PUNJAB TRACTORS LIMITED

CHAPTER :-1 INTRODUCTION OF COMPANY

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

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.

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.

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PUNJAB TRACTORS LIMITED

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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PUNJAB TRACTORS LIMITED

INDIAN TRACTOR INDUSTRY MARKET DIMENSION

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PUNJAB TRACTORS LIMITED

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.

TRACTORS:Swaraj 724 Swaraj 735 26.5 BHP 39.0 BHP 1974 1975

Swaraj 722

19.5 BHP

1978

Swaraj 855

55.0 BHP

1983

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PUNJAB TRACTORS LIMITED

Swaraj 922 Swaraj 744

22.0 BHP 44.0 BHP

1995 1999

Swaraj 978

78.0 BHP

2007

Swaraj 939

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PUNJAB TRACTORS LIMITED

SWARAJ ENGINES LIMITED

Swaraj engines limited are as part of Swaraj enterprise. Swaraj Engines Ltd., situated at phase 9, Industrial Area, Mohali. This plant was established in technical and financial collaboration with Kirloskar oil engines Ltd. For manufacturing diesel engines for Swaraj Tractor Division. The Governor of Punjab S.S. Ray paid the foundation stone of the factory on 29th Dec. 1987. It started production from 28th Dec. 1988. This plant produces engines in the range of 20hp to 50hp. This plant had produced 18000 engines in the first year of his production. But now it is producing 50 engines averagely every day. There are 300,000 tractors working successfully in the fields which are having engines of Swaraj engines limited .This plant is a boon for agricultural automotive industry.

The various engine models being produced at SEL are:1.

2. 3. 4. 5. RV2 RV3 S15 RB33 RB30 --------------------------------------------------two cylinders three cylinders Single cylinder three cylinders three cylinders ; ; ; ; ; 24 B.H.P. 39.5 B.H.P. 25 B.H.P. 55 B.H.P. 44 B.H.P.

The manufacturing of Tractor is performed in various steps. It is manufactured after passing through various processes in various shops. Firstly, various operations on various parts are performed in the L.M.S. (Light Machine Section) and H.M.S. (Heavy Machine Section). In H.M.S. generally there are four major heavy parts that are given proper machining operations. These include Gear Box Casing, Differential Housing, Trumpet Housing and Rear Cover. Similarly, in L.M.S. the light parts are given proper machining. These include various parts such as Gears, Shafts, Cage Assembly casing etc.

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PUNJAB TRACTORS LIMITED In Heat Treatment Shop, the light parts such gears, shafts etc are given the heat treatment to ensure their strength. Firstly the part after passing through various operations in L.M.S. is taken to the Heat Treatment Shop. Here the part is kept in the furnace for suitable time period up to certain high temperature. Then it is taken to the Quenching tank where it is dipped in the oil tank. After that it is taken to washing tank for washing of dirt and oil etc. Then it is taken to the Assembly line. In Assembly line various parts are being assembled into a single unit termed Tractor. During assembling the various parts are being fitted according to the stage. This would includes the assembly of important parts such as Rear Cover, Gear Box, Differential Housing and trumpet Housing. Firstly the Various sub-parts of the Rear Cover are being fitted. Then the various parts such as gears, shafts, bearing, oil rings, clutch actuator and circlip etc are fitted into the Gear Box. After that both the Rear Cover and the Gear Box are taken to the line where Gear Box if fitted ahead of the Differential Housing whereas the Rear Cover on the Top. Then various things such as Brakes, P.T.O. Shaft, Cage Assembly, Trumpet Housing etc are fitted to the Differential Housing. Then this whole assembly is fitted with the engine against the Gear Box. After whole assembly is fitted with the Engine, this assembly is taken to the Chassis Paint Area where it is washed and dry followed by Paint on the chassis.

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PUNJAB TRACTORS LIMITED

CHAPTER :-2
HEAVY MACHINE SHOP (H. M. S.)
All heavy casting of tractors is machined in this shop with the help of variety of special machine (SPM). These machines are tailors made by IIMT to suit component requirements. In addition, facilities of this shop include general-purpose turning, drilling and milling machines. About 20 SPM and 30 GPM are installed in a covered area of 47,000 sq. Ft. At a cost of 20 million, 2600 tones of castings are machined every year on a twoshift basis. In addition to the machining of casting for the tractor, some jobs are also performed for Swaraj Mazda Limited.

COMPONENTS MACHINED IN THE SHOP

Gearbox housing (Material R-33, Casting, 180-230 BHN, 76-Kg wt.).

Differential housing.

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PUNJAB TRACTORS LIMITED

Rear cover.

Trumpet housing

Brake housing

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PUNJAB TRACTORS LIMITED

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SOP FOR STUDS FITMENT ON DIFFERENTIAL HOUSING.

(fig. of studs) Tool1. A Diff. Lifting tackle. 2. Impact wrench. Procedure1. Fitment of stud. a. Pick up washed diff. Hsg. With drain plug from the conveyor with lifting tackle. b. Pick up & lift 12nos. of studs on right & left side of diff. Hsg. c. Pick up & fit 14 nos. of studs on right & left side of diff. Hsg. d. Pick & fit 11 nos. studs in from of diff. Hsg. e. Tighten all the studs with stud runner by impact wrench. 2. Place trumpet gasket & trumpet of diff. Hsg,

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(Fig. of gasket) a. Pick up trumpet gasket insert on right & left side of diff. Hsg. b. Place the diff. Hsg. Fitted with all the studs on trolley of loop-1 by eot crank.

2. SOP FOR SUB ASSEMBLY OF CAGE.

(Fig. of cage)

Tool management
1. Pilot pins. 2. TRB cup pressing tool. 3. O cone pressing tool. 4. Torque wrench. 5. Look chisel.
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PUNJAB TRACTORS LIMITED 6. Hex socket 17 mm. 7. Hex socket 19 mm. 8. Ferros hammer. 9. Lock chisel for 251012. 10. Lock chisel for 75014. 11. Cone pressing tool J 47566. 12. Cone pressing tool J 475006. 13. Holding fixture.

Procedure
a) fitment of crown wheel to shift supervisor.

1. Pick up washed & rust free cage from trolley. 2. Dismantle it by unscrewing the 2nos. of hex. Head bolt by hand. 3. Bring both the cage at hyd. Press. 4. Pick up washer crown wheel from trolley to hyd. Press by hand. 5. Locate the right cage on crown wheel through pilot pins & insert it in the crown wheel. 6. Press fit the crown wheel on right cage with pressing fixture.

Why to do?
1. To fit crown wheel to cage. b) Pressing of TRB cups.

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PUNJAB TRACTORS LIMITED

( Hyd. Press) 1. Pick up TRB cup & press fit on right cage with cup pressing tool. 2. Place the assy. on the roller track. 3. Pick up left cage assy. & press fit taper roller brg cup on it with cup pressing tool. 4. SOP FOR TAIL PINION CARRIER SUB ASSY AND

PRELOADING.

Tools
1. TRB Cup. 2. Base for tail pinion. 3. TRB cone pressing tool. 4. SPL. Socket for WD Nut. 5. C type spanner.

Procedure
a) Pressing of bearing cone in tail pinion carrier. 1. Collect tapes roller bearings from elmira and place them on the table. 2. Open the packing of bearings. 3. Pickup washed tail pinion carrier from trolley and bring it to the press. 4. Pick up TRB cup and press fit on one side of TPC with cup pressing tool.
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PUNJAB TRACTORS LIMITED 5. Reverse TPC and press fit another TRB cup on other side of TPC with another cup pressing tool. 6. Ensure due seating on bearing cup TDC and cones should be pressed straight.

Why to do?
1. To press cone in tail pinion carrier. 2. To prevent damaging of bearing. b) Fitment of tail pinion in tail pinion carrier. 1. 2. tool. 3. 4. 5. 6. Insert tail pinion carrier over tail pinion and pressing fit second TRB Ensure due seating of bearing on tail pinion. Add 3-4 props of eo-80 oil on the brgs. Of TDC to lubricate the keep the TPC assy. On the track.. Brg. Cone it with bearing cone pressing tool. Pick up washed tail pinion from trolley and place it on the base. Pick up TRB cone and press fit on tail pinion with cone pressing

brgs. For proper preloading.

Why to do?
1. To fit tail pinion in carries. 2. For proper seating of bearing in cone. 3. TO lubricate the bearing to ensure free rotation. c) Fitment of thrust washer and lock washer: 1. Pick up thrust washer and lock washer from rack. 2. Insert thrust washer through sp line cut of tail pinion and locate it. Pick up with drawl nu7t and screw up it on TPA assy. With SPL. Tightening socket. 3. Tighten the with drawl nut with c type spanner so that bearing are properly preloaded. 4. Insert locking washer through the given cut in tail pinion. 5. Screw up the second with drawl nut on tail pinion for the locking of preload.
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PUNJAB TRACTORS LIMITED

Why to do?
1. To fit thrust washer. 2. To prevent damaging of bearing. 3. For proper preloading of bearing. 4. To lock the with drawl nut. 5. To ensure proper locking of first with drawl nut. d) Preloading of tail pinion: 1. Pick up TPC assy. And locate it in the preloading fixture. 2. Pick up the preloading bar with wt. mounted on the scale of preloading bar at 17 ensure that correct bar is picked according to the model. 3. Pick up the preloading bar & locate its dowel pin in the holes of tail pinion carrier. 4. Bring the bar at horizontal position & release it to move through 90 degree observe that it should go down slowly along with TPC assy. By initial hand tapping.

Why to do?
1. For preloading of bearing of bearing. 2. To prevent use of wrong preloading bar. 3. To check the preloading value and if wrong correct it. e) Adjust nut of preload valve: 1. If preloading bar goes down fast or unable to rotate TPC assy. Read just its preload by adjusting the preloading wd nut. 2. Repeat the procedure to ensure preloading ok. 3. Ensure the locking of the preloading wd nut after finalizing correct preloading and thus ensuring that preloading wd nut is locked prior to tightening of locking wd nut. 4. look the with drawl nut with locking star washer and also check nut with second wd check nut with second wd nut by locking chisel. 5. Keep assy. On track.

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PUNJAB TRACTORS LIMITED

5. SOP FOR SUB ASSY. OF CAGE.

(Sub assy. Of cage)

Tools management
1. Torque wrench. 2. Look chisel. 3. Hex socket 17mm. 4. Hex socket 19mm. 5. Ferros hammer. 6. Lock chisel for 251012.
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PUNJAB TRACTORS LIMITED 7. Lock chisel for 75014. 8. Fixture for torque. 9. Holding fixture. 10. Torque wrench.

Procedure
a) Fitment & torquing of screws on crown: 1. Pick up 8nos. lock washers from rack and slightly bend its small end for proper locking washer. 2. Put right case assy. On the holding fixture and hold or restrict movement of cage with locking pins. 3. Pick up 8nos. of hex had. Screws & apply lock it on their threads. 4. Fit crown wheel to right case with there hex. Had. Screws with locking washer and tighten it. 5. Torque all hex. Had. Screws to 65 lb 5 ft. 6. Bend and lock the lock washer with lock chisel by using ferrous keep assy. aside.

Why to do?
1. To torque screws on crown wheel. 2. Locking pin used for proper alignment. 3. Loc title is used to prevent loosening. 4. Locking washer in used to lock the screw. b) Placement of bevel gear cross & bevel pinion. 1. Pick up right cage and crown wheel assy. And reverse it. 2. Pick up washed bevel gears cross bevel pinion from. 3. Place bevel wheel in right cage. 4. Insert bevel pinions on the arms of cross & place 4nos. of thrust cu washer over the bevel pinion. 5. Place this set of bevel pinion & cross in position over bevel wheel and in the right cage.
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PUNJAB TRACTORS LIMITED 6. Place bevel wheel on the bevel pinion and check the back lash & smooth rotation of the assy.

What to do?
1. To place bevel gas cross & bevel pinions. 2. Cross & pinion gear are used to provide relative motion between the two rear wheel during turning. C) Fitment of left cage to right cage. 1. Place the left cage over the above sub assy. Of bevel pinion by matching the number punch on the right cage. 2. Assemble the left cage to the right cage with 8nos. of zinc passivated as per R & D memo dated hex. Bolt with 4nos. of locking strips & tighten it. 3. Torque all hex. Had. Bolt to ft on holding fixture.

What to do?
1. To fit left cage on to right cage. 2. Zinc passivated hex. Had. Bolt are used to prevent rusting & for long life. d) Looking of locking strips. 1. Bend & lock the above locking strips at its end corner properly with locking chisel. 2. Ensure the proper locking of hx. Had. Bolt m 10.

Why to do?
1. To lock locking strips. 2. Locking restricts loosening of bolts.

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PUNJAB TRACTORS LIMITED

6. SOP FOR PRELOADING OF CAGE ASSY. Tools management

1. Preloading bar in blue in colour. 2. Bubba boot pressing tool. 3. Preloading bar in green colour.

Procedure
1. Pick up wet brake hsg. Left and right from pin and place it on working table. 2. Pick up 2nos. of rubber boot and apply small quantity of lactate sealant on the metal portion of rubber boots. 3. Presses fit the rubber boot in the both wet brake housing with pressing tool and ensure the full butting of rubber boot with break housing.

What to do?
1. Preloading of cage.

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PUNJAB TRACTORS LIMITED

7. SOP FOR CAGE ASSY. PATTREN AND BACK LESH CHECKING.

Procedure
1. Pick up o ring & fit in the groove given on hollow bush b2 using special tool. 2. Fit the hollow bush assy. on each side of threaded hole meant for this in differential housing through brake housing through and tighten with socket 32 mm. 3. Torque hollow bush assy. To 65lbs. ft. 4. Recheck the backlash and contact pattern by running the back lash and contact pattern by running the test ring finally.

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PUNJAB TRACTORS LIMITED

8. SOP FOR FITMENT OF TRUMPET ASSY (left & right).

(Left trumpet) Tools management1. PTO extraction tool. 2. Hex. Socket 30mm. 3. TPT rear axle lifting tackle. 4. Bull gear locking chisel. 5. Rotating handle. 6. Hex socket 36mm. 7. Open D/E spanner 19mm. 8. Ring spanner 8.9. 9. Non ferrous hammer. 10. Rear axle holding tool. 11. Open end torque wrench.

(Right trumpet)

What to do?
Fitment of TPT assy. lt. rt. On diff hsg.

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PUNJAB TRACTORS LIMITED

Procedure
1. Tack out PTO shaft from its place by using electric tool. 2. Unscrew the bull gear from lock screw m24 & remove lock washer. 3. Pick up the bull gear from trumpet assy. & keep it on diff. hsg. On. 4. Pick up rear axle holding tool and lock the TRB brg. Of trumpet hsg. Axle. 5. Pick up trumpet hsg and rear axle assy. From trolley with tackle by insert the bull gear sp line bore to the rear arise sp line. 6. Repeat 3,4 for left side TPT rear axle assy. fitment.

What to do?
Fitment of implement plate and wiring clamp. 1. Pick up plate assy. From bin and fit on diff. hsg. 2. Pick up wiring clamp from rear and fit on left side on diff. hsg. On trumpet hsg.

Procedure
Frightening and torque of nuts:1. Pick up 28no. hex. Nut m12 & m12 spring washers and fit on both side of TPT with implement plate.. 2. Tighten all hex nuts m12 with spring washer. 3. Torque all to 65,120 ft.

What to do?
Tight inning and torque of bull gear:

Procedure
1. Apply the lactate in m24 hex bolt thread to be fitted in rear axle hole. 2. Put spaces plate in spring dowel sleeve fitted on bull gear and screw up the m24 hex bolt in diff. hsg. With socket 36mm. 3. Torque to m24 hex screw to 120lbs. ft.

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PUNJAB TRACTORS LIMITED

Procedure
1. Pick up locking plate from rack and fit on the spacer plate of bull gear with 2nos. 2. Tighten the hex screws m8*16 and lock the washer with locking shierel. 3. Rotate the bull gear axle assy. With rotating handle in order to make locking approach of m8*16 hex screw which is in the inner side. 4. Lock left and right hex screw with locking chisel and ensure the proper locking. 5. Put p to shaft along with the bearing at its desirable place.

Why to do?
To avoid losing of nut.

What to do?
Tight ening and troquing of cover plate.

Procedure
1. Pick up 8nos.of hex had Screws in m12*12 and spring washer from the rack. 2. Adjust cover already fitted on tpt assy. for correct position and tighten it to TPT hsg. With m8*20 hex Screws with spring washer by D/E. 3. Pick up gear nipple and gighten with . 4. Repeat for RHS TPT end cover bolt tight ening. 5. Torque there hex m8*20 screws with open end TBE torque wrench to torque 18 lbs ft.

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PUNJAB TRACTORS LIMITED

9. SOP FOR FITMENT OF PTO END COVER ASSY.

Tools
1. Oil seal protection tool. 2. Her socket 19mm. 3. Torque wrench.

What to do?
Fitment of PTO end cover assy.

Procedure
1. Pick up PTO end cover assy. With oil seal pressed from stand. 2. Pick up 2nos. of hex seal screw m12*35 and m12 spring washer from bin and assemble end cover with oil seal to gasket on diff hsg with seal protection tool. 3. Torque all the screw to 65lbs ft.

Why to do?
1. Gasket fitter to prevent leakage. 2. To ensure tightening of screw to specified limit.

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PUNJAB TRACTORS LIMITED

10. SOP FOR BULL GEAR TESTING.

(Bull gear testing) Tools

1. External circlib plier. 2. Holding tool. 3. Test rig with universal joint. 4. Dial gauge with magnetic stand.

What to do?
Testing of bull gear rear axle assy.

Procedure
1. Bring up pendent type test rig to diff assy. For checking and couple with sleeve and tail pinion sp line. 2. Check bull gear noise independently i.e check independently noise of bull gear by locking the BDS contrarily with lock tool check back lash by using dial gauge with respect to bp shaft which should be between 0.01 to0.03mm. 3. Check independently rotation of BPS by holding one shaft at a time by holding tool. 4. Uncouple diff assy. From test rig. 5. Keep the sub assy. A side one the track.
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PUNJAB TRACTORS LIMITED

CHAPTER :-3 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 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
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.

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PUNJAB TRACTORS LIMITED 5. PTO shaft fitted. 6. Rear axle/trumpet is fitted. 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.

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.

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: 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 &
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PUNJAB TRACTORS LIMITED 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 Drop arms. Tie rods. Bucket. Clutch plates Alternator. Self starter. Fuel pump.

the fitting of the wheels.

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
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PUNJAB TRACTORS LIMITED 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.

DIFFERENTIAL SYSTEM
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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 faster than the inner wheel, i.e., there is the relative movement between the two rear wheels. If the two rear wheels are rigidly fixed to a rear axle, the inner wheel will slip which will cause: Rapid tyre wear. Steering difficulties. 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.

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PUNJAB TRACTORS LIMITED 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-wheel-drive (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-wheel-drive system is engaged.

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 To transmit the power to the wheels while allowing them to rotate at dif-

speed of the transmission one final time before it hits the wheels ferent speeds (This is the one that earned the differential its name.)

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DIFFERENTIAL ASSEMBLY
It consists of following sub-assemblies:-

1. Cage Assembly
a.

Left Cage: It consists of following parts: Four planet gears which are bevel pinion. One cross (or spider) housing the planet gear. Two bevel gears with internal splines.

b. Right cage: It consist of :-

Crown Wheel having spiral teeth

1. Tail Assembly

It consists of following sub-assembly: a. Tail Pinion Carrier. b. Tail Pinion. c. Taper roller bearing.
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PUNJAB TRACTORS LIMITED Tail Pinion is integral with Tail Pinion Shaft. Other end having splines to take power from the Gear Box.

2.

Left Bull Pinion Shaft (LBPS)

It consist of two taper bearing. It has a bore on its right side which provide place for the entry of the RBPS so to support it with eccentricity. So LBPS is also known as female type of shaft.

3. Right Bull Pinion Shaft (RBPS)

It also consist of two taper bearing. It is the male type of shaft of which very few part enters into the bore of the LBPS to have eccentricity.

4. PTO Shaft
Both ends of this shaft are splined. One end is connected to the lay shaft of the gear box, while the other end (only the splined part) is outside the differential housing. PTO shaft transfers the torque from the gear box to other agricultural equipments like Reaper, generator, etc.

5. Two Bull Gear

These gears transfers torque from the Bull Pinion Shaft(BPS) to the rear axle through trumpet assembly.

6. Differential Housing
It is the casting that houses all the above Sub-Assemblies.

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PUNJAB TRACTORS LIMITED

REAR COVER ASSEMBLY

Rear cover is mounted on the differential assembly. It is used to cover the differential assembly. It performs various other operations also. The different components are as follows: Hydraulic cylinder. Control valve. Operating sector components. Response valve. Sensor tube.

FUNCTIONS OF DIFFERENT COMPONENTS

HYDRAULIC CYLINDER: This hydraulic cylinder completes lift arm CONTROL VALVE: It is used to control the position of the lift arm. OPERATING SECTOR COMPONENTS: Position lever is required for

mechanism.

positioning of the lift arm. Draft lever is used to give the maximum and minimum position to the lift arm. RESPONSE VALVE: This is used to give response to the lift arm. SENSOR TUBE: Its function is to operate the lift arm on uneven surface. It

automatically lifts the arm when any hard surface is hit.

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PUNJAB TRACTORS LIMITED

CHAPTER :-4 DISMOUNTING STAGE

INTRODUCTION
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
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PUNJAB TRACTORS LIMITED tractor for better performance. After all this procedures of testing etc., the tractor is ready to be supplied to the market. 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.

STAGE 1
Alternator connection Horn Brake rod Brake switch connection Fan belt

STAGE 2
Speedometer wire Rear frame Fuel tank Overflow pipes Felt pads

STAGE 3
Fan Radiator Hose pipes

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PUNJAB TRACTORS LIMITED temperature gauge, speedometer) Dash board cover Number plate Dash board (it mainly has instru-

mental panel which contains engine oil meter, fuel gauge, ampere meter,

STAGE 4
Battery Steering wheel Head lights Clutch connection Hooks and side panel Knobs and covers Sealings

STAGE 5
ers, side shield, bonnet, front grill)
1

Seat Sheet metal covers (side panel covFenders Tyres fixing Batter cover Torque checking Engine oil pouring and greasing Charts and stickers

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PUNJAB TRACTORS LIMITED 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: just. Air cleaner Exhaust Front tyres distance check and ad-

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