutch: and tightened from front side of

gear box with a hexagonal nut. he whole assembly consist of gear G+'* i. e.

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9 constant mesh gear with input shaft gear: spacer &*mm, gear -*, gear G+(, spacer

-/mm, gear G+(, spacer (*mm bearing with circlip. he whole assembly is washed.

In case of dual clutch tractors model the drive shaft is placed through the hollow lay

shaft. he drive shaft consist of splines on one end and the gear 9G+*(: on the other

end. he constantly meshed with the gear of intermediate shaft. he main function of

the lay shaft is to rotate fixed gear on it from where we can get different speed with

the help of sliding gear on drive shaft.

/lut3

In HM, all the tractors have spring loaded dry friction type dual clutch

various parts of clutch are pressure plate, clutch plate and spring. Eelease bearings

mounted on !> shaft are always in contact with shaft when the clutch is pressed the

release bearing depress with release level with further produce tension in compression

springs and as a result of this the gap is produce between pressure plate and flywheel

and disc become free on pressing the clutch up to 0cm, the drive to clutch shaft is

stopped and when full clutch is pressed drive to !> as well as clutch shaft is also

stopped. 6ut in first position !> rotates and wheels are in standstill position.

he main function of clutch is to engage or disengage the power coming from the

engine.

>n the basis of working there are two type of clutches.

$ingle clutch

5ouble clutch

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Aenrally double clutch is used in HM ractor

1O4LE /L4T/H>+ his clutch is provided with two clutch plates one for the

main transmission the other for !..> drive. In b?w the two clutch plates, an

intermediate plate is provided. ut of six three are for engine disengaging the rest of

three are for disengaging the !..> drive.

MT Housing Asseml"

It is the rear part of the tractor cheesy. he main function of the differential in

tractor to reduce final speed and also turn the drive around at / degree. he reduction

of the speed is done two stages. he first stage is reduction in tail pinion and crown

wheel meshing and second stage is reduction in bull gear meshing with left and right

6.!. shaft. Its also consisting the !..>. shaft, which is used to the threshers, pumps,

rotavator and other accessories components with the help of pully attached on it.

Following are main parts of differential housing+

&. )rown wheel.

(. 6evel pinion.

-. 5ifferential assembly. 9 with sun and star gear:

'. !..>. shaft.

*. 6ull gear.1. 6evel gear.

0. 6earing.

. Half shaft.

. 6rakes housing.

1i77erential it is the a special arrangement of gears to permite one of the rear wheel

of the tractor to rotate slower or faster than the other. @hile turning the tractor on

curved path, the inner wheel has to travel lesser distance than the outer wheel.

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he bevel pinion is in mesh with large bevel wheel known as crown wheel.

he main function of crown wheel is to transmit power through right angle drive to

suit the tractor wheel.

%ssembling of different component in M.. Housing.

&. )lean M housing with dry air and cloth.

(. Mount hydraulic pump and link brackets on M housing.

-. %ssemble the differential kit on the M housing. It consist of crown wheel, two sun

gears, four planet gears, two planet pins, left and right cages, taper bearing and tail

pinion with two roller bearing and flanges. $hims are used for maintaining proper

backlash between pinion and crown wheel.

'. %ssemble hydraulic pump lift gear.

*. %ssemble hand brakes in the M housing and gear shifting rods with forks on the

gear box.

1. %ssemble pump shaft and !> shaft in M housing and gear shifting rods with

fork for pump shaft.

0. %ssemble top cover on gear box with reduction gear change lever, pump shaft

change lever hand brake, pin and plug etc.

$him is provided to increase or decrease the distance of the bevel pinion shaft.

'im Ti3kness and a3klas

$him and thickness !KJKEK$

! Eeading of bevel pinion in sub assembly or the fixture it is always negative

with respect to the setting gauge block its nominal position valve must

always be taken account.

J Eeading as given on M housing, it gives the variation of the bevel pinion

mounting face from the two coaxial flange bores with respect to the

theoretical valves.

E Eeading as given on crown wheel. It gives the variation in the mounting

distance for smooth running as determined in the lapping machine.

$ Eeading as given on the bevel pinion. It the thickness on the bevel pinion

from theoretical vales, it is always negative.

6acklash to be maintained for all models /.(* to /.(0.

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Portal and 1ire3t A2le Mounting

%ssemble differential shat with two roller bearings, wheel shaft along with

flange, tapered rolling bearing, a bull gear along with spring tube and locking device

to prevent axial movement of bull gear, on the portal housing.Rear a2le ousing asseml"

Mount brake shoes, brake shoes holder, expander unit, refractor springs on the

rear axle housing.

%ssembly rear axle housing on the portal and then assembly the crown on the

differential shaft around the brake shoes.

&. %ssembly this rear axle and portal assembly on the M housing such that hand

brake shoes are on the brake drum.

(. %ssembly brackets on the M housing and portals and connect these by a

Oork.

-. %ssembly the lift assembly on the M housing.

'. %ssembly brackets to mount master cylinder arrangement and differential lock

pedal. hen engagements on and make the linkage to connect these

arrangements to the respective systems.

*. Fill gear box housing and portal with lubricating oil and assembly the rear

cover on M housing and portal.

6. %ssembly tailor end coupling, channel hook, lower and upper linkages, hinges

on the rear of M housing.

7. %ssembly clutch linkage in the gear boxes. It consists of clutch pedal and

thrust bearing, release fork, fork lever, spring and ad"usting nuts etc.

Li7t Mounting

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%fter mounting of axle on the differential lift is mounted on the main

transmission housing which is used for lift the load up to &(//kg and &'//kg. 5rive is

given with the help of hydraulic pump which is set bottom of the M housing. %fter

mounting left and right hand portals on the sides of differential housing, hydraulic lift

is mounted on the top of the differential housing hydraulic lift mainly consist of

kinematics systems that operates the distributor unit. he oil from the distributor unit.

hen, it follows two paths, inner circuit and outer circuit. he inner circuit is used for

lifting the plough as the putter circuit is used for trolley purpose for automatic loading

and unloading. he lift permits the simultaneous use of outer and inner circuit for

three positions, whereas

! !osition control, 5 5epth control and M Mixed control.

Position 3ontrolG in this system, constant depth of ploughing is maintained by

automatic ad"ustment of draft of tractor. In this system the control valves can be

operator directly by the driver to raise lower or hold an implement mounted on the

linkage at any chosen height.

1ra7t 3ontrol> in this system the working depth of any implement can be controlled

continuously without the need for a depth wheel on the implement.

Mi2ed 3ontrol> it is the combination of position control and draft control.

>il is sent to ram cylinder for lifting the arms of the lift oil is entered in

distribution box and enters a gallery. From where oil goes to differential shaft through

binder valve and outer and inner valve at the same time from outer circuit valve, it

enters inner circuit gallery. Inner circuit gallery sends oil other gallery which has three

opening for Free circuit, %nti slip circuit and 2owering circuit.

Free circuit means, no work is being done and pump is working i. e throwing

oil with pressure. $o free path circuit is provided to discharge oil and to protect the

pump from bursting.

%nti slip circuit is provided so that when the oil reaches the gallery having

differential bush, different #uantity of oil is supplied for outer and inner circuit fort

lifting the arms of the lift. @hen the lift is lowered, the inner circuit valve changes its

position and allows the oil to go through lower circuit hole.

Engine Mounting

he tested ok engine after trial is send to the assembly shop, where it is

mounted on the gear box, and M housing and portal assembly with the help of bolts.

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Front A2le Mounting

&. %ssembly front axle wheel hub, pivot, king pin, track record on the

extension along with locking devices, bush and bearings.

2. )onnects these two connections with each other by the extension tube.

-. %ssemble front axle bracket on the above arrangement with help of

center pin.

4. %ssemble all the parts with the tractor body.

'teering Asseml"

'teering>D the system governing the angular movement of front wheel of tractor is

called steering system. his system minimizes the efforts of the operator in turning

the front wheel with the application of leverages.

)omponent of steering system+

&. $teering wheel.

(. $teering shaft.

-. $teering gear.

'. !itman arm 9 drop arm:.

*. 5rag link.

1. $teering arm.

0. ie rod.

. ;ing pin.

$teering is used in tractor is screw and nut type steering. %fter mounting all

the accessories, steering is assembled on gear box.

here are two types of steering system are used in HM ractors.

&. Mechanical steering system.

(. !ower steering system.

'teering geometr">

Carious angles in steering geometry are

1. )aster angle it is the angle between the centre line of the king pin of the

vertical line

(. )amber angle it is the angle between the center line of the tyre and vertical

line.

-. ;ing pin inclination angle it is the angle between the vehicle line and the

king pin centre line is known as king pin inclination angle.

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'. oe Din it is the difference in the distance of the centre lines of the back end

and front end of front wheels of tractor.

*. oe+out toe+out is the spreading apart of the front wheels on turns. he

purpose of toe+out is to give correct turning alignment and to prevent

excessive tyre wear.

rake asseml">D

his tractor having heavy duty self+energizing, water sealed disc with

spherical roller and ventilation pipe which gives better cooling. he ventilated results

in reduction of about -/4 pad temperature. 6rake housing cover containing two disc

made of asbestos base non+metallic. he max. temp. resistance about -// degree )

between this two disc plate a cast iron plate is fixed which contain steel spherical

roller and hold by spring. @henever brake is applied the spherical roller move are left

from there place in the plate and try to expanded the plate. 5uring expanding of plate

the disc are strongly mounted on 6.! left and 6.! right shaft stop the speed of

differential. he also having actuators and link with rubber seal.

here are two types of brake system used in HM ractor.

&. Mechanical brake

2. Hydraulic brake

H"drauli3 rake and Floor Asseml"

Hydraulic brake system is based on the principal of pascal8s law he brake

fluid which is usually a mixture of gylcerine and alchol is filled in the master

cylinder .when in the master cylinder is forced into the cylinder and the entire

system turns to a pressure system.Immediatly the piston of the wheel cylinder slides

outward which move the break shoes to stop the rotating drum. @hen the pedal is

released,the return spring of the a sudden pressure drop in the the line. he retracting

spring of the break shoe bring them back to their original position.hus the piston of

the wheel cylinder returns back.

%fter assemble various accessories on the body Master cylinder and floor is

attached with body. Master cylinder is used for apply the force in the brake pads.

he basis component of hydraulic system.

@heel cylinder

Maser cylinder

!iston rod

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Eetraction spring

6rake drum

Wasing one- 1r"ing O,en and Painting

%fter mounting all the parts on the body it sends to washing zone for remove

the unwanted material like dust and machining material.

%fter washing of the body, it sends to oven for drying the body where we dry

it. %fter drying the body painting is done on the body. Arey paint is used for painting

the body and the chassis.

Pro=erties o7 =aint

6ase painting of chassis

6ase hardness 0&Ciscosity (/+(' sec.

>perating pressure *+1 ;gcm-

hinner (/+-/4

+reasing @one

Areasing is done all the greasing points with the help of pneumatic gun.

he following are the grease points

. Front wheel hub. Front axle extension

&/. Front axle pin

&&. )lutch shaft

&(. Eight hand stud

&-. hree point linkage

&'. ie rod end

hree free play of foot brake is maintained (mm.

Air /leaner- Radiator and Fuel Tank

%fter washing and painting air cleaner and radiator mount on the tractor body.

Heavy duty type of air cleaner is used in the tractors.

his is of oil bath type cleaner. It consists of a filter element saturated with oil.

%t the bottom there is separate oil pun. he air from atmosphere enter in to the gap

and when air takes turn it leaves the impurities there and after it impinging on the

surface of oil and leaves the impurities there and at last air pass through the filter and

cleaning of air is done.

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Air /leaner

%fter fitting the air cleaner radiator is attached with engine. he main purpose

of radiator is providing the cooling to the engine i.e. the remove the heat from engine.

@ater and alcohol is used as coolant in the radiator.

T"re Mounting

%fter attached all parts tyre is attached with tractors. %fter assembly the tyre

alignment of wheel is done.

Alignment =arameter

oe in of wheel ' mm i. e. from front distance is constant and from the back

side the distance is increased ' mm. ( to - deg. camber is given to wheel.

Pur=ose o7 alignment

1. It provides good balancing to the tractor.

(. It prevent from wear and tear of tyres.

-. It helps in steering system.

%fter this, bonnet and electrical items are attached to the tractors.

Following electrical items are mounted,

0. Horn

. Head 2ight

. 6rake 2ight

&/. !arking 2ight

&&. !lough 2amp

&(. 5irection Indicators

&-. 5ashboard pilot lamp.

%fter this, tractor is completed up to bridge out stage.

TRA/TOR TE'TI0+

&. $inking

(. Berking

-. 5rafting

'. Hand brake setting up to forth teeth.

*. Foot break to be checked combined and individually.

1. 5ifferent locks to be checked for its normal function at*//+0//E!M.

0. ractor to be checked for any unusual sound from.

. Eoad testing.

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. Eoller testing.

Time and Work For3e Reuirement 'tud" 7or Assemling Engine

4nits o7 1i77erent Models

$r. no. Model ime re#uired to

assemble one unit

9hr.:


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iv. o avoid delays on assembly line, every component should be given

after complete inspection to tractor assembly line.

v. ractor assembly store like A.6. housing, M.. housing shifting of

engine etc. should be properly handled by expert person concerned to

avoid the wastage of material and proper accounting automatically.

112537953-hmt-report of training and development

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