Harpreet

SIX MONTHS INDUSTRIAL TRAINING
TRAINING REPORT
UNDERTAKEN AT
INTERNATIONA L TRACTORS LIMITED

IN
FINAL ASSEMBLY
SUBMITTED IN PARTIAL FULFILLMENT OF THE DEGREE
OF
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Under the Guidance of :
Submitted By :
Mr. Vikram Sharma
Harpreet Singh
Training & Placement Officer
Univ. Roll No 100351196023
______________________________________________________
GULZAR INSTITUTE OF ENGINEERING & TECHNOLOGY
Ludhiana, Punjab
ACKNOWLEDGEMENT
The authors are highly grateful to the Dr. M.P. Kaushal, Principal, Gulzar Group of
Institutes, Khanna, for providing this opportunity to carry out the six month industrial
training at International Tractors Limited, Hoshiarpur. The constant guidance and
encouragement received from Vikram Sharma T&P, GGI Khanna has been of great help
in carrying out the project work and is acknowledged with reverential thanks. The authors
would like to express a deep sense of gratitude and thanks profusely to Company.
Without the wise counsel and able guidance, it would have been impossible to complete
the report in this manner. The author like to express courtesy to all the staff of the
organization for rendering me full support and assistance during my training period. The
author expresses gratitude to other faculty members of Mechanical Engineering
department of GGI for their intellectual support throughout the course of this work.
Finally, the authors are indebted to all whosoever have contributed in this report work
and friendly stay at International Tractors Limited.
Harpreet Singh
PREFACE
Industrial Training plays very much significant role in the course of engineering. It
provides the student during the engineering course a boost to enhance his technical skills,
abilities and creativity. Industrial training backens up the theoretical knowledge by
practical knowledge gained during the course. As is widely said, ounce of practical is
better than the tons of theory. In fact, both these two things are incomplete without
each other. In this report, I have tried my level best to present the work undertaken by me
during my training period in liquid, concise and precise manner. Engineering means
optimum utilization of resources for the achievement of the desired objectives. Projects
and some suggestions given by me in this report under the guidance of my Industrial
Tutor, Mr. SANDEEP SINGH is a step forward towards the definition of engineering.
TABLE OF CONTENTS
Sr.
Topic
Page No.
Executive Summary
Introduction
Group Companies
Definition of Tractor
Training At Training Centre
1
2
4
6
8
No.
1
2
3
4
5
Main Assemblies of Tractor

6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Basic Terminology of Engine

Features of Sonalika Tractor
Products Manufactured by Sonalika International
Competitors Companies in India
Drawbacks of Competitors of Sonalika
Specification of 1,2,3,4- Cylinder
Engine Quality
Engine Parts
Engine Testing
Engine Faults
Differential Assembly
Gear Box
Rear Cover
Hydrolic
Front Axle
Main Loop Chassis
Final Assembly
Contenarization & Dispatch
Research and Development Department
Other Terminologies Used
10
15
16
17
18
20
25
26
34
36
45
53
60
63
67
70
75
85
87
93
EXECUTIVE SUMMARY
This report gives description from learning to drive a tractor till the dispatch of tractor
from the gate of plant .There are various assemblies in tractor like engine , differential ,
4
gear box , rear cover ,front cover, final assembly ,etc. through which a tractor is being
manufactured and inspected by quality control department at various stages . After this
also it has to go through roller testing , rework section ,PDI, dispatch before it is finally
dispatched. We also learnt about the maintenance schedule of tractor .
This report starts from introduction of the company which shows the company
foundation, vision, mission, core values, product range and financial partners.It also
describes tractor history and terminology. Tractor field training with implements,
implements attachment and detachment and calculating field area and specific fuel
consumption Further it gives description of manufacturing of engine, differential, gear
box, rear cover and front axle. Assembly of Chassis assembly, paint shop (chassis and
sheet metal), final assembly and then tractor proceed to Roller testing and road test to
check tractor at various stages. If any fault found during test it handover to minor and
major rework section and at last tractor send to PDI(pre-delivery inspection) and further
to QARS for quality check and later send to washing and then to dispatch.This report
describe the system and working of Spare part catalogue, warranty policy and SAP.
Research and Development section was most challenging part in training (Product design,
Mockup, Protoshop, Vendor development, Vendor quality control and Testing and
Product management). Also gives information about how tractor is tested for various
specifications at Budni.
In engine, it describes how material of engine come in engine plant area and material
quality is checked as per standard of ITL further , Assembly of engine at various stages in
assembly line and how engine is tested at Idle rpm, Rated rpm and Max. rpm and get
standard results towards Backup torque, Max. Torque and SFC and also check working
status of various components (Reduction pump, thermostat valve and FIP etc.) for engine
oil pressure, cooling system and delivery of fuel at standard rate. And if engine does not
pass the test or do not give standard results than it further proceed to rework section.
At differential, gear box, rear cover and front axle it describes the assembly, parts of
differential, gear box and rear cover and their working.
Paint shop it describes the process of chassis and sheet metal, and at final assembly it
describes the tractor other fitments i.e. harness, radiator, fuel tank and assembly parts, 3point linkage, tyres , fenders, meter plate, horn plate, lubricant and diesel filling etc.
INTRODUCTION
Established in 1969, Sonalika group from the very beginning has tried to understand
customer need so that they get better value for their money, hard earned. Sonalika group
is one of the top automobile and agriculture machinery manufacturers in India. Apart
5
from tractors its product line includes multi utility vehicles, three wheelers, engines and
various farm equipment and implements. Established in 1969, Sonalika group since the
inception has tried to understand customers need to be able to facilitate them with its
value for money products. The company has a state of the art manufacturing facilities,
spread in acres, located in Punjab and Himachal Pradesh.
Today the group stands-tall with an approximate turn-over of 1000 crore. An average
growth rate of 30% makes it the fastest growing corporate in India. It also happens to be
very few debt free companies in the world. It employs about 2500 people including some
of the renowned names in the industry. The company works on the maxims of low
production cost and clean and safe environment. Such efforts have fetched the company
the accreditations like ISO 9001 and ISO 14001.
The company has a strategic alliance with Yanmar of Japan, earlier it had joint venture
with Renault agriculture of France which is now part of Class, Germany. CITI bank
and 3I are major financial partners of Sonalika group. Sonalika is also environmentally
responsible and has developed in-house engines that confirm to Euro II norms. It is now
in the process of developing Euro III compatible engines. Sonalika products have created
a niche for themselves not only in India but also in foreign markets including France,
Africa, Australia, Bangladesh, Srilanka, Senegal, Malawi, South Africa, Mali, Canada,
Syria and many of the south-asian countries.
LOGO RATIONALE
Red symbolizes the, arouses cheerfulness, stimulates

mental activity, and generates the same. Green Leaf in
the center symbolizes growth, harmony, freshness,
and fertility. Black underlining the logo associates
with power, elegance, and formality. And Orange
surroundings
enthusiasm,
the
complete
fascination,
logo
represents
happiness,
creativity,
encouragement, and stimulation. All this permutation

of persona represents the Sonalika group as an asset
in the industry.
VISION
The Dream Project of Sonalika group is to cater the agricultural and auto industry with
quality abrasive products through untiring dedication and leadership.
MISSION
Sonalika group pays personal attention to their customers so that they get the products
which satisfy their needs.
CORE VALUES
To accomplish our mission, the ownership, staff and management go to great lengths to
treat each customer like a member of the family and provide them with the best choice of
products and highest quality of service in the industry.
GROUP COMPANIES
International Tractors Ltd
International Tractors Limited was incorporated on October 17, 1995 for the manufacture
of Tractors and has since then built a distinct position for itself in the Tractor industry.
7
ITL is manufacturing various Tractors of Sonalika brand between 30 H.P to 90 H.P. The
tractors manufactured by company have secured a reputation of performance, quality and
reliability in the market because of their maximum pulling power, minimum fuel
consumption and low emission. All this makes ITL one of the top five tractor selling
companies in India. These tractors are also exported to various countries including South
Africa, Australia, Zimbabwe, Sri Lanka, Canada, Bangladesh, Algeria, Zambia, Senegal,
Ghana
etc.
International Cars & Motors Ltd

International Cars & Motors Limited (ICML), is a Group Company of the Rs 1200
Crores SONALIKA Group. The Company is promoted by Mr. L.D.Mittal, Chairman, Mr.
A.S.Mittal, Vice Chairman & Mr. Deepak Mittal, Managing Director, who are having
vast experience in manufacturing of tractors, Farm machines & Automobiles.
ICML is a project of its kind and is the Pride of Himachal Pradesh. The Company is
having its state-of-the-art production facility, with centrally air-conditioned, dust &
pollution free environment, to manufacture multi-utility vehicles / sports utility
vehicles, in Amb, Himachal Pradesh.
The Company is a Mother Unit as its establishment shall attract many other ancillary &
small units for meeting the raw material requirements yielding manifold employment
avenues, revenue & industrialization in the state.
The Company has entered into Technical Collaboration Agreement with MG Rover of
UK, with the technical know how from MG Rover, UK. The Company has
manufactured MUV with the name of RHINO RX & the same MUV boasts of Rover
engines. The company is in-process of developing its own Common Rail Direct injection
(CRDi) engines.
Sonalika Agro Industries Corporation

Sonalika Agro was established in 1971 to support the Indian farmers with mechanization
technology to facilitate persistence of green revolution. Sonalika Agro Industries
8
Corporation, the groups maiden venture is one of the foremost Farm equipments and
implements manufacturing companies in India with 80% share in threshers alone. Its
product line includes Combine Harvesters, Tractor/Self Driven straw reapers, Potato
Planters, Maize seller cum-Dehuskers, Seed Cum- Fertilizers Drills, various kinds of
threshers, etc.; Sonalika Agro is a pioneer in manufacturing tractors mounted combine
harvester, which is not popular in India, but also in various others countries across the
globe. Today, the company is supporting the farmers with world class farming equipment
to ease the process of making the Green Revolution II, a dream come true. In the light of
the company's mission, highly qualified and experienced staff is working as a family in
the manufacturing facility at Hoshiarpur (Pb).
International Autotrac Finance Ltd
International Autotrac Finance Limited is a non banking finance company approved

by RBI.
IAFL provide finance to customers of International cars & motors limited in rural &
semi urban areas across India through customer friendly schemes.
Its parent company of Sonalika Group ranks among the largest tractor & farm
equipment manufacturer in India
TRACTOR
History of Tractor:In the year 1856, all such machines used for traction purposes were
known as traction motors and later in 1906 , these were designated as tractor by taking
half the word from traction , i.e. trac and the other half from motor , i.e. tor.
9
Definition of Tractor:The tractor is such a machine which is used to pull or push

agricultural implements in the fields.
Traction Formula:-
F = A.C + W. tan
Where,
F = Traction Force
A = Area of contact between tyre and soil
C = Cohesively of Soil,
= Angle of internal friction among soil particles
TRACTOR - A BRIEF INTRODUCTION

A wheeled, self-propelled vehicle for hauling other vehicles or equipment and for
operating the towed implements; also, a crawler, which runs on an endless, self-laid track
and performs similar functions.
A farm tractor is a multipurpose power unit. It has a drawbar for drawing tillage tools and
a power takeoff device for driving implements or operating a belt pulley. The acreage to
be worked, type of crops grown, and the terrain all impose their requirements on tractor
design. Accordingly, models vary in such details as power generated, weight, ground
clearance, turning radius, and facilities for operating equipment. All models can,
however, be grouped under four general types: four-wheel, row-crop or high-wheel,
tricycle, and crawler.
Tractors are rated by their horsepower they deliver at the drawbar and at the belt. On
small models, the drawbar and belt horsepower may run as low as 10 (7.5 kW); on large
models the drawbar horsepower runs as high as 132 (98 kW), while belt horsepower
reaches about 144 (107 kW).
The major components are engine, clutch, and transmission. These components are
intimately related and designed to work in conjunction with each other to accomplish
specific work. Tractor engines are relatively low-speed; their maximum horsepower is
generated at crankshaft speeds in the neighborhood of 2000 rpm. These engines have one,
two, three, four, six, or eight cylinders and operate on gasoline, kerosene, liquid
petroleum gas, or diesel fuel. They are of the spark-ignition or diesel type, operating on
the four-stroke-cycle principle, and are cooled by water or air.
Power is transmitted to the rear wheels or to all four wheels. Drive to the front wheels is
mechanical or hydrostatic, its purpose being to increase drawbar pull at the will of the
operator. Transmissions have 3, 4, 5, 6, 8, 10, or 12 forward speeds and one or two
reverse gears. Clutch less hydraulic transmissions are also used, making it possible to
10
shift gears while in motion. Vehicle speeds are low, ranging from slightly more than 1
mi/h (1.6 km/s) to about 18 mi/h (28 km/h) in high gear.
The basic design of an industrial tractor for hauling and for operating construction
equipment departs little from that of a farm tractor, and differences in design of models fit
the vehicle to its intended work. Because high ground clearance is not needed for
industrial work, the tractor is commonly built with a lower center of gravity and is
capable of traveling a few miles per hour faster than a farm tractor. If its use is confined
to hauling, it may not be equipped with hydraulic power. If it is to be used for operating a
scraper, backhoe, or front-end loader, its structure may be heavier and more rugged.
11
TRAINING AT
At training center, we went through various training, which is illustrated below1)

2)
3)
4)
Introduction about ITL.

Plant visit
Tractor history
Competitors and their drawbacks
12
5) Field training
6) Assembly and disassembly of Engine, gear box, differential and hydraulic
system.
7) Various terminology about tractor.
Main Assemblies of Tractor :Engine :- Engine is a set of mechanical devices which convert chemical energy into heat
energy and heat energy into mechanical energy. Engine provides the source of power to
drive the tractor .Sonalika engines are Compression ignition , Water cooled ,Four stroke,
Diesel engines.
Clutch :- Clutch is fitted between the engine and gearbox and is used to connect or
disconnect the engine drive to the gearbox.
Transmission :- Gearbox is fitted in the tractor to increase the driving torque so as to
enable the tractor to pull more load. In the gearbox housing ,differential and reduction
gears are also fitted. The differential helps to take a turn without its inner wheel spinning
while the reduction gear fitted further increases the driving torque to the wheel.
Wheels :- Two wheels are fitted to the front axle and two rear wheels to the reduction
gear shaft , drive is transmitted through the rear wheels . For better traction in tractors ,
rear tyres are provided with high lugs.
Front Axle :- Front axle is fitted at the front of the tractor and the two stub axles fitted at
either end through which the steering linkage is connected and wheels are steered.
Steering System :- Steering system enables the operator to steer the tractor to right or
left as the case may be.The steering unit in power steering tractor is hydrostatic i.e. there
is no mechanical connection between steering column and steered wheels .Instead there
are hydraulic pipes and hoses between steering unit and steering cylinders.When the
steering wheel is turned , the steering unit meters an oil volume propotional to the rate of
rotation of steering wheel.This volume is directed to the appropriate side to the steering
cylinder, while simultaneously the displaced oil is directed to tank.
Brake System :- Brake system provided in the tractor so as to enable the operator to
stop the moving tractor or slow down the speed when required.
Electrical System :- Electrical system provided in the tractor enables it to work in the
night through the electricity produced by dynamo. Moreover , engine is also started
through self starter which draws its electric current through batteries.
Hydraulic Lift :- With the help of hydraulic power the implements are raised or lowered
Down or their depth is controlled.
Power Take Off :- Provision is made in the tractor to drive stationary or moving
implements such as Sprayer, Duster, etc.
13
Technical Terms :1) Track :- It is the distance between centres of front two tyres.
2) Ground Clearance :- It is the clear smallest distance from the deepest point of the
axle to the level ground .
3) Wheel Base :- It is the distance between centres of hubs of front and rear wheels.
4) Height of Frame :- It is the distance from the upper edge of the frame from the
ground level.
BASIC TERMINOLOGY OF AN ENGINE

Bore :-
Internal diameter of cylinder liner is known as bore.
Stroke :-
The distance traveled by piston from TDC to BDC or from BDC to TDC is
called stroke.
T.D.C. (Top Dead Center)
:- It is the position from where piston cannot move further up.
B.D.C. (Bottom Dead Center)
:- It is the position from where piston cannot move further
down.
C.C.(Cubic Capacity)
:- It is the volume swept by the piston in one stroke.
Idle R.P.M.:- R.P.M. at no load and no accelerator. It is required R.P.M. for just keeping
the engine in starting position without doing any kind of work.
Maximum R.P.M. :- R.P.M. at no load and full accelerator.
Rated R.P.M.:- R.P.M. at full load and full accelerator .At this R.P.M. , engine develops
its maximum power.
Maximum Load R.P.M.:- R.PM. at full accelerator and max. load . At this point ,
engine take up maximum load.
HORSE POWER :- If the rate of doing work is 75 kg-m/sec = 746 (I.S.) & 735.5 watt
(S.A.E.).
B.H.P.(Brake Horse Power) :- It is the power available at the engine flywheel.It is also
known as the input power.
Back up Torque :- Reserved torque in the engine with respect to the torque at
maximum power of engine OR Torque reserved in the engine after developing maximum
power. When we increase the load further after rated rpm condition then only torque
increases, rpm decreases.
Back up Torque = (Max. Torque Full Torque )
14
--------------------------------------- X 100 %
Full Torque
Specific Fuel Consumption: - The fuel consumed by the tractor for developing 1 HP of
power in 1 hour. Its units are gm/bhp/hr. The value to attain SFC is max. 200gm/bhp/hr.
Spill Timing: - It is the point from where the injectors begin to inject the fuel into the
combustion chamber.
Tappet clearance: - It is the clearance between the rocker arm and the tappet when the
value is in the closed position.
Valve Clearance: - It is the clearance between the rocker arm and the valve when the
valve is in the closed position.
Bumping clearance: - It is clearance between the top of the piston and the cylinder head.
It remains 1.9-2.1 mm.
Back compression: - It is the leakage of compression through the piston ring via
crankcase breather.
Blow-by: - It is the escaping of hot gases/vapors through the crankcase breather provided
in the crankcase.
Lapping Position: - It is the position when both the inlet and exhaust valve remain open
that position is called lapping position.
ALFIN PISTON: - The piston in which upper groove is inserted with aluminum and
ferrous materials.
Speed Drop: - Speed at full load speed at no load.
Different RPM Conditions

Idle RPM
: No Load + No Accelerator
Maximum RPM
: No Load + Full Accelerator
Rated RPM
: Full Load + Full Accelerator
Maximum Torque RPM
: Maximum Load + Full Accelerator
H.P. Horse Power

Power :- Rate of doing work is power.
15
Horse Power - If the rate of doing work is 75 Kg-m / sec.

It will be considered as 1 H.P.
Two Standards for Measuring Power are:I.S. (H.P.) - International Standard (746 watts)
S.A.E. (Ps) - Society of Automotive Engineers (735.5 watts)
RPM Conditions
Sonalika Model
Simpson Model
2 Cyl. & 3 Cyl.
4 Cyl.
S -325
Idle RPM
700
700
750
Maximum RPM
2300
2400
2200
Rated RPM
2100
2200
2200
Maximum Torque RPM
1100
1200
1500
POWER TAKE OFF SHAFT

PTO Standards:6 Spline - 540 10 Rpm
21 Spline 1000 25 Rpm
16
GROUND PTO :When PTO speed is governed by ground speed of tractor ,this is
known as Ground PTO.
LIVE HYDRAULICS:In this system , the hydraulic system is directly mounted on the
engine. Hence it takes direct power from the engine , the position of clutch will not effect
the operation of hydraulics system.
CLUTCH
Single Clutch - Useful for those operations where one thing is in working at one time
whether P.T.O./ Transmission .
Dual Clutch :- Useful for those operations where both P.T.O./ Transmission are in
working at same time.
HP AND CATEGORY
TRACTOR
HP
CATEGORY
TOP LINK PIN DIA.
LIFT ARM PIN DIA.
Upto 20
5 / 8 inch
5 / 8 inch
20 to 45-55
3 / 4 inch
7 / 8 inch
45-55 to 90
1 inch
1 1/8
90-95 & Up
1 1/4 inch
1 7/16 inch
17
T
O
R
Q
U
E
BACK UP TORQUE :- Reserved torque in engine after developing maximum
power is known as back up torque.

TBU% = MAX. TORQUE FULL TORQUE * 100
FULL TORQUE
FEATURES OF SONALIKA TRACTOR

18
THE COMPLETE AND BALANCED TRACTOR:1) Well Balanced Tractor: - Sonalika is a balanced tractor due to proper
distribution of weight which enables its rear tyres to firmly grip the ground and
prevents slippage on being overloaded.
2) Maximum Wheel Base :- Sonalika tractor has maximum wheel base, so it
doesnt lift up in front and pulls heavy load on steep slopes while maintaining its
balance. Whereas all other tractors have small wheel base which lifts-up their
front side while moving the uphill.
3) Maximum Ground Clearance :- As Sonalika tractor has maximum ground
clearance it does not damage the standing crop while ploughing and weeding out.
Due to this reason , it easily crosses the bunds in the field while moving in the
field.
4) High Back up Torque :- The back up torque of Sonalika tractor is highest
.Back up torque is the reserved torque stored in engine after developing
maximum power. This is the reason a 35 HP Sonalika tractor works as efficiently
as a 50 HP tractor of any other company.
5) Smoke Emission is Less :- Sonalika tractor emits very less smoke even at high
loads.
6) Doesnt Break Motion :- Sonalika tractor doesnt break motion or does not stop
even after 1000 rpm drop .
7) High Pulling Power :- Due to high pulling power of Sonalika tractor, it is able
to turn at corners of field without lifting up the cultivator.
8) Maximum Yield :- Sonalika tractor is very efficient in deep ploughing which
gives maximum yields and minimum weeds.
PRODUCTS MANUFACTURED BY SONALIKA

19
INTERNATIONAL
1) Tractor 16 models
2) Tractor mounted combine harvester
3) Back Hoe and Loader
4) Multi Crop Threshers
5) Harvesting Attachments
6) Crop Reapers
7) Potato Planters
8) Maize Sheller (Corn Threshers)
9) Potato Diggers
10) Paddy Threshers
11) Seed cum Fertilizers Spreaders
12) Diesel Engines
13) MUVS
14) Three Wheelers
PRODUCT RANGE
Sr.
No.
1
2
3
4
5
6
7
8
9
10
11
12
Model
DI 730
II
DI 730
III
DI 35
DI 740
DI 740
III
DI 745
III
DI 750
II
DI 750
III
DI 60
DI - 60 III
DI 75
DI 90
H.P.(SAE)
Engine Model
Cylinder
Bore / Stroke
CC
Rated
RPM
Rear Tyre Size
30
2102F
102 / 110
1798
2100
12.4 x 28
30
35
42
3095F
3097FL
S-325
3
3
3
95 / 110
97 / 118
91.4 / 127
2339
2616
2500
2100
2100
2100
12.4 x 28
12.4 x 28 , 13.6 x 28
13.6 x 28
40
3097FL
97 / 118
2616
2000
13.6 x 28
45
3100F
100 / 110
2593
2100
13.6 x 28
50
3102FL
102 / 118
2854
2100
13.6 x 28
50
60
60
75
90
4095F
4100FL
3100TL
4100TL
4105TL
4
4
3
4
4
95 / 110
100 / 118
100 / 118
100 / 118
105 / 118
3346
3707
2779
3707
4088
2200
2100
2100
2200
2200
13.6 x 28 , 14.9 x 28
16.9 x 28
13.6 x 28
16.9 x 30
16.9 x 30
COMPETITORS COMPANIES IN INDIA:20
1) Mahindra & Mahindra

Plant: - Kandiwali (Maharastra).
2) Tractor & farm equipment
Plant: - Madurai.
3) Escorts LTD.
Plant: - Faridabad (Haryana)
4) Mahindra & Mahindra (Swaraj Division)
Plant: - Mohali (Punjab)
5) Hindustan machine tools LTD.
Plant: - Pinjore (Haryana).
6) Tafe motors & tractors LTD
Plant: - Mandideep (M.P.)
1) Fiat (New Holland tractors India pvt. LTD.
Plant: - Noida (U.P.)
2) John Deer Tractors equipment LTD.
Plant: - Pune (Maharastra)
10) Indofarm industries LTD.
Plant: - Baddi (H.P.)
3) Force Motors
Plant: - Pune (Maharastra)
4) Same Deutz Fahr Pvt LTD.
Plant: - Ranipet (Tamil nadu)
5) Standard combines Pvt LTD
Plant: - Barnali
6) Mahindra Gujarat tractors LTD
Plant: - Baroda
7) Preet Tractors
Plant: - Nabha (Pb.)
15) Ace Motors
Plant: - Balabgarh Faridabad (Haryana)
DRAWBACKS OF COMPITITORS OF SONALIKA

21
MAHINDRA & MAHINDRA

This is a unbalanced tractor whose proof is that company given front weights in spite of
which it gives front lifting which is very dangerous for operators. In the condition of
sudden load tractor stops due to less TBU. Due to high engine RPM there is more wear
and tear and needs frequent over-hauling Hydraulic operations are not performed
correctly and problem of hydraulic hunting is normally observed which causes high
diesel consumption and more tyre wear. Engine oil is less, which causes lesser cooling,
and engine components get wear out early.
TAFE:Light weight tractor causes an increase in diesel consumption and more tyre wear.
Gear section being lighter is a reason for inefficiency to trail heavy implements or trolley.
Less ground clearance causes a hindrance in pudding and riding in rough terrain.
Lesser wheelbase cause front lifting even on attaching a small implement.
FARMTRAC:High diesel consumption.

Costly spares and high on maintenance cost.
Having a lesser weight &length the tractor gives front lifting on attaching heavy
implements.
Rear side is light in weight causes more wear of tyre and lesser area coverage.
SAWARAJ:High diesel consumption even on fewer loads.

Tractors give smoke even on fewer loads.
Having old technology manufacturing is continuously reducing sale.
Costly spare parts and maintenance.
Have gone through no changes in design and having a similar bonnet & fender gives a
look like a tin box.
JOHN DEERE:Lesser wheelbase causes front lifting which is not good for drivers security.
Costly and non-availability of spare parts.
At turning, there is a heavy drop in engine RPM, which cause load on engine and reduce
engine life.
22
NEW HOLLAND:Speed reduction is not direct so power loss is grater.

At turning there is a heavy drop in engine RPM which cause load on engine and reduce
engine life.
23
SPECIFICATION OF 1, 2, 3, 4-CYLINDER
SINGLE CYLINDER ENGINE
Bore * stroke (mm): 127 * 140

Swept volume: 1774
Engine aspiration: naturally aspirated
Cooling: Air-cooling
Type of combustion: DI
Compression ratio: (18:1)
24
2-CYLINDER ENGINE
Type : 2-cylinder engine (2102F)

Naturally aspirated
Water cooled
Features: Drive from compressor
Live hydraulics
Bore * stroke (mm): 102*110
Capacity: 1.8l
Power: 28ps@2100rpm
Compression ratio: (18.7:1)
Firing order: 1-2
Emission: TREM-3
Weight: 195kg
25
3-CYLINDER ENGINE
Type : 3-cylinder engine

Naturally aspirated
Water cooled
Feature: Drive from compressor
Live hydraulics
Power range: 30 to 48ps@2100rpm
Torque range: 130Nm to 148Nm@2100rpm
Firing order: 1-3-2
Emission: TREM-3
26
4-CYLINDER ENGINE
Type : Four cylinder engine (4100F)

Turbo charged
Feature: Drive for power steering application
Bore * stroke (mm): (100 *118)
Capacity: 3.7l
Power: 70ps@2200rpm
Torque: 276Nm@1200rpm
Firing order: 1-3-4-2
Emission weight: 420kg
27
DROP BOX
This is a device used in four wheel drives of the tractor.
This is a device that splits power between the front and rear axis on four wheel drive .
The drop box is as- wheel drive system contains a device that allows for a speed
difference between the front and rear wheels.
These devices allow an all wheel drive system to function properly on any surface.
The drop box on a part time four wheel drive system lock the front axle drive to the rear
axle drive shaft , so the wheels are forced to spin at the same speed.
This requires that the tyres slip when the vehicle goes around the turn .
Part time systems like this should only be used in low traction situations in which it is
relatively easy for the tyres to slip.
On dry concrete , it is not easy for the tyres to slip ,so the four- wheel drive should be
disengaged in order to avoid jerky turns and extra wear on the tyres and drive train.
TRANSFER CASE
A transfer case is unique to 4 wheel drive vehicles, and is what directs power to both
needs (axles ) of the vehicle through two separate drive shafts . Two wheel drives dont
need a transfer case as drive comes directly out of the transmission to the drive wheels.
The transfer case is attached to the rear of the transmission and gets its input directly
from the transmission . Power is directed from the engine through the transmission and
then through the transfer case to either rear wheels or both front and rear wheels .
This is accomplished inside the transfer case by either the chains or gears .
In any case , a 4- wheel drive vehicle will have a selection of two gears ranges.
This is called High range and Low range.
This is one of the characteristics that distinguish 4 wheel Drive from All wheel
Drive.
As the transfer case accepts input from the transmission , and the Hi-Low range is in Hi
position , the transfer case uses highest gear ratio. This ratio is usually near of exactly 1-1
ratio.( Same input and output speed of the transfer case i.e no speed reduction and no
torque multiplication).
If the driver chooses the 2WD Mode of the transfer case , power is transferred to only the
rear wheels , leaving the front drive shaft without any driving duties .
If the driver chooses the 4-Hi Mode of the transfer case ,the front drive shaftis engaged
inside the transfer and power is now transferred to both the rear and front wheels ,
allowing the front and rear wheels to pull the vehicles.
When the driver selects the 4 Low Mode , the second gear ratio is used and power is
directed to both the rear and front axle.
The lower gear ratio is used when a multiplication of torque is required for steeper hills
or when more engine power must be used to pull the vehicle.
28
ENGINE QUALITY
Quality standards:In engine quality, the quality procedure followed for engine components is TS-16949. It
is a quality norm for automobile components. In which supplier and vendor has to give
certain information to the company:1) Vendor has to give raw material data, which he uses for manufacturing of that
component.
2) Vendor has to give information about process he followed for manufacturing of
that component. If there is any change in the process than vendor has to inform
the company for the changes.
3) Vendor has to give its quality inspection report to the company. On the other
hand, procedure for checking the quality of component.
4) Company also do periodic audit after 3 and 6 months to check the procedure of
production.
5) Vendor also send pre- delivery inspection list during supply.
MODE OF FAILURES:1)
2)
3)
4)
FIELD FAILURE.
MANUFACTURING FAILURE
ASSEMBLY FAILURE
DESIGN FAILURE
29
Engine Parts
PART LIST OF ENGINE
Cylinder block
Cylinder head
Crank shaft
Cam shaft
Crank case
Piston
Piston rings
Connecting rod
Cylinder head gaskets
Flywheel
Oil sump
Cylinder liners
Piston pins
Push rod
Exhaust manifold
Front cover
Rear cover
Dowell pin
Inlet manifold
High pressure pipe
Tappet cap
Rocker arm
Fuel filter
Oil pump
Bearing
30
Injector
Water pump
Alternator
Return valve
Thermostat valve
Strainer
Oil dipsticks
1. CLYINDER BLOCK
The cylinder block and crankcase from a single casting, which gives a rigid structure.
Ribs are cast in the crankcase to give it extra strength and to support the main and, in
some case the crankshaft bearing. A cylinder block consists of three parts:
a) The cylinder bore in which the piston slide up and down.
b) The ports or openings for the valves.
c) The passages for the flow of cooling water.
d) Passage for lubrication
The round cylinder surfaces are given precision mirror finish by accurate grinding and
honing processes.
2. CYLINDER HEAD
The top of the cylinder is covered by a separate cast piece known as cylinder head.
Cylinder head is bolted to the top of the cylinder block. It contains combustion chamber.
The bore of the cylinder or liner should not be distorted by the pull of the holding down
studs. The circulation of coolant in the cylinder head should be carried as nearly as
possible to the top end. To ensure a sound gas tight joint, the holding down studs must be
distributed as uniformly as possible around the circumference of each cylinder.
3. CRANK SHAFT
Crankshaft is the first part in the power transmission system on to which the reciprocating
motion of the piston is converted into the rotating motion with the help of connecting rod.
A crankshaft consists of crankpins, webs (crankarms or cheeks) balancing weight and
main journals. Big end of the connecting rod is connected to the crankpin of the
crankshaft. Centre to centre distance between the crankpin and crankshaft is half of the
piston displacement, during a stroke. Thus, one complete revolution of the crankshaft
makes two strokes of the piston. The part of the crankshaft inside the main bearings is
called the main journals.
4. CAM SHAFT
A camshaft is simply a shaft on which cams are mounted. The camshaft is mounted in
bearings in the lower part of the cylinder block in most in-line engines. In a few engines
it is located on the cylinder head. In V-8 engines it is located between the two banks of
cylinders. A cam is a device that changes rotary motion of the camshaft into linear motion
of the follower or lifter. The cam has high spot or lobe. The follower riding on the cams
will move away from or toward the camshaft as the cam rotates.
31
A camshaft is responsible for opening the valves. A camshaft has a number of cams along
the length, two cams for each cylinder, one to operate the inlet valve and the other the
exhaust valve. In addition, the camshaft has an eccentric to operate the fuel pump a gear
to drive the ignition distributor and oil pump. This gives 1:2 gear ratio, the camshaft turns
at half the speed of the camshaft.
5. CRANKCASE
Crankcase is attached to the bottom face of the cylinder block. It acts as the base of the
engine. It supports the crankshaft and camshaft in suitable bearings and provides the arms
for supporting the engine on the frame. The oil pan and the lower part of the cylinder
block together are called crankcase.
6. PISTON
Piston is considered to be one of the most important parts in a reciprocating engine in
which it helps to convert the chemical energy obtained by the combustion of fuel into
useful mechanical power. The purpose of the piston is to provide a means of conveying
the expansion of the gases to the crankshaft, Via the connecting rod, Without loss of gas
from above or oil from below. Piston is essentially a cylindrical plug that moves up and
down in the cylinder. It is equipped with piston ring to provide a good seal between the
cylinder wall and piston. Although the piston appear to be a simple part, it is actually
quite complex from the design stand point.
7. PISTON RINGS
Piston rings are fitted into the grooves of the piston to maintain good seal between the
piston and the cylinder wall. There are three functions of piston rings as follows:
1. To provide a pressure seal to prevent blow-by of burnt gases. Blow-by is the name
that describes the escape of burnt gases from the combustion chamber, past the
piston, and into the crankcase.
2. To from the main path for conduction of heat from the piston crown to the cylinder
walls.
3. To control the flow of oil to the skirt and rings themselves in adequate quantity
while preventing an excessive amount reaching the combustion chamber with
consequent waste and carbonization.
8. CONNECTING ROD
The connecting rod is the connecting between the piston and the crankshaft. It joins the
piston pin with the crankpin. Small end of the connecting rod is connected to the piston
pin and big end to the crank pin. The function of the connecting rod is to convert linear
motion of the piston into rotary motion of the crankshaft.
The connecting rod usually has I-beam cross-section, and is made of forged steel.
Aluminum alloy is also used for connecting rods. They are carefully matched in sets of
uniform weight in order to maintain engine balance. The lighter the connecting rod and
the piston, the greater the resulting power and the less the vibration because the
32
reciprocating weight is less. The connecting rod carries the power thrust from piston to
the crank pin and hence it must be very strong, rigid and as light as possible. The cap is
secured to the body of the connecting rod by two bolts and nuts.
9. CYLINDER HEAD GASKETS

A gasket is placed between the cylinder head and cylinder block to retain compression in
the cylinder, to prevent leakage and to ensure metallic tight fit joint. The gasket should be
able to withstand not only high pressure but also extreme temperature.
Following important gaskets are in automobile engines:
1. Copper-asbestos gasket.
2. Steel-asbestos gasket.
3. Steel-asbestos-copper gasket.
4. Single steel ridged or corrugated gasket.
5. Stainless steel gasket.
10. FLYWHEEL
A flywheel is a fairly heavy steel wheel attached to the rear end of the crankshaft. The
size of the flywheel depends upon the number of cylinders and the general construction
of the engine. The function of the flywheel in a better way, take the example of a fourstroke, single-cylinder engine. There are times when more power is being delivered than
at other times. This tends to make the crankshaft speed up and then slow down. The
engine delivers power during one stroke only-the power stroke, and it absorbs power
during the other three strokes-to push out the exhaust gases, to intake fresh charge in the
cylinder and to compress this charge. Thus, during power stroke the engine tends to speed
up and during the other three strokes it tends to slow down.
11. OIL SUMP

The bottom half of the crankcase is called the oil pain or sump. It is bolted or screwed to
the lower flange of the main casting and usually is made of pressed steel or aluminium.
The oil pan serves as a reservoir for the storage, cooling and ventilation of engine
lubricating oil.
12. CYLINDER LINER

The problem of cylinder wear is considerable and this has been solved by the use of
cylinder liners. The cylinder liners are in the form of barrels made up of special alloy iron
containing silicon, manganese, nickel and chromium. They are cast centrifugally. The
cylinder liners are of the two types-dry liners and wet liners.
13. PISTON PIN

Piston pin or wrist pin or gudgeon pin connects the piston and the small end of the
connecting rod. Piston pin generally hollow and made from case hardened steel heat
treated to produce a hard, wear resisting surface.
33
14. PUSH ROD

Push rod is attached the tapped guider and rockerarm. Rockerarm up and down by the
push rod.
15. EXHAUST MANIFOLD

The pipe, which connects the exhaust system to the exhaust valve of the engine and
through which the products if combustion escapes into the atmosphere is called the
exhaust manifold.
16. FRONT COVER

Front cover is covered the timing gear.
17. REAR COVER
Rear cover is covered the rear engine part. Rear engine outside attached the flywheel.
18. DOWELL PIN

Dowell pin in the cylinder head and it is used design for cylinder head.
19. INLET MANIFOLD

The pipe which connects the inlet system to the inlet valve of the engine through which
air is drawn into the cylinder is called inlet manifold.
20. HIGH PRESSURE PIPES

These are made of steel heaving inner diameter of 2mm and outer diameter of 7mm
.Their outer surface is oxidized in order to prevent from rust or corrosion. The length and
internal diameter of high pressure pipe kept equal timing and pressure.
21. TAPPET CAP

Tappet cap is covered the cylinder head.
22. ROCKER ARM

It is used the inlet and exhaust valve open and closed. Rocker arm placed the cylinder
head.
34
23. FUEL FILTER

Fuel filter is connected the water separator and fuel feed pump. Its clean the fuel.
fuel filter is two types:
a) Primary
b) Secondary
The
24. OIL PUMP

Its function is to pump the lubricating oil from sump to all parts of cylinder blocks at
constants pressure
25. HOUSE PIPE

House pipe is connected the water manifold and thermostate valve.
26. STARTER MOTER

Starter motor is also known as cranking motor or self starter. It is an electrical machine,
which converts electrical energy into mechanical energy. As we know for starting engine
more torque is required for a short time. So these motors are high torque motors available
for starting the engine. Starter motor is connected the battery.
27. OIL FILTER

Oil filter is connected the oil sump and oil pump. It is clean the oil.
28. BEARINGS
Bearing is connected the crankshaft and connecting rod.
29. INJECTOR
Injector injected the fuel by the nozzle. It is placed the cylinder head and nozzle in the
injector.
30. WATER PUMP

It is used in the system of centrifugal type, the water enter into the center of the pump
when impeller shaft rotates the water between veins are thrown out by the action of
centrifugal force and water is forced into the water jacket.
31. ALTERNATOR
Alternator is an AC machine. It produces an alternating current. It has a rotor fitted on a
shaft, which runs on the ball bearing fixed in the housing. Drive to the rotor is given
through pulley fitted on the rotor shaft with the help of V-belt.
35
32. RETURN PIPE

They are employed so that excess diesel from the injector and FIP can go to diesel tank.
33. THERMOSTATE VALVE

It is a valve, which automatically controls the temperature of the cooling water to
accelerate the warming of engine after starting because diesel engine performance the
best when the engine temperature is in between 80-90 degree C.
34. STRAINER
Its function is to screen the foreign particles from entering into the engine oil.
35. OIL DIPSTICK

Its function is to measure the level of engine oil in the sump.
36. FUEL INJECTOR: Fuel injector is the heart of engine.Fuel injector injects diesel in appropriate amount
to the engine. It delivers fuel through high-pressure pipe and injectors. The components
that drive Fuel Injection Pump are:1)
2)
3)
4)
5)
6)
Plunger.
Barrel.
Sleeve
Quadrille
Rack
Governor
1) Plunger: - A plunger is a part in which helix grooves are formed. When this
groove comes across holes at barell than oil spill from that groove. A plunger
reciprocates as well as rotates.
2) Barrel: - Barrel is an integral part at the plunger. In which plunger reciprocates.
3) Sleeve: - In sleeve, plunger fits and rotates at its own axis.
4) Quadral: - In a quadral pinion teethes are cut which is exposed to rack and also
guide and drive plunger.
5) Rack: - Rack is a horizontal bar in which teethes are formed which exposed to
pinion on qadral.It further attached with FIP cam gear.
6) Governor: - Governor is used for regulating the fuel according to load conditions.
It regulates the fuel by moment of inertia of the balls. It works on the equation of
F=RN.
36
Procedure for valves placement in cylinder head:1) Water jacket cylinder head tests of air at 4 kg/cm.
2) Valve guides placed in the cylinder head.
3) Valves (inlet and outlet) inserted in the cylinder head. Lapping operation (finishing on
Valves) performed on valves.
4) Insert 2 springs big and of small sizes in to valve.
5) Insert rubber seal, which is called valve seal.
6) Insert locking nut to lock the assembly.
Types of engine manufactured:S-TYPE AND P-TYPE, S type engines complete TREM II norms and further lead to
TRIM III. P Type engines are TREM III norms.
37
ENGINE TESTING
PROCEDURE OF ENGINE TESING

Check the engine from engine assembly visually for any missing part, which should be
replaced from engine assembly, then mount the engine on test bed. Connect cardian shaft
of dynamometer with engine flywheel with the help of Allen bolts and connect the fuel
pipe to feed pump. Double stage fuel filter is filled with fuel and Priming done .Air
cleaner is connected with inlet manifold of engine .Water mixing tank to be connected
with engine water pump and engine return line manifold of engine water gauge to be
connected with engine gallery. Throttle lever of F.I.P. is connected with throttle control
lever, before starting the engine water circulation of dynamometer to be checked.
Remove any fault if found.
Engine to be tested at idle speed (700 rpm) and following points to be checked:1)
2)
3)
4)
5)
6)
Engine water circulation is checked.

Engine lubrication oil pressure is checked.
Oil oozing out of rocker arm bush.
Movement of rocker arm and rotation of push rod.
Rotation of transmission elbow.
Checking leakage of lubrication oil, water and fuel.
Engine is run at different speed (rpm) for 1:30 hrs.

1)
2)
3)
4)
5)
Firstly, five minutes engine is run at 700 rpm without load.

For 10 minutes at 1000 rpm and 25% load.
For 15 minutes, it is run at 1500 rpm and 50%load.
For 10 minutes to be run at 1800 rpm and load 75%.
After this cycle engine is stopped.
38
Then cylinder head nuts is re- torque with the help of torque wrench (18 kgm to 21 kg
meter). Tappet clearance is done with the help of filler gauge For Cam shaft diameter
38 clearance is set (Inlet and exhaust valve -0.25 mm).For Cam shaft diameter 42
clearance is set for inlet manifold 0.3 and for exhaust -0.4.
Engine is started again for 40 minutes at different load and speed:1) For five minutes engine is run at 1000 rpm and load 50%.
2) For ten minutes engine is run at 2000 rpm and load 80%.
3) For ten minutes engine is run at 2000-2200 rpm and load 100%.
During running of engine at different rpm the following reading, we take:1)
2)
3)
4)
5)
6)
Rpm is noted from RPM meter

Torque is noted from Torque meter.
Fuel consumption is noted from fuel consumption unit.
Engine water, outlet temperature is noted from temperature digital gauge.
Engine run at idle speed for 15 minutes to check lubrication oil pressure.
From above reading, we calculate BHP, SFC and TBU.
1) BHP:- RPM * Torque/7023.746

2) SFC:-To produce 1 HP in one hour the amount of fuel consumed is called specific
fuel consumption.
SFC = 297000/bhp* fuel time in sec. gm/hp/sec.
3) Back up Torque = Max. Torque Rated Torque / Rated Torque*100.
If observed parameters of engine satisfies the standard values than that engine is
excepted if it does not satisfy the standards. Those engines send to engine rework
During testing if any component is found faulty, the same is changed and rejected
component is sent to engine assembly for N.C report. Select any engine of regular
production, run it for 50 HRS endurance, Test at 100% load, and rated RPM.
Test man generate the performance data in engine testing report i.e. code qf/75/64.
Fit bell housing and hydraulic pump and send the engine-to-engine store.
Certain points should be remembered during engine testing:1) Engine RPM should not drop less than 50 and more than 200.
2) Water temperature should not exceed 78c.
3) Lubrication oil pressure at normal working condition should in between 0.5 to 4.5
kg/cm and may exceed 6 kg/cm.
4) Dynamometer water inlet pressure in between 0.5 to 1 kg/cm.
39
ENGINE FAULTS
40
ENGINE FAULTS
PROBLEM OF ENGINE ARISES IN FIELD
1)
2)
3)
4)
5)
6)
7)
More lubrication oil consumption

Excess fuel consumption
Low pulling power
Engine overheating
Smoke problem
Blow by
Low oil pressure
1) More Lubrication oil consumption:- checking procedure for lubrication oil

pressure.
1) Run the tractor for half an hour on full load.
2) Place the tractor at plane surface and mark tyre position
3) Open the drain plug and note down the time.
4) Allow engine oil to draw from chamber
5) Measure oil in a measuring jar.
6) Re-fill the engine oil in the engine.
7) Run tractor for four hour
8) Place the tractor at plane surface
9) Open drain plug
10) Drain engine oil from chamber completely
11) Measure the oil level in jar and note down the difference.
Types of leakage in engine regarding to lubrication oil.
Internal: - We cannot measure it at first time.
External:- we can check it easily because we can see it through our naked eyes.
Leakages points in the engine:1) Gasket
2) Seal
3) Through valves
41
Procedure to check internal leakages:1) Remove the exhaust manifold and check is there any wet particles with smoke.
2) Remove the cylinder heads and check valve seal is it broken or not.
3) Remove cylinder head and check engine block:4) Piston: - check the scratches on piston skirt.
5) Piston rings: - check piston rings is they wear out.
6) Check Main bearing and connecting rod bearing is they wear out or not.
7) Check the cylinder liner.
Causes for liner defects and lubrication oil heat up:1) SCUFFING: - due to heat increase in the engine, the lubrication film will finish
and piston ring and liner will come in contact and scratch will form from top to
bottom dead center.
2) SCORRING: - Due heat in the engine
oil film get heat up and deep
circumferential scratch will form in the liner.
3) Mirror finish: - In Mirror finish dusty air come into the cylinder through air filter
and stick on the honing area of the liner and this dust work as a ambry paper due
to this plain surface will form at honing area and lubrication oil heat up.
4) Ridge formation:- When the cavity is formed horizontally on the liner due to
piston rings can not work properly thus consumption of oil increases.
2) EXCESS FUEL CONSUMPTION AND LOW- PULLING POWER:Data we should have when we simplify the excess fuel consumption:1)
2)
3)
4)
5)
6)
7)
How much fuel consumed at load condition and without load condition.
Area coverage by the tractor on field.
Rpm setting while driving tractor on field.
Depth set (implement) during working in field.
Implements coupled from tractor during work on fields.
Tyre air pressure.
Type of soil on which tractor work.
Procedure for checking of fuel consumption and low pulling power:1)

2)
3)
4)
5)
6)
7)
8)
Condition of fuel filter.

Condition of fuel tank.
Condition of coke at fuel tank.
Condition of feed pump.
Condition of fuel injectors.
Condition of high-pressure pipe.
Condition of air filter.
Calibration of F.I.P.
42
1) Condition of fuel filter:- If condition of fuel filter is not ok than fuel will go in
2)
3)
4)
5)
6)
7)
less or at excess rate .

Condition of fuel tank:- If dent is formed on fuel tank and fuel tank position is
disturb than fuel circulation will disturb.
Condition of coke:- If coke at the fuel tank is not correct than it also effect the
supply of fuel.
Feed Pump:- If Fuel feed pump plunger is defective than it may cause for excess
fuel consumption..
Injector:- If injector nozzles dripping than excess fuel consumption may occur.
High pressure pipe condition:- If high pressure pipes do not work accordingly
fuel consumption will rise.
F.I.P.:- If calibration setting of F.I.P. will disturb than it will increase fuel
consumption.
For Low-pulling power if these above mentioned are ok than we have to check gear
ratio and speed.
3) ENGINE OVER HEATING:Procedure to find causes of engine overheating:1) Water leakage from hoses.
2) Water leakage from radiator.
3) Water leakage from pressure cap.
4) Temperature gauge condition.
5) Temperature sensor on water manifold.
6) Blow by will more and mist will be visible.
7) Condition of injectors if dribbling and dripping is more while spraying fuel.
8) Condition of air cleaner.
9) Condition of cylinder liner.
10) Condition of main and big end bearings.
11) Condition of Top intermediate gear assembly.
12) Working of camshaft is it jam or not.
13) Condition of Thermostat valve
14) Condition of fuel delivery.
5) BLOW BY
Procedure to find causes of blow by:1)
2)
3)
4)
5)
Check ventilation or breather pipe. Is there mist formed.

Condition of injectors.
Compression pressure test of engine.
Condition of big end and main bearing.
Condition of timing gears.
43
6) Condition of Injectors.
6) LOW OIL PRESSURE

1) Oil pressure at idle cold.
2) Oil pressure at idle hot.
3) Oil pressure at rated speed.
4) Oil pressure gauge to check.
5) Engine Oil quantity.
6) Condition of reduction valve.
7) Condition of oil pump.
8) Condition of cam shaft.
9) Main or big end bearing condition.
10) Condition of oil filter.
11) Crank and cam bore machining.
ENGINE FAULTS
SR.
NO.
FAULT
POSSIBLE CAUSE
Low cranking speed
Battery capacity low.

Bad electrical connection
Faulty strater motor
Incorrect grade of lub. Oil.
Will not start
Low cranking speed

Fuel tank empty
Blocked fuel lift pump
Faulty fuel lift pump
Choked fuel filter
Air in fuel system
Faulty fuel injection pump
faulty atomizer
Broken fuel injection pump drive
Incorrect fuel pump timing
Poor compression
Incorrect type or grade of fuel
Worn cylinder bores
Pitted valves and seats
Broken ,worn or sticking piston rings.
Difficult starting
Low cranking speed

Choked fuel filter
44
Air in fuel system

faulty atomizer
Incorrect valve timing
Poor compression
Worn cylinder bores
Lack of power

Choked fuel filter
Restriction in ait cleaner
Air in fuel system
faulty atomizer
Poor compression
Exhaust pipe restriction
Sticking valves
Worn cylinder bores
Misfiring

Choked fuel filter
Air in fuel system
faulty atomizer
Poor compression
Sticking valves
Cylinder head gasket leaking
Over Heating
Incorrect Tappet adjustment
Sticking valves
Worn cylinder bores
Excessive fuel
consumption
6
Restriction in air cleaner

faulty atomizer
45

Poor compression
Sticking valves
Cold running
Sticking valves
Worn cylinder bores
Black exhaust

faulty atomizer
Poor compression
Sticking valves
Cold running
Sticking valves
Worn cylinder bores
Blue/White exhaust

Poor compression
Cold running
Sticking valves
Worn cylinder bores
Low oil pressure

Worn or damaged bearings
Insufficient oil in sump
Inaccurate gauge
Oil pump worn
Pressre relief valve sticking open
Broken relief valve spring
Faulty suction pipe
Chocked oil filter
Blocked sump strainer
46
10
Knocking

faulty atomizer
Over Heating
Sticking valves
Worn cylinder bores
overfilled air cleaner or use of incorrect grade of
oil
Worn or damaged bearings
Piston seizure/pick up
Incorrect piston height
Broken rings
11
Erractic running

Choked fuel filter
Restriction in ait cleaner
Air in fuel system
faulty atomizer
Poor compression
Sticking throttle or restricted movement
Over heating
Incorrect tappet adjustment
Sticking valves
Incorrect high pressure pipes
Broken,worn or sticking piston rings
overfilled air cleaner or use of incorrect grade of
oil
12
Vibrarion

Faulty automiser
Poor compression
Sticking throttle or restricted movement
Over Heating
Cold running
Sticking valves
Incorrect high pressure pipes
Broken,worn or sticking piston rings
Faulty engine mounting
13
High oil pressure

Inaccurate gauge
47
Pressre relief valve sticking closed

14
Over heating
Restriction in air claeaner

Faulty automiser
Damaged fan
Faulty thermostat
Restriction in water jacket
Loose water pump drive belts
Chocked radiator
Faulty water pump
Coolant level too low.
15
Excessive blow by

Worn cylinder bores
Broken , worn or sticking piston rings
Worn Valves stems and guides
Chocked breather pi[pe
16
Poor compression
Restriction in air claeaner

Sticking valves
Worn Valves stems and guides
Incorrect piston height
Broken rings
17
Starts and stops
Chocked fuel filter

Air in fuel system
48
DIFFRENTIAL ASSEMBLY
49
PROCESS CHART OF DIFFRENTIAL

ASSEMBLY
PTO shaft sub
assembly
Clean the
casting and
punch serial
number
Fit the seal carrier
on BP shaft with
shim (0.2 - 0.5
mm) & tight it
temporarily
Load the
casting on
the trolley
Insert the studs

in front and top
of differential
Insert the left BP

shaft in the casting
and cage and insert
the right BP shaft
with little
hammering
Fit PTO shaft in

the casting
Fit the thrust

bearing cone
on the left side
of the casting
Wash the cage

and BP shaft
sub assembly
in washing
machine
If backlash is not ok then it is

corrected by adjusting the shims
Preloading (12 kg)
is done to check
the number of
shim and bearing
seating
Fit the plain

cover with oil
filter and PTO
shifter sub
assembly
Fit the sliding

and fixed PTO
gear
Fit the TP
carrier with
shim (0.2 - 0.5
mm) &tight it
temporarily
Fit the brake

housing on the
spline of B.P.
shaft
Apply yellow
paint to
check the
backlash and
teeth pattern
Fit the link

plate and PTO
shaft cover
Brake housing
sub assembly
50
Tight the seal

carrier and
T.P. carrier
tightly
Fit the trumpet

assembly and
bull gear in
differential
housing
DIFFERENTIAL HOUSING ASSEMBLY PHASE

It is rear part of the tractor cheesy. The main function of differential in tractor to reduce
the final speed and to turn the drive round at 90 degree. The reduction of speed is done in
two stages. First stage reduction in tail pinion and crown wheel meshing and second stage
reduction in bull gear meshing with left and rights B.P.shaft. Its also consisting the P.T.O.
shaft (Power take off shaft), which is used to run the thrashers, pumps Rotavator, and
other accessory components with the help of pulley attached on it.
Following are main parts of differential housing: (A) Crown wheel.
(B) Tail pinion.
(C) Cage assembly. (With sun, planet gears and cross)

(D) P.T.O. shaft.
(E) B.P. shaft left.
(F) B.P. shaft right.
(G) Bull gears.
(H) Bevel gears.
(I) Bearings.
(J) Bearing cones.
(K) Brakes housing assembly (with disc and etc).
(L) Oil seals, gaskets and fasteners etc.
ASSEMBLY OF CASE CROWN WHEEL: First components are washed with oil to remove the dirty particles. Cage having two
dowel holes in these holes dowels is tightening fitted for accurate fitting of crown so that
all other holes of cage and crown come into same line. The crown wheel is pressed on
cage with hydraulic press and then tightens by bolts with lock washer. Then right bevel
gear is placed on their cage seat. The four planet gears are put on cross with washer and
then this assembly put on their placed on cage. Then placed left bevel gear on planet on
gear. Operator to check the motion of gears does manual inspection. Cage left is placed
on left side of right cage assembly and then tightens by bolts and washer.
TAIL PINION ASSEMBLY: First in T.P. assembly, the cone for taper roller bearing is pressed with hydraulic press.
The bearing is heated before the tight fit. Then tail pinion is inserted inside bearing. The
diff. size shims are also placed before the tighten of rear cover of cage. Whole assembly
is tightening by nuts and bolts.
51
REAR AXLE ASSEMBLY: In rear axle assembly of tractor the bolts are tight fitted in holes of hub. Where the rear
tire is tighten with their bolts to whole assembly. For tight fitting the hydraulic press is
used and 120-kg\cm sq. forces is apply. Two bearing either side of trumpet housing are
tighten at their respective place of cone. The rear axle is passed through these two bearing
with seal in trumpet. The cove is used to cover the open side of trumpet housing (hub
side). The inner side bearing is lubricated with oil and outer bearing is lubricated with
grease.
BRAKING ASSEMBLY: This tractor having heavy duty Self-energizing, water sealed disc with spherical roller and
ventilation pipe which gives better cooling. The ventilated results in reduction of about
30% in pad temperature. Brake housing cover contain two disc made of asbestos base
non-metallic. The max. Temp. Resistance about 300 degree C b\w these two disc plate a
cast iron plate is fixed which contain steel spherical roller and hold by spring. When ever
brake is applied the spherical roller move or lift from there place in the plate and try to
expanded the plate. During expanding of C.I. plate the disc are strongly mounted on
B.P.left and B.P. right shaft to stop the speed of differential. It also having actuators and
link with rubber seal.
P.T.O. SHAFT ASSEMBLY: Two bearings are tightly fit on P.T.O.shaft at their proper placed with help of circlip lock,
which provided on both side of bearing first of all the P.T.O. shaft assembly is pass
through rear P.T.O. hole of differential housing. Then two cones are one on B.P. left and
other on B.P. right shafts hole side inserted tightly. The B.P. left and right shaft assembly
is placed through their hole then cage housing of differential is placed b\w left anted right
B.P. shaft. The seal carrier with different size of shims is tightening by bolts on both side
of differential housing (right and left B.P. shaft side). Then pre loading test is done with
10 kg force to rotate the cage assembly. If pre load force is increase the efficiency of
taper bearing is decrease due to over friction b\w cage of bearing if decrease pre load
force then the efficiency of taper bearing also decrease due to less contact with cover
cage of bearing. Then tail pinion assembly is inserted in to respective hole with shims and
tail pinion teethes meshed with crown wheel teethes.
Following three testing is done: (A) Back lash testing.
(B) %Age of contact.
(C) Pattern test

52
BACK LASH TESTING: This test is performed with help of plunger dial gauge. Backlash in crown wheel is not
more then 20 to 30 micron if it is deviated from this value then packing is change on
either side (left or side) of cage of bearing housing. But never change the number of
shim. If backlash is more then 30 micron then shims from right side is removed and
shifted in to left side. If it is less then 20 micron then vice versa.
%AGE OF CONTACT TEST AND PATTERN TEST: Pattern test and %age contact test is done with help of yellow paint apply on teethes of
crown wheel. Then rotating crown wheel with hand %age contact and pattern of tail
pinion is impressed on the teeth of wheel. The %age of contact is 60% to 70% required. It
can be increase or decrease by using the shims by fastening it on tail pinion carrier. When
increase in number of shims the pattern goes increase and vice versa.
T.P. pre load
8 kgf
C.W. pre load
12 kgf
C.W. run out
.05-.1 mm
B.L.
.2-.3 mm
53
PARTS OF DIFFRENTIAL
DIFFERENTIAL
DIFFERENTIAL PARTS:
1) Tail pinion: It transmits the power from the output shaft of gearbox to the crown
wheel.
2) Crown wheel: It gives housing to the cage assembly where differential action takes
place.
3) Differential cage: It gives housing to the spider kit i.e. cross, star, sun pinion.
4) Cross: Its remains fixed in cage assembly and support the motion of the star pinion.
5) Star pinion: Distributes the power between sun pinion according to load applied by
them. Consist four-star gear.
6) Sun pinion: Transmits power from star pinion to bull pinion shaft. Consist four-star
gears.
7) Bull pinion shaft: Gives power to the bull gear and bear the action of break.
54
8) Bull gear: Transmits power from bull pinion shaft to rear axle.
9) Rear axle: Transmits power from bull pinion shaft to rear wheel.
10) Differential lock: Differential lock is made on bull pinion shaft a hollow shaft
and we provide an extra coupler assembly in differential. When differential is free from
lock the coupler are in disengaged position and when we apply the differential lock
couplers are in engaged position.
11) Break: - In differential, we use two kinds of brakes according to HP (Horsepower)

of tractors and specifications by customer.
1) Dry brakes.
2) OIL Immersed brakes.
1) Dry brakes:- In a dry brakes two discs and two break liners are assembled along
with steel balls in brake housing. It is attached with rocker shaft assembly when
brake is pressed than rocker shaft stops bull gear and rear wheels get stop. In
tractors mechanical brakes are employed. In dry brakes, wear and tear of disc is
more because heat dissipation is more due to friction and cooling is less.
2) OIL Immersed brakes:- OIL Immersed brake consists of a housing bolted to the
vehicle frame containing four discs with an actuating assembly between the two
discs. The discs have lining material on each face and a splinted shaft running
through the housing drives them. The actuating assembly is composed of two
plates separated by hardened steel ball located in recess in the plates, and the
assembly is held by short springs. The lugs on the actuating plates are connected
to the yoke or jaw end on the pull rod by two links. In oil immersed brakes wear
and tear is less as compared to dry brakes.
55
DIFFERENTIAL DISASSEMBLY
Remove the hand lever.
Remove the break.
Remove the B.P. shaft.
Remove the P.T.O. shaft.
Remove the spacer, axle, stud and gasket.
Remove the bull gear.
Remove the pinion shaft and pinion.
Remove the B.P. carrial left side.
Remove the crown case.
Remove the B.P. carrial right side.
56
GEAR BOX
57
GEAR BOX
GEAR BOX ASSEMBLY

Clean and load the
rear cover on the
working Trolley
Bolt
coupler
Lockthe
the
coupler
with
Place
the
Ram
arm
Gauge
the
position
connection
bush with
on
Ram
cover
of
draft
lock
nutassembly
rear cover
with
gauge of 53.5
housing
mm
Fit the sensor bush

to the sensor hole
Bolt
Place
the
the
coupler
rock
shaft
Turn
Couple
the
the
rear
fork
cover
on
connection
in
Ram
arm
bush
with
upward
coupler
and
assembly
attach
to
RV Housing
assembly
by
light
the
control
RV
Housing
valve
&bolt
rear
cover
assembly
hammering
assembly
the RV housing
Fit the stud on the

rear end
58
Place
the
gasket
on
Bolt
Fix the
the
sensor
Ram
spacers
Couple
the
reartube
the
position
draft
Position
&the
Draft
one
cylinder
on
the
bywith
stud
one
assembly
with
and bolt
cover
section
on
assy.
Sensor
tube
sub
sub
mandrel
with
itcoupler
rear
cover
chassis
section
assembly
assembly
Fix the breather bolt

& cap it with breather
cap
Check
Place
Fit
the
the
for
lift
arm
connecting
proper
to the
Turn
Lift
the
the
rear
rear
cover
cover
working
shaft
rockshaft
Ram
and
&on
arm
bolt
and
place
theit
downward
maximum
inside
lift
Ramplate
with a the
retainer
testing
machine
Lift
arm
assembly
capacity
cylinder assembly
of the lift
Assembly of gears on shafts and other parts assembly on gear housing:LAYSHAFT ASSEMBLY
1) Insert the ball bearing (6210) onto the lay shaft
2) Insert the spacer 21mm onto the lay shaft
3) Insert the gear reverse Z-29 onto the lay shaft.
4) Insert the spacer 9 mm onto the lay shaft.
5) Insert gears for 1st gear pair (Z-28,Z-29,Z30) and 2nd ( Z-34,Z-35) gear pair
6) Insert the spacer 18mm onto the lay shaft.
7) Insert gear for 3rd gear pair( Z-43)
8) Insert the spacer 16 mm onto the lay shaft
9) Insert input gear on the lay shaft
10) Insert external circlip.
11) Insert ball bearing (6211)
12) Insert washer at end.
HI-LOW LAY SHAFT ASSEMBLY:1)

2)
3)
4)
5)
Insert ball bearing of 6211 on hi-low lay shaft.

Insert circlip on hi-low lay shaft.
Insert gear Z-45 on hi-low lay shaft.
Insert ball bearing on hi-low lay shaft.
Z-19 gear in formed on hi-low lay shaft.
INTERMEDIATE SHAFT ASSEMBLY

1)
2)
3)
4)
5)
6)
Insert taper roller bearing (30210) on intermediate shaft.

Insert the spacer on intermediate shaft.
Insert dog gear assembly/reverse gear Z-32 on intermediate shaft.
Insert the hub on to intermediate shaft.
Insert dog sleeve on intermediate shaft.
Insert dog gear assembly/1st gear Z-41.
59
7) Insert external circlip.

8) Insert locking washer
9) Insert dog gear assembly/2nd gear Z-36,Z-37.
10) Insert dog sleeve on intermediate shaft.
11) Insert hub on intermediate shaft.
12) Insert external circlip on intermediate shaft.
13) Insert gear Z-28 3rd gear on intermediate gear.
14) Insert locking washer.
15) Insert External circlip on intermediate shaft.
16) Insert dog sleeve on intermediate shaft.
HI-LOW INTERMEDIATE SHAFT ASSEMBLY:1)

2)
3)
4)
5)
Insert taper roller bearing on the hi- low intermediate shaft.

Insert Z-44 0n hi low intermediate shaft.
Insert the hub on hi-low intermediate shaft.
Insert the sleeve on hi-low intermediate shaft.
Insert taper roller bearing.
TYPES OF BEARINGS USED IN GEAR BOX:1) BALL BEARING: - It is used to provide high speed.
2) Taper roller bearing: - It is provided for high load.
3) Needle bearing: - It gives straightness to the shaft.
CLUTCH ACUTATOR (C.A.) ASSEMBLY: C.A. assembly contains clutch actuator guide on which the bearing is tighten , fitted and
locked with circlip. Inner bush is placed and hold it with C.A. guider springs.
DUAL CLUTCH ASSEMBLY:In some agriculture equipment like potato cultivator etc-required continuous power from
P.T.O. shaft but in single clutch, it is not possible because when we press clutch it slow
down the speed of tractor. The lay shaft is disconnected which further stops the working
of P.T.O.shaft, which is connected to the lay shaft but in double clutch intermediate shaft
is placed over the input shaft, which is connected to the connecting shaft through gear Z43. The power in this case is transferred through connecting shaft. Now two clutches are
there which have different setting on clutch lever. The first press of the clutch will stop
the power transmission to lay shaft through input shaft, which further stops the power
transmission to the differential, but seconded clutch is connected to the intermediate
shaft, which transmits the power from connecting shaft to P.T.O. shaft
60
Types of gears used and assembled in plant:-
SLIDING MESH GEAR

In this transmission, the power comes from the engine to the clutch shaft and hence to the
clutch gear which is always in mesh with a gear on the lay shaft. All the gear on the lay
shaft are fixed to it and as such they are all the time rotating when engine is running and
clutch is engaged. Three direct speeds and one reverse speed are attained on suitably
moving the gear on the main shaft by means of selector mechanism. In tractor, we are
providing extra planet carrier for HI-LOW. In a High low gear, we provide one internal
gear with sleeve that accomplish the engagement and disengagement of high and low
gears. In a sliding, mesh gears
Spur gear are used so gears can easily slide as well mesh to each other so power can
distribute according to the gear ratio.
61
CONSTANT MESH GEAR BOX
In this type of gearbox, all the gears of the main shaft are in constant mesh with the
corresponding gears of the intermediate shaft. Two dog clutches are provided on the main
shaft-one between the clutch gear and the second gear, and the other between the first
gear and reserve gear. The main shaft is splined and all the gears are free on it. Dog
clutch can slide on the shaft and rotate with it. All the gears on the counter shaft are
rigidly fixed with it.
When the left hand dog clutch is made to slide to the left by means of the gearshift lever,
it meshes with the clutch gear and the top speed gear is obtained. When the left hand dog
clutch meshes with the second gear, the second speed gear speed is obtained. Similarly,
by sliding the right hand dog clutch to the left and right, the first speed gear and reserve
gear are obtained respectively.
In this type of gear box, because all the gear are in constant mesh, they are safe from
being damaged and unpleasant grinding sound does not occur while engaging and
disengaging them. In tractors, we are providing the hi-low shaft for variation in power.
During HIGH, the power coming from the transmission is direct send it to differential
through the hi-low intermediate shaft. During low, the power is first transmitted to hi-low
lay shaft or counter and then it is transmitted to the differential.
62
GEAR BOX DISASSEMBLY

Remove the gearbox cover.
Remove the fork nut.
Remove the clutch bearing.
Remove the shifter rod.
Remove the fork.
Remove the output shaft.
Remove the hi-low shaft.
Remove the input shaft.
Remove the intermediate shaft.
Remove the lay shaft.
Remove the idler shaft and idler gear.
63
REAR COVER
64
PROCESS CHART OF REAR COVER

Clean and
load the rear
cover on the
working
Trolley
Fit the sensor

bush to the
sensor hole
Fit the stud on

the rear end
Fix the breather bolt

& cap it with
breather cap
Position & Draft

coupler sub assembly
Bolt the
coupler
connection
bush with
rear cover
Bolt the
coupler
connection
bush with
rear cover
Place the gasket

on the position
draft section on
assy. section
Turn the rear cover

downward
Lift arm assembly

Place the Ram
arm on Ram
cover housing
Place the rock

shaft in Ram arm
assembly by
light hammering
Place the Ram

arm on Ram
cover housing
Place the rock

shaft in Ram arm
assembly by
light hammering
Gauge the
position of
draft assembly
with gauge of
53.5 mm
Couple the fork

on coupler
assembly to
control valve
&bolt the RV
housing
Place the
spacers one
by one with
mandrel
Place the rock

shaft in Ram
arm assembly
by light
hammering
Bolt the Ram

cylinder
assembly with
rear cover
Lock the coupler

with lock nut
Turn the rear

cover upward
and attach the
RV Housing
assembly
RV Housing assembly
Fix the sensor

tube on the
stud and bolt it
Sensor tube
sub assembly
Couple the rear

cover with the
chassis
Fit the lift arm

to the rockshaft
& bolt it with a
retainer plat
Place the spacers

one by one with
mandrel
Place the
connecting
shaft Ram
arm inside
the Ram
cylinder
assembly
Lift the rear
cover and
place on the
testing
machine
Check for proper

working and maximum
lift capacity of the lift
65
PARTS OF HYDRAULIC SYSTEM

PART LIST OF THE REAR COVER
Rear cover housing.

Control valve.
Rocker shaft.
Ram cylinder.
Piston with insert.
Response valve housing.
Release valve.
Relief valve.
66
HYDRAULIC
DEFINITION: The system where fluid properties are used for transferring the power.
PARTS OF HYDRAULIC SYSTEM
There are the four part of hydraulic system.
1. Controller-It controls the oil in the system and control valve assembly, R.V.
housing, lever assembly, sensor assembly, etc.
2. Converter- It converts the hydraulic power of oil into the mechanical power to
do the work (ram cylinder, three point linkage)
3. Shifter-It ensures the safety of the system(safety valve, relief valve, release
valve)
4. Supplier- Supplier the supply the oil from pump to delvers pipes
Rear cover assembly is used to cover the differential housing. It contains lift control
system, which is hydraulically operated. The response valve housing (R.V.) control valve,
cylinder and other components assembly fitted inner and outer side of rear cover
assembly. The main components are fitted in rear cover assembly
(a) Control valve assembly.
(b) R.V. housing assembly.
(c) Hydraulic cylinder and piston assembly with lift arm.

(d) Operating sector assembly.
(e) Sensor tube assembly.
(f) Gaskets, bolts, nuts.
(g) Other components.
RAM CYLINDER ASSEMBLY:It contain cylinder for single lever with piston inserted in side the cylinder. The relief
valve assembly is mounted at top front of cylinder. The connecting rod is placed in piston
rear side and one side is locked with ram arm assembly. A rock arm, spacer and seals are
placed. At the end of rock arm assembly lift arm assembly is placed on the splinted and
then locked with bolts on both side.
R.V. HOUSING ASSEMBLY:It contain the response valve which having different valves and components are placed at
their respective place. It contains one response valve, check valve and realize valve. Two
dome nuts are placed at their respective place. It is also connected with control valve
through pipe housing. The knob is placed at top of response valve to close or open the
response valve as per requirements.
67
CONTROL SECTOR ASSEMBLY:

-It contains the draft crank assembly, which is placed through the hollow position crank
assembly. Both these assembly are connected to their lever. The position crank assembly
is connected to black mark lever and draft crank assembly is connected to red mark lever.
All assembly is fastened with bolts, nuts, washer and locknuts.
COUPLER ASSEMBLY:In coupler assembly, a draft rod having a flange and position rod contains spring on it.
Draft rod assembly is connected to the draft lever and position rod to position lever
through the control valve. Whole assembly is fitted inside rear cover.
First rear cover is mounted on the moving trolley and tight with bolts. The control sector
assembly is placed at there respecting place with actuator shaft and compiler assembly. A
sensor tube with burn is placed at rear side of rear cover. Then a ram cylinder assembly in
haunted inside rear cover.R.V.housing is placed out side rear cover, which is connected to
control value through pipes. All other components assembly is a placed their respective
place control value container three value i.e. Back measure value (3-6kgf) unloading
value and scroll value. When oil from pump goes into R.V.housing through pipes, which
is further connected, to the check value through inner hole of R.V.housing and
Backpressure value of control values. The opening pressure of check value is 9-12kgf and
opening pressure of backpressure value is 3-6kgf. During un-operated position, the oil is
continuously. Through the backpressure value of control valve.
During operating of position arm the unloading valve, close the gallery of oil to back
pressure valve. Thus the pressure in R.V.housing built up which open the check valve at
9-12kgf. As this position, the oil goes in the Ram cylinder, which further operates the lift
arm. For required of any position lift the knob of response value of
R.V.housing is rotate which cut the supply of oil and the position of ram arm is got.
Sensor tube is work in field working during ploughing of shaft nature soil with harrow
and when harrow deeply dug in soil, which over load the tractor. However, to avoid
deeply dug of harrow in soil. The draft is set at there position through sensor tube. The
rocker arm attached to sensor and harrow link, which push the sensor tube inside and
automatically control value control oil supply.
WORKING OF HYDRAULIC LIFT AT VARIOUS STAGES WHICH

ARE:A) NEUTRAL POSITION
B) RAISING POSITION
C) LOWERING POSITION
68
A) NEUTRAL POSITION: - when engine starts oil is sucked by hydraulic pump

from oil reservoir and is discharged through delivery pipe into inlet port of RV
housing. In hydraulic system it has two passages, one going towards back
pressure valve and other two the check valve. When both valves closed pressure
starts developing inside the system. When it exceeds the limit of 3-6 kg/cm back
pressure valve opens and oil starts flowing to the ports of unloading valve towards
reservoir.
B) RAISING POSITION:- When we move position lever towards upper direction

then spool valve pushed to inner side. Ports of spool valve get opened
consequently. Oil exerts pressure on unloading spring through these ports. as a
result unloading valve moves in and close the ports of back pressure valve and oil
rushes to check valve and open the check valve. Further oil enters into the ram
cylinder. It pushes the piston upwards and three point linkage moves up.
69
C)LOWERING POSITION:-when we move position lever at down side then spool

valve moves outward and port of spool valve comes at its initial position and oil
rushes to the reservoir through spool valve gallery, unloading valve spring comes in
its initial position and oil passes to the back pressure valve and then to the reservoir.
70
FRONT AXLE
71
PROCESS CHART OF FRONT

AXLE
Insert the bearing
cones in both side of
the hub.
Prepare the other

stub axle same as
mentioned above.
Place the front axle

bracket on
conveyor trolley
and assembled it
with front axle
beam.
Put steering arms

on both stub
axles and bolt it.
Connect the track

rod in between
both the steering
arm.
Insert the wheel

bolts in hub
Put the Dust seal

and bearing to the
stub axle.
Put O ring holder and

o ring and thrust
bearing
Put thrust PAD and
o ring and
hardened washer.
Insert the stub axle in to

the hub put the other side
bearing and screw the
check nut at 16 lbf and
check the preloading and
bolt the hub cap on hub.
Clean front axle

beam and front
axle bracket with
air pressure.
For mounting front axle bracket

insert pivot pin into the bush of
front axle bracket and front axle
beam.
Insert the stub axle

left and right into
the king pin of
front axle beam.
Check the
movement of hub
and rotation of
king pin front axle
beam.
Insert the locking bolt and

nut in the pivot pin for
locking purpose and cover
the rubber boot.
Bolt the bumper

and front toe hook.
Couple the front axle

assembly with engine.
72
DIAGRAM OF FRONT AXLE
HUB CAP
SPLIT PIN
CASTLE NUT
LOCKING
WASHER
TAPPERED
BEARING
OUTER
RAGE
AXLE HUB
OUTER
RAGE
TAPPERED
BEARING
OIL SEAL
&WEAR
RING
FILT RING &
KING PIN
STUB AXLE
THRUST
BEARING, O
RING AND O
RING
HOLDER
KING PIN STUB

AXLE
73
MAIN LOOP CHASSIS
74
PROCESS CHART OF
CHASSIS LOOP
DIFFRENTIAL
LOOP
Differential
loading on trolley
Footrest board
fitment
Coupling of engine and

front axle
Paint shop
Attachment of
T.P.L. with
differential
housing
T.P.L.
connected with
lift
Hydraulic
connections tie rods
&bumper fitting
Battery box
fitment
75
Gear box
coupling with
differential
housing
Mounting rear
cover assembly
Brake and
clutch fitment
and adjustment
Accelerator rod
and lever fitment
PAINT SHOP
INTRODUCTION: -
Paint gives protection to tractor from corrosion for enhancing the appearance for a longer
period and at the same time it protects the body from rust. the paint consists of
linseed oil, pigment (as per requirement of master piece) and turpentine oil or some other
solvent to thin the mixture. Magnesium silicate is also added to impart improved
resistance to cracking of the paint film. The drying time hardness and elasticity of paint
film depend principally on the drying oil, temperature of oven, and the time for which it
is kept in the oven. The procedure and process chart of sheat metal and chassis are
illustrated below-
76
SEQUENCING OF OPERATIONS IN CHASSIS PAINTING

1) Pre treatment of chassis
Zone1:- Degreasing of chassis with chemical solution to remove oil and grease
Zone 2:- Misting Spray
Zone 3:- Water Rinse
2) Water Drying
The chassis dries in oven at 90c temp. for 10 minutes
3) Primary Inspection and Surface Preparation
4) Spray Booth
1) Primary application
2) Flash off for 2-3 min.
5) Flash off zone for 10 minutes during travel in line.
6) Baking of chassis in oven at 120c for 30 minutes.
7) Chassis ready for assembly.
SEQUENCE OF OPERATIONS IN SHEET METAL

PAINT SECTION
1) Pre Degrease:- To clean sheet metal part by water and castic soda.
Temp: - 63-70c
Point age: - 40-70 ml
Ph: - 12
Dip time: - 5 minutes.
2) DEGREASE:- It is same process to clean so rust cam remove from the surface.
Temp. : - Ambient
Point age: - 10-15ml
Ph: - 12
Dip time: - 5 minutes
77
3) DERUSTING: - To clean the rust completely from the surface.

Temp. : - Ambient
Point age: - 10-15ml
Ph: -1.3
Dip time: -3 min
4) WATER RINSE: - To clean the surface after derusting.
Temp. : - Room temp.
Dip time: -1 minute
5) ACTIVATION: - This treatment is given to charge the sheet metal parts before
Phosphate operation.
Temp. : - 35- 40c
Point age: - 8 to 7ml
Ph: - 8 to 7
Dip time: - 1 minute
6) PHOSPHATING: - To coat Iron phosphate (feso4) to make the surface rust proof.
Temp. : - 50-55c
Point age: 18-25ml
Ph: -1 to 2
Dip time: - 5 minutes
7) WATER RINSE: - To clean the surface of sheet metal after passivation so no
Foreign partical can stick on the surface.
Temp. : - Room
Dip time: - 1 minute
8) WATER RINSE: - Same treatment again gives to sheet metal.
8) PASSIVATION: - This operation is performed to prevent sheet metal from rust and
air particles.
78
FINAL ASSEMBLY
79
PROCESS CHART OF FINAL

ASSEMBLY
Sub assy. of
fuel tank
Fitment of fan
and belt
Chassis received
from oven
Sub assy. of
radiator
Assy. of fuel tank

and radiator fitting
and side wiring
Engine
oil filling
harness
Fitment of
rear tyre
left and
right
Greasing and
fitment of
dashboard
Fitment of
3-point
linkage
Fitting of fender
light and driver seat
Sub assy. of
rear tyre
Gear oil
filling
Downing
on slat
conveyor
Fitment of
switch panel
Grill frame
fitting
Fitment of
sheet metal
Fitting of battery and

filling of water and
diesel
Sub assy. of
mid part
and top
hood
Sub assy. of air

cleaner
Pasting ok sticker
and fitting of head
light and front
grills
Fender seat
fitting
Sub assy. of
grill frame
Sub assy. of
switch
panel
Sub assy. of
exhaust duct
Fitment of
steering,
accessories,
and air
cleaner
Fitting of
mid plates
Final inspection before

handling to testing
80
PROCESS FLOW OF TRACTOR ASSEMBLY LINE
Cooling zone.
Fuel tank frame, fuel tank along with cork and fuel supply system.
Radiator& fan fitment.
Electrical harness fitting.
Fender mounting.
Diver seat fitment.
Stay bar and tension spring and anchor chain fitment.
Rear and front wheel fitment.
Bonnet, bumper, grill meter plate and horn plate fitment .
Diesel, transmission oil filling.
Pre cleaner fitting.
Air cleaner fitting.
Line inspection.
81
ROLLER TESTING
ROLLER TESTING
Place the tractor on the roller.

Tie up the tractor with the hook provided for it.
Remove one end of draw bar and insert the end of the chain weight in it.
Run the tractor at idle rpm for 5-7 min.
Gradually increase the rpm to the full throttle for 15min.
After this, check all joints and leakages from the pumps.
Check all the shifting of the gears and run them for 1-2min.
Check hydraulic lift is working by lifting the weight.
During running at idle rpm and full, throttle rpm check all the meters on
dashboard whether they are working properly or not.
Unhook all the chain and hook from the rear.
Hang the weight chain back on their place.
82
Remove the tractor from the roller.

Check left-right hand brakes separately on the road.
83
ADJUSTMENT OF TOE-IN
Toe-in should be between 2mm to 6mm.

Adjust the toe in of the tractor by adjusting the length of the track rod using
spanner of 24mm.
ADJUSTMENT OF CLUTCH PEDAL
Adjust the free play of the paddle it should be between 20mm to 25mm.
Adjust the free play of clutch pedal using the spanner of 14mm.
ADJUSTMENT OF BRAKE PEDAL
Adjustment of the brake pedal, it should be between 55mm to 65mm.

Adjust the free play of the brake pedal from the screw-using spanner of 17mm.
Checking of differential
Check abnormal noise in forward running at engine RPM 1800-2000.
Check for abnormal noise in forward and backward running at 725 -1000 rpm.
Check any abnormal noise from spider kit while driving left and right.
Checking of gearbox.
Check proper engagement of gears while driving.
Check any noise from gear while driving it following gear ratios.i.e.
H1:- AT HIGH-speed gear with first gear.
H2:- AT HIGH-speed gear with second gear.
H3:-AT HIGH-speed gear with third gear.
H4:-AT HIGH-speed gear with forth gear.
L1:-At Low-speed gear with first gear.
L2:-At Low-speed gear with second gear.
L3:-At Low-speed gear with third gear.
L4:-At Low-speed gear with forth gear.
HR1:-At Low-speed gear with reverse gear.
LR1:-At Low-speed gear with reverse gear.
Checking of engine
Check engine oil pressure at 725-750 rpm > 0.5 kg/cm.
Check engine oil pressure at 2150 2200 rpm > 0.5 kg/cm < 4.5 kg/cm.
Temperature of water in working condition 70 to 80c
84
Checking of hydraulic problem

Check hydraulic arms for self-rising
Check hydraulic lift at idle rpm .is it support the load or not.
Checking of vibration at full rpm in hydraulic arm.
Checking for jerking problem while lifting load.
Checking a noise from sensor while lifting.
Checking a noise from rocker shaft.
Checking of response valve.
PTO SHAFTS CHECK POINTS

All double clutch (DC) models = 06 splines.
All single clutch 540 rpm = 06 splines.
All models above than 50 hp and four cylinder = 06 splines.
All models below 50 hp = 21 splines.
85
FLOW CHART OF TRACTOR INSPECTION
Tractor rolls out from final assembly
Gap setting and pre-inspection
Toe in setting
Roller testing or road testing
Minor rework
Oil filtration
Pre-Delivery Inspection
Washing
Re-greasing and electrical inspection
Paint touch-up if required
Sent to stock yard
Quality audit before dispatch
Dispatch of a tractor
After roller, testing if any fault is found it sends to two working stations:MINOR REWORK.
MAJOR REWORK.
86
MINOR REWORK
In a minor rework, minor problems are solved which are:Leakage problem.
Light harness problem.
Fender mounting problem and sheet metal adjustment problem etc.
Leakage problem: - leakage problem that comes in the tractors are fromPrimary and secondary filters.
Hydraulic delivery pipe.
Hose pipes of radiator and power steering.
Leakage from cork of fuel tank etc.
Light harness problems: - In harness problem certain points are checked:Meters at dashboard
Front and rear lights
Fuse
Plough light
Alternator
Starter motor.
Fender mounting problems:Any noise from fenders,
Any fitment problems in dashboard, middle area and grill portion.
Any fitment problem in tool kit box, battery box.
87
MAJOR REWORK
In major rework problems; we dismantle the chassis if any noise comes during road test
or roller testing:Noise and leakage from gearbox.
Noise from and leakage from differential.
Noise from rear cover.
Gear Box: - If noise comes from gearbox, certain parts are checked.
Assembly of gears on respective shafts.
Bearings in the gear housing.
Gear conditions (any faults on gear teeth i.e. pitting, scratch etc.)
Clutch actuator and actuator bearing.
Forks and gear lever links and pairs
If any leakage from gearbox we check gasket.
.
Differential: - In differential, certain parts are checked if any noise and trouble is found
during road test and roller testing.
Assembly of crown wheel, differential cage (spider kit assy.) and tail pinion and trumpet.
Backlash of crown wheel and tail pinion.
For leakage, we check drain plug and gasket in differential housing.
Rear cover: - In rear cover the component we check.
Assembly of rocker shaft and levers (draft and position) and ram cylinder.
Sensor checking if any noise is found during test.
Bearings of rocker shaft are checked.etc.
88
PRE-DELIVERY INSPECTION
1.
2.
3.
4.
5.
6.
7.
8.
9.
Chassis number and the engine number are matched.

Water level in the radiator is checked.
Then the electrolyte level is checked in the battery.
The engine oil level is checked with the dip stick.
Oil level in the Air Cleaner is checked.
Gear box and steering oil level is checked.
Oil level in the FIP is checked.
Then the engine oil and gear oil drain plug is checked for any kind of leakages.
All hose pipe clamps, exhaust and inlet manifold joints are checked for any kind
of leakage.
10. All hose pipes and electrical harnesses are checked is they are fouling with the
sharp edged parts or the silencer.
11. Fan belt tension is checked, it should be 10 mm.
12. Clutch pedal free play is checked, it should be between 25 to 35 mm.
13. Nuts and bolts of gear box housing are checked and adjusted.
14. Air pressure in the tyres is checked, air pressure in the front tyres is 26- 28 pounds
and in the rear tyres is 14 16 pounds.
15. Toe in is checked, it should be between 2 to 5 mm.
16. Three point linkage is checked.
17. Starter switch is checked for its proper functioning.
18. Indicators, front and back lights and plough light are checked for proper
functioning.
19. Warning lights and horn is checked.
20. Headlight alignment is checked.
21. Idle and maximum engine speed is checked with both hand and foot accelerator.
22. Water temperature is checked when the engine is running.
23. All the gear engagements are checked both in forward as well as in reverse.
24. Steering wheel is checked for proper movement.
25. All the gauges are checked such as temperature gauge, oil pressure gauge, ampere
meter gauge and hour meter gauge etc.
26. Hydraulic is checked for proper movement.
27. Then the hydraulic is checked by putting the implement to it, draft and position
lever levers are checked for proper functioning.
28. All the leakages are checked again after putting the implement.
29. Then visual inspection is done for any kind of scratches and marks on the painted
parts of the tractor.
89
CONTENARIZATION
&
DISPATCH
90
Container is a steel box having dimension

TEU - (Long 20, Breadth 8, Height 8.6)
FEU - (Long 40, Breadth 8, Height 8.6)
A standard 20 container has an internal volume of approx. 31 cubic meter and a pay load
of 18 tonnes.
Internal Parameters
1)
2)
3)
4)
Length 39.4 feet

Width - 7.9 feet
Height - 7.9 feet
Volume 2458.954 cuft
Density 0.6 Tones / cubic meter

( 18 tones / 31 cubic meter)
Tractors are dispatched in SKD (Semi knock down) and CKD (complete knock
down) form, which is as per customer negotiation with the company.
During SKD condition certain components are dissembled which are:1) Front Axle
2) Fenders
3) Silencer
4) 3 point linkage
5) Swinging draw bar and bracket
6) Rotating toe hook
7) Mirrors
8) Top link
9) Leveling rod
10) Lifting rod
11) Stay bar
12) Fender spacer
13) Fender bracket
14) Rubber pads
15) Front and rear tyres
16) Front weights
17) Front toe hook
18) ROP
19) Canopy
20) Plough lamp
91
21) Registration plate and light
Research and Development

Department
92
Research and Development (R & D) Department

Different departments comprising R&D are:
1)
2)
3)
4)
5)
6)
7)
8)
Product Development
Design Department
Protoshop
Mock up
Vendor Development
Vendor Quality Control
Testing
Product Management
93
THE PROCESS: The product development department collects information from any of the following
sources:a) New markets
b) Export Marketing Department
c) Domestic Marketing Department
d) Competitor Analysis
e) Existing Customers
f) Service Department
The information collected from above sources is used for the up gradation of existing
technologies or development of altogether new technologies. For this purpose the
product development department has a close interaction with the design department.
The feasibility for developing a product is measured on various parameters. Some
important parameters being volumes that can be sold, return on investment (ROI)
and the complexity of the product. After checking the feasibility of the change the
Design department issues an ECN (Engineering Change Note) if the change is
minor and the changed part can be interchanged with the old one and if the
development is entirely new then EDN (Engineering Development Note) is issued.
After the issuance of ECN/ERN the initial samples are prepared. The vendor
development department procures raw material for initial samples. The quality of the
raw material is checked under Vendor Quality Control.
A prototype of the product is then developed. The prototype undergoes rigorous
testing. Then 5 samples are prepared which are also tested, if these samples pass then
next lot of 25 samples is prepared and similarly these are tested and if these samples
pass the R & D department issues an ERN (Engg. Release Note). If the model is
entirely new then it goes for testing at Central Farm Machinery Training and Testing
Institute, Budhni from where it must get ICA (Initial Commercial Approval) before
it goes for full-scale production. If the product passes in all the above stages then the
product management department creates a new independent BOM code for that
particular model. The BOM code consists of minutest of the details of that particular
model. After this the SOP date is issued and the product is put on the assembly line
and is manufactured and assembled as per the market demand.
DEPARTMENT DETAILS
Product Development
Product development is a bridge between marketing and R & D. This department looks
after new product development, old product enhancement and taking appropriate action
94
against the feedback obtained. Whenever some kind of problem is to be solved then
ORC (Open Resolved and Closed) sheet is prepared in which the issue is approached
i.e. it is opened and the sequence of steps are followed to come to a short term and long
term solution, at this point when the solution for the problem is found the issue is said to
be resolved and when the solution is implemented at that point the issue is said to be
closed.
The main source of information for the PD department is:1) Export Market
2) Domestic Market
3) New Market survey
4) Existing Customer survey
5) Feedback from Service Department
6) Competitor analysis
1) Export Department
Export marketers after visiting different countries inform the PD department about the
new developments going on in other countries. Marketers generally provide PD
department with either snaps or video or pamphlets of the technology being used in that
particular country from which the idea is further verified by the PD department in
consultation with Designing Department for its feasibility.
2) Domestic Marketing
The domestic marketing department provides feedback to the product development in
terms of the buying patterns of the customers, they may also give feedback on brand
awareness of the customer and consumer buying behavior.
3) Customer survey
In this case, we study the customer satisfaction level in a particular area. We make a
report of the response given by customer called customer satisfaction index (CSI).
4) New market survey

In the case of export marketing, export marketers study various countries having
different soil conditions and altogether different norms for emission etc. For these
markets new ideas are designed according to the market survey (HP requirement,
implement required, feasibility study, technical analysis, quantity required etc.). The
climatic conditions of different countries are also a concern.
5) Competitor analysis
The competitor analysis aim at studying the product range of competitors and comparing
it with our product line in similar range. The newly developed features of competitors are
then imbibed into our products. The positioning and promotion strategies of competitors
are also analyzed. For complete competitor analysis the PD department refers to Budhni
reports. Four reports were analyzed by us (refer to Annexure).
95
6) Service Department
When the service engineers visit the customers and the dealers for servicing of the
tractors, they get the opportunity of coming in direct contact with the customers from
where they get to know about the needs and wants of the customers and also about some
new ideas which can be implemented in our tractors. Further the service engineers give
the feedback to the product development department, which test for the feasibility and
marketability of the product under consideration. The service engineers also encounter
certain technical problems frequently. It could be a design fault or any other technical
fault, which is then rectified by the R & D department.
Design Department
This department looks after all the design related aspects of the tractors and it works in
close coordination with the Product Development department. The software used for
making designs is IDEAS. The designing department gets input from the Product
Development department and the design related feasibility is being checked by the
Designing Department. At present Projects like RX, the designing department is handling
World Trac and higher HP range tractors. Reverse engineering is an important concept,
which is implemented in the design department. Reverse engineering is the process of
backtracking the product from its final stage to its initial stage. Benchmarking is
generally done from the existing leader technology in the market.
Vendor Development
After the production department and the design department reports the product to be
feasible, the vendor development department procures the raw material from the vendor.
The raw material is not ordered in bulk but only for manufacturing few samples, the
vendor is generally reimbursed with the tooling cost and other costs incurred to
manufacture the new kind of raw material. The vendor development cell also interacts
with the vendors to check the commercial feasibility of a particular raw material. The
initial samples procured could be 5, 25 or 100.
Vendor Quality Control
The vendor quality control department checks for the quality of the raw material and at
times the process by which the material is manufactured, if this department passes the
raw material then only the material is put to use for making the prototype.
Mock Up
96
After the new model passes the feasibility test conducted by Product development
department and designing department, an initial physical model is prepared. To prepare a
mock up a sample of the raw material may be procured from vendor department or a
mock up can also be prepared with any other material easily available.
Prototype
Once the product is made in the mock up section further samples are made in the
prototype. In this the exact material, which is to be used in a tractor, is procured from
vendor development to prepare a prototype. When the prototype is prepared then the
inspection is done from various departments on following parameters:1)
2)
3)
4)
5)
6)
7)
To check if the new proto can be easily serviced

To check if it can be easily assembled on main line
To check if it can be easily dis assembled when required
To check for easy serviceability of the product
To check for aesthetic appeal
To check for any leakage
To check for overall quality of the prototype
Photographs of the prototype are taken for further references. The prototype may also be
prepared on the main line if required. Also after an initial prototype the first 100 samples
will be prepared on the main line.
Testing
The testing department plays a very important role in R & D as it undertakes the
responsibility of the first practical test of the new tractor model. The testing department
tests all the minor and major testing parameters of the tractor so that the model could be
rectified and sent to the assembly line as soon as possible.
Product Management
Once the testing department passes the entire model, the product management department
issues an independent BOM code for the tractor model prepared. It stands for Bill of
Material. The BOM code consists of a lit of all the parts to be used in the tractor. This
BOM code represents the particular tractor model and once the BOM code is freeze, the
assembly line assembles the product as per the specifications of the BOM code.
97
OTHER TERMINOLOGIES USED

ECN It stands for Engineering Change Note. It is issued during the mock up and
protoshop stage when the design and the product development department ask for a
technical change and the change is minor wherein the new product can be interchanged
with the new product.
ERN It stands for Engineering Release Note. After the testing when the newly
developed product is said OK then an engineering release note is released. After this a
new BOM is prepared.
EDN it stands for Engineering Development note. It is issued during the mock up and
protoshop stage when the design and the product development department ask for a
technical change and the change is entirely new and the new product cannot be
interchanged with the old model.
ICA It stands for Initial Commercial Approval. After the Samples for the newly develop
product are created. A sample is sent to Budhni (Central Farm Machinery Training and
Testing Institute) for further testing. After the product passes through the various test, it is
said to be fit for commercial sale.
CAT I , II Category I and Category II are the internationally accepted design standards
of lengths and diameter. In ITL both the standards are used. In USA category II is used.
PRR It stands for Protoshop Requirement Report. The requirement of the protoshop
department to prepare a protoype is given to the vendor department.
Tractor Audit the Product development department conducts a surprise audit. The PD
department can randomly pick up any tractor, which has passed the PDI and is standing at
the Dispatch. A thorough check up regarding quality, leakage, breakage, scratches, and
fitment is conducted. A report is prepared for the same. The tractor may also be stopped
at the dispatch if the required standards are not met.
98
99

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SIX MONTHS INDUSTRIAL TRAINING

INTERNATIONA L TRACTORS LIMITED

Under the Guidance of :

Mr. Vikram Sharma

Training & Placement Officer

Univ. Roll No 100351196023

Main Assemblies of Tractor

Basic Terminology of Engine

Red symbolizes the, arouses cheerfulness, stimulates

encouragement, and stimulation. All this permutation

International Cars & Motors Ltd

Sonalika Agro Industries Corporation

International Autotrac Finance Ltd

International Autotrac Finance Limited is a non banking finance company approved

Definition of Tractor:The tractor is such a machine which is used to pull or push

TRACTOR - A BRIEF INTRODUCTION

At training center, we went through various training, which is illustrated below1)

Introduction about ITL.

BASIC TERMINOLOGY OF AN ENGINE

Internal diameter of cylinder liner is known as bore.

:- It is the position from where piston cannot move further up.

B.D.C. (Bottom Dead Center)

:- It is the position from where piston cannot move further

:- It is the volume swept by the piston in one stroke.

Different RPM Conditions

: No Load + Full Accelerator

: Full Load + Full Accelerator

Maximum Torque RPM

: Maximum Load + Full Accelerator

H.P. Horse Power

Horse Power - If the rate of doing work is 75 Kg-m / sec.

2 Cyl. & 3 Cyl.

Maximum Torque RPM

POWER TAKE OFF SHAFT

TOP LINK PIN DIA.

LIFT ARM PIN DIA.

BACK UP TORQUE :- Reserved torque in engine after developing maximum

power is known as back up torque.

FEATURES OF SONALIKA TRACTOR

PRODUCTS MANUFACTURED BY SONALIKA

Rear Tyre Size

COMPETITORS COMPANIES IN INDIA:20

1) Mahindra & Mahindra

DRAWBACKS OF COMPITITORS OF SONALIKA

MAHINDRA & MAHINDRA

FARMTRAC:High diesel consumption.

SAWARAJ:High diesel consumption even on fewer loads.

NEW HOLLAND:Speed reduction is not direct so power loss is grater.

SINGLE CYLINDER ENGINE

Bore * stroke (mm): 127 * 140

Type : 2-cylinder engine (2102F)

Type : 3-cylinder engine

Type : Four cylinder engine (4100F)

9. CYLINDER HEAD GASKETS

11. OIL SUMP

12. CYLINDER LINER

13. PISTON PIN

14. PUSH ROD

15. EXHAUST MANIFOLD

16. FRONT COVER

18. DOWELL PIN

19. INLET MANIFOLD