A report on six months industrial training at

Standard Corporation India ltd.

BABA BANDA SINGH BAHADUR ENGG. COLLEGE

Submitted to:Mr.

Submitted by:Uni. Roll no.90061124009 College Roll no. 882/09

Declaration
I here by declare that the project work entitled power steering in tractor is an authentic record of my own work carried out at standard corporation India ltd as a requirement of 6 months for the award of the degree of MECHANICAL ENGG.

Under the guidance of Sachin Garg during ..to ..

.., .

Certified that above statement made by the student is correct to the best of our knowledge and belief

Training Incharge Sachin Garg

Acknowledgement
First of all,I would like to convey my thanks to Dr. A.P.S. SETHI H.O.D Mech dept. for giving me a chance to join the industry for six months. I am deeply grateful to Mr. Sachin Garg for their valuable guidance and motivation. I am highly thankful to Mr.Nachhatar Singh (Managing Director) for permitting me to join the industry and to get useful information about the plant. For full completion of my industrial training project report and the help during the training period, I express my sincere thanks to Mr.Pardeep Singh (QA dept. head), Mr.Jagdeep Singh (HOD of engine testing dept) and S.K Palival (HOD assembly line). It is also my pleasure to express my gratitude towards the staff of parts inspection department for their full cooperation and giving me the knowledge of instruments and process to their best. To sum up a bevy thanks to all those who in formal or informal way guided me throughout my project work, I will cherish their support for the years to come. Finally I would like to convey my thanks to all the workers for their co-operation.

Preface
A report on the working of Standard Corporation India Limited (Tractor Section) is Submitted to Shaheed Bhagat Singh College of Engineering & Technology in accordance with requirement of industrial training for 20-weeks after 7th Semester of B.tech Course in MECHANICAL Engineering

Standard Corporation (I) Ltd.

is situated on Bathinda Road. Near

Handiaya Chownk hardly fifteen minutes drive from the main Bus Stand of Barnala. Standard Combine is a private Concern of India Particularly in Punjab State.

I am very thankful to Human Resources Development (HRD) department and senior executives of Standard Corporation (I) Ltd. who had put all their facilities at my disposal and had been kind enough to guide me to remove all my doubts.

It is a matter of great pleasure and satisfaction that this project report prove more benefit and helpful to the new users or trainees.

Content
1.

Page no
7-26

INTRODUCTION

Company profile
2.

Company Objective Quality policy R&D DEPARTMENT 27-27 28-34

3. INDUSTRIAL ENGINEERING Personal Department Material handling department Tool Room Accounts department Purchase department Maintenence department Store QUALITY ASSURANCE DEPARTMENT Quality engineering [receipt]
4.

35-42

Quality Engineering [machine shop] Quality Engineering [assembly] Quality Engineering [testing] 5. MACHINE SHOP Introduction Light machine shop Heavy machine shop 6. ENGINE ASSEMBLY 54-60 43-53

7. ENGINE TESTING 8. TRACTOR ASSEMBLY SHOP Differential housing assembly Rear cover assembly

61-66 67-84

Project: Study of Gear box assembly

Painting phase 9. DUAL CLUTCH 10. PROJECT:- STUDY OF POWER STEERING IN TRACTORS 11. PROJECT:- INDUSTRY PROBLEM AND REMEDIES 12. PROJECT:- STUDY OF TRACTORS SAFTY 13. INDUSTRIAL SAFETY 111 14. BIBLIOGRAPHY 106-110 111112-112 104-105 85-86 87-103

INTRODUCTION TO STANDARD GROUP

Standard group is an establishment of standard combines. This plant was established in 1973 with the initial investment of 20 lakh. Till now it is in progress. New machinery & new techniques are being installed. Since 1975, combine manufacture by standard group are being supplied all over India and Asia. The company has sale of l millions combines thousand of them were repaired. There are three models of combines i.e. TSE 513, TSE 514, TSE 412. 2. After seeing the response of farmers & due to increased use of machinery in agriculture sector, Standard Group decided to start the production of tractors in the year of 1999.In the beginning production was 5 tractors a day & assembly of engine was not done here. But in the year 2002 engine assembly was also started in the factory itself. 3. Standard group has technical and financial collaboration with various national companies. Having established standard in the national market the group made a determined effort to get a foot hold in the international market. Over the years a large number of standard tractors have been exported to Nepal, Bhutan, Indonesia, Thailand, Pakistan, Sri Lanka, and Italy. Combines of standard group are generally exported to the countries of mid east. 4. Till now much investment has been done & is still being done For the sake of industry quality and image.

Company profile
STANDARD is a well known brand in the field of Agricultural Machinery and construction equipment in India today. Standard Corporation India Limited (Formerly Standard Combines Pvt. Ltd.) is a leading manufacturer of Tractor driven combines and self propelled harvesters since 1975. The Standard Group of Companies led by its Chairman & Managing Director S. Nachhattar Singh is serving the farmers/ users by manufacturing & providing high quality Machinery inputs for the last over three decades. Mr. Singh is ably supported by his younger brother S. Joginder Singh as Joint Managing Director. Standard Corporation India Limited is situated at Standard Chawnk Barnala, Punjab, India and the corporate office of the company is based in New Delhi. The company also has manufacturing and assembly facilities at Baddi in Himachal Pradesh. Now this company has SIX improved models of tractor 1. DI- 335 2. DI- 345 3. DI -450 4. DI -460 5. DI- 475 6. DI- 124

LOCATION
THE factory is located at Barnala district of Punjab. Standard tractors is situated on Sangrur-Bathinda road about 3 km from Barnala city at Handiaya chowk hardly fifteen minutes from the main bus stand of Barnala. Standard combine is a private concern of India particularly in state of Punjab. This factory was among the first to set up in this industrial town.

Company Objective
DEVELOPMENT : To enrich its design capabilities and to improve catalyst manufacturing to fulfill the requirement of customer. ORGANISATIONAL ENVIRONMENT : To develop and maintain an organizational environment for initiative, innovation. DIVERSIFICATION : Diversifying business in addition to Tractors. BUSINESS DEVELOPMENT : To generate adequate profitable business by utilizing the existing resources to the maximum extent.

Quality policy
We at Standard Corporation India Ltd. are committed to total customer delight by :

1.

Providing utmost customer satisfaction with Quality and Cost effective

products. To create such work environment and culture which promotes initiative & teamwork.

2.

Company is also committed to provide adequate resources in terms of documents and information needed to continually improve effectiveness of its quality management system.

3. 4.

Maintaining a safe and satisfying work culture. Adhering to quality management systems based on iso 9001:2001.

Available models of Tractors

9

The company conducted a detailed study to manufacture a rugged tractor suitable for all types of farming conditions in the world. STANDARD Tractors were well received in the market and continue to show a phenomenal growth year after year. Currently Standard is marketing tractor models in 24,30, 35,40,45,50,55,60 & 75 HP range fitted with single cylinder, two, three & four cylinders. These include tractors with 2-wheels and 4-wheels drive models with latest salient features for all types of farm and off farm applications.

Standard-DI-124 ENGINE

10

Power /Cylinder 24 H.P./1 Bore/Store(mm) 120/135 Model/Make Maxi. RPM Engine Retaed(RPM) Capacity CC SE-124/Standard 1770 1650 (Rated) 1558 CC

TRANSMISSION Clutch Brakes STEERING HYDRAULIC SYSTEM Hydraulic System Lift Capacity Draft & Position Mixed Control 1200 kgs. Dry friction plate single clutch Oil immersed type (wet disc type)

Live Hydraulic Engine Driven Gear Pump POWER TAKE OFF Spline Speed P.T.O (Engine R.P.M ) Road Speed Low High TYRE SIZE 6 540(1650) 1234R 2.42,3.65,5.39,7.50,3.00 8.70,12.74,18.68,26.90,10.77

11

Front Rear Weight(kg.)

6.0 16(6/8 PLY) 12.4-28(12 PLY) 1800 kgs.

DIMENSIONS (mm) Length Width Height Upto Exhaust Ground Clearence 3530 (mm) 1600 (mm) 2200 (mm) 420 (mm)

CAPACITY (Ltrs.) Diesel Tank Engine 48 Ltrs. 5.5 Ltrs.

Cooling System Ltrs. Transmission 25 Ltrs

12

Standard-235 ENGINE Power /Cylinder 35 H.P./2 Bore/Store(mm) 105/118 Model/Make Maxi. RPM Engine Retaed(RPM) Capacity CC SE-235/Standard 2250 2100 (Rated) 2044 CC

TRANSMISSION Clutch Brakes STEERING HYDRAULIC SYSTEM Hydraulic System Lift Capacity Draft & Position Mixed Control 1200 kgs. Dry friction plate single clutch Dry Disc Brakes

Live Hydraulic Engine Driven Gear Pump POWER TAKE OFF Spline Speed P.T.O (Engine R.P.M ) Road Speed Low High TYRE SIZE Front 6.00 x 16(6 PLY) 6 540(1764) 1234 5 R 2.11,2.41,4.02,5.44,7.62,2.47 8.32,9.50,15.84,21.44,30.03
13

Rear Weight(kg.)

12.4 x 28(12 PLY) 1820 kgs.

DIMENSIONS (mm) Length 3310 (mm) Standard-330

Width 1650 (mm) ENGINE Height Upto 2100 (mm) Power /Cylinder 30 H.P/3 Exhaust

Bore/Store(mm) 92/110 Ground 400 (mm) Clearence Model/Make SE-330/Standard CAPACITY (Ltrs.) Engine 2100 (Rated) Retaed(RPM) Diesel Tank 48 Ltrs. Capacity Engine CC 2192 CC 5.5 Ltrs.

TRANSMISSION Cooling System 8.5 Ltrs. Clutch Transmission Brakes STEERING Type With Brake Without Brake Worm And Screw Type 5.66 meter 6.98 meter Dry Single Clutch 47 Ltrs Dry Disc Mechanical

HYDRAULIC SYSTEM Hydraulic System Lift Capacity Draft & Position Mixed Control 1200 kgs.

Live Hydraulic Engine Driven Gear Pump POWER TAKE OFF Spline Speed 21

14

P.T.O (Engine R.P.M ) Road Speed Low High TYRE SIZE Front Rear Weight(kg.)

1025(2100) 12345R 2.06,2.37,3.77,4.87,6.64,2.88 8.12,9.36,14.95,19.09,26.16,11.37

6.0 16(6/8 PLY) 12.4-28(12 PLY) 2096 kgs.

DIMENSIONS (mm) Length Width Height Upto Exhaust Ground Clearence CAPACITY (Ltrs.) Diesel Tank Engine 68 Ltrs. 8 Ltrs. 3610 (mm) 1680 (mm) 2200 (mm) 390 (mm)

Cooling System 8.5 Ltrs. Transmission 47 Ltrs. Standard-335 Engine

15

Power /Cylinder POWER TYPE Bore/Store(mm) Model/Make Engine Retaed(RPM) Capacity CC P.T.O(HP) TRANSMISSION Clutch Brakes STEERING Type With Brake Without Brake HYDRAULIC SYSTEM Hydraulic System Lift Capacity Live Hydraulic POWER TAKE OFF Spline Speed Road Speed Low

35H.P/3 Diesel 95/110 SE-335/Standard 2100(Rated) 2340 CC 31.5 HP

Dry Single Clutch Dry Disc Mechanical

Worm and Screw Type 3.15 meter 3.65 meter

Draft & Position Mixed Control 1200 kgs. Engine Driven Gear Pump

6 12345R 2.06,2.38,3.78,4.84,6.64,2.88

16

High TYRE SIZE Front Rear Weight(kg.) DIMENSIONS (mm) Length Width Height Upto Exhaust Ground Clearence CAPACITY (Ltrs.) Diesel Tank Engine Cooling System Transmission

8.11,9.37,14.82,19.05,26.10,11.36

6.0-16(6/8 ply) 12.4-28/13.6-28 (12 ply) (optional) 2096 kgs.

3450 (mm) 1675 (mm) 2210 (mm) 400 (mm)

68 Ltrs. 8 Ltrs. 8.5 Ltrs. 47 Ltrs. Standard-345

Engine Power /Cylinder Bore/Store(mm) Model/Make Engine Retaed(RPM) Capacity CC P.T.O(HP) 45 H.P/3 102/110 SE-345/Standard 2200 (Rated) 2696 CC 42.6 HP

17

TRANSMISSION Clutch Brakes STEERING Type With Brake Without Brake HYDRAULIC SYSTEM Hydraulic System Lift Capacity Live Hydraulic POWER TAKE OFF Spline Speed P.T.O (Engine R.P.M ) Road Speed Low High TYRE SIZE Front Rear Weight(kg.) DIMENSIONS (mm) 6.0-16(6/8 ply) 12.4-28/13.6-28 (12 ply) (optional) 2120 kgs. 6 540(1764) 12345R 2.31,2.67,4.22,5.41,7.42,3.22 9.07,10.47,16.61,21.30,29.21,12.69 Draft & Position Mixed Control 1200 kgs. Engine Driven Gear Pump Worm and Screw Type 2.94 meter 3.26 meter "Dry Single Clutch , Dual Clutch (Optional)" Dry Disc Mechanical

18

Length Width Height Upto Exhaust Ground Clearence CAPACITY (Ltrs.) Diesel Tank Engine

3500 (mm) 1760 (mm) 2210 (mm) 435 (mm)

68 Ltrs. 8 Ltrs.

Standard-450 Engine Power /Cylinder Bore/Store(mm) Model/Make Engine Retaed(RPM) Capacity CC P.T.O(HP) TRANSMISSION Clutch Brakes STEERING Type Worm and Screw Type Dry Double Clutch Dry Disc Mechanical 50 H.P/4 95/110 SE-450/Standard 2200 (Rated) 3120 CC 45.5 HP

19

With Brake Without Brake HYDRAULIC SYSTEM Hydraulic System Lift Capacity Live Hydraulic POWER TAKE OFF Spline Speed P.T.O (Engine R.P.M ) Road Speed Low High TYRE SIZE Front Rear Weight(kg.) DIMENSIONS (mm) Length Width Height Upto Exhaust Ground Clearence CAPACITY (Ltrs.) Diesel Tank

3.02 meter 3.51 meter

Draft & Position Mixed Control 1200 kgs. Engine Driven Gear Pump

6 540(1764) 12345R 3.04,3.51,5.56,8.47,9.64,4.30 11.97,13.81,21.91,33.31,37.98,16.76

6.0-16(6/8 ply) 13.6-28/14.9-28 (12 ply) (optional) 2158 kgs.

3640 (mm) 1760 (mm) 2180 (mm) 435 (mm)

68 Ltrs.

20

Engine Cooling System> Transmission

12.5 Ltrs. 10 Ltrs. 47 Ltrs Standard-460

Engine Power /Cylinder Bore/Store(mm) Model/Make Engine Retaed(RPM) Capacity CC P.T.O(HP) TRANSMISSION Clutch Brakes STEERING Type With Brake Without Brake HYDRAULIC SYSTEM Hydraulic System Lift Capacity Live Hydraulic POWER TAKE OFF Draft & Position Mixed Control 1500 kgs. Engine Driven Gear Pump Worm and Screw Type 3.70 meter 4.36 meter Dry Double Clutch Dry Disc Mechanical 60 H.P/4 100/110 SE-460/Standard 2250 (Rated) 3456 CC 55.2 HP

21

Spline Speed P.T.O (Engine R.P.M ) Road Speed Low High TYRE SIZE Front Rear Weight(kg.) DIMENSIONS (mm) Length Width Height Upto Exhaust Ground Clearence CAPACITY (Ltrs.) Diesel Tank Engine Cooling System> Transmission

6 540(1764) 12345R 2.95,3.40,5.40,6.93,9.9,4.13 11.61,13.39,21.24,27.26,37.38,16.25

6.5-20(6/8 ply) 16.9-28 (12 ply) 2325 kgs.

3640 (mm) 1930 (mm) 2235 (mm) 490 (mm)

68 Ltrs. 12.5 Ltrs. 12 Ltrs. 47 Ltrs. Standard-475

Engine Power /Cylinder Bore/Store(mm) 70 H.P/4 105/118

22

Model/Make Engine Retaed(RPM) Capacity CC P.T.O(HP) TRANSMISSION Clutch Brakes STEERING Type With Brake Without Brake HYDRAULIC SYSTEM Hydraulic System Lift Capacity Live Hydraulic POWER TAKE OFF Spline Speed P.T.O (Engine R.P.M ) Road Speed Low High TYRE SIZE Front

SE-470/Standard 2400 (Rated) 4088 CC 69.7 HP

Dry Double Clutch Dry Disc Mechanical

Worm and Screw Type 3.69 meter 4.52 meter

Draft & Position Mixed Control 1500 kgs. Engine Driven Gear Pump

6 540(1764) 12345R 2.82,3.25,5.16,6.62,9.07,3.94 11.09,12.80,20.30,26.04,33.71,15.52

6.5-20(6/8 ply)

23

Rear Weight(kg.) DIMENSIONS (mm) Length Width Height Upto Exhaust Ground Clearence CAPACITY (Ltrs.) Diesel Tank Engine

16.9-28(12 ply),18.4-30(Optional) 2450 kgs.

3640 (mm) 1930 (mm) 2235 (mm) 475 (mm)

68 Ltrs. 11.5 Ltrs.

24

RESEARCH AND DEVELOPMENT DEPARTMENT

It is an integral and sustaining department of any organization which want to sustain its place in the ever developing industrial training .The emphasis on research and development in the standard group proved by a long list of new products that have been introduced and established in the years ever since the establishment of the standard group. Research work is carried out in this unit and design work is accomplished presently, the research and development is going on with new products. The organization of standard tractor division operates functionally, through a series of shops and departments. Standard tractor division is undergoing expansion on a large scale. Standard establishes well advanced testing shop for testing of engines produced in order to maintain strict control. A full fledge administrative block is produced for effective management and improved work place. The production of engine is being planned to raise engine per day.

RESEARCH AND DEVELOPMENT ACTIVITIES 1. Design and development of new product based on market requirements. 1. Product improvement 2. Value engineering 3. Product reliability
4.

Testing of components for performance and product reliability Coordination period testing and evaluate on of tractor models at certain farm.

25

INDUSTRIAL ENGINEERING
Personal department
Any industry depends upon human being. It has acquired workers and creates an acceptable environment and rule of practice to encourage the greatest degree of participation from its employee. The dept. concerned with this called personnel dept. the personnel exist in every enterprise regardless of its size and irrespective of the fact whether or not there is a personnel dept. a small concern the owner itself carries on the personnel function where as in a large organization it is given a maximum individual development desire able working conditions and desirable relationships between employees and effective molding of human resources for the purpose of contributing to the organization goals. Aim, objective and function 1. Procurement and maintenance of adequate work force as regards to both number and quality of personnel. 2. Education and training of present employees. 3. Maintaining satisfactory personnel contacts and employees relationship. 4. Maintaining satisfactory group relationship by contacting employers groups. 5. Maintaining employees health. 6. Maintaining employees safety. 7. Maintaining employees service activities and employees welfare.

26

Material handling mechanism

It involves the movement of material manually or mechanically in batches or one item at a time with in a plant. The movement may be in a horizontal or vertical or both. The various equipments used in machine shop of standard are: 1. roller conveyor 2. wheel conveyor 3. screw conveyor 4. haulage conveyor 5. power hoists 6. trolley

Roller conveyor

27

Tool room
It is an essential part of any industry. Tool room takes care of jigs and fixtures make, new ones, reshape tools etc.

Making and repair of tooling Tool room makes different tool as per design given by IE department. The different tool includes insert setting fixture tendons bushes & many more items. Repair of worn tool is done.

Accounts department
The main objective is to determine, classify and analyze the cost and income of business enterprise. It has the following function 1. sales accounting 2. purchase accounting 3. labor accounting 4. financial accounting

28

Purchase department
It is responsible for purchasing all type material in correct qualities and at most economical prices. It occupies a vital and unique sit in in a concern because purchasing is one of the main notions in the success of a modern manufacturing. It is an agency which operates between factory outside vendors on all matters of procurement

The various objectives and function of department are:

1. 2. 3. 4. 5.

To avail right material. To avail material in right quantity To avail material economically. Maintain records of reliable sources of supply. Making controls with right sources of supply. standardizing.

6. Revives material specification with an idea of simplifying and Avail and analyze quotations. Maintain records of all purchases. Place and follow up purpose orders. prepare purchasing budget. prepare and update list of material required by department. handle subcontracts at a time of high business activity. ensure that prompt payments are made to the vendors in the sell waste material and scrap.

7. 8. 9.

10. To 11. To

12.to keep an uninterrupted supply of materials.

13. To 14. To

interests of good public relations.

15. To

29

Maintenance department
In the modern industry, equipment and machinery are very important part of the total productive effort. Lot of capital is invested in the plant and machinery. These are deteriorated by their exposure to environment and working condition. If their damage is not checked at proper time, these makes the equipment non usable. Thus it is very important to maintain, repair and recondition these to increase their life and make them available for maximum number of operations hours. The various objectives of department are 1. To achieve minimum breakdown. 2. To keep plant in good working condition at the lowest possible cost. 3. To prevent loss in production services. 4. To maintain various plant services. 5. To provide plant protection including fire protection. 6. To establish and maintain a suitable share of maintenance materials. 7. Insurance administration. 8. Overhauling of plant equipment and machinery. 9. Generation and distribution of power and other facilities. 10. To carry out corrective repairs to alleviate unsatisfactory conditions found during preventive maintenance inspection.

30

Store
1. Material and supplies constitute the most important assests in the majority of business enterprise. The success of business beside other factor depends to a large extent on the efficient storage and material control. 2. Material pilferage deterioration of material and careless handling of stores leads to produce profits. Storage management takes care that:That material is never out of stock. That material is available in much excess than required. There is adequate producer of receipt and issue of material. That there is proper method of keeping store records. Proper storing of material is done. Various functions:To receive materials, goods, equipments and to check them for identification. To receive parts and components which have been processed in the factory. To record the receipt of goods. To correct positioning of all materials and supplies in the stores.

31

PATTERN OF PLACING THE COMPONENTS AND FEEDING TO STORES The different components are placed in the bins of different sizes and shapes. Relative to size, shape and safety aspect of the components in std the area of store is too short. So in order to store the maximum components fork lifter places the bins one over another. These are so placed that it takes the maximum time to take component to all relative shops. The feeding of components to shops is pre planned by ppc deptt. Whatever is the requirement of tractor division ppc plans the feeding of component accordingly so that there will not be accumulation of the trolleys as well any type of storage of the material etc.

32

QUALITY ASSURANCE DEPARTMENT

The quality assurance dept. takes care of the quality of different products that are purchased from outside as well as the parts that are manufactured in the plants. The quality is maintained in terms of dimensional tolerance, surface characteristics, hardness etc.

Quality Engineering Department at STANDARAD TRACTORS is divided into four sections:

1.Quality engineering [receipt] 2.Quality Engineering [machine shop] 3.Quality Engineering [assembly] 4.Quality Engineering [testing]

Quality at Receipt:
Quality at receipt inspects all material send by various vendors to STANDARAD TRACTORS. The objectives of inspection of these materials are: 1. To reject those components, which do not meet specification as required. 2. To evaluate the vendors quality to supply acceptable material. Inspection of incoming material may involve a visual checkup only, a dimensional checkup, test of property, chemical property etc.Raw material depending upon their characteristics and use may be requiring
33

100% inspection. The producer of checking the material is as the standard Parameter is noted from drawing. Finally remarks are given on them. The right quality of material is then sending to stores.For these purposes various instruments are available in the quality shop, some of which are described as following:-

Micrometers: The micrometer is a precision instrument designed to accurately measure engine components. It is very important to be able to read micrometers accurately to be able to correctly make judgements on engine part condition. Micrometers come in various designs each with a specific purpose

Outside Micrometers:

Principle :- Rotary motion of thimble is converted in linear motion of spindle.

34

 The basic measurement tool in power mechanics. Used extensively for engine measurement. The base for other micrometer designs. If used correctly extremely accurate Designed for outside measurements only If used with other devises it can be more versatile

Dial Bore Gauge:Principle: - Linear motion of Plunger is converted into magnified rotary motion of Dial. The dial bore gauge takes repetitive inside measurements

Faster than Inside Micrometer

Must be set-up before each use Less versatile and more expensive

35

Vernier caliper:Principle: - It works on the principle of difference between two differently graduated scales.

Uses :1. Outside linear measurement 2. Inside linear measurement 3. Depth measurement

36

Constr uctional Featur es of Ver nier caliper

6 8

Parts :- 1. Fixed jaw 2. Movable jaw 3. Beam/ Main scale 4. Vernier scale 5. Fine adjusting unit 6. Nibs 7. Depth bar 8. Locking screws Range :- 150 mm, 250mm, 900mm, 1200mm.(Metric) 6, 9, 36 ( British)

Vernier hight gauge:

Principle: - It works on the principle of difference between two differently graduated scales. Use :- Precession Marking and Measurement of height. Parts :2. Beam/Main scale

1. Base

3. Fine adj. unit 4. Scriber 5. Vernier slide 6. Locking screws

37

Rockwell Hardness test: Hardness is a function of the degree of indentation of the test piece by action of an indenter under a given static load (similar to the Brinell test) Rockwell test has a choice of 3 different loads and three different indenters The loads are smaller and the indentation is shallower than the Brinell test Rockwell test is applicable to testing materials beyond the scope of the Brinell test Rockwell test is faster because it gives readings that do not require calculations and whose values can be compared to tables of results (ASTM E 18)

38

Rockwell Test Description: Specially designed machine that applies load through a system of weights and levers Indenter can be 1/16 in hardened steel ball, 1/8 in steel ball, or 120 diamond cone with a somewhat rounded point (brale) Hardness number is an arbitrary value that is inversely related to the depth of indentation Scale used is a function of load applied and the indenter Rockwell B- 1/16in ball with a 100 kg load Rockwell C- Brale is used with the 150 kg load Operation Minor load is applied (10 kg) to set the indenter in material Dial is set and the major load applied (60 to 100 kg) Hardness reading is measured Rockwell hardness includes the value and the scale letter

OTHER EQUIPMENTS:1. Vernier depth gauge 2. Surface plate 3. Slip gauges 4. .Puppy dial gauges 5. Bevel protector 6. Digital height gauge 7. Digital vernier caliper
39

8. Digital micrometer 9. Dial indicator 10. V-block

Quality at Machine shop:

Here, the qualities of in house

components like cylinder head, connecting rod, gears casting are checked. The process is to avoid the flow of faulty material into the production line and to maintain the required checking is carried out in two ways 1. Self inspection by workers on line 2. Inspection by inspectors

Quality at Assembly:
1. The inspection is needed in assembly shop is due to 2. To avoid improper flowing of the sequence of assembly by worker. 3. To examine the critical parameter of engine like torque of various nuts bolts, fittings,proper clearance. 4. Just like the machine shop, here also the inspections carried out by the self inspection by the workers and by inspectors .For guiding the workers on the assembly line, some check lists are pasted there for the instant looking of quality requirements.

Quality at Testing:
Before finally dispatching the engine, it is tested for BHP, SFC, Oil pressure, loose nuts, leakage, noise level etc.

40

MACHINE SHOP
Introduction:
As the name suggests machine shop is the shop with machine in it .It would not be over if machine shop is called the lung of an industry .Shafts, nuts, bolts, & very simple parts are machined here which could be required any time during assembly process. Except this sizes of few parts are corrected here. Many types of machine are installed here for the metal removal process. Such as: Lathes Milling machines Drilling machines Power hacksaw Grinder

Machine shop at standard tractor is divided into two parts: LIGHT MACHINE SHOP
Introduction LMS is a shop for manufacturing small components of the tractor in std. this is a small shop where light components are performed on different components for production work.

41

MAIN OPERATIONS PERFORMED IN LMS ARE AS FOLLOWS: DRILLING TAPPING REAMING MILLING FACING TURNING BORING GRINDING Major machines used in LMS are: 1. LATHE Lathe is the mother of entire machine & probably the oldest machine

tool finds its great application in industry. Here in this industry lathes of sizes 6 feet & 8 feet are installed owing to their use. Lathe removes the undesirable material from the rotating work piece held between two lathe centers of head & tail stock. The lathes are installed here are centre lathes. Major operations are performed on lathe: Turning Facing Grooving Drilling Boring Reaming Knurling
42

2. MILLING MACHINE Milling is the process of removing metal by feeding the work past a rotating multi point cutter. In milling operation the metal removing rate is high because cutter rotates at high speed and has many cutting edges. The surface finish is also better due to multi cutting edges. Column & knee type milling machines has been installed in machine shop. In this type of machines three types of motion are possible 1.Vertical (up & down) movement of knee 2.Transverse (in & out) movement of saddle 3.Longitudinal (back & front) movement of table

3. SHAPER The shaper makes use of the single point tool that transverse the work and feeds over at the end of each stroke. It is used principally machine or plane surface in horizontal, vertical, and angular position. In body Agro Industries vertical shapes has been installed owing to the reason that is used in the formation of the key ways in round pulleys. Vertical shaper is preferred over the horizontal type because the thrust acts directly on table bed, so there is no possibility of deflection of table. Only a simple fixture is needed.

4. POWER HACKSAW For cutting of the large sized job reciprocally power hacksaw has been

kept in machine shop .Although it is a slow and expensive method of

43

cutting but owing to its advantage, it is widely suitable. Several bars may be cut at same time and continuous attention is not needed, since the saw stops automatically when cut is finished. A lubricant is often used for easier cutting action and longer life of blade. A crank mechanism is provided to raise the blade on each return stroke, to protect the teeth of blade while it dragged backward. Average cut is of 3 mm.

5. GRINDER it is one of the simple and useful machine required in the industry .Grinding is a process of removing metal by rotating abrasive wheel. Abrasive particles acts as cutting tool tips. Grinder is used for: 1. To remove a very small amount of metal from work space and to achieve small tolerances. 2. To obtain better surface finish. 3.To sharpen the cutting tools 4. To cut hardened steel.

HEAVY MACHINE SHOP

Introduction

The heavy machine shop (HMS) is one of the most important shops of the industry. It plays vital role in the production of tractor. As the name suggests all heavy components namely differential housing, gear box, the cage and trumpet are machined here. This shop is divided into five sections:-

44

1. Differential housing line 2. Trumpet line 3. Rear cover line 4. Crankcase housing line 5. Tool room

All sections are highly equipped with modern machinery and equipment. Each section has process layout i.e. the raw material is received at one end and finished component is dispatched from other. The material received generally is in the form of cast iron. The machining processes are carried out under strict quality norms. There is a process inspection at each workstation. The component is made to go through final inspection before it is dispatched for assembly. The material handling system in the HMS consists of hydraulic lift truck, power hoists, roller conveyors, overhead crane, fork, etc. The shop has well designed network of roller conveyors. At the end of each conveyor a section has been made so as to make the component to go through the inspection.

Differential housing line

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Following are the machines in the differential line:1. Duplex milling machine 1 2. Radial drill machine 1 3. Duplex milling machine 2 4. Duplex milling machine 3 5. Boring machine 6. Fine boring machine 7. Radial drilling machine 2 8. Radial drilling machine 3

Duplex milling machine 1:The machine is called duplex because it has two tools parallel to the axis of job. It is fully automatic and high precision machine. Automatic system regulates the feed and rpm of the tool and also the movement of job by itself. In this machine the tool is stationary and job moves horizontally. The movement of tool is restricted to y-axis only. This machine is made of Honsberg. Top and bottom milling operations are done in it. The movement of tool is upward milling. The size of differential has to be made 4450.5mm only. Face milling is done on this. It is special purpose machine.

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Radial drilling machine 1:This machine is fitted with an arm which can rotate about 360. This machine is made of hmt. The operation performed on this machine is to drill the hole for drain plug of diameter 10.2x24mm and then tapping is done of diameter 24x1.5mm and dowel hole of 18x24mm.

Duplex Milling Machine 2:This is called duplex milling machine because in this machine there are two tool parallel to the axis of the job. It is fully automatic and high precision machine. This machine is made of Kearney and Tracker Milway England. Only face milling is done here. Differential is milled to size 4000.2mm and2800.2mm

Duplex Milling Machine 3:This machine is made of Jagdeep Foundry, Batala. Front &back milling is done here. The size of differential is made 9000.2mm.

Boring machine 1:-

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It is hydraulically controlled boring machine. It is used to bore the holes of diameter 130mm for trumpet mounting and for brake housing mounting of diameter 110mm , simultaneously by fixing the fixture with the machine.

Boring Machine 2:It is a special purpose machine. This is used to bore the fine holes for tail pinion carrier and PTO shaft and also drill the hole for mounting the T.P. learner and PTO shaft cover and other accessories on the backside of differential housing. It is made of BDSS Phagwara. Size is to be made 1150.35 and 720.3mm.

Drilling machine 1:This machine can drill 20 holes on differential housing. Drilling is done for making tapped holes on the differential housing for mounting the trumpet & brake housing. Tapping is done on this machine by tapping tool.

Drilling machine 2:This machine is used for front and back drilling and tapping. Drilling of 10.2x26mm of 6 holes at front and
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two holes of size 11x13mm is done. Drilling of 10.2x30mm and tapping of 12x1.75mm of 6 holes inside the differential housing. Drilling of 14x28mm and tapping of 14x2mm at backside of differential.

Trumpet Housing Line

Following are the machines in the trumpet housing line:1. Central Lathe machine 1 2. Boring machine 3. Final boring machine 4. Central lathe machine 2 5. Vertical milling machine 6. Radial drilling machine 7. Tapping machine

Central lathe machine 1:The machine is used for rough turning of trumpet. It is made of Sant lathe Ludhiana. Size has to be made

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along length 574.50.2mm and along diameters of 13200.4, 1800.1, 2830.1mm.

Boring machine:In this machine rough boring is done. Size has to be made 110+0.18, 80+0.2 in diameters and in lengths 33.50.2, 38.50.2, 39.50.2, 380.2, 500.2. Threading is done on the rear side of differential housing for mounting the axle with them.

Central lathe machine 2:It is used for final finishing. Size has to be made 130+.046mm in diameter and 575+0.1, 524+0.5 in length.

Vertical milling machine:It is used for side milling. It is made of Batliboi and Co. Ltd, Surat.

Radial drilling machine:-

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In this machine, a hole is drilled at the front side for mounting the axle of diameter 10.2mm with trumpet. A hole is also drilled of 13mm through trumpet.

Tapping machine:It is used for tapping 4 holes of M16x1.5 and 7 holes of M12x1.75.

Crankcase line

List of machines in the Crankcase line:1. Horizontal Machining Center (CNC) 1 2. vertical Machining Center (CNC) 3. Horizontal Machining Center (CNC) 2 4. Horizontal Machining Center (CNC) 3 5. Notching machine 6. Milling machine 7. Radial drilling machine1 8. Radial drilling machine 2

Horizontal Machining Center (CNC) 1:-

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It is computer numeric control machine. It is called horizontal because its tool is in horizontal position. It is made by Makino. There are 30 tools in its tool line. This machine is used to sump face, drilling, reaming of crank set.

Vertical Machining Center:It is CNC machine and called vertical because tool is in vertical position. It is made from Kafo. There are 23 tools in its tool line. This machine is used to face the pump side.

Horizontal Machining center 2:This machine is used for drilling on both sides of crankcase. It is made by HMT. It is used to make 2 dowel holes of 15mm each, cap seat of 132mm.

Horizontal Machining center 3:This machine is used to bore pump diameter of 620.2 mm, hole of dia 100.3 mm, cap hole of dia 20+.05, dowel hole of dia 8.005 mm and pump bore counter of dia 68.10 mm and depth of 5 mm.

Notching machine:52

This machine is used to make notches in the crankcase.

Milling machine:This machine is used to mill pump seat.

Radial drilling machine:This machine is used to drill 4 holes on the back of crankcase.

Radial drilling machine:This is used to drill and tap 8x1.20 mm and 14x1 respectively. This machine is also used for drilling and tapping at an angle of 34 with the help of jig.

Pneumatic tapping machine:This machine is operated eith the pressure of air. It is used for little tapping upto 5 mm dia. It can be rotated in both directions clockwise and anti-clockwise.

ENGINE ASSEMBLY

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Details of engine assembly

Stage 1: The cylinder has two seats:1. For water 2. For oil

Crankshaft Fitting:-

First of all bush type liners are inserted into the bearing holes. The liner is provided with recess to store a minimum amount of oil, which wets as the crankshaft during storing engine. The bearing cap is opened and crankshaft assembly is placed into it. The bearing cap is tightened again with 10-12 kg-m torque rod and crankshaft is checked that it is revolving easily or not

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Stage 2: Timing gear fitting:The idle shaft is pushed into the crankcase and roller type bearing with lock is inserted into the shaft. The idle timing gear is then pressed into the bearing. The timing gear is punched at two places and punched sigh has to be matched with punched mark of {on} crankshaft.

Timing gears

Piston assembly fitting:-

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The piston assembly is fitted into the liner and the big end is tightened to crankshaft line is fitted with piston assembly. The grade mark is towards the camshaft. The piston ring cuts should be so adjusted that there should not be in same line.

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Assembly of piston and connecting rod with crank shaft Stage 3:

Lubrication Oil Pump Mounting:The lubrication oil pumps connected to crankshaft gear by an idle gear of 2-3 degree. The crankshaft and pump gear has 22 teeth each. The pump is provided with relief valve through which it opens at 4kgf. In the case of are loading or something injected in the main gallery then pressure is released from their valves.

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Rear cover and front cover mounting:The rear cover and front cover are cleaned perfectly with air and filled to engine with seals in between mounted

Front end cover Stage 4:Cam shaft fitting:-

Rear end cover

The camshaft is inserted into the camshaft hole with bearing and bolt ends are locked by circle. The camshaft is forged from alloy steel or cast iron and is case hardened. The one end of the camshaft is provided with gear, which is locked, gear z-50 for exact timing of the camshaft gear mark is matched with the mark on idle gear. Another gear pump is

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attached with idle gear, which serves the purpose of driving the fuel injection pump.

Cam shaft

Flywheel mounting:The flywheel is mounted on the crankshaft and bolts are tightened with 11-12 kg-m force. The F.I.P is connected to F.I.P gear through F.I.P shaft The F.I.P drive shaft is specifically designed to advance the time of injection. The both ends of F.I.P drive shaft is provided with spline, One side a key is provided which is locked to timing gear and recess on their side is pushed into F.I.P slots. The angle between the key and recess of 18 degree thus the fuel injection is advanced by 18 degree. Setting of fuel injection pump with respect to crankshaft:-

This timing is set by setting the flywheel i.e. crankshaft angle into particular designed value by using following procedure:-

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First of all, supply of fuel injection pump is disconnected from the 1st cylinder.

Rotate the flywheel to make the piston executing compression stroke in the same cylinder. Then a flask containing fuel, is placed at a level higher above the pump and inlet to pump is connected to the flask by a pipe. This arrangement provides inflow of fuel to the F.I. pump. Outlet of F.I. pump is connected to a small pipe to collect the fuel. Now the flywheel is rotated so that piston moves towards the TDC. As we know when piston moves towards the TDC, the plunger in the F.I pump covers the spill port and fuel starts flowing out through the outlet pipe. Now the flywheel is brought to the marked position according to design and then the F.I. pump is tilted, keeping its input shaft fixed so that fuel starts flowing out. Now the FI pump is fastened on the same position. Hence angle of fuel injection is set. Stage 5:-

Cylinder head mounting:The cylinder head assembly is placed on the piston and studs are passed through it. If the height of the piston at TDC from the surface is more then 0.1 mm than the gasket of given thickness are used. If it is 0.1 to 0.5 mm then 1.2mm thick gasket is used. If

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it is 0.5 to 0.8mm then 1.5mm thick gasket is used. The cylinder nuts are tightened by 17-18 kg-m forces. Stage 6:Water body and pulley mounting:The water body is mounted with thermostat control valve opens at 70 degree Celsius. The pulley is mounted on camshaft. Stage 7:The assembly is removed from the trolley, is placed on the stationary frame. Stage 8:Fuel injection pump mounting and setting of fuel injection pump The gear of F.I.P is first of all meshed with F.I.P drive shaft and is loosely tightened to set the timing of gear first of all pointer is tightened on the crankcase and flywheel us rotated which is meshed for 16, 18, 20, 24 angles. The pointer is set at 18 of flywheel and then pump is rotated clockwise till one from first nozzle stop out blowing. At this position a cut mark is made on both the pump and crankcase for further setting. The pump is tightened properly and pipes are tightened over nozzle and injectors. The head of position is covered with covers and the complete engines are sending to engine testing shop. The whole of engine shop is air-cooled.

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ENGINE TESTING
Introduction
Engine testing is done for checking the performance of newly assembled engine to find out any assembly fault, their HP, leakage and other fault. Engine testing shop of standard is equipped with latest digital control equipment. The engine testing is done with the help of turbine (water) or hydro dynamometer is four in number so that four engines are tested at one time. The shop is equipped with heavy duty oil filter, which is used to clean the oil from dust or other large particles the shop has bush pump tester is measured on the based of S.A.E rating. The society of automobile engineers USA has specified die method of measuring the power output of the engine for standardized purpose. The engine is run without generator.

Tractor testing
Tractor testing is done under the international organization for standardization (ISO). The first tractor with an internal combustion engine was introduced in American agriculture in the
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year 1889. The tractor testing act was passed in U.S.A in 1920. In India tractor testing station was finally establish at Budani in 1959 for tractor testing atmospheric pressure shall not be less than 96.6 Kpa. The basic task is design and development of engines is to reduce the cost and improve the efficiency and the power output. In order to achieve the above task the development engineer has to compare the developed engine with the other engines in terms of its output and efficiency. Towards the end, engineer has to test the engine and make measurements of relevant parameters that reflect the performance of the engine

ENGINE TESTING AT STANDARD TRACTORS, PURPOSE OF TESTING A TRACTOR ENGINE

In general purpose of testing an I.C engine is to determine the following: a) To determine the rated power output with respect to the fuel combustion in kg per kw hr brake power output b) To determine the mechanical and thermal efficiencies of the engine c) To see the performance of the engine at different loads d) To determine the quality of lubricating oil required per B.P.Kw-hr.

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e) To determine the quality of cooling water required per B.P.Kw-hr. f) To determine the overload carrying capacity of the engine g) To prepare the heat balance sheet of the engine

SOME IMPORTANT TERMS AS ISI STANDARAD TERMINOLOGY

Speed: The speed of a engine is the mean speed of its crankshaft in R.P.M expect in the case of free piston engines where the speed is the number of cycles per minute of the reciprocating components.

Steady load speed band: It is the maximum total variation in speed expressed as a percentage of the mean speed, which may occur while there is no change in the external load conditions

Continuous power The power which engine is capable of delivering continuously between the normal maintenance intervals stated by the

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manufacturer at the stated speed and under stated operating conditions

Indicated power It is the total power developed in the working cylinder by the gases on the combustion side of the working pistons

Friction power It is the power consumed in friction resistance

Brake power: It is the total power consumed in friction resistance

Fuel consumption: It is the quantity of fuel consumed per unit power per unit of time. It is general expressed in grams of fuel consumed per B.H.P.

Mechanical efficiency: It is defined as the ratio of the power obtained at crankshaft i.e. brake power to the indicated power.

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Thus mechanical efficiency = brake power (B.P.) / indicated power (I.P) Thermal efficiency: Indicated thermal efficiency: It may be defined as the ratio of heat converted into indicated work to the heat energy supplied by the fuel, during a specified period of time. So, indicated thermal efficiency = heat equivalent to I.P per min. / heat supplied by fuel per min. =I.P. *60 / Mf*CV Brake thermal efficiency:It may be defined as the ratio of heat equivalent to brake power (B.P) to the heat energy supplied by the fuel during a specified time So brake efficiency = heat equivalent to B.P per min. / heat supplied by fuel per min. =B.P. *60 / Mf*CV

Preparation for test:Test runs shall be made on an engine as being offered to the consumers. Before starting the engine tests, the engine shall have been thoroughly run in the fuel and lubricating oil used during the test shall be specified by the engine manufacture

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In general the engine operating temperatures and the lubricating oil pressure during the test shall be maintained at the values recommended by the manufacturer

In engine testing we note down the following data: a) Revolution per minute (R.P.M.) b) Fuel time c) Engine Lub. Oil pressure d) Water outlet temp. e) Lubricating oil temp. f) Torque (N-M) g) Smoke reading with the help of bosch smoke meter h) In case of silencer a noise meter & u-tube manometer for measuring backpressure With the help of the data we calculate following parameters 1) B.H.P = R.P.M *N-M / Dynamometer constant Per B.H.P per hour (Which are 7023.746 for dynamometer used at STANDARD) 2) IN KILOWATTS = R.P.M *N-M / 9549.305 3) Specific fuel consumption (S.F.C) = 297000 / B.H.P*fuel time Gram per B.H.P per hour

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Where 297000=0.825*100*3600

1.

torque brake up (T.B.U) = (Max. torque Rated torque) / Rated torque Dynamometer is the instrument used at standard to measure the engine power and it must include at least four essential elements: A means for controlling torque. B means for measuring torque. C means for measuring speed. D means for dissipating the power

Dynamometer are of mainly two types: 1. Absorption type: a) Mechanical b) hydraulic

1. Prony brake 2. Rope brake

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3. Band brake

2. Transmission type: a) Mechanical b) Electrical

In STANDARD TRACTORS hydraulic type dynamometer are used for reading TRACTOR ENGINE TESTING.

TRACTOR ASSEMBLY SHOP

Introduction

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Tractor assembly shop is main shop of Standard Tractor division. In this shop, different machined parts, housing & other components, which are machined in other shops or purchased from outside, are assembled. Then sub assemblies like differential housing, gear box, rear cover and other parts are sent to main assembly line. Then the tractors are sent to painting section. Type of PTO tractor:1. Multi PTO Tractor 2. Ground PTO Tractor 3. Simple PTO tractor Multi PTO Tractor:In this type, speed of PTO shaft can be varied as there is an arrangement that either it can be run from the output of gear box or from input to the gear box, which provide it 6 speeds of PTO shaft in high speed mode as well as 6 in low speed mode. However, there is provision that PTO can be run while tractor is not moving i.e. wheels are in rest position. Ground PTO Tractor:The basic difference between this type and multi PTO shaft is that it provides different speeds only when tractor is moving, while Multi PTO shaft can provide different speeds even when tractor is in rest position. It is particularly used when PTO is to drive thoster and reaper.

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Simple PTO Tractor:In this type PTO can run only at one speed of 540 rpm, doesnt matter whether tractor is moving or not. Assembly takes place in following phases:1. Differential housing assembly 2. Rear cover assembly 3. Gear box assembly 4. Main assembly line 5. Painting phase

Differential housing assembly

It is rear part of the tractor chassis. It is filled with CL-90 hydraulic fluid, which is used for hydraulic purposes as well as lubricating differential components and gear box components. PTO shaft is also passed through this housing. Various functions performed in differential housing are as following:1.

Differential turns the drive through 90 from gear box output shaft to bull gear shafts which in turn drive rear wheels.

2.

Very important function of differential is distribute the power at wheels according to whether tractor is running straight or is turning towards left or right.

3.

Reduction of speed in two stages; 1st reduction at tail pinion and crown wheel, 2nd at bull gear and bull pinion gear drive.

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Main parts of differential housing 1. Crown wheel 2. Tail pinion 3. Cage assembly with sun and planet gears 4. PTO shaft 5. Bull pinion shafts; B.P. left & B.P. right 6. Bull gears 7. Bearings 8. Brakes housing assembly 9. Oil seals, Gaskets etc

Assembly of crown wheel:72

1st of all, all components are washed with oil to remove dirty particles. Cage has two holes. In these holes dowels are tight fitted for accurate fitting of crown so that all holes of the cage & crown are in same line. The crown wheel is pressed on cage with hydraulic press and tightened by bolts with lock washer, and then the right bevel gear is placed on its cage seat. The four planet gears are put on across the four arms of rigid member along with the washers. This assembly is placed in the cage and then left bevel gear is placed. Operator checks the motion of assembly by manual inspection.

cage assembly Tail pinion assembly:In tail pinion assembly, cone for tapered roller bearing is fitted with hydraulic press. The bearing is heated before the tight fit. Then tail pinion is inserted inside the bearing. Different no. of shims are used for preloading purposes and proper positioning of tail pinion. Whole assembly is tightened by nuts & bolts.

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Rear axle assembly:In rear axle assembly bolts are tight fitted in the holes of hub. Two bearings on either side of the trumpet housing are tightened at gang drill.

Brake assembly:Standard tractors are provided with heavy self energizing water sealed disc brakes with ventilation pipe, which gives better cooling. This ventilation results in 30% reduction in pad temp. Brake housing cover contains two discs made up of asbestos base. The max temp resistance is about 300C. Below these discs there are two cast iron disc plates (with steel balls), which are held by springs. Whenever brake is applied, the CI plates rotate and due to presence of balls these plates moves axially 7 press the brake pads against broke housing and differential housing. As the brake pads are mounted on BP left & right, therefore above discussed process results into braking action.

Brake assembly

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PTO shaft assembly:Firstly bearings are fitted on the supports of PTO shaft in the housing and then PTO shaft is inserted through the rear of the housing.

Tests performed on differential housing

1. Backlash Testing 2. % age of Contact Test 3. Preloading Test

Backlash Testing This test is performed with the help of plunger dial gauge. Backlash in crown wheel is not allowed more than 20 to30 micron. If it deviates from this value then packing is changed on either side of cage in bearing housing. If it exceeds the 30 micron value then shims are removed from right side and shifted to left side. If it is less than 20 micron then vice versa. Also run out for crown wheel is 0.5-1 mm.

%age of Contact Test & Pattern Test

This test is done with the help of yellow paint. It is applied on some of
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teeth of crown wheels. Then it is made to rotate with the help of handle, then tail pinion meshes with these teeth and meshing leaves impression on the yellow painted teeth. This impression indicates the contact line on the teeth as well as the point where contact is broken. The contact shouldnt brake in a way such that contact doesnt follow through the complete tooth width. Proper adjustment can be made by selecting suitable no. of shims used for fastening the tail pinion assembly on the housing.

The bull gears are tighten to trumpet housing assembly by lock nut and the whole assembly is also tightened by nut and studs on the outer side of differential housing. Then PTO shaft head cover is tightened to protect its outer teeth. The sliding gear and PTO shifter rod assembly is mounted on differential housing. Two filters are placed inside the differential housing and then whole assembly is sent to main line.

Rear Cover Assembly

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It is used to cover the differential housing. It contains lift control system, which I hydraulically operated. Driver seat is fitted on the upper side of rear cover. The Response Valve housing(R.V. housing), control valve, ram cylinder and other components are fitted inside and outside the rear cover. The main components of rear cover assembly are:1. Control valve assembly 2. R.V. assembly 3. Ram cylinder and piston assembly 4. Operating sector assembly 5. Sensors tube assembly 6. Gaskets, Bolts and Nuts 7. Other components

Ram Cylinder Assembly;It contains cylinder with piston inserted inside it. The relief valve assembly is mounted at the top front of cylinder. The connecting rod is placed in piston rear side and one side is locked with ram arm assembly. Then ram arm, spacer and seals are placed. The ram arm is keyed to a shaft called rocker shaft. At the end of rock arm assembly, lift arm assembly is placed and then looked with bolts on both sides.

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R.V. Assembly:It contains one response valve, check valve and release valve. It is also connected with control valve through pipe housing. The knob is placed on the top of response valve to close or open the response valve as per requirements.

These days R.V housing and control valve are integrated into single unit.

Control Sector assembly:It contains the draft control assembly and position control assembly. Both these assemblies are connected to their respective leavers. The positional control assembly is connected to black marked leaver & draft control leaver is connected to red marked leaver. In simple words, positional control leaver lower or up the lift linkages, while draft control leaver change the sensitivity of sensor.

First of all, rear cover is mounted over the moving trolley and tightened with bolts. Then operating sector assembly is placed at its respective place. A sensor tube is placed at rear side of the rear cover. Earlier R.V. housing was used to fit outside the rear cover which was connected to the control valve through piping in the rear cover housing. But now

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these days both R.V. housing & control valve are integrated into single piece and it is fitted inside the rear cover. Control valve contains three valves i.e. back measure valve(3-6 kgf), unloading valve and scroll valve. Oil from pump goes to R.V. through pipes, which is further connected to the check valve through inner hole of R.V. housing and back pressure valve of control valve. The operating pressure of check valve is 9-12 kgf and operating pressure of back pr valve is 3-6 kgf. During un-operated position, the oil flow continues through back pr valve of control valve. During operation of position arm the unloading valve closes the gallery of oil to the back pr valve. Thus the pressure in the R.V. housing builds up which opens the check valve at 9-12 kgf. At this position, the oil goes in the ram cylinder, which further operates the lift arm. For requirement of any position of lift, the knob of response valve of RV housing is rotated which cut the supply of oil and position of ram arm is achieved. Sensor tube works in the field during ploughing of soil with harrow. When harrow deeply dug in soil, draft is set at position through sensor tube. The rocker arm attached to sensor and harrow link, when push the sensor tube inside and automatically controls oil supply.

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Project: Study of Gear box assembly

Introduction Gear box in the standard tractors is of sliding mesh type. It is the main assembly b/w the engine and differential housing. Advantages of using constant mesh type gear box are higher mechanical efficiencies and lower noise level due to use of helical gears instead of straight spur gear. It gives the tractor a top speed of 30 kmph and a minimum speed of 2 kmph. There are 5 forward and one reverse gears with a high and low level.

Speed in different gears:-

1-L 2-L 3-L 4-L 5-L R-L

2.25 kmph 2.58 kmph 4.26 kmph 5.75 kmph 8.80 kmph 4.50 kmph

1-H 2-H 3-H 4-H 5-H R-H

8.80 kmph 10.00 kmph 16.77 kmph 22.70 kmph 31.72 kmph 17.08 kmph

Main components of gear box:80

1. Input shaft assembly 2. Output shaft assembly 3. Lay shaft assembly 4. Intermediate shaft assembly 5. Actuator shaft assembly 6. Gears 7. Gear box housing 8. Shifter rods 9. Shifter forks 10.Bearings 11.Fasteners, Gaskets and spacers 12.Planet gear and carrier assembly with internal gear 13.Clutch actuator (C.A.) assembly

Transmission gears

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Clutch actuator:Clutch actuator assembly contains clutch actuator guide on which bearing is tight fitted and locked with circlip.

Lay shaft assembly:The lay shaft is hollow shaft with splines on the outer surface. One end of lay shaft is threaded (in case of single clutch) and tightened from front side of gear box with a hexagonal nut. The whole assembly consists of gear Z-49 (i.e. constant mesh gear with input shaft gear), spacer 15 mm, gear Z-42, gear Z-38, spacer 30 mm, gear Z-31, gear Z-29 and a spacer 25 mm and bearing with a circlip. In case of dual clutch tractor model, the drive shaft is placed through hollow lay shaft. The drive shaft consists of splines at one end and a gear (Z-45) on the other end. The gears are constantly meshed with the gears on the intermediate shaft. The main function of the lay shaft is to rotate the fixed gears on it from where we can get different speeds with the help of sliding gear on the drive shaft. Input Shaft Assembly:-

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Input shaft consists of helical gear on one end and splines on the other end. Splined part is attached to clutch and gear is in constant mesh with Z-49 gear on the lay shaft. Input shaft is put into gearbox with the bearing, which is locked by circlip.

Output Shaft Assembly:Output shaft assembly consists of a solid shaft with the splines on the outer surface. The shaft is placed into the bearings and locked by circlip. Some of the back part of the shaft is projected outside the gear box to get drive from it. The assembly of shaft consists of gears with no. of teeth 18, 22, 30, 32. The sliding gear 2 is used for 1st and reverse gear; sliding gear 30 is used for 2nd gear and sliding gear 22 is used for 3rd gear; sliding gear 18 is used for 4th gear and it can be keyed to the splines of the input shaft for the 5th gear.

Assembly of Gear box:First of all, the gear box is mounted over the trolley, which can be moved with the help of chain conveyor system. The idler gear is placed with their idler gear shaft in the gear box at its respective place. Then lay shaft assembly is inserted into its respective holes and tightened from front of gear box housing by a hexagonal nut. Z-19 gear of input shaft is in constant mesh with Z-49 gear of lay shaft. Then output shaft assembly is placed into the gearbox where its one end is supported over the needle bearing in the input shaft and other one is supported in the gearbox housing.

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For D.C. models, the intermediate shaft, which is hollow, is placed over the input shaft, but both shafts are free with respect to each other. A gear Z-21 is keyed to this shaft, which is meshed with a gear Z43. This Z-43 gear is keyed to the shaft which drives the PTO shaft. This particular shaft is passed through the hollow lay shaft and supported on needle bearings in the lay shaft. The four selector rods are placed in the holes with spring loaded ball for each rod. The gear selector forks are inserted into the groove of sliding and then tightened over the gear shifter rods with the help of bolts. Then another selector rod is fitted, which protrude on the back side of gearbox. This rod actuate epicyclic gear train of the highlow shifting assembly. Then the top of gear box is covered with its top mating part and then fastened with the bolts. Then the gear box is sent to the main assembly line.

Paint shop
Introduction: The paint shop is the most modernized shop of STANDARD TRACTOR DIVISION. Paint give the protection to tractor from effluents, enhances the appearances for a longer period and at the same time .It protect the body from rust. The paint consists of linseed oil, pigment turpentine oil or some other solvent to thin the mixture. Magnesium silicate is also added to impart improved resistance cracking of the paint film. The drying time, hardness and elasticity of flint film depend principally on the drying oil, temperature of oven and for which it is kept in oven.

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The component provide different tractor in different colors: 1.Sky blue 2.Dark blue 3.Red

Components painted in paint shop: 1.Front rim 2.Rear rim 3.Side panel [left] 4.Side panel [right] 5.Head light front 6.Tool box 7.Channel 8.Top bonnet 9.Grill frame 10.Top bonnet plate 11.Dash board 12.Top plate 13.Grill [left] 14.Grill [right] 15.Grill [front] 16.Meter plate 17.Other accessories

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Paint quality:
EVELUATION OF PAINT QUALITY IN PAINT SHOP:1. Even covering of paint should be there on component. The surface should be smooth and there should be no unevenness. 2. The minimum required thickness of painted surface should be 65micrones 3. The minimum gloss level required is 95% 4. The component should be free from dust particles. 5. Minimum allowable dust is 5%. 6. The component should be free from dent and other superficial 7. Minimum allowable dents are 1% and not be on the face surface 8. The shade should be matching with the master shade (This test will be performed at the time of receiving of paint however in doubt the master panel should be consulted.) Firstly planning is done about how much quantity. What type of components is to be painted, which is ordered by the assembly department. Then material or components are recapture store. The material and component received area inspected visually. Right inspected component are only selected for paint pretreatment follows the visual inspection which primarily include the process starts from the preparatory store to finishing process the cleaning include removal of dirt ,oil sand oxide scale grease and other harmful ingredients which ultimately hamper the life of components pretreatment are done in different steps. Operation in paint shop: 1. Degreasing-1

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2. Degreasing-2 3. Water rinse-1 4. De rusting 5.Water rinse-2 6.Water rinse-3 7.Activation 8.Phosphate 9.Water rinse-4 10.Water rinse-5 11.Passivation DEGREASING-1: In degreasing cleaning is done with the help of alkali. It is efficient and economical in removing oil &grease by saponification emulsification from the components. In this process a bath is prepared for cleaning agent I.e. caustic soda or sodium Meta silicate and some soap to aid in emulsification. The mixture produced an alkali which serves as the cleaning agent. The components are dipped into the bath which is at the temperature of 70 degree and the time for dip depends upon oil and grease sticking with component. DEGREASING-2: In degreasing -2 section again same alkali is used in this bath the oil and grease left on the component during degreasing -1 is completely removed by the same process WATER RINSE-1: In water rinse bath the hot water at a temperature of 75 degree is used for washing the components. The water temperature is adjustable .The component are washed in water rinse to remove the effects of alkali. The washing is done by dipping the components in water.

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DERUSTING: This bath contains phosphoric acid, so it is called as acid pickling. It is used to remove light rust from the components. It also removes surface oxides when components are immersed in it, and the time consumed by the components depends upon the scale (maximum times 7 minutes). WATER RINSE 2-3: In water rinse bath 3&4 all the components that that are washed in derusting bath are washed to avoid the further action of phosphoric acid. ACTIVATION: Components are performed at or slightly above room temperature. Parts are cleaned by immersing in the solvent without agitation. The time taken by components is 1 to 2 minutes. PHOSPHATING:-In phosphating process the phosphate chemical is used .This process creates layer of phosphate on the surface of components which increase the adherence property of paint .The components are dipped in the solution of magnesium dehydrogenate phosphate at separate out and from coating on the components. WATER RINSE: The phosphate which does not stick properly to the components, are removed in the two-water rinse. PASSIVATION:-In passivation process the chromium chemical issued. The component are dipped in to bath at temreture80 degree Celsius for about 10 minutes .Passivation is done on component to stop any further corrosion reaction and protect against any further oxidation of component in atmosphere. After the completion of pretreatment process the components are dried in oven and then visual inspection is done. Before panting the components are again cleaned with sand paper to remove the

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dirty particles left on components. The air is also used &removes the dirty particles if any sticking to surface .All components are put on to overhead conveyor and again washed with the air at high pressure. Conveyor is moved with slow speeds. Firstly the components move to first booth, which is used to spray primer on components, primer is used to increase the cohesion property of paint. Then it goes to second booth where second coating of primer is given. In booth no. 3, 4 the top coating is done on the components. After the completion of final coating the components moves towards the oven, where components are heated up to 120degree Celsius for 25 minutes .After baking, the visual inspection is done.If any defect appears during inspection, the component is repainted by same procedure. Major Defects: 1.Sanding improper 2.Improper cleaning 3.Primer paint fault 4.Water splash 5.Dust after paint 6.Pin hole 7.Paint coat 8.Dent on surface 9.Improper matching of shade

WORKING OF DUAL CLUTCH

The dual clutch is used when gear box is to be disengaged while power is to be delivered to the PTO shaft. In the dual clutch (DC) there are two

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pressure plates and two clutch plates, one each for PTO shaft and gear shaft.

Schematic representation of DUAL clutch When half of the clutch is pressed, three forks got pressed which correspond to the pressure plate corresponding to gear box shaft so that
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the gear box is disengaged. Further, when full clutch is pressed, remaining three forks corresponding to the PTO clutch got pressed and PTO shaft also got disengaged.

PROJECT: STUDY OF POWER STEERING IN TRACTORS

The term power steering is usually used to describe a system that provides mechanical steering assistance to the driver of a land vehicle, for example, a car or truck. The power steering system in a vehicle is a type
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of servomechanism. Power steering is a hydraulic system for reducing the steering effort on vehicles by using hydraulic pressure to assist in turning the wheels. It is intended to provide for easier driving direction control of the vehicle. For many drivers, turning the steering wheel in a vehicle that doesn't have power steering requires more force (torque) than the driver finds comfortable, especially when the vehicle is moving at a very slow speed. In a vehicle equipped with power steering, when the driver turns the steering wheel, he feels only a slight retarding force, so a vehicle equipped with power steering can be driven by any healthy driver, even when the vehicle is being parked. This is because the power steering system furnishes most of the energy required to turn the steered wheels of the car. 5-6% power steering is used in tractors.

There are two types of power steering systems

1. Electric/Electronic power steering 2. Hydraulic power steering 1. Electric power steering: Electric power steering works with the help of an Electric Motor and a control unit which has some sensors. The motor runs on battery and will use electric power to assist the movement of steering when the driver turns the wheel. Electric power steering (EPS) is more efficient than the hydraulic power steering, since the electric power steering motor only needs to provide assistance when the steering wheel is turned, whereas the hydraulic pump must run constantly. In EPS, the assist level is easily tunable to the vehicle type, road speed, and even driver preference. An added benefit is the elimination of environmental hazard posed by leakage and disposal of hydraulic power steering fluid. Also in the event

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of the engine cutting out, assist will not be lost whereas hydraulic will stop working, as well as making the steering doubly heavy as the driver has to turn the power-assist mechanism on top of the steering system itself. Electric power assisted steering consumes less fuel than conventional hydraulic power steering systems. Using an electric motor results in significant weight and space savings compared with hydraulic belt driven pump systems that need to provide a constant hydraulic pressure. EPS systems also provide the required level of power assistance when needed, based on vehicle speed and how quickly the steering wheel is turned. In this system the electronic control unit is used to controlling the steering system as in fig. In electronic control unit a number of sensors is used to control the steering system.

Electric steering system

Hydraulic power steering: Hydraulic power steering (HPS) uses hydraulic pressure supplied by an engine-driven pump to assist the motion of turning the steering wheel. Power steering is a hydraulic system assisting the driver in turning the
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front wheels. The system usually consists of a hydraulic pump and fluid reservoir, a power-actuating mechanism such as a power cylinder, a control valve arrangement and a series of flexible hydraulic hoses and couplings to route the hydraulic fluid under pressure as shown in fig 2.2. The pump derives power from the engine. Most power steering systems in tractors today are hydraulic (that is, the force to turn the wheels is provided by a hydraulic piston, which is powered by high pressure hydraulic fluid), but in a some new tractors, the steering force is provided by an electric motor.

Hydraulic steering system control valve is in a neutral state. The second control portion has two supply paths communicating with A power steering apparatus is composed a fluid source for discharging pressurized fluid, a power cylinder, a control valve responsive to operation of a steering wheel for supplying the power cylinder with pressurized fluid from the fluid source
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and a reservoir. The control valve has a first control portion for controlling the flow of pressurized fluid from the fluid source to the reservoir and a second control portion for controlling the flow of pressurized fluid to the power cylinder. The first control portion has four paths communicating with the fluid source and the reservoir and each of the four paths is formed with a center-open variable orifice which opens when the the fluid source and a pair of chambers of the power cylinder, each of the two supply paths is formed with a semi-center-open variable orifice which opens when the control valve is in the neutral state, and two drain paths communicating with the chambers of the power cylinder and the reservoir, each of the two drain paths is formed with a center-closed variable orifice of which closes when the control valve is in the neutral state. OBJECTIVES: Hydraulic fluid supply from the front side to the pump: This technique is implementing in tractors model standard 460 and 355.In this system the hydraulic fluid supply to the pump is from front of the tractor. The individual fluid reservoir is attached on the front side of tractor with radiator. This is due to reason so that the surface area of the pipes is to increase for better cooling purpose. Use double hydraulic pump: This technique in tractor model standard 460.The efficiency of the double hydraulic cylinder is more than single hydraulic cylinder. Only single shaft is used in double hydraulic pump.

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Hydraulic systems

Most power steering systems work by using a hydraulic system to turn the vehicles wheels. The hydraulic pressure is usually provided by a gerotor or rotary vane pump driven by the vehicles engine. A doubleacting hydraulic cylinder applies a force to the steering gear, which in turn applies a torque to the steering axis of the roadwheels. The flow to the cylinder is controlled by valves operated by the steering wheel; the more torque the driver applies to the steering wheel and the shaft it is attached to, the more fluid the valves allow through to the cylinder, and so the more force is applied to steer the wheels in the appropriate direction. One design for measuring the torque applied to the steering wheel is to fix a torsion bar to the end of the steering shaft. As the steering wheel rotates, so does the attached steering shaft, and so does the top end of the attached torsion bar. Since the torsion bar is relatively thin and flexible and the bottom end is not completely free to rotate, the bar will soak up some of the torque; the bottom end will not rotate as far as the top end. The difference in rotation between the top and bottom ends of the torsion bar can be used to control the valve that allows fluid to flow to the cylinder which provides steering assistance; the greater the twist of the torsion bar, the more steering assistance will be provided. Since the pumps employed are of the positive displacement type, the flow rate they deliver is directly proportional to the speed of the engine. This means that at high engine speeds the steering would naturally operate faster than at low engine speeds. Because this would be undesirable, a restricting orifice and flow control valve are used to direct some of the

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pumps output back to the hydraulic reservoir at high engine speeds. A pressure relief valve is also used to prevent a dangerous build-up of pressure when the hydraulic cylinders piston reaches the end of the cylinder. Some modern implementations also include an electronic pressure relief valve which can reduce the hydraulic pressure in the power steering lines as the vehicles speed increases (this is known as variable assist power steering). Some heavy machines use hydraulic-only systems where there is no backup if the pump motor fails. 5-6% power steering are used in tractors. A double hydraulic pump which pressurizes CL-90 in this system. An armitol which is major link of pipes. 4 pipe lines are used in armitol. 2 go to the hydraulic cylinder. One goes to hydraulic pump and other is used as return unwanted fuel. When we introduced in one tractor, it worked easily as compared to other tractor. It becomes easy to move or turn the tractor in any direction. A road steering system requires some hand power to operate. But power steering can be operating with one hand easily with very less power that is main advantage of this system. Hydraulic system: Hydraulic pump is the main component of the power steering system. It plays a very important role in this system. Different types of hydraulic pumps are used. In the ordinary power steering we use a single hydraulic pump which works for rear cover. But in power steering we use a double
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hydraulic pump which works for a steering and rear cover. This type of hydraulic pump is the combination of two hydraulic pumps. Working of this hydraulic pump is simple. Hydraulic pump gives the power and pressurize the fluid. This hydraulic pump is driven by engine. Hydraulic pump pull the hydraulic fluid from Differential at low pressure and force it to outlet at high pressure. The amount of fuel provided by the pump is depends upon the engine speed. It must be designed to provide adequate flow when engine is idling. As a result the pump gives much more fluid when engine is running. Hydraulic pump contains a pressure relief valve to make sure that pressure does not get to high, especially at high engine speed when so much fluid is being pumped.

Double gear hydraulic pump Advantages of double gear hydraulic pump: 1. The single pipe supply is used to circulate the hydraulic fluid the differential to the pump. 2. It has more efficiency than single gear pump.
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from

3. It works in both directions. 4. The difference between the differential and the pump is minimum. 5. Backlash of double gear hydraulic pump is minimum. 6. The double gear hydraulic pump is used in model STANDARD 460. Disadvantages of double gear hydraulic pump: 1. High pressure generate by double gear pump which causes the more leakage 2. It increases the load on cam shaft gear. 3. Unwanted particles in the hydraulic fluid is excess. TRACTOR POWER STEERING PARTS:1. power steering pump 2. steering arms 3. Streeing wheel 4. Tie rod ends bi-metal bushes 5. Manual arm steering system 6. Jacket tube 7. Colum ring bush 8. Guide washer 9. Steering cap 10.Locking plate 11.Dust seat
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12.Shaft oil seal 13.Shim 14.Housing Hydraulic fluid supply from the front side to the pump: This technique is implementing in tractors model standard 460 and 355.In this system the hydraulic fluid supply to the pump is from front of the tractor. The individual fluid reservoir is attached on the front side of tractor with radiator. This is due to reason so that the surface area of the pipes is to increase for better cooling purpose. A single gear pump is shown in fig.

Single gear pump

Advantages of the hydraulic fluid supply from the front side of the tractor: 1. It provides the better cooling to the hydraulic fluid. 2. A separate filter is used in front reservoir. 3. Individual fluid supply to the steering pump. 4. Fluid life is more because lesser amount of unwanted particles

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Hydraulic pressure: Fundamental features at using hydraulic compared to mechanics for force and torque increase decrease in a transmission. Hydraulic machinery: Are machines and tools which use fluid power to simple & easy work .Heavy equipment is a common example. In this type of machines hr pressure fluid called hydraulic fluid is transmitted throughout the machine to various hydraulic motors & hydraulic cylinders the fluid is controlled directly or automatically by control valves & distributed through hoses and tubes. The popularity of hydraulic machinery is due to very large amount of power that can be transferred through small tubes and flexible hoses and high power density wide arrangement of actuators that can make us use of this power. Hydraulic machinery is operated by the use of hydraulics, where a liquid is powering medium Pneumatic on the other side is based on the use of gas as the medium for power transmission, generation and control. Power steering assembly: Two types of filters are used in this assembly: Magnetic filter: Magnetic filters use a permanent magnet or an electromagnet to capture ferromagnetic particles. An advantage of magnetic filtration is that maintaining the filter simply requires cleaning the particles from the surface of the magnet. Automatic transmissions in vehicles frequently have a magnet in the fluid pan to sequester magnetic particles and prolong the life of the media-type fluid filter. Some companies are
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manufacturing magnets that attach to the outside of an oil filter or magnetic drain plugs to aid in capturing these metallic particles, though there is ongoing debate as to the effectiveness of such devices.

Magnetic filter

Hydraulic membrane filter: Filters are an essential component of every hydraulic system. Their function is to remove particle contaminants from the hydraulic fluid, which reduce the service life of system components through abrasive wear. A hydraulic filter is shown in fig.

Hydraulic filter
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CL-90 oil is used as lubricant. To purify the CL-90 filter body is used Tractor power steering parts: Power steering pump: Means of hydraulically assisted steering. A geardriven power steering pump creates system pressure as shown in fig. The pressurized fluid is then routed into a cylinder that helps push the wheels one-way or the other when the steering wheel is turned. The two most common power steering complaints are noise and leaks.

Power steering pump

Steering arms: The most conventional steering arrangement is to turn the front wheels using a handoperated steering wheel which is positioned in front of the driver, via the steering column, which may contain universal joints (which may also be part of the collapsible steering column design), to allow it to deviate somewhat from a straight line.

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Steering arm Steering wheel: A steering wheel also called a driving wheel or hand wheel is a type of steering control in vehicles Steering wheels are used in most modern land vehicles, including all mass-production automobiles as well as light and heavy trucks. The steering wheel is the part of the steering system that is manipulated by the driver

Steering wheel
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Tie rod ends bi-metal bushes: The tie rod is part of the steering mechanism in a vehicle. A tie rod is a slender structural rod that is used as a tie and capable of carrying tensile loads only. The working strength of the tie rod is that of the product of the allowable working stress and the minimum cross-sectional area. Washer: A washer is a thin plate (typically disk-shaped) with a hole that is normally used to distribute the load of a threaded fastener, such as a screw or nut. Washers usually have an outer diameter about twice the length of their inner diameter. Washers are usually metal or plastic. High quality bolted joints require hardened steel washers to prevent the loss of pre-load due to Brine ling after the torque is applied. Steering cap: The billet aluminum power steering cap cover is not only a cosmetic accessory, but also a functional part. The back surface of the part is precision machined and keyed to fit the top surface of the power steering cap, Use to connect a vacuum gauge to the power steering reservoir for bleeding the Hydraulic Power Steering system.

Steering cap Locking plate: it is a simple thin cutting piece of steel is used for lock the bolts properly. It prevents the tight seal against any vibrations and forces.

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Dust seal: The dust cover seals used to prevent the bushes from allowing contaminants such as sand, dirt, or other debris from entering the mechanism.

Dust seal Army dole: An army dole which is major link of pipes. 4 pipe lines are used in army dole. 2 go to the hydraulic cylinder. One goes to hydraulic pump and other is used as return unwanted fuel. Contents of hydraulic pressure: Force and torque multiplication, The fundamental feature of hydraulic system is the ability to apply force or torque multiplication in easy way Independent of the distance between the input and output without the need for mechanical gears or levers either by staring the effective area in two connected cylinder or the effective displacement between pump and motor For the hydraulic fluid to do work it must flow to the actuator and for motors then return to reservoir The path taken by the hydraulic fluid is called hydraulic current Pressure of fluid is transmission in all directions engineering dealing with mechanical properties of the liquids.
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Hydraulic pressure is used in pumps. A pump is a device used to move fluid, such as liquid or slurries Hydraulic pressure is also used in Kaplan turbine .A water turbine is a rotary engine and that takes energy from moving water

OTHER PARTS:1. Lubricant pump 2. Steering column 3. Army dole + 3 doctor pipes + ben20 bolt 4. Hydraulic pump (double) 5. 2 flanges 6. 1 hydraulic cylinder 7. 2 tie rod ball end

Working:-

1.

First stage:- CL-90 lubricant comes from differential though the filter pipe to the filter body

2.

Second stage:- in the second stage the CL-90 comes in the filter body. To purify two filters are used in this stage it first comes in magnetic filter.

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3.

Thired stage:- in this stage the CL-90 comes in the member brave filter. This membrane allows the oil to go without unwanted particles.

4.

Fourth stage:- in the fourth stage lubricant oil comes in hydraulic pump and hydraulic pump pressurize it. And allow the CL-90 to go to the army dole under high pressue. Army dole is connected wth steering column.

5.

Fifth stage:-further army dole is connected with two pipe to hydraulic cylinder. One pipe in internal and another is external. Further this cylinder is connected with two rods ball and two ball end at tie rods slightly rotate during rotation at flywheel and give power to the hubs.

6.

Sixth stage:- in this stage lubricant oil return from army dole to filter pipe.

ADVANTAGE OF POWER STEERING IN TRACTORS Power steering is used in cars but now it is being used in tractors Advantages are as following:1. Power steering is a hydraulic system to make the steering easy without a power steering it will be hard to make a turn 2. Also helps the driver to have better control in highway 3. Also helpful in if one of the tyre is deflated or blow up 4. Power steering makes vehicle easier to steer when you are parking your vehicle
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5. In a power steering a small portion of necessary force is provided by steering as compared to ordinary steering

PROJECT:- INDUSTRY PROBLEM AND REMEDIES

There are many problems which I have noticed in project semester. Description is given below:
1.

Less educated workers:- the staff kept here is generally less educated due to this it is easy to communicate and made aware of industries demand. Remedies:*the program should be launched to educate the with emphasis on industry demand *recruitment process should be made more answerable so that proper persons get selected jobs

2. improper availability of raw material:- sometimes raw material available is not proper. The sizes are little short or large. So material get wasted. REMEDIES:-

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*the industry should contact the manufacturing unit and should ask them to send in accordance with the drawing provided to them. *quality department should be made to tackle this problem and coordination between purchase and quality department on this issue should be made properly. 3.improper material handling:- material is not handled properly, breaking up of cutting tools are the example.

REMEDIES:*workers must do work with more concentration and obey the industrial safety rules. *for drunkard and undisciplined worker. There should be punishment system 4. poor or improper layout:- layout of machine shop is not proper which is major cause of wastage of time and power. REMEDIES:*layout should be made proper which will help to reduce the idle time.

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PROJECT:STUDY OF TRACTOR SAFETY

Tractors are often considered a farmers best friend. Yet, tractors continue to cause serious injury and death among users & ground workers. Even though tractor hazards have been identified for years, the same injuries/accidents continue to occur, even though there are known engineering controls and standard procedures to deal with these hazards. Few of the recorded tractor injury accidents have been caused by equipment failure. TRACTOR OPERATOR RESPONSIBILITIES: Stay alert and avoid potential hazards

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 Preview your route for obstacles, holes, slopes, ditches, terrain, etc. Remove debris Maintain and use the tractors safety features (such as, ROPS, seat belt, & PTO shields) Conduct tractor pre-operation checks Operate the tractor and implements safely and according to manufacturers directions Use the right tractor and implement for the job Know equipment blind spots Use tractor as intended

Before dismounting switch off the engine and wait for the tractor and PTO implements to come to a complete stop

COMMON MISHAPS: Rollovers: rear and side Front-end loader incidents Falls from tractor Tractor run-over's Caught-between crushing PTO shaft entanglement By-pass starting

TRACTOR ROLLOVERS
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Tractor rollovers happen when the center of gravity moves past a baseline of stability, either to the side or rear of the machine. Many rollovers happen at speeds <8 mph and on slopes less than 5. Avoid sudden motions. Contributing factors to rollovers are: Various sizes, shapes and weights of implements Speed!!! Human error

CENTER OF GRAVITY
Center of gravity affected by slopes, loads, turns & terrains

Stay Centered!

When the center of gravity is raised the risk of rollover increases

REARWARD ROLLOVERS Common causes for rear-ward rollovers: Tractor is stuck in mud or snow preventing rear wheels from rotating

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 Rear wheels cant turn because of chains, boards, or other materials used to improve traction Climbing a hill that is too steep Clutch is released too quickly w/ transmission in a lower gear and engine at high speed Load is too heavy and/or hitched above the drawbar of the tractor

PREVENTING REARWARD ROLLOVERS Release clutch only when rear wheels can rotate forward Do not climb steep hills in a forward direction. Instead, use a reverse gear to back the tractor up a the hill Use only enough engine speed to start tractor moving while engaging the clutch smoothly Change speed gradually by applying power smoothly Ballast (counter-balance) the tractor properly for the job Hitch loads properly to drawbar Use reverse gear to break tractor tires free from frozen conditions

SIDEWAYS ROLLOVERS Driven on hillside that is too steep Driven too close to the edge of a roadside ditch or embankment
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 Cornering too sharply or too fast (centrifugal force pivots tractor on outside wheels)

The tractors front-end loader is elevated too high on a hillside or in a turn at excessive speed

ROLLOVER PROTECTIVE STRUCTURES (ROPS) ROPS work by limiting a rollover to 90 and preventing the operator from being crushed under the weight of the tractor. ROPS work only if the operator is wearing a seatbelt to keep them in the operator station as the tractor is rolling. ROPS and a seatbelt keep the operator within this safe space in the event of a rollover

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ROPS AND SIDEWAYS ROLLOVER DEMO

PAST POINT OF NO RETURN 3

TWO HILLSIDE DEPRESSIONS

TRACTOR HITS DEPRESSION & TIPS

ROPS & SEATBELT PROTECT OPERATOR

INDUSTRIAL SAFETY
1 Some of the safety precaution hazard cheeks measures and rules required to be taken in care which very much to cheeks any sort of possible accident of loss of material machine. 2. Concentration towards work in the key most think one should not allow his mind to fly here and there. Throwing of things here and there .fun with tools and teasing of co worker should not be there.

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3. Safety training should be given to the worker and they must be made aware of safety requirement by expert lectures etc. 4. A hazard cheeks list of all industry should be made where its made be cleared that were guards against accident is not provided and where it should be provided. 5. Safety rules should be general not much broad. Changing with new environment and should be too much than required. 6. Steps should be taken to reduce noise in the industry. 7. Fire fighting appliances and fire exists should be ready for immediate use. 8. As there is lot of welding work so goggles safety caps, jackets should be there, Jewelers, ring, wristwatch, and chain should not be allowed around moving machinery. 9. Proper earthling of machine and other appliances should be done. 10. Proper light, ventilation equipment easy to use should not be there. 11. Smoking running and working of drunken workers should not be allowed.

Bibliography

1. Daily diary 2. Operator manuals from STD

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3. how stuff works 4. Wikipedia

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