Six Months Industrial Training Report at Punjab Tractors Limited (PTL

Six Months Industrial Training Report
PUNJAB TRACTORS LIMITED
PROJECT REPORT ON SIX MONTHS INDUSTRIAL TRAINING (JUNE 2013 to DEC 2013)
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR B.Tech (Mechanical Engineering) At
PTL, Mohali
SUBMITTED BY: AMRITPAL SINGH Branch Roll No.: 1410013 Univ. Roll No.: 100031127688
Mechanical Engineering Department AMRITSAR COLLEGE OF ENGINEERING & TECHNOLOGY,

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AMRITSAR, INDIA
PROJECT REPORT ON SIX MONTHS INDUSTRIAL TRAINING (JUNE 2013 to DEC 2013)
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR B.Tech (Mechanical Engineering) At
PTL, Mohali
SUBMITTED BY: AMRITPAL SINGH Branch Roll No.: 1410013 Univ. Roll No.: 100031127688
Mechanical Engineering Department

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AMRITSAR COLLEGE OF ENGINEERING & TECHNOLOGY, AMRITSAR, INDIA
ABSTRACT OF THE REPORT
Training is an investment and hence should be able to get due returns in terms of better quality of workmen and Engineering for future. P.T.L. today is one of the major Tractor Producer Industry, giving their best performing machines to their customers. As concerned with my Industrial training it is of my best opportunity during my Engineering to learn many things about Automobile Industry through this Industry. During my training I learn many things that would pay to me in my near future. I pay thanks to the training faculty of our college and to staff and operators of P.T.L. Swaraj for their co-operation during my Industrial Training. Not only did I have chance to learn technical skills but also a lot of good human qualities have been invested by this training tenure. Once again thanks to head of deptt. and faculty members for giving us this prime opportunity to let us make most of this time which in turns is like gold-dust for us.
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ACKNOWLEDGEMENT
I am highly grateful to Dr. MS Aujla, Principal, Amritsar College of Engineering and Technology, Amritsar for providing this opportunity to carry out the six month industrial training at Punjab tractors limited (PTL), Mohali. The constant guidance and encouragement received from Er Gaurav Tejpal (Head, Mechanical Engg. Deptt) and training Coordinator Er. S. B. S. Kalsi (Associate Professor) has been of great help in carrying out the project work and is acknowledged with reverential thanks. I would like to express a deep sense of gratitude and thanks profusely to Mr. S.S. Mangat (Manager Assembly Deptt.). Without the wise counsel and able guidance, it would have been impossible to complete the report in this manner. The help rendered by ER. Tarun Honda ( Assistant Manager Assembly Deptt.). for experimentation is greatly acknowledged. I express gratitude to other faculty members of Mechanical Engineering Department, Amritsar College of Engineering & Technology, Amritsar for their intellectual support throughout the course of this work. Name of student & Signature AMRITPAL SINGH
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Contents
S.No. 1. 2. 3. 4. 5. TOPIC INTRODUCTION TO COMPANY COMPANYS PROFILE PRODUCT PORTFOLIOS SWARAJ ENGINES LIMITED DEPARTMENTS 1. Production planning and control 2. Quality engineering 3. Industrial engineering 4. Personal department 5. Accounts department 6. Purchase department 7. Machine shop 8. Assembly shop 9. Maintenance Page no..
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INTRODUCTION TO PUNJAB TRACTORS LIMITED

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HISTORY
In the mid-sixties, with the Green Revolution triggering large-scale tractor usage, there was a need for the country to build sufficient indigenous capacity to meet this growing demand. In 1965, the Central Mechanical Engineering Research Institute (CMERI), Durgapur initiated design and development of Swaraj Tractor based on indigenous know how. That is how the idea for development of what was to become Swaraj was initiated. The first prototype was ready in May 1967 and by April 1970, field experience of over 1,500 hours had been gained. At that point, it was decided to christen a name for the product signifying Indian, easy to pronounce and signifying power and grace. The name `Swaraj', was approved by the then Prime Minister, Mrs Indira Gandhi. In 1970, the Government of Punjab acquired the Swaraj tractor's design and established Punjab Tractors Limited (PTL). The tractors were produced and sold under the brand name of Swaraj. In 2007, Mahindra & Mahindra Ltd. acquired majority stake in PTL, and in Feb 2009, it was merged into M&M as the Swaraj Division of Mahindra & Mahindra.
OVERVIEW
Swaraj has become synonymous with tractors that are powerful and reliable because of their long term expertise in delivering such products consistently. We have been manufacturing tractors that serve the need of our buyers in agricultural as well as commercial operations. Our product range starting from a 22 HP category tractor to a 72 HP category tractor straddles every HP category requirement. The brand enjoys a strong equity in the market and commands a market share of close to 12%. The brand is known for producing tractors that are powerful and reliable. Presently, there are more than 7,00,000 satisfied customers of Swaraj in the country. Swaraj tractors are also exported to various countries including Bangladesh, Nepal, Sri Lanka, Nigeria, Ghana, Gambia, Zimbabwe, Zambia, Tanzania and the USA.
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ORIGIN OF THE WORD SWARAJ

In Hindi, the word SWARAJ means Freedom from Bondage. Since P.T.L. was the only first largest tractor project in India, moreover fully based upon Indian technology. So SWARAJ was appropriately chosen as its brand name. SWARAJ GROUP sells its product under this brand name.
POSITION OF SWARAJ PRODUCTS IN MARKET

With more than 2 lacs of tractors & harvester combines operating in Indian farms, SWARAJ are now a well-established brand name in country. SWARAJ is now an internationally recognized name in the developing world. The products of SWARAJ are not only restricted to Indian market but they had entered in international market. SWARAJ tractors find an important place in developing countries like Ghana, Tanzania, Zambia, Kenya, Sudan, Uganda, Indonesia & Malaysia, etc. they are also sending their combines to South Korea having first A.C. cabin combine in India. Long way back, they had also transported the machined rims to Japan, a project millions of dollars.
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OBJECTIVES
1. The main objective of the company is to bring the latest technology of high quality and cost
advantage to its customers. By having a strong R&D and the fully computerized manufacturing facility, SEL ensures a non-stop supply of quality tractors.
2. Apart from the general objective, every department has their own objectives, which are in tune
with the main objective of the company. In that sense the main objective of department is to have the best in product development with maximum utilization of the human resources available.
3. To achieve international standards of excellence in all aspects of agriculture and diversified

business with focus on costumer delight.
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COMPANYS PROFILE
SWARAJ HISTORY The Indian Tractor Industries, as it is now, is a major segment of its engineering industry. However till 1974, Indian firms assembling semi knocked down (SKD) kits in collaboration with foreign manufactures met the tractor requirements of the country largely through imports & partly. Though the first Tractor Company was set up in India in 1960, but the growth in real terms started from 1974, when the government banned the import of tractors. Today India is the largest tractor producing and consuming country. In an effort to reduce imports & develop indigenous technology, the government, permitted setting up of the major manufacturing companies.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Eicher Good Earth TAFE International Tractors Escorts Tractors Ford Tractors HMT Punjab Tractors Kirloskar Harsha Auto Tractors Universal Tractor
1960 1964 1965 1966 1971 1973 1974 1974 1975 1981 1982
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THE INDIAN MARKET DIMENSION
GEOGRAPHICALLY
TERRITORY
%age of Domestic Sales
North (Punjab, Haryana & Uttar Pradesh) Central (Madhya Pradesh & Rajasthan) East (Bihar, West Bengal, Orissa & Assam)
32% 26% 10%
West (Gujarat & Maharashtra)
12%
South (Andhra Pradesh, Tamil Nadu, Karnataka & Kerala)
20%
SEGMENTWISE
HP Range
%age of Total Sale
Up to 30 HP
19%
31-40 HP
51%
Above 40 HP
30%
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INTRODUCTION
PTL S BIRTH
Keeping in mind Punjab agrarian economy it was decided by Punjab Govt. to encourage the growth of industries which complements Punjabs agricultural growth. This task was entrusted to P.S.I.D.C. and with dual objective of industrial and agricultural growth; PTL was established on 27th June 1974.
INDUSTRY BASICS
The Indian tractor market is dominated by low price, rugged, versatile and low to medium powered tractors; the main reason being the inability of farmers to invest in farm mechanization. Tractors are categorized on the basis of horse power (HP) of the engine. In India, the popular range of tractors is 20-40 HP compared to 60 HP in Europe and 90 HP in the USA. Though large tractors were economically unviable in India, there has been an increasing demand for highpowered tractors due to soil conditions, particularly in states of MP, Gujarat and Maharashtra. But more recently, higher-powered tractors are also being sold in states like Punjab where it is considered as a status symbol. Tractors available in India are 1/4th of the prices of similar powered tractors internationally or in developed countries. Availability of credit is the most crucial factor impacting tractor demand, as in India 90% of the tractors are financed by bank credit at concessional rates. Increased use of irrigation facilities, shift towards multi-cropping, consolidation of lands holdings, promotion of co-operatives and higher investment in agriculture also contributes to higher tractor demand. The tractor segment comprises players like Eicher, Escorts, HMT, Punjab Tractors, M&M, TAFE, Sonalika, which control about 98% market share. India is the worlds largest market in tractors since 1996. A few international players like Case New Holland, John Deere have also set up facilities in India. Punjab Tractors is promoted mainly by Punjab State Industrial Development Corporation
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Limited and has acquired the second highest market share in the tractor segment from 9.1% in 1975. In 1970, PTL had major competition from other companies like Eicher, Tractors and Farm Equipment (TAFE), Mahindra & Mahindra (M&M), Escorts and HMT. PTL is one of the leaders in its business and has put up a heady performance in contrast to other private sector players. Punjab Tractor is the only major tractor company, which entered this business without any foreign collaboration. The company has beefed up its R&D capabilities in the last two to three years. PTLs Swaraj -735 is in a class of its own and has been benchmarked by its competitors to which 16 new features have been added. PTL has single mindedly focused on increasing its market share in tractors.
Current Scenario
During the first half of 2001-02 PTL increased its market share from 18.5% to 21.4%. With the total industry volumes plummeting by 16.6% the sales of PTL fell only a trifle 3.1%. Under these circumstances, though the revenue has fallen by a 0.38% the operating profitability has risen by 1.03%. PTL garnered the operating margins of 19.4% in the first half of FY2001-02, while the lead players like M&M, Escorts and Eicher have reported operating margins of 4.4%, 0.7% and 2.9% respectively. The Net Profit has increased by 1.4% to Rs.564 million and the contribution of 40-50HP tractors has increased by 30%, which indicates higher margins from bigger tractors due to a strong foothold in Punjab and Haryana markets.
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SWARAJS YEARLY PROGRESS

1965:- Govt. of India's research institute (CMERI) at Durgapur initiates design and development of SWARAJ tractor based on indigenous know-how.
1970:- Punjab Govt. through PSIDC acquires SWARAJ tractor's design from CMERI and establishes Punjab Tractors Ltd. (PTL) for its commercialization.
1971-73:- PTL sets up SWARAJ Project for 5,000 tractors per annum at a capital outlay of Rs. 37.0 million with an equity base of Rs 11.0 million.
1974:- Swaraj 724 (26.5 HP) tractor commercially introduced.
1975:- 2nd tractor model SWARAJ 735(39 HP) developed by own R&D, commercially introduced.
1978:- 3rd Tractor model SWARAJ 720 (19.5 HP) developed by own R&D, commercially introduced. Maiden equity divided declared.
1980:- Guided by social concerns and responsibility, PTL takes over PSIDC's scooters unit Punjab Scooters Ltd. (subsequently renamed as SWARAJ Automotives Ltd.) India's first Self propelled Harvester Combine - SWARAJ 8100 developed by own R&D, commercially introduced. SWARAJ Foundry Division set up in backward area.
1983:- 4th Tractor Model - SWARAJ 855 (55 HP) developed by own R&D, commercially introduced. Expansion of annual capacity to 12,000 tractors per annum at Plant 1.
1984:- SWARAJ MAZDA Ltd. promoted in technical and financial collaboration with Mazda Motor Corps. & Sumitomo Corp. Japan for manufacture of Light Commercial Vehicles. PTL's equity participation is Rs. 30.4 million (29%) and that of Mazda and Sumitomo's Rs. 27.0 million (26%).
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1985:- SWARAJ Industrial Forklift Trucks developed by own R&D, commercially introduced. 1986:- SWARAJ ENGINES Ltd. promoted in technical and financial collaboration with Kirloskar Oil Engines Ltd.(KOEL) for manufacture of diesel engines. PTL's equity participation is Rs. 6.9 million (33%) and that of KOEL's Rs 3.6 million (17%).
1995:- Setup of tractor Plant II at Village Chappercheri with annual capacity of 12,000 per annum.
1998:- Commencement of expansion to 60,000 tractors (30,000 at each plant). Capital outlay of Rs 1000 million, funded mainly through internal accruals.
1999:- 5th and 6th tractor models - SWARAJ 733 (34 HP) & SWARAJ 744 (48 HP) developed by own R&D, commercially introduced.
2000:- Expansion of annual tractor capacity to 60,000 completed.
2001:- PTL won National Championship trophy in competition organized by All India Management Association (AIMA) for young managers. Economic times and Boston Consulting Group selects PTL as one of the India's finest 10 companies out of Economic times top 500 Companies.
2002:- Cumulative tractor sales crosses 5,00,000/-.
2003:- PSIDC's disinvestment of its entire Equity holding (23.49%) in PTL in favour of CDC Financial Services (Mauritius) Ltd. With this, total holding of CDC & its associates in PTL stands at 28.48%.
2004:- 7th & 8th tractor models - Swaraj 939 (41 HP) & Swarj 834 (34 HP) developed by own R&D, commercially introduced.
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2005:- PTL disinvested 15,73,000 equity shares of Rs. 10/- each of Swaraj Mazda Ltd. (constituting approx. 15% of SML's paid up capital) in favour of Sumitomo Corporation, Japan, a joint venture partner in Swaraj Mazda Ltd. at a total consideration of Rs. 629.2 million.
2007:- CDC/Actis Group and Burman Family's disinvestment of their Equity holding in PTL (43.3%) in favour of Mahindra Group (M&M).
2008:- Swaraj 3 Tonne Battery forklift, designed and developed by in-house R&D, commercially launched
Punjab Tractors Ltd. (PTL) has commercially launched another model - Swaraj 939 FE at a function in Indore.101 units of this new generation tractor were delivered to farmers from all over Madhya Pradesh and Chhattisgarh, by Mr. R.Gopalan, Managing Director, State Bank of Indore in the presence of PTL's Mr. Yash Mahajan (VC & MD) and Mr. A.M. Sawhney (SVP-Mktg). Powered by a future ready, fuel - efficient 41 HP SAE, three-cylinder water-cooled diesel engine, Swaraj 939 FE has a constant mesh gear box, diaphragm clutch and neutral safety switch. Upgraded variants of this model can also be supplied as per customer needs/requirements.
M&M made open offer to shareholders for another 20% equity of the Company.
Mahindra Group's equity holding in the Company stands at 64.6%
Cumulative Tractor Sales cross 600,000.
Swaraj Track Type Combine designed and developed by in-house R&D, commercially launched.
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INTERNATIONAL AND NATIONAL COLLABORATION OF SWARAJ GROUP

Swaraj group has entered into technical and financial collaborations with various national and international companies.
Swaraj Mazda Limited was set with technical and financial collaborations with Mazda Motors Corporation of Japan.
Swaraj Combine Division was entered into with Komatsu Forklift Company of Japan for manufacturing fork lifters.
Swaraj Engines Limited was set up in technical and financial collaboration with Kirloskar Oil Engines Limited, Pune for manufacturing diesel engines.
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MILESTONES
1970 Establishment of PTL for making Swaraj brand of tractors
1974 Commercial production started with 2 models: 724 FE & 735 FE
1980 Swaraj 8100, Indias first self-propelled combine harvester launched
1983 Swaraj 855 launched in the 50 hp category
1995 Establish of the 2nd plant for manufacturing Swaraj tractors in Chhaparchhedi
1999 Launch of Swaraj 744
2002 Cummulative sales of Swaraj tractors (till date) touches 5,00,000
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2007 Swaraj 724 FE Orchard and Swaraj 978 launched
2007 M&M (the leaders in domestic tractor industry) acquires majority stake in PTL
Merger of PTL into M&M and subsequent transformation as the Swaraj Division of 2009 Mahindra & Mahindra Ltd.
2009 Launch of 735 XM the first of the XM series of models
2009 Launch of 843XM building on the XM series
Rated Highest In Industry for Customer Satisfaction Index (CSI), Sales Satisfaction Index (SSI) & 2011 CaPS
2011 Swaraj Division achieved Stage-5 in MQW Assessment
2012 Launch of 825XM, 841XM, 744XM, 855XM - strengthening the product portfolio with XM Series
2012 Swaraj becomes the second tractor company in the world to win the prestigious DEMING Prize
2012 Rated Highest In Industry for Customer Satisfaction Index (CSI)

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2013 Swaraj Division Plant 1 and Plant 2 Won TPM Excellence Award From JIPM
INTRODUCTION TO SWARAJ GROUP

Swaraj Engines Ltd., situated at Phase 9, Industrial Area Mohali was established in technical and financial collaboration with Kirloskar oil Engines Ltd. For manufacturing diesel engines for Swaraj Tractor Division Phase 4, Industrial Area, Mohali. During the few years of its existence, it has not only increased its product range but also increased its production from 345 in the first year more than 18000 engines now. These engines are sent to the Swaraj Tractor Division where they are fitted on various Tractors. Swaraj group came into existence with the establishment of Punjab Tractor Limited on 27th June, 1974. The company was Indias first large scale based on totally indigenous design & technology, was promoted by Punjab State Industrial Development Corporation (PSIDC) with the help of Govt. of India & Public financial institutions.
VARIOUS DIVISIONS OF SWARAJ GROUP Swaraj consists of six divisions: 1) Swaraj Tractors Division. 2) Swaraj Mazda Ltd. 3) Swaraj Automotives Ltd. 4) Swaraj Engines Ltd.
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5) Swaraj Foundry Ltd. 6) Swaraj Combine Division.
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MERGER WITH MAHINDRA&MAHINDRA IN YEAR 2007
M&Ms president (farm equipment sector) Anjani kumar Choudhari, who took charge as PTLs chairman over the weekend, told ET: Swaraj has tremendous brand value in many northern markets and we are going to exploit it fully. M&M bagged the bid at about Rs 360 per share, and is acquiring about 43 per cent stake in the Chandigarh-based tractor firm for close to Rs 1,000 crore in an all-cash deal.
The 43 per cent stake includes 29 per cent owned by private equity firm Actis and 14.2 per cent by the Delhi-based Burman family. It was the second largest tractor company a few years ago and we would be promoting Swaraj aggressively to regain its lost market share. Some price improvements in the product are also being planned, which would be followed by a publicity campaign. While both the tractor brands would exist independently, a synergy in production and other back-end operations has been planned. M&M would utilize the low-cost vendors of PTL for its own tractors and eventually have a common vendor base for both the products. We are planning major capital investment for modernization and expansion of foundry operations. There is a huge shortage of casting capacity in the market, so a major integration of the PTLs foundry business with M&M operations is being planned. The company is also planning an expansion of PTLs combined harvester (mechanized harvesting vehicle) manufacturing facility. Iran Tractor Manufacturing Company, our business partners in Iran, has shown keen interest in the combined harvesting facility. Officials of the company have visited the PTL factory and are looking for exports of these machines.
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SWARAJ TRACTORS DIVISION:It is located in Phase-IV, SAS Nagar. The construction work of PTL was started in March 1972 and the first batch rolled out on 14th November 1973. It started with an annual capacity of 5000 tractors with a capital of Rs. 37 million. In 1974 it went into commercial production with Swaraj 724 26.5 BHP tractors as its first model. During its 22 year of production, it has not only expanded its manufacturing capacity to more than 24000 tractors per annum but adds more products into its manufacturing range. Its product range includes the following.
PRODUCT PORTFOLIO
Less than 30 hp 724 XM
SPECIFICATIONS Engine Transmission Gear Speeds PTO Speed Brakes Steering Hydraulics Tyres Electricals Weight & Dimensions Warranty Features
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ENGINE Model HP Category Type No. of Cylinders Bore and Stroke Displacement Rated Engine Speed Air Cleaner Cooling System RV-2 XM + 3A 25-30 HP 4 Stroke, Direct injection, Diesel engine 2 100 X 116 mm 1824 cc 1800 rev/min 3- Stage Oil Bath Type Water Cooled with No loss tank
Transmission Standard Clutch Optional No. of gears NA Single dry disc friction plate
8 Forward, 2 Reverse speeds
Gear Speeds (Km/hr) With 6.00 * 16 front & 12.4*28 rear type Forward Reverse 2.19 to 27.78 2.74 & 10.77
PTO Speed
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Standard 1000 rpm PTO Speed Optional 540 rpm
Brakes Standard Dry Disc type Brakes Brake type Optional NA
Steering Type Standard Steering type Mechanical Steering with Heavy Duty single drop arm for better manoeuvrability & comfort to operator
Optional NA
Hydraulics Live Hydraulics Position control: To hold lower links at any desired height Automatic draft control:To maintain uniform draft Mix Control: For optimum field output Standard 1000 Kgf at lower link ends Lifting Capacity Optional NA Linkage 3 point linkage Category-I suitable for Category-II type implement pins.
Hydraulics
Tyres Front Rear Front/Rear Standard 6.00 x 16 Standard 12.4 x 28 Optional NA
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Electricals Electricals Instruments 12 Volt, 88 Ah. Battery Starter motor & Alternator Engine rpm cum hour meter with direction indicators, Fuel Gauge, Ammeter, and Water Temp. Gauge & Oil Pressure Indicator
Weight & Dimensions O.A.Length O.A.Width O.A.Height Wheel Base Min.ground Clearance Weight of Tractor Wheel track Rear :1350 mm (with 12.4*28 tyre size) 3320 mm 1675 mm 2270 mm 1935 mm 375 mm 1750 kgs Front :1300 mm
Features More fuel efficient engine meeting with Bharat Trem -IIIA norms Concealed lockable battery near starter 11" clutch for easy gear engagement & longer life Telescopic stabilizers bars for easy adjustment and better implement stability Live Hydraulics 1000 Kgf Hydraulic lifting Capacity Adjustable P.U sliding seat for operator comfort Mobile cum carrier charger Neutral safety switch Transparent water separator for easy access & timely drainage of water from fuel system Quick release coupler with tap off pipe for tipping trailer application Steering lock Safety from theft
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Higher capacity 88AH battery for easy start & longer life
724 XM ORCHARD
Engine Model HP Category

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RV-2 XM + 3A 25-30 HP
Type
4 Stroke, Direct injection, Diesel engine
No. of Cylinders 2 Bore and Stroke Displacement Rated Engine Speed Air Cleaner Cooling System 100 X 116 mm 1824 cc 1800 rev/min Dry type, Dual element with dust unloader Water Cooled with No loss tank
Transmission Standard Clutch Optional No. of gears NA 6 Forward, 2 Reverse speeds Single dry disc friction plate
Gear Speeds (Km/hr) with 5.00 x 15 front & 11.2 x 24 rear type Forward Reverse 2.29 to 24.22 2.28 & 09.02
PTO Speed Standard 1000 rpm PTO Speed Optional NA
Brakes Standard Oil Immersed Brakes Brake type Optional NA
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Steering Type Standard Steering type Mechanical Steering with Heavy Duty single drop arm for better manoeuvrability & comfort to operator.
Optional NA
Hydraulics Live Hydraulics Position control: To hold lower links at any desired height Automatic draft control:To maintain uniform draft Mix Control: For optimum field output Standard 1000 Kgf at lower link ends Lifting Capacity Optional NA Linkage 3 point linkage Category-I suitable for Category-II type implement pins
Hydraulics
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Features More fuel efficient engine meeting with Bharat Trem -IIIA norms. Concealed lockable battery near starter Live Hydraulics Hydraulic lifting Capacity -1000 Kgf Oil Immersed Brakes Adjustable P.U sliding seat for operator comfort Dry type air cleaner with dual element with dust collector Side draft downward draft silencer for orchard application Rear track (1034mm) width suitable for inter cultivation crops Better wheel traction for farm operations Transparent water separator for easy access & timely drainage of water from fuel system Tap off connection for tipping trailer application
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30-40 HP 834 XM
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Engine Model HP Category Type RV-3 XM + 3A 30-35 HP 4 Stroke, Direct injection, Diesel engine
No. of Cylinders 3 Bore and Stroke 100 X 110 mm Displacement Rated Engine Speed Air Cleaner Cooling System Transmission Standard Clutch Optional No. of gears NA 8 Forward, 2 Reverse speeds Single dry disc friction plate - 280 mm dia. (11") 2592 cc 1800 rev/min 3- Stage Oil Bath Type Water Cooled with No loss tank
PTO Speed Standard 1000 rpm PTO Speed Optional 540 rpm
Brakes Brake type Standard Dry Disc type Brakes
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Optional Oil Immersed Brakes
Steering Type Standard Steering type Mechanical Steering with Heavy Duty single drop arm for better manoeuvrability & comfort to operator
Optional NA
Hydraulics
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Features More fuel efficient engine meeting with Bharat Trem -IIIA norms. Concealed lockable battery near starter Oil Immersed Brakes* Telescopic stabilizers bars for easy adjustment and better implement stability Live Hydraulics 1000 Kgf Hydraulic lifting Capacity Adjustable P.U sliding seat for operator comfort Mobile cum carrier charger Neutral safety switch Transparent water separator for easy access & timely drainage of water from fuel system Tap off connection for tipping trailer application Steering lock Safety from theft Higher capacity 88AH battery for easy start & longer life
735 XM
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Engine Model HP Category Type RV-3 XM + 3A 35-40 HP 4 Stroke, Direct injection, Diesel engine
No. of Cylinders 3 Bore and Stroke 100 X 116 mm Displacement Rated Engine Speed Air Cleaner Cooling System 2734 cc 1800 rev/min 3- Stage Oil Bath Type Water Cooled with No loss tank
Transmission Standard Clutch Optional No. of gears NA 8 Forward, 2 Reverse speeds Single dry disc friction plate - 280 mm dia. (11")
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PTO Speed Standard 1000 rpm PTO Speed Optional 540 rpm
Brakes Standard Dry Disc type Brakes Brake type Optional Oil Immersed Brakes
Steering Type Mechanical Steering with Heavy Duty single drop arm for better Standard manoeuvrability & comfort to operator Optional Power steering
Steering type
Hydraulics
Tyres Front Rear Front/Rear

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Standard 6.00 x 16 Standard 12.4 x 28 Optional 6.00 x 16 / 13.6 X 28
Features More fuel efficient engine meeting with Bharat Trem -IIIA norms. Single piece front tilting bonnet for ease of maintenance Concealed lockable battery near starter Oil Immersed Brakes* Power Steering* Bigger Rear Tyre - 13.6 x28 * Telescopic stabilizers bars for easy adjustment and better implement stability Live Hydraulics 1000 Kgf Hydraulic lifting Capacity Adjustable P.U sliding seat for operator comfort
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Mobile cum carrier charger Neutral safety switch Transparent water separator for easy access & timely drainage of water from fuel system Tap off connection for tipping trailer application Steering lock - Safety from theft
40-50 HP 841 XM
Engine
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Model HP Category Type
MDI 2385 S - 3A 40-42 HP 4 Stroke, Direct Injection, Diesel Engine
No. of Cylinders 4 Bore and Stroke Displacement Rated Engine Speed Air Cleaner Cooling System 88.9 x 110 mm 2730 cc 1900 rev/min 3- Stage Oil Bath Type Water Cooled with No loss tank
Transmission Standard Clutch Optional No. of gears NA 8 Forward, 2 Reverse speeds Single dry disc friction plate - 280 mm dia. (11")
Gear Speeds (Km/hr) With 6.00 * 16 front & 12.4*28 rear type Forward Reverse 2.3 to 29.3 2.8 to 10.9
PTO Speed Standard 540 rpm PTO Speed Optional NA
Steering Type
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Standard Steering type
Mechanical Steering with Heavy Duty single drop arm for better manoeuvrability & comfort to operator
Optional NA
Hydraulics Live Hydraulics - SENSILIFT Hydraulics for better operations in Loose & Sandy Soil Position control: To hold lower links at any desired height Automatic draft control:To maintain uniform draft Mix Control: For optimum field output Sensilift Hydraulics: For better operations in loose &sandy soil Standard 1200 Kgf at lower link ends Lifting Capacity Optional NA Linkage 3 point linkage Category-I suitable for Category-II type implement pins.
Hydraulics
Tyres Front Rear Front/Rear Standard 6.00 x 16 Standard 12.4 x 28 Optional 6.00 x 16 / 13.6 x 28
Weight & Dimensions
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O.A.Length O.A.Width O.A.Height Wheel Base Min.ground Clearance Weight of Tractor Wheel track
3390 mm 1680 mm 2200 mm 1935 mm 370 mm 1820 kgs Front 1330 mm Rear 1350 mm (with 12.4*28 tyre size)
Features More fuel efficient engine meeting with Bharat Trem -IIIA norms. Compact design with new attractive decals Live Hydraulics Sensilift Hydraulics - for smooth operation with seed drill & cultivator in sandy soil 1200 Kgf Hydraulic lifting Capacity Transport lock Isolator valve for auxillary application Oil Immersed Brakes Telescopic stabilizers bars for easy adjustment and better implement stability Adjustable P.U sliding seat for operator comfort Mobile cum carrier charger
SWARAJ ENGINES LIMITED
Swaraj Engines Ltd., situated at Phase 9, Industrial Area Mohali was established in technical and financial collaboration with Kirloskar oil Engines Ltd. For manufacturing diesel engines for Swaraj Tractor Division Phase 4, Industrial Area, Mohali. During the few years of its existence, it
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has not only increased its product range but also increased its production from 345 in the first year more than 18000 engines now. These engines are sent to the Swaraj Tractor Division where they are fitted on various Tractors. The foundation stone of the Swaraj Engine was laid by the governor of Punjab Mr. S. S. Ray on 29th December, 1987 and the production started from 28th December, 1988. SEL is spread over an area of 12.72 acres. Having built covered area for manufacturing block is 13500 sq.mtrs & administration block is 1600 sq.mtrs. & Canteen blocks covers about 1300 sq.mtrs Investment on plant, machining, tooling etc 52 Crores. Machine shop houses 151 machines out of 29 are computerized numerical control machines. All components, before assy. are thoroughly cleaned by special purpose washing machines. Cleanliness level of components is regularly monitored. Great emphasis is laid on general hygiene of the plant, machinery & components offered for assy. The engines are assembled in air pressurized shops, where ambient temperature during summer is maintained at 32C with 30 air changes per hour. Each test cell is sound proof & air pressurized; where 130 air changes take place/ hr. Engines are tested as per the latest norms laid out by ARAI. Tested engines are dispatched to tractor or Combine Division the very next day. In addition to components for tractor engine we are having a dedicated machine shop, which is manufacturing & supplying 100% Cylinder Blocks & Con Rods required by SML, on day to day basis. Supply of SML cylinder head is also made from here. The various engine models being produced at SEL are:
1. S-15, Single Cylinder: Engine Specifications Model : HP : Tractor :

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S-15 ; Swaraj 24.5 S.A.E. SWARAJ 722

Type : Bore and Stroke : Displacement : Rated Engine Speed : Cooling System :

4 - Stroke, Direct Injection, Diesel Engine 120 X 126 mm 1425 cc 1900 rev/min Water Cooled
2. RV-2, Two Cylinder: Engine Specifications Model : HP : Tractor : Type : Bore and Stroke : Displacement : Rated Engine Speed : Cooling System : RV-2 xm KIRLOSKAR 26.5 S.A.E. SWARAJ 724 FE 4 - Stroke, Direct Injection, Diesel Engine 100 X 110 mm 1728 cc 2000 rev/min Water Cooled
3. RV-3, Three Cylinder: Engine Specifications
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Model : HP : Tractor : Type : Bore and Stroke : Displacement : Rated Engine Speed : Cooling System :

RV-3 xm KIRLOSKAR 39 S.A.E. SWARAJ 735 FE 4 - Stroke, Direct Injection, Diesel Engine 100 X 110 mm 2592 cc 2000 rev/min Water Cooled.
4. RB-30, Three Cylinder: Engine Specifications Model : HP : Tractor : Type : Bore and Stroke : Displacement : Rated Engine Speed : Cooling System : RB-30 xm KIRLOSKAR 48 S.A.E. SWARAJ 744 FE 4 - Stroke, Direct Injection, Diesel Engine 110 X 110 mm 3136 cc 2000 rev/min Water Cooled with Oil Cooler for engine oil.
5,
RB-33, Three Cylinder: Engine Specifications
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Model : HP : Tractor : Type : Bore and Stroke : Displacement : Rated Engine Speed : Cooling System :

RB-33 xm KIRLOSKAR 50 S.A.E. SWARAJ 855 FE 4 - Stroke, Direct Injection, Diesel Engine 100 X 116 mm 3308 cc 2000 rev/min Water Cooled with Oil Cooler for engine oil.
These engines are sent to the Swaraj Tractor Division where these are fitted on various model tractors. The S-15 engines are manufactured in the Swaraj Combine Division and fitted on Swaraj 922 model tractors. But now S-15 engines are also manufacture by Swaraj engines and soon its full production will started in Swaraj engines.SEL manufactures diesel engines for Swaraj Tractor Division.
DEPARTMENTS:
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Department is the breaking down an enterprise into various departments. Grouping of activities into department is very essential because it limits the number of subordinates to supervise by a manager. The various departments in SEL are: 10. Business Excellence (ISO department) 11. Production planning and control 12. Quality engineering 13. Standards room 14. Industrial engineering 15. Personal department 16. Accounts department 17. Purchase department 18. Machine shop 19. Assembly shop 20. Tool room 21. Stores 22. Maintenance
DETAILS OF ALL THESE DEPARTMENTS:

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1.) PRODUCTION PLANNING AND CONTROL (PPC)

The PPC at SEL is in charge of maintaining the inventory status, of arranging receipt and dispatch of components and of follow up. It also supervises transfer of components from the machine shop and stores to the assembly area and maintains the shop floor status of the components. PPC indicates two functions: Production planning is the function concerned with the planning, Directing and controlling of the methods to be used to make products and the way in which the production facilities etc. should be laid out in the space available for production. Production Control is the function of the management, which plans, directs and controls the material supply and processing activities of an enterprise. So that specified products are produced by specific methods to meet and approved sales program.
2.) QUALITY ENGINEERING DEPARTMENT

Another important part of the plant is the Quality Shop. With the increasing competition in the market it is desired by the company to produce such a quality product so as to satisfy the various needs of the customer and the level of quality of the product. This work is done by the quality department. Quality seeks on every minute defects and smallest of dimension that could bring much risk of poor quality, defects and line reject. The quality shop is 24 by 7 hours running. By this you can yourself judge how much the company is putting in to maintain the quality of the products and also that their customers get the best quality product every time. It is the shear responsibility of the quality shop only that the materials within the maintained dimensions are being transferred on to the machines so that it doesnt causes any further problems and also to minimize line rejection losses. Also it is the responsibility of the quality department to put various materials on rework if they cause problem like line rejection.
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The quality shop comprised of three main parts: Quality Receiving Department Coordinate Measuring Machine Room Standard Room
Before I begin explaining about various parts within the quality shop, it is important to know that all its branches work towards the ultimate goal of maintaining quality only. Quality is relative term and is generally explained with reference to the product. Quality can be defined as fitness for purpose. The Quality engineering department at SEL is divided into four sections. These are Quality engineering [receipt] Quality engineering [Machine shop] Quality engineering [Assembly] Quality engineering [Testing]
3.) INDUSTRIAL ENGINEERING DEPARTMENT

Industrial Engineering (I.E.) is concerned with the design, improvement and installation of integrated system of people, materials, equipment and energy. It draws upon specialized knowledge and skill in the mathematical, physical and social sciences together with principles and methods of engineering analysis and design to specify predict and evaluate the results to be obtained from such system. I.E. is engineering approach to detailed analysis of the use and cost of resources of an organization. The main resources are men , money , materials , equipment and machinery. The industrial Engineer carries out such analysis in order to achieve the objectives (to increase productivity or profits etc.) and policies of the organization. An Industrial Engineers technique is too go beyond
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the mechanical cost factor. He is associated with organization structure, administrative techniques, and labour problems and at the same time he understands the relationship between efficiency and consent (of the working group). Essentially the industrial engineer is engaged in the design of a system and his function is primarily that of management. If he is to focus on only one concept to describe his field of interest and objectives, it would have to be productivity improvement. The mission of I.E. would be try to produce more to serve better without increasing the resources being consumed. 3.1 OBJECTIVES OF I.E. Industrial engineers are concerned with two basic objectives: improving efficiency and reducing wastage. Efficiency is improved on resources employed such as men, material, machine management and money. It therefore, means improving efficiency in manufacturing process, methods, capital investment and efficiency of plant. In practical 100% efficiency is impossible to achieve. The second objective of I.E. is to reduce wastage. Since the two objectives are of universal application, the area of operation of Industrial Engineering is also very wide 3.3 ROLE OF INDUSTRIAL ENGINEERING IN SEL The most important and result oriented dept. in the terms of production planning, designing, optimization of methods etc. is the industrial engineering dept. It is the backbone of all types of process industries. The various functions of the I. E. dept are the following:
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PROCESS PLANING: - It deals with process capabilities of various machines, and constantly works on projects for productivity improvements, optimum layouts, Programming of CNC Machine, Productivity Improvement Studies, Optimum Utilization of material resources etc.
TOOL CONTROL CELL: - It deals with tooling, jigs, and fixtures being used throughout. It also does inventory control, dealing in various cutting materials available and their respective usage, different types of cutting tools, tool-holders etc; their nomenclature and corresponding applications. TOOL DESIGN: - It deals with the designing aspect of equipment, sets various standards for QE etc. for designing the different parts of engines.
ASSEMBLY/PROJECTS: - Its deals with the process of Engine Assembly shop, Conducting Trials for different tooling required in Assembly, Implementing any design change in Engine as recommendation from R&D , Project related work like new machine installation, Civil related works in plant etc.
4. PERSONNEL
Any industry depends upon human beings. It has to acquire workers and it creates an acceptable and rule of practice to encourage the greatest degree of participation from its employees. The department concerned with this called personnel department. The personnel function exists in every enterprise regardless of its size & irrespective of the fact whether or not there is personnel department. In small concern, the owner itself carries on the personnel function whereas a large organization it is given a maximum individual development, desirable working condition and desirable working relationship between employees and employers
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and between groups of employees and effective moulding of human resources for the purpose of contributing to the organizational goals.
5.) ACCOUNTS
The main objective of the accounts department is to determine, classify and analyze the cost and income of the business enterprise. Accounts department provides information for the following: Cost control through accumulation and utilization of cost data Profitability of products Budgeting Standard costing Continuation of business Proper matching of cost with revenues Control of material and supplies Wages and overhead costs Determining expansion and contraction policies
6.) PURCHASE
The purchase department is responsible is responsible for purchasing all types of materials in correct qualities and at the most economical prices. The purchase department occupies a vital and unique position in a concern because purchasing is one of the main functions in the success of a modern manufacturing concern. The purchasing function acts as a liaison agency, which operates between the factory and the outside vendors on all matters of procurement delivery of the articles in accordance with terms of purchase agreement.
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7.) MACHINE SHOP

Facilities at this shop include equipment for drilling, boring, fine boring, grinding, lapping etc. Machining to components, cylinder heads, connecting rods, cylinder blocks, crank case and gear casing is done in this shop. The various functions of this shop are: 1. Machining of cylinder, cylinder heads, crank cases, gear casing etc. of the entire engine models being manufactured at SEL 2. Assembly of cylinder heads 3. Machining & assembly of connecting rods of RV engine models. 4. Machining & assembly of connecting rods of SM Some of the operations being carried out for the processes being performed at the SEL m/c Shop for machining the different components are:
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Grinding Drilling Boring Turning

Semi finish boring Finish Boring Tapping Milling Chamfering Reaming Lapping Washing
MACHINES USED IN MACHINE SHOP: Vertical milling machine Horizontal milling machine Radial drilling machine Gang milling machine Rough boring machine Semi-finish boring machine Finish boring machine Honing machine Gun drilling machine Washing machine Rotary grinder Rough milling machine XLO valve lapping machine Line boring machine
MACHINING PROCESS OF VARIOUS COMPONENTS:

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CRANK CASE

CYINDER HEAD GEAR CASING CYLINDER BLOCK SML CYLINDER BLOCK SML CYLINDER HEAD CONNECTING ROD
CRANK-CASE Crankcase is the housing for accommodating crank shaft and cam shaft. In SWARAJ tractors, crank case is cast separately and attached to cylinder block. The bottom face of crank case walls is flanged to strengthen the casing and to provide a machined joint face for sump to be attached. Crank-shaft is supported in the crank case through a number of bearings called main bearings. The construction of the crank case has to be such as to provide very high rigidity because it must provide reactions for the heavy forces set up to gas pressure in the cylinders. The cylinder block is mounted above the crank case. At the top of the cylinder block is attached the cylinder head. Attached to crank case is sump, flywheel, gear casing, fuel filter, water separator etc. The material of crank case is cast iron because it has following advantages:1. Good foundry material 2. High machinability 3. It does not warp under high temp. & pressure developed in cylinders 4. It is slightly porous nature as it retains better lubricant oil film 5. It does not wear too much 6. Sound damping properties 7. Low coefficient of thermal expansion 8. It is relatively cheap
CYLINDER HEAD
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Cylinder head is attached to the top of the cylinder block by means of studs fixed to the block. The gaskets are used to provide a tight leak proof joint at the interface of the head and the block. The cylinder head forms a combustion chamfer above each cylinder. It also contains injector holes and cooling water jackets. Besides valve openings are provided in the head. Upon which is also mounted the complete value operation mechanism. In all the cylinder heads of swaraj engines, the inlet and exhaust manifolds are placed on different sides of the cylinder head, it is called offset cross-flow type. Detachable head type has many other advantages over the integral construction. 1. From production point of view, the cylinder block casting with open bore for the detachable type head, is much more simplified. 2. Operations like de carbonizing and value grinding are simplified 3. The comp. ratio can be changed slightly by changing the thickness of gasket used between the block and the head. The material used for cylinder head is cast iron There are separate sets of pipes attached to the cylinder head which carry the air and the exhaust gases. These are called manifolds.
The cylinder has the nozzle bore in which the injector is inserted. The function of injector is to inject the fuel in the cylinder in properly atomized from and in proper quality. The cylinder head apart from having the inlet and exhaust manifolds (attached to cylinder head) has a water outlet manifold. On the top of cylinder head, is mounted the rocker arm, rockers shaft, push rods, springs rocker cover etc. The cylinder head also contains the inlet and exhaust valves. There is a water jacket in the cylinder head for the circulation of cooling water. The lubrication oil for the lubrication of rocker assembly enters from Rocker supply hole. Where it enters through rocker supply hole where it enters through rocker supply pipe from crank-case. RV2 and RV3 have the same cylinder head while RB30 and RB33 have the same. The S-15 has completely different cylinder head.
1. WATER GALLERY TESTING MACHINE:
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After above operations water gallery is tested by passing pressed air from water exhaust while water inlet is closed by on arrangement and then dipped in coolant for checking any leakage in plugs or blow holes in valve holes.
2. VALVE SEAT LAPPING:

1. Apply lapping paste on valves periphery and insert in valve seats 2. Hold the valves by rubber lapper. 3. Start the machine and lap the valves 4. Stop machine and release the job 5. Clean the seats- Valves with cloth properly 6. Place the comp. with top side up on washing unit. 7. Clamp cylinder head and start machine cycle. 8. Tap 1-hole M 10 1.5 and 15 deep. 9. Rotate camp and place on fixture to bring inlet side on top. 10. Tap 1-hole M 101.5 and 10 deep. 11. Feed the comp. in the washing booth 12. Remove the comp from booth after washing 13. Clean the comp with air Jet and cloth. 14. Alloy lockset on care plug holes 15. Fit case plugs in core holes by hammer and punch
3. PRESSURE TESTING MACHINE

1. Place and clamp are cylinder head on the unit. 2. Clamp cylinder head pneumatically and dip ass in tank 3. Start air and check for any air bubble. Lift the head and release the job pneumatically and kept cylinder Head on conveyor. 4. Drain out excess coolant clean with cloth and put rubber stamp with CuSO4.
4. LEAKAGE TESTING AND FINAL ASSEMBLY:
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1. Remove cylinder head from washing unit and clean residuals with clean and dry cloth as per shop practice. 2. Insert valves from bottom side and place cylinder head on base plate. 3. Place the cylinder head on table put valve cup in the valves from top side. 4. Place 2 no. of valve springs with the help of fixture on inlet valve. Side and exhaust valve side. 5. Press cups along with springs with the help of fixture on inlet valve. Side and exhaust valve side. 6. Insert collets pairs to take the proper seat with valve cup. 7. Test for leakage on valve leakage testing machine at air pressure of 4 kg/cm2 8. Re-lap the seats is leakage appears The emery paste is used in lapping process which acts as a grinder and grinder both valve and valve seat.
5. FINAL INSPECTION:
After leakage test and final assembly, final inspection of cylinder head is done. In this inspection the tap of holes and valve seats and valve guides are inspected by a quality inspector and then pieces are moved to assembly shop. GEAR CASING As the name suggests, gear casing is the casing for gears. It encloses the crank shaft gear, cam shaft gear, idler gear, FIP driving gear, lubricating oil pump assembly. It has following faces. 1. covering face or oil filler body mating face 2. crankcase mounting face 3. sump mating face 4. lubricating oil filter mating face 5. Plate face 6. Water pump mounting face
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Covering face: On this face, timing setter, tension lever, and pulley for driving crankshaft are mounted. Crank case mounting face: It is a face which meets with the gear end face of crank case. Sump face: On this face, sump is mounted. On water mounting face, water pump is mounted in RV2&RV3. but in case of RB30&RB33, the water pump is mounted on cylinder block. On this face alternator bracket is mounted in RV2&RV3. But in case of RB30&RB33, it is mounted on cylinder block
MACHINING PROCESS OF GEAR CASING:
1. VMC-40:
FIRST SET UP: This is a machine made by Kirloskar, on this machine, the operations on the crank case mounting face are done. There are two machines on which same operations are done on this face. Dowel holes accommodates dowel pins so that the gear casing can be easily supported during fitting as these pins gets fitted into dowel holes on the gear end side of crankcase 4 drilled holes of 5mm are around bearing hole. Here plate is mounted 4 drilled holes of 8.4 around FIP mating hole. Here FIP is mounted. Through FIP mating hole the FIP shaft passes on which adapter flange is mounted. With this adapter flange, the FIP driving gear is tightened
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Bearing hole accommodates bearing.
The extended portion of gear casing where the plate is mounted accommodates the gear. This gear transmits motion to the hydraulic pump which is used for operating the lift hydraulic pump. SECOND SET UP: set-up is also done on a V.M.C.-40 machine. On this machine the following operations are done on the oil filler body mating face. Here also two machines are used for same operation. Oil seal hole accommodates the end of shaft where oil seal is mounted which prevents the oil to come out of gear casing. On this end of crankshaft, the pulley for giving a drive to it is mounted.
2. HMC-500
Third set-up of gear casing is done on H.M.C. machine. This machine is used for operations done on lubricating oil mating face, sump face, plate face and top face are done . Operations done are drilling chamfering & tapping .
3. FLEXIARM:
The tapping of all faces are done on this machine by clamping in fixture specially designed for this operation& also side drilling is done.
4. WASHING MACHINE:
After oil gallery drilling washing of gear casing is done on washing machine with coolant. Washing is done to remove chips and other components from oil galleries and other drilled holes. After washing cleaning of gear casing is done with air jet and de burring of gear casing is done.
5. LEAKAGE TESTING AND INSPECTION:
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After washing oil gallery leakage test is done. First gear casing is dipped in coolant and air passed through oil gallery. If bubbles appear then there is leakage in oil gallery otherwise there is leakage in gear casing. After this final inspection of gear casing is done and then send to assembly shop.
8.) ASSEMBLY SHOP

Most of the products are formed from a large no. of single parts produced at different times by various production processes. All these may not be made at a single place but procured from different sources. The objective of assembly is to combine individual components into a useful product of higher value. The assembly shop at SEL assembles the engines of various models. Assembly is done manually in which workers perform various assembly operations by using dexterity, sense organs and intelligence using various tools and fixtures. Different components are brought from the stores and the machine shop and engines are assembled from these components. After the assembly of engine, their testing is done. Engine testing is also part of assembly shop. The Assembly at SWARAJ TRACTOR DIVISION deals with the assembly of tractor models 722, 724, 733, 735, 744, and 834. Assembly is the joining of various constituents to form a final
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product. The assembly process is carried out on the main line, which has various sub assemblies along its length. Assembly shop can be divided in two main areas: 1) 2) Before paint area After paint area.
BEFORE PAINT AREA: The area before painting can further be divided into sub assemblies/ loops namely Differential loop. Gearbox loop. Rear cover loop. Engine assembly loop.
DIFFERENTIAL LOOP:-
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Differential casting mounted on trolley after washing. Bull pinion Shaft left and right fitted. Cage assembly fitted. It consists of:
1. Crown wheel. 2. Tail pinion assembly. 3. Roller bearing. 4. Bevel wheels. 5. PTO shaft fitted. 6. Rear axle/trumpet is fitted.
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7. PTO shifter assembly fitted. 8. Gearbox assembly is lifted. 9. Rear cover assembly fitted. 10. Brakes are fitted. 11.Parking brake.
12.Suction pipe 13.PTO cover
14. Trailer hook is fitted. 15. Angle bracket is fitted. 16. Rocket link is fitted. 17. Footboard is fitted. 18. Clutch pedal is fitted.
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GEAR BOX LOOP:-
Gearbox housing mounted on trolley. Drive shaft & input shaft assembly. Output shaft assembly. Lay shaft and connecting shaft assembly. Shifter rod assembly. Steering assembly.
GEAR BOX:The gearbox used in the tractors being manufactured by the P.T.L. is of the SLIDING MESH TYPE. This is the simplest type of gearbox. The power comes from the engine to the clutch shaft and hence to the clutch gear which is always in mesh with a gear on the lay shaft. All
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the gears on the lay shaft are fixed to it and as such they are all the time rotating when the engine is running. The clutch is engaged three direct and one reverse speed are attained on suitably moving the gear on the main shaft by means of selector mechanism.
REAR COVER LOOP:-
Rear cover mounted on trolley. Control valve and response valve assembly. Ram assembly. (This consists of cylinder, piston and piston rods.) Testing of hydraulic lift.
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ENGINE ASSEMBLY LOOP
Engine mounted on trolley Dynamo is fitted. Self-motor is fitted. Oil pump is fitted. Front axle beam and bracket is fitted. Clutch plate is fitted.
After that the chassis is carried to the next level by the lift where the engine & the 3-point assembly of the tractor along with the other components are fixed. The parts fitted here are:
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3-point linkage which contains the following parts: Bracket. Lower link fitted at the left side. Leveling rod fitted at the right side. Stabilizer stainer. Draw bar. Top link.
Battery frame. Front frame. Tie rod attached with the drop arm of the steering system. Accelerator link. Delievery pipe. Engine attachement The engine is attached with the chassis system in this level of assembly. The engine is also
carried to this level with the help of the lift crane, which lifts the engine assembly & delievers it to this level. Shlug is applied at the corneror we can say at rhe circumference of the gearbox where engine is attached with studs & bolts. Shlugs works as gaskets or seals & avoid the oil leakage & water mixing in the engine. the engine, which is suplied to this level of assemble where the engine is attached contain the following parts attached on it:
Front axle. Extension in the front axle used for the setting of the wheels. K.P.S.A. (King Pin Shaft Axle) with the wheel disc & nuts fitted in there for the fitting of the wheels. Drop arms. Tie rods. Bucket. Clutch plates Alternator. Self starter.
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Fuel pump.
The above parts are already fitted with the engine when it comes to the engine chassis assembly. The make of the engine is KIRLOSKOR or SWARAJ KIRLOSKOR depending upon the model as 3-cylinder, 2-cylinder or 1-cylinder. The engine was imported from this company from Pune. SWARAJ also has its own engine plant where the engines are assembled. After assembling the chassis & engine arrangement, the fitments are checked by the workmen appointed there at this level & if there is some part missing, it is attached here. Then the whole assembly is mounted over the conveyor, which takes that piece to different chambers of washing, drying, primering, baking, painting & again baking. After painting the conveyor takes the assembled piece to the DISMOUNTING STAGE where different parts & components are fitted on the tractor & the tractor was completed. After that the testing of the tractor is done. A tractor has to pass through different tests to claim itselfs to be as perfect & if there is some problem coming out in this stage, the tractor is send to the recovery shop, where the problem of the tractor is recovered. After the recovery the tractor is again tested & after passing the test the tractor finally send to the yard from where it is send to the R & D Complex for further tests. Now we shall discuss the DIFFERENTIAL, GEAR BOX, REAR COVER AND DISMOUNTING STAGE in detail.
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GEAR BOX
The power, which the engine develops, is transmitted to the wheels of the tractor by certain essential parts. The application of engine power to the driving wheels through these parts is called POWER TRANSMISSION. These parts are clutching, gear box, differential and rear axles. To start a tractor from rest, the inertia of its whole weight must be overcome. Diesel engine does not develop its full power at low speed. It has to run at fairly high speed before it develops maximum power and torque. Since much power is needed in starting, climbing uneven land and in pulling varying loads, a provision must be made to permit the engine to run at high speed while the wheels run at lower speed. This is achieved by a system called GEAR BOX. With the help of gearbox we can achieve this and pulling power of the tractor can be increased or decreased by varying the speed of tractor. For these tractors gearbox used is of the type of SLIDING MESH GEAR type.
TYPES OF GEAR BOX:
Selective gearbox. a. Sliding mesh type b. Constant mesh type. c. Synchronous type.
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Planetary gear transmission. Automatic gearbox
WORKING IN GEAR BOX
The Constant Mesh (CM) gear is rigidly fixed to the input shaft or clutch shaft. It remains always connected to the drive gear (also CM gear) of the lay shaft. Three other gears are also rigidly fixed to the layshaft. They are the second speed gear, first speed gear and reverse speed gear. Two gears are mounted on the splined main shaft or output shaft (also known as intermediate shaft) which can be slided by the shifter fork when the shaft lever is operated. These gears are the second speed gear and first and reverse speed gear. They can be connected to the corresponding gears of the layshaft and always remains connected to the reverse gear of the layshaft.
Gears in neutral: When the engine is running and clutch is engaged, the CM gear drives the layshaft gears. The layshaft rotates opposite in direction of the clutch shaft. Note that in neutral position, only the CM gear is connected to the CM gear of the layshaft. Other gears are free, and hence the transmission intermediate shaft is not turning. The vehicle is stationary.
First or low speed gear: By operating the gear shift lever, the larger gear on the intermediate shaft is moved along the shaft to mesh in the first gear of the layshaft. The intermediate shaft turns in the same direction as the input shaft. Since the smaller layshaft gear is engaged with the larger intermediate shaft gear, a gear reduction of approximately 3:1 if obtained. That is, the input shaft turns three times for each revolution of the input shaft. Further gear reduction in the differential at the rear wheels produces a still higher gear ratio, approximately 12:1, between the engine crankshaft and the wheels.
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Second speed gear: By operating the gearshift lever, the larger gear of the intermediate shaft is demeshed from the first gear of the layshaft and then the smaller gear of the input shaft is meshed with the second gear of the layshaft. The intermediate shaft turns in the same direction as the input shaft. A gear reduction of approximately 2:1 is obtained. The differential gear reduction increases this gear ratio to approximately 8:1.
Third, top or high speed gear: By operating the gear shaft lever, the second gear of the intermediate shaft and layshaft are demeshed, and then the second and top gear of the input shaft is forced axially against the CM gear of the input shaft. External teeth on the input shaft gear mesh with the internal teeth in the second and top gear. The intermediate shaft turns with the input shaft and the gear ratio of 1:1 is obtained. The differential reduction reduces a gear ratio of about 4:1 between the engine crankshaft and the wheels.
Reverse gear: by operating the gear shaft lever, the larger gear of the intermediate shaft is meshed with the lever idler gear. The reverse idler gear is always in mesh with the layshaft reverse gear. Interposing the idler gear between the layshaft reverse gear and intermediate shaft bigger gear, the intermediate shaft turns in the direction opposite to that of the input shaft. This reverses the rotation of the wheels so that the vehicle backs.
High/Low Gear: High/low gear shifter enables to achieve either high torque-low speed or low torque-high speed with the help of planet gear & carrier assembly.
High Gear: Low torque-high speed is achieved when hi-lo shifter is shifted in high gear position. Coupling intermediate shaft and output shaft with the help of sleeve transmits the power.
LOW GEAR: High torque-low speed is achieved when hi-lo shifter is shifted in low gear position. The power is transmitted to output shaft from intermediate shaft, planet gear and
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carrier assembly and sleeve. The planet gear & carrier assembly reduces the high speed and subsequently torque is increased.
LUBRICATION OF GEAR BOX
Proper lubrication of gear box is extremely important. The transmission gears operate in a bath if lubricant. The fear box should always remain filled with lubricant. It prevents metal to metal contact which would generate so much heat that the gear teeth would be burned away. It lubricates bearing if the fear box.
Special Tools Used In Gear Box Assembly:
1. Dowel Pressing Tool used for internal gear. 2. Planet Pin Fitting used for planet carrier. 3. Base for Planet Carrier. 4. Pin aligning tool used for planet gear. 5. Extraction tool used for planet carrier. 6. Needle bush used for Input shaft and intermediate shaft.
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DIFFERENTIAL SYSTEM
If the car 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 two rear wheels. The propeller shaft may be geared rigidly, in the case, with the rear axle to rotate the rear wheel together. But when the car takes the turn, the outer wheel travels on the longer radius than the inner wheels. The outer wheel turns
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faster than the inner wheel, i.e., there is the relative movement between the two rear wheel. 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. Poor road holding.
Therefore, there must be some devices to provide relative movement to the two rear wheels when the car takes a turn. And here comes the purpose of differential. The differential is a device that splits the engine torque two ways, allowing each output to spin at a different speed. The differential is found on all modern cars and trucks, and also in many all-wheeldrive (full-time four-wheel-drive) vehicles. These all-wheel-drive vehicles need a differential between each set of drive wheels, and they need one between the front and the back wheels as well, because the front wheels travel a different distance through a turn than the rear wheels. Part-time four-wheel-drive systems don't have a differential between the front and rear wheels; instead, they are locked together so that the front and rear wheels have to turn at the same average speed. This is why these vehicles are hard to turn on concrete when the four-wheeldrive system is engaged.
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The differential has three jobs:
To aim the engine power at the wheels To act as the final gear reduction in the vehicle, slowing the rotational speed of the transmission one final time before it hits the wheels To transmit the power to the wheels while allowing them to rotate at different speeds (This is the one that earned the differential its name.) WORKING of DIFFERENTIAL:
The engine drives the crown wheel mounted on the cage assembly through tail pinion. Four bevel pinions are mounted on the cross, which is fitted in the cage assembly. Cross-moves along with the cage assembly and bevel pinions are free to rotate on the cross. Two bevel gears are mounted on the splined bull pinion shafts lt. and rt., which are supported on the taper roller bearings in the differential housing. These taper roller bearings give rigid support to cage assembly.
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CASE-1:
On straight roads, the cage moves along with the crown wheel carrying the bevel pinions and bevel gears without any relative motion among them. At this time bevel pinions do not revolve around the cross but act as a key between bevel gears lt. and rt. causing the bull pinion shafts to rotate at the same speed.
CASE-2: Now consider that if the tractor is moving and the bull pinion shaft rt. is being held stationary by applying the brake for a shorter turn in the field, due to this bevel gear rt. cannot rotate while cage assembly is still rotating in the same direction. As bevel gear rt. is stationary, bevel pinions will roll over bevel gear rt., or we can say it will walk along bevel gear rt. while revolving around its own axis. On the other hand bevel gear lt. will move two times faster. The reason for the faster speed of bevel gear lt. is that while it is rotating on its axis due to the speed of cage assembly in the same direction an additional speed has been added due to the relative motion between bevel pinions and bevel gear lt. CASE-3: As soon as any of the rear wheels of tractor come across a loose/wet soil where resistance to both the wheels is not equal or when the tractor is on a turn (say right turn), unequal resistance will come across both wheels, causing speed reduction of rt. wheel & rt. bull pinion shaft. But the cage assembly will keep on rotating at the same speed & in same direction. Now bevel pinions will roll over bevel gear rt. at a slower speed. Hence bull pinion shaft lt. will rotate at slightly higher speed due to the speed of cage assembly and the additional speed given to bevel gear lt. by bevel pinions. This is the working principle of the differential system. On the straight roads the speed of both rear axles remains same and on turns, the inner wheel is subjected to more resistance and hence it moves at a slower speed and outer wheel moves faster.
The DIFFERENTIAL SYSTEM is very useful in the automobiles. This help in the turning of the vehicle. As already discussed in the above cases that how the vehicle differential
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works while the vehicle takes the turn. During the turning, the inner speed of the vehicle reduces & the outer wheel moves faster than the inner wheel. The differential on the vehicle distributes the power between the two wheels by giving the less power to the inner wheel then the outer one & the vehicle moves easily. Steering system is used for the turning of the vehicle. The following is the layout of the differential assembly, which helps in understanding the things in easy way:
Differential Trouble Shooting

1. Noisy Differential: a. Less lubricating oil in the differential housing. b. Low viscosity oil or use of poor 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 Tail Pinion. f. Less Backlash of Crown Wheel and pinion teeth. g. Worn out bearing of Crown Wheel or Pinion. h. Crown Wheel misaligning on cage. i. Loose star Pinion. j. Broken or worn out thrust washers of star pinion or bevel gear. 2. Vehicle does not move when put in gear: a. Broken axle shaft. b. Broken pinion flange key. c. Broken teeth of crown wheel and pinion. d. Broken cross or star pinion.
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DISMOUNTING STAGE
INTRODUCTION:
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DISMOUNTING means the removing of the complete assembled tractor piece from the conveyor. The conveyor is a long rail like carrier system, which carries the tractor chassis & engine assembly through the different chambers of washing, drying, primering, baking & then to the dismounting stage. After the attachment of the complete assemblies of differential housing, gearbox & engine fitting, the assembled piece is mounted on the conveyor which takes the assembled piece to the different chambers of washing, drying, primering, baking & then further to the dismounting stage. First of all the chassis & engine part is washed in the washing chamber. After washing the assemble piece is dried with the blowers in the drying chamber. After that the assembled piece is coated with the primer in the primering chamber. A primer makes a thin layer on the assembled piece, which helps the paint to be attached to the assembled piece. After the primering the assembled piece is dried out. Then the assembled piece travels to the painting chamber & paint is sprayed on the assembled piece of the tractor containing the chassis & the engine. After the paint section, the assembled piece travel to the baking chamber. In this the paint dried out & fixed on the assembled piece. Then at last the assembled pieces reaches to the dismounting stage. In this stage the wiring, sheet metal work attachment & other parts of the tractors like radiator, steering, fuel tank, etc. is fitted. When the fitting of the parts of the tractor is complete the tractor piece is removed from the conveyor called the DISMOUNTING of the tractor. Then the further test like road testing, rig test, engine test, etc. is done. After the dismounting stage, we get the complete tractor but without testing. So testing of the tractor is done after dismounting & after passing the tests, the tractor is sent to the yard from where it is supplied to R & D COMPLEX. Here further testing of the tractors is done on the engine & other parts like lifting, etc. & improvement or development is done in the tractor for better performance. After all this procedures of testing etc., the tractor is ready to be supplied to the market.
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DISMOUNTING STAGE: After the processes of washing, drying, painting, baking, the assembled piece is finally arrived to the DISMOUNTING STAGE through conveyor. This dismounting stage is further divided into different small stages & in each stage, 2 persons works at a time, on an assembled piece of chassis & engine. The work is divided between these 2 men at the different stages. The dismounting stage is divided into 5 different stages in which the parts of the tractor are fitted on the assembled piece of chassis & engine & in every 6 minutes, we got a complete tractor, which is removed from the conveyor of the dismounting stage.
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STAGE 1:
Alternator connection Horn Brake rod Brake switch connection Fan belt
STAGE 2:
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STAGE 3: Fan Radiator Hose pipes Speedometer wire Rear frame Fuel tank Overflow pipes Felt pads
Dash board (it mainly has instrumental panel which contains engine oil meter, fuel gauge, ampere meter, temperature gauge, speedometer) Dash board cover Number plate
STAGE 4: STAGE 5:
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Battery Steering wheel Head lights Clutch connection Hooks and side panel Knobs and covers Sealings
Seat Sheet metal covers (side panel covers, side shield, bonnet, front grill) Fenders Tyres fixing Batter cover

Torque checking Engine oil pouring and greasing Charts and stickers
After completing all the above stages the tractor reaches the point where it is removed from the conveyor, which is known as the DISMOUNTING STAGE of the tractor. A platform is there & when the tractor reaches the platform the conveyor is removed & the tractor is free. After that the tractor slides down the platform & reaches the stage, which is the final stage after the dismounting of the tractor. This stage comes before the testing of the tractor. In this following functions & equipments are fitted on the tractor: Air cleaner Exhaust Front tyres distance check and adjust.
TOOL ROOM
In industry various types of tools are used. The tool room caters to the needs for manufacturing of gigs, fixtures, gauges, dies, etc. During machining wear & tear of the tool takes place. The tool room is provided in order to re-sharpen these tools.
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FUNCTIONS OF TOOL ROOM RE-SHARPENING OF THE TOOLS- whose wear & tear has taken place. This ensures that there is no delay in production due to blunt tools. NEW JIGS & FIXTURES- In order to improve the production rate & quality of the work & to decrease the job setting time, new jigs & fixtures are developed in the tool room. MAINTENANCE OF OLD JIGS & FIXTURES- Old jigs & fixtures that lose their accuracy due to breakage or wear & tear are repaired in the tool room. NEW DEVELOPMENT WORK- Any modification & development work is carried out in tool room, for e.g. a new component is to be installed in a tractor, its die assembly is developed in the tool room. MANUFACTURING OF MEASURING TOOLS- Certain measuring tools used in the metrology lab for quality check are manufactured in the tool room.
MAINTENANCE DEPARTMENT
Maintenance is another very important factor, which influences the productivity; there are different kinds of maintenance practices like:
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1. 2. 3. 4.
Scheduled Maintenance. Breakdown Maintenance. Preventive Maintenance. Predictive Maintenance.
Its importance is mainly due to the fact that it reduces breakdown time and health is achieving production targets at low costs It caters to repairing replacing, and adjustment or modification of parts used in various machines. Each machine has a symbol, which indicates whether maintenance has to be on daily basis, weekly basis, quarterly basis or monthly basis. The maintenance scheduled is maintained for each month after consultation with the shop in charge.
CHECK POINTS AT ENGINE TESTING
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1. Engine load at rated RPM 2. SFC at rated RPM 3. Oil Pressure at Idle RPM & NLFT 4. Engine Idle RPM & NLFT 5. FIP Hunting 6. FIP model 7. Engine Number & Code 8. Lubricating Oil Level 9. Check for Unusual noise of Compression Leakage a. Tappet Noise b. Gear Noise c. Head Noise d. Valve Touch Noise
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e. Humming Noise
10. Water leakage Al. Bend / Adaptors / Water manifolds / Hose pipe 11. Water Leakage from water Pump mtg. / pump seal 12. Water leakage from Thermostat Assembly 13. Lubricating oil leakage LO. Filter / Pipes 14. Lubricating oil Leakage from Joint for Gov. hsg. 15. Lubricating oil Leakage from Joint for Oil sump 16. Lubricating oil Leakage from GES / FWES Seal / FAB Studs 17. Fuel Leakage from Fuel connections / Sed. Bowl 18. Fuel Leakage from Feed pump / Banjo 19. Water mixing in Engine oil 20. Fuel supply noise at 1400 RPM No Load (Any erratic noise) 21. Seating of rubber bush bottom (Push rod Tube) in RV Engines Leakage check points 1. Injector Leak off Pipe 2. Rocker Cover 3. Water Inlet Manifold 4. Water Hose Pipes 5. Lubricating Oil Cooler Pipe 6. Water Pump 7. Water Separator 8. Diesel Filter 9. Gear Casing Mounting Studs 10. Lubricating Oil Filter 11. Rocker Supply Pipe 12. Crank Case 13. Oil Seal Housing 14. Oil Sump 15. Cylinder Head 16. Cylinder Block
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CHECK POINTS AT ENGINE DESPATCH 1. Tested OK Sticker 2. Engine code & FIP code 3. Engine No. Punching 4. Engine Flywheel & Hsg. As per code / model 5. FIP & Fuel Filter seals 6. Missing Components
7. Lubricating. Oil in sump with colour (For Water Mix). 8. Completion of Engine with all Parts 9. Dipstick in dipstick guide. Loose / tight 10. Crank Nut for tightening 11. Protrusion of M14 Cyl. Head studs & FAB studs 12. Tightening & Positioning of Rubber Pipes & Polymer Thermostat hsgs. 13. Tightening of Rocker covers 14. Tightening of FIP mtg. Nuts 15. Water Pump as per model 16. Fuel cut - off Lever spring- leakage & Tension 17. Threading for Tachometer in Oil filler Body 18. Threading in Flywheel hsg. 19. Any Dent on L.O. Sump (Sheet metal) 20. Oil Leakage from drain plug 21. GES / FWES Main Oil seal leakage 22. Casting Finish / Fettling marks on Crank Case, Gear Casing 23. Breather tube Seating
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Six Months Industrial Training Report at Punjab Tractors Limited (PTL

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Six Months Industrial Training Report at Punjab Tractors Limited (PTL

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Six Months Industrial Training Report

PUNJAB TRACTORS LIMITED

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR B.Tech (Mechanical Engineering) At

Mechanical Engineering Department AMRITSAR COLLEGE OF ENGINEERING & TECHNOLOGY,