ASSEMBLY SHOP

INDUSTRIAL TRAINING REPORT

AT
PREET TRACTORS

SUBMITTED TO:Dr. I.P.S. Ahuja

HOD (ME)
UCoE

SUBMITTED BY:Harish Badhwar

B.Tech. 3rd yr.
Roll No. 11003073(ME)

UNIVERSITY COLLEGE OF ENGINEERING

PUNJABI UNIVERSITY
PATIALA

The Company
PREET is India's leading manufacturer of Combine Harvesters,
Agriculture Tractors and Agriculture Implements. An ISO 9001:2008
certified company is well equipped with ultra modern amenities in its
plant. All these establishments meet the expectations of Indian as well
and international standards. PREET also offers its employees a
promising future and the place to pursue a career.
Our Philosophy
It is our philosophy to give our domestic and overseas customers
exceptional experiences with friendly & warm service and retain talents
who can support these values. We provide a caring, motivating and
progressive environment with productive training programmes that
range from apprenticeships to management trainees.
About PREET AGRO Industries Pvt. Ltd.
PREET AGRO Industries Pvt. Ltd. Indias leading manufacturer of
Combine Harvesters, Agriculture Tractors & Agricultural implements,
started its journey way back in the year 1980. Initially the company was
producing

Straw

Reapers,

Threshers

and

other

Agricultural

Implements. Three years later Mr. Hari Singh (Managing Director)

founded PREET Agro Industries. In 1986 with the help of his younger

brother Mr. Gurcharan Singh (Director) they successfully made first

Tractor Driven Combine Harvester. They continued their Research &
Development work and they introduced PREET 987, The most admired
Self Propelled Combine Harvester of India that brought huge success to
PREET AGRO Industries.

Incepted as a small scale unit today PREET AGRO Industries is

Indias largest Combine Harvester Manufacturer. PREET is market
leader in segment of Self Propelled Combine Harvester. PREET
Combines are manufactured in fully automated plant equipped with
latest machine tools that meets highest standards of industry. With
highly experienced technicians and world-class infrastructure, PREET
has been able to produce high quality agricultural products and
prominent after sales service. Due to transparency in business practice

and utmost quality products PREET has become a brand name in

Indian agricultural market as well as in international market.
MANUFACTURING Plant Facility.
PREET has state-of-art manufacturing plant. The products are
manufactured on a fully automated assembly line using latest machine
tools and equipments that are latest and highest in industry standards.
We have all the essential tools and equipment that are required for the
smooth and fast production of the bulk orders. Our manufacturing unit
sprawls in a vast area of land with a high installation capacity to meet
the increasing demands of the market. The company has installed a
poweder coating unit in its plant to improve the color quality and makes
product lasting long in all type of weather conditions. Also, we give our
greater emphasis on the regular up gradation and modernization of our
unit. In house R & D department ensures that the products
manufactured are up to date in terms of technology and also
compliances with environmental guidelines given by Govt of India.
Some of our efficient machines installed at our unit are following:

HMC Machines.

VMC Machines.

CNC Turning Machines.

Shearing Machines.

Bending Press.

Computerized lathe machines.

Power Press.

Laser Cutting Machines.

Turret Punch Machine.

Shapers.

Radial Drill Machine.

In addition, we have an in-house R&D and design unit which assists us

in fabricating the newest designs and patterns as per the international
demand of the market. Also, all our machines are regularly maintained
to achieve high efficiency and smooth production.

MD's Message!

I am delighted to share with you that PREET has realized stronger

growth than the market and exceeding customers expectation with
world class quality products while essentially acting with reference to
the companys mission, vision, values and code of business
principle. We have set our sight higher and all geared up to evolve
PREET brick by brick which is vibrant & stronger from within, powering
execution with commitment & professionalism, creating empowered
motivated team for accelerating growth, generating confidence of
brighter future and better place to work and delivering results for the
benefit of all while contributing towards a better and greener world.
Our focus is on specific growth opportunities by:

Redefining the market boundaries.

Moving the decision making process closer to the market &

farmers through empowerment.

Addressing & responding the need of the market faster and in

time.

Working closely with farmers to understand the need gaps in a

better and intimate way.

Providing Crop Solutions by valuable, differentiated products &

services.

Developing trust & confidence of farmers and stockists,

distributors, dealers, retailers in PREET as a valued, reliable
partners.

Helping them to help us in winning the market share.

PREET is being identified as a Company of Quality Products

with Value for Money and indeed a great feat. It would be our
constant endeavour and unending urge to excel on this quality
bestowed on us through improvement & economies of scale in our
manufacturing, supply chain and technology development processes
and service functions.
This year we are cascading our Mission, Vision, Values and Code of
Business Principles within the company as we believe that Values
constitute the foundation for integrating key business requirements

within a result oriented frame work and that create basis for action and
feedback. We are ensuring that everybody in the organization should
have a clear picture of what our value mean in practice What
does it mean to me? and What should I do more and What
should I stop doing The objective is that everyone in PREET through
thought and action convert the values to behavioural actions in day to
day working. We have a clear vision for PREET and strategies are set
out. We achieve & surpass the business plan & objectives through
partnering with our valued customers, farmers, distributors, dealers,
retailers to realize success and generating their Trust & Confidence in
PREET. We at PREET, are committed to retain excellence in quality of
our products and after sales service, with focus on customer
satisfaction and market leadership. We vow to remain a responsible
corporate citizen, contributing to the lives of our people and the
preservations of our Planet's eco-balance. We extend ourselves as your
partner in growth.
Wishing Good Luck!

Hari Singh
Managing Director.

PREET Agriculture Tractors

PREET 6049 DI (4x4) (New Model): PREET Agriculture Tractors are

Powerfull & Fuel Efficient at unbeatable price. These tractors are Tested
& Approved by Govt. of India. Ministry of Agriculture...

PREET 6049 DI (New Model): PREET Agriculture Tractors are Powerfull

& Fuel Efficient at unbeatable price. These tractors are Tested &
Approved by Govt. of India. Ministry of Agriculture...

PREET 6049 DI (4x4). (New Model): PREET Agriculture Tractors are

Powerfull & Fuel Efficient at unbeatable price. These tractors are Tested
& Approved by Govt. of India. Ministry of Agriculture...

PREET 6049 DI: PREET Agriculture Tractors are Powerfull & Fuel
Efficient at unbeatable price. These tractors are Tested & Approved by
Govt. of India. Ministry of Agriculture...

PREET 5049 DI: PREET Agriculture Tractors are Powerfull & Fuel
Efficient at unbeatable price. These tractors are Tested & Approved by
Govt. of India. Ministry of Agriculture...

PREET 4549 DI: PREET Agriculture Tractors are Powerfull & Fuel
Efficient at unbeatable price. These tractors are Tested & Approved by
Govt. of India. Ministry of Agriculture...

PREET 4049 DI: PREET Agriculture Tractors are Powerfull & Fuel
Efficient at unbeatable price. These tractors are Tested & Approved by
Govt. of India. Ministry of Agriculture...

PREET 3549 DI: PREET Agriculture Tractors are Powerfull & Fuel
Efficient at unbeatable price. These tractors are Tested & Approved by
Govt. of India. Ministry of Agriculture...

INTRODUCTION
TO
ASSEMBLY SHOP

DIFFERENTIAL:
When the Vehicle is taking a turn, the outer wheels have to travel
greater distance as compared to the inner wheels in the same time, If
therefore, the Vehicle has a solid rear axle only and no other device,
there will be tendency for the wheels to skid. Hence if the wheel
skidding is to be avoided, some mechanism must be incorporated in the
rear axle. which should reduce the speed of the inner wheels and
increase the speed of the outer wheels when taking turns; it should at
the same time keep the speeds of all the wheels same when going
straight ahead, Such a device, which serves the above function, is called
a DIHTRENTIAL. To the crown wheel of the final drive is attached a
cage, which carries a cross pin or a spider' four planet pinions are used
in the differential. To sun gears mesh with the two or four planet
pinions. Axle half shafts are splined to each of these sun gears. The
crown wheel is free to rotate on the half shaft as shown.
When the vehicle is going straight the cage and the inner gears as a
single unit and the two half shafts revolve at the speed. In this situation
there is no relative movement among the various differential gears. To
understand what happens when the vehicle is taking a turn assumes
that the cage is stationary. Then turning one sun gear will cause the
other to rotate in the opposite direction. That means that is left sun

gear rotates n" times in a particular time, the right sun gear will also
rotate n times in the same period but of course in the opposite
direction. This rotation is super imposed on the normal wheel speed
when the vehicle is taking a turn. Thus, for example, consider a vehicle
with wheel speed N rpm going straight, when it takes a turn toward
right. At this time there will be a resistance to the motion of the right
wheel and a result of differential action if the right wheel rotates back at
'n' rpm then the left wheel will rotate forward at 'n' rpm.

PROCESS CHART OF DIFFERENTIAL ASSEMBLY

P.T.O. shaft sub
assy.
Clean the casting &
punch the serial no. On
the casting

Load the casting on

the working trolley

Fit the drain plugs

with the washer &
tight it.

Cage & B.P. shaft

sub assy.

Cage & B.P. shaft assy.

Insert the left B.P. shaft on the left side of

casting & cage & insert the right B.P. shaft
into the cage from the right side of casting
with little hammering

Fit the seal carrier on

B.P. shaft with shim
(0.2-0.5mm) &tight it
temporary

Fit the thrust bearing

cone on the left side
of casting

Preloading (12kg) is
done to check the
No. Of shim &
bearing setting

Fit the T.P. carrier

with shim (0.20.5mm) & tight it
temporary.

Wash the cage & B.P.

shaft sub assy. In
washing machine

Apply yellow paint to

check backlash &
setting of teeth
If backlash is less than
0.2mm move shim Rt.
to Lt.

Brake housing sub

assy.
Fit the Brake
housing on the
spline of B.P.
shaft.

Fit the P.T.O.

shaft in the
casting

Trumpet sub. Assy.

Fit the link plate
& P.T.O. shaft
cover.

Fit the trumpet

assy & bull gear in
Diff. Housing.

Tight the seal

carrier & T.P.
carrier tightly

Oil filter & P.T.O

shifter sub assy.
Fit the plain cover
with oil filter & P.T.O.
shifter sub assy.

Fit the sliding

& fixed P.T.O.
gear

Fit the
angle

Fit the
rocker link
Bkt.

Fit the
Chain

DIFFERENTAL HOUSING ASSENBLY PHASE

Differential is rear part of the tractor chassis. The main function of

differential in tractor to supply the power from gearbox to the wheels, it
also helps to turn the tractor with the wheels at different speed. It also
helps to reduce the speed. 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. It also consists of the P.T.O. shaft (Power take off shaft),
which is used to run the thrashers, pumps and other accessory
components with the help of pulley attached on it.

Following are the main parts of differential housing:

Crown wheel.

Tail pinion.

Cage assembly. (With sun, planet gears and cross)

P.T.O. shaft.

B.P. shaft left.

B.P. Shaft right.

Bull gears.

Bevel gears.

Bearings

Bearing cones.

Brakes housing assembly (with disc etc)

Oil seal, gaskets and fasteners etc.

Assembly of the crown wheel: First of all components are washed with oil to remove the dirt particles.
Cage is having two dowel holes, in these holes dowels are tightened for
accurate fitting of crown, so that all other holes of cage and crown come
into same line. The crown wheel is pressed with hydraulic press and
then tightened by bolts with lock washer. Then right bevel gear is
placed on the cage seat. The four planet gears are put on cross with
washer and then this assembly put in the cage. Then the left bevel gear
is placed on the planet gear. Operator o checks the motion of gears and
does the manual inspection. Cage left is placed on left side of right cage
assembly and then tightens by bolts and washers.

Tail pinion assembly: First of all in tail pinion assembly, the cone for taper roller bearing is
pressed with hydraulic press. The bearing is heated before the fitting.
Then the tail pinion is inserted inside bearing. Different sized shims are
also placed before the tightening of rear cover of cage. Whole assembly
is tightening by nuts and bolts.

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 /cm2 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 cover 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.

Brake housing assembly: This tractor having heavy duty self-energizing, water sealed disc brakes.
The brakes operate 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 substance. The maximum temperature

resistance is about 300 0 C. Between these two discs a cast iron plate is
fixed which contain spherical steel rollers and held by spring. When
ever brake is applied the spherical roller move or lift from there place in
the plate and try to expand the plate. During expansion of cast iron
plate the discs are strongly mounted on B.P. left and B.P. right shaft to
stop the axle. It also has actuators and link with rubber seal.

P.TO. shaft assembly: Two bearings are tightly fit on P.T.O. shaft at there proper placed with
help of circlip lock, which are provided on both side of the bearing.
First of all the P.T.O. shaft assembly is passed through rear P.T.O. hole
of differential housing, then two cones one on B.P. left and other on B.P.
right shafts are inserted tightly. The B.P. left and right shaft assemblies
are placed through the hole in cage housing of differential. The seal
carrier with different size of shims is tightened by bolts on both side of
differential housing (right and left side). Then pre - loading test is done
with 10 Kgf to rotate the cage assembly. If pre - load force is increase
the efficiency of taper bearing is decrease due to over friction between
cages of bearing, and if pre - load force is decreased then the efficiency
of taper bearing also decrease due to less contact with cover cage of

bearing. Then tail pinion assembly is inserted into respective holes with
shims and tail pinion teeth meshed with crown wheel teeth.
Following three testing is done on crown wheel and tail pinion: 1.) Back lash testing.
2.) Percentage of- contact.
3.) Pattern test

1) Backlash testing: This test is performed with help of plunger dial gauge. Backlash of
crown wheel is not more than 20 to 30 micron. If it is deviated from this
value then packing is change on either side (left or right) of cage of
bearing housing. But the numbers of shims are never changed. 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.

2) Percentage of contact:Pattern test and percentage contact test is done with help of yellow
paint which is applied on teeth of crown wheel. The crown wheel is then
rotated with hand and percentage contact and pattern of tail pinion is
impressed on the teeth of wheel. The percentage 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.
Tail pinion pre

8 kgf.

crown wheel pre -

12 kgf.

Crown wheel run out

0.05 - 0.1 mm

backlash is

0.2 - 0.3 mm.

The bull gears are tighten to trumpet housing assembly with lock nut
and the whole assembly of trumpet housing is also tightened by nuts on
studs and on outer side of differential housing. The P .T .O. shaft head
cover is tightening on P .T .0. Shaft to protect the outer teeth. The
sliding gear and P.T.O. shifter rod assembly is mounted on differential
housing. Two filters are placed inside of differential housing and then
whole assembly of differential housing is sent to the main line.
In ITL it is the main shop. In these tractors the sliding mesh type
gearbox are used for transmission the power at various speed from
engine to differential. It is the main assembly between the engine and
differential housing. An improvement was achieved in the form of
constant mesh gear used in gearbox, which gives better results in
higher mechanical efficiencies and lower noise level due to the use of
helical gears instead of straight spiral gears. It gives the tractor a top

speed of 3O km / hr and a minimum speed of 2 km / hr. There are 8

forward and 2 reverse gears with a high and low selection:
Gear

Max. Speed

I-Low

2.25 km/hr

I-High

8.86 km/hr

II-Low

4.24 km/hr

II-High

16.76 km/hr

III-Low

6.45 km/hr

III-High

25.40 km/hr

IV-Low

8.85 km/hr

IV-High

28.75 km/hr

Reverse-Low

2.81 km/hr

Reverse-High

11.08 km/hr

Following are the main components of Gearbox: (a) Input shaft assembly.
(b) Output shaft assembly.

(c) Lay shaft assembly.

(d) Intermediate shaft assembly.
(e) Actuator shaft assembly.
(f) Gears.
(g) Gear box housing.
(h) Shifter rods.
(i) Shifter forks.
(j)Bearings.
(k) Fasteners, gaskets and spacers.
(l) Planet gear and carrier assembly with internal gear.

Clutch actuator assembly: C.A. assembly contains clutch actuator guide on which the bearing is
tight fitted and locked with circlip. Inner bush is placed and held with
C.A. guider springs.

Lay shaft assembly: The lay shaft is hollow shaft with splines on outer surface. One end of
the lay shaft is threaded (in case of single clutch) and tightened from

front side of gearbox with a hexagonal nut. The whole assembly consists
of gear Z-45 (i.e. constant mesh gear with input shaft gear) spacer
15mm, gear Z-36, gear Z-30, spacer 30mm, gear Z-25, spacer 15mm
and bearing with circlip. The whole assembly is washed. In case of dual
clutch, model the drive shaft is placed through the hollow lay shaft. The
drive shaft consists of splines on one end and a gear (Z-45) on the other
end. The gear constantly meshed with the gear on intermediate shaft.
The main function of lay shaft is to rotate fixed gear on it from where we
can get different speeds with the help of sliding gear on drive shaft.

Input shaft assembly: Input shaft consists of spiral gear on one end and splines on the other
end. Splined part is attached to clutch and geared part (Z-19) is
attached the constant mesh gear of lay shaft i.e. Z-45. Input shaft is put
into the gearbox with the bearing, which is locked by circlip.

Output shaft assembly: Output shaft assembly is solid shaft with splines on outer surface. The
shaft is placed in to gearbox with both ends supported by bearings and
locked by circlip. The back part of shaft is projected out side the
gearbox to give drive from it. The assembly of shaft consists of gears 24,
31 and 34 gears. The sliding gear 34 is used for first and reverse gear,

sliding gear 31 is used for second gear and sliding gear 24 for third and
fourth gear. These gears are provided with grooves on one side to attach
gear shifter fork.

Internal gear assembly: On internal gear two dowels are inserted at their proper place and
faceplate with thrust plate is placed over dowels. The purpose of the
dowels is to locate holes on the plate with respect to internal gear. The
planet carrier contains three planet gears, which are fixed to carrier
with, help of pins inserted through them. The planet gear and carrier
assembly is placed inside the internal gear them thrust plate and outer
plate is placed and tightened by nuts.

Assembly of Gear box: First of all the gearbox is placed over the trolley which is continuously
moving with the help of the chain system. The idler gear is placed with
their idler gear shaft in gearbox its respective place. Then lay shaft
assembly is inserted into the respective holes and tightened from front
side by hexagonal nut. After this input shaft is placed from front side of
the gearbox housing. Its Z-19 is meshed with C.M. Z-45 of lay shaft.
Then the output shaft assembly is placed into the gearbox where its one
side is inserted into the input shaft hole. For dual clutch models the

intermediate shaft, which is hollow, placed over the input shaft and its
Z-21 gear is meshed with Z-43 of connecting shaft, which placed
through the hollow lay shaft. The internal gear assembly is tightened on
the outside of gearbox with output shaft. The four selector rods are
placed in the holes with spring-loaded ball. The gear selector forks are
insel1ed in to the groove of sliding gears and then tightened to the gear
shifter rods with help of the bolts. The forth selector rod is meant for
low and high-speed selection. This rod is connected to the drive shaft,
which is placed into the internal gear. Then Z.F. cover bracket is placed
over the upper side of the gearbox. Z.F. cover plate is consists have the
steering assembly and high, low speed shifter assembly. Then whole
assembled gearbox is send to the main line assembly

REAR COVER ASSEMBLY

Rear cover assembly is used to cover the differential housing. It
contains lift control system, which is hydraulically operated. Driver seat
is fitted on the upper side of rear cover. 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.
(t) 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 ands 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 release 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.

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. This
assembly is fitted inside rear cover. First of all rear cover is mounted on
the moving trolley and light with bolts. The control sector assembly is
placed at there respecting place with actuator shaft and compiler
assembly. A sensor tube with bush is placed at rear side of rear cover.
Then a ram cylinder assembly is mounted inside rear cover. Response
valve 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 checks
value is 9-12kgf and opening pressure of backpressure value is 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 912kgf. As this position the oil goes in the ram cylinder, which, further
operate the lift arm. For requirement of any position lift, the knob of
response value of R. V. housing is rotate which cut off the supply of oil
and the position of ram arm is got. Sensor tube is work in field working
during plugging with harrow and when harrow deeply dug in soil, which
over load the tractor. But to avoid deep digging of harrow in soil the
draft is set at required position through sensor tube. The rocker arm
attached to sensor tube and harrow link, which push the sensor tube
inside and automatically control value control oil supply.
In line phase assembly all the components are assembled together.
Firstly the differential housing assembly is put on moving trolley, which
is connected to the conveyor. Then the gearbox assembly is joined with

help of bolts to differential housing and then accessories mounting are

joined. Two lower links (L T. and RT.) are joining with link plate. The
anchor chain attached with angle plate (with attached to diff. rear side)
and lower side attached with lower link hook. The lift rod upper and
right leveling rod assembly is attached with end of rear cover. Two
straight bars are attached with trumpet housing and lower side link for
supporting. Rocker link is attached with angle plate rocker bar. The
rocker attached to the sensor tube of rear cover assembly. Then engine
assembly is attached to gearbox assembly with nuts and bolts. At front
side of engine assembly the front axle beam assembly is fitted. In axle
beam assembly pivot pin is placed at their hole with thrust washer and
the front axle bracket is attached with axle beam Assembly with nuts
and bolts. Two king pin stub axle assembly (L T. and RT.) are placed in
front axle beam assembled with their steering arm (L T. and RT.) tie rod
end (L T. and RT.), tie rod assembly, steering arm, hub, and wheel rim
front (L.T. and RT.) and other components. Whole brake assembly fitted
on tractor and connected with brake housing through mechanical links.
Then clutch assembly is placed at their place. All other mounting and
accessory are fitted on tractor then it is sent to paint shop through
overhead conveyor. Firstly tractor is washed and then paint on it. Whole
assembly is heated in oven Then tyres, electrical panel, wiring system,

meters, other components, accessory and mounting are placed at their

proper place and then it send to testing department for testing.

Paint Shop
Introduction
The paint shop is the one of the most modernized shop of International
Tractors Ltd, The out looking and surface finish is of world class
quality, Paint give 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 consits 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 present paint
shop is giving an excellent coating, production and finishing of
components of tractors parts.

PROCEDURE FOR PAINT QUALITY:1. Even covering of paint should be there on the components. The
surface should be smooth and there should be no unevenness.
2. The minimum required thickness of painted surface should be 65
microns.
3. The minimum gloss level required is 95%.
4. The components should be free from dust particles.
5. Minimum allowable dust is 5%of the total painted area.
6. The components should be free from dents and other superfical
marks.
7. Minimum allowable dents are 1% and these should not be on the
face surface
8. The painted surface must pass cross batch test 100/100.
9. The shade should be matching with the master shade (this test
will be performed at the time of receiving of paints .however in
doubt the master panel should be consulted.)

Firstly planning is done about how much quantity, what type of

components is to be painted, which is ordered by the assembly
department. Then material or components are recipt from store.
The material and components received are inspected visually. If there is
any welding crack, porousity, crackes present on sheets then material
is rejected and send back to vendor. Right inspected components are
only selected for paint.
Pretreatment follows the visual inspection which primarily
includes the cleaning process. The cleaning process starts from the
perpatory to finishing process. The cleaning includes removal of dirt, oil.
and oxides, scale, greese and other harmful ingredents which ultimately
hamper the life of components pretreatment process are done in
different steps.
I. Degreasing-I

2.

Degreasing-2

3. Water rinse-I

4.

De rusting

5. Water rinsc-2

6.

Water rinse-3

7. Activation

8.

Phosphating

9. Water rinse-4

10.

Water rinsc-5

11. Passivation.

DEGRESING: - IN Degreasing ,the cleaning is done with the help of

alkali. It is efficient and economical in removing oil & grease by
saponification emulsification from the components

removing oil &

grease by sapoinfication agent i.e. caustie soda or sodiummetasilicate

and some soap to aid in emlisisification. The mixture produce serve as
the cleaning agent. The components are dip into the bath the
temperature of 70 degree and the time for the dip depends upon oil and
grease sticking with the components.
DEGRESING - 2:- In this section again same alkali is used. In this bath
the and greese left on the components during degreasing I is
completely removed by the same process.
WATER RINSE - 1:- In water rinse bath the hot water at a temperature
of 75 degree is used for washing the components. The water temp is
adjustable. The components are washed in water rinse to remove the
affects of alkali. The washing is done by dipping the components in the
water.
DERUSTING:This bath contains phospharic acid, so it is also called as acid pickling.
It is used to remove light rust from the components. It also removes
surface oxides when components are immersed in it, and the time

consumed by the components depends upon the scales (maximum time

is 7 minutes). Sometimes pickling inhibitor such as detergent, Liquid
glycol, ether etc. is added to decrease the action of acid upon
components of alumininum and non-ferric.
WATERRINSE3-4:In water rinse bath 3-4 all the components that washed in derusting
bath are washed with water to avoid the further action of phosphoric
acid.

ACTIVATION
In Activation bath, the phosphix chemical is used . In this process the
cleaning of components is performed at, or slightly above room
temperature. Parts are cleaned by immersing in the solvent without
agitation. The time taken by components is 1 to 2 minutes.
PHOSPHATING: In phosphate process the phosphating chemicals is used. This process
creates layer of phosphate on the surface of components which
increases the adherence property of paint. The components are dipped
in the solution of magnesium dehydrogen phosphates at temperature of
70 degree about 10 to 12 minutes. During dipping time the phosphate

from magnesium dihydrogen phosphate decomposes and phosphate

seperate out and form a thin coating on the components.
WATER RINSE 4-5:The phosphate, which does not stick properly to the components is
removed in the two water rinse.
PASSIVATION:In passivation process the hexagonal chromium chemical is used. The
components are dipped into bath at temperature 80 degree for about 10
minutes. Passivation is done on components to stop any further
corrosion reaction and protect against any further oxidation of
components in atmosphere.
After the completion of pretreatment process the components are dried
in oven and then visual inspection is done.
Before painting the components are again cleaned with sand paper to
remove any dirty panicles left on components. The air is also used to
remove the dirty particles if any sticking to surface.
All components are put on to overhead conveyor and again washed with
the air at high pressure. Conveyer is moved with slow speeds.

Firstly the components moves to first booth, which is used to spray

primer on components primer is used to increase the cohesion property
of paint. Then it goes to second booth where second coating of the
primer is given. In booth no 3-4 the top coating is done on the
components. After the completion of final coating the components
moves towards oven where the baking of components is done at 120
degree C far 2S minutes. After baking the visual inspection is done. If
any the following defects is found the components is rejected and
repainted through the previous procedure.
I)

Sanding improper.

2)

Cleaning not OK.

3)

Primer paint fault.

4)

Water splash/oil in air.

5)

Dust after paint.

6)

Pin hole. (due to incorrect temperature).

7)

Paint cloat

8)

Orange peal

9)

Shade not matching.

10)

Denting on surface.

Following are main components which are paint in the paint shop
1) Front rim

2)

Rear rim

3) Side panel (right side)

4)

Head light front

5) Tool box

6)

Channel

7) Top Bonnet Plate

8)

Top plate

9) Top bonnet plate

10)

Top plate

11) Other accessories

ASSEMBLY OF TRACTOR AFTER PAINT OF CHASIS

1. Wiring of Tractor
a) Fiting of self wire
b) Fiting of alternator wire
c) Fiting of parking light wire etc.
2. Fiting of drive seat
i)

Fiting of oil tant

ii)

Fiting of fan

iii)

Fiting of hose pipe.

3. a) Fiting of radium plate

4. a) Fiting of battery
b) fitting of race lever at top with meter
c) fiting of radiato
5. Back mudgourd fitting on the both sides
6. Fitting of backlight and seats on back mudguard.
Fitting of Other Parts
1. Greasing of lift aarm and various parts by pneumatic greasing
gun.
2. Fitting of front tyres

Fitting of rear tyre

1. Fitting of front cover and oil tank cover.
2. Testing of all lights and indicators.
3. Fitting of engine covers.
4. Fitting of air
5. Fitting of front cover.
6. Now tractor is ready for roller testing

ROLLER TESTING
The started tractor is placed on the roller resting m/c such that its rear
wheel should be on the runs for 15 min. at full speed with the
adjustment of its accelerator some load is also applied on the tractor
during the roller testing so that its loading capacity can be checked. If
these are no problem is tractor it is ready for sale.

PROCESS OF ROLLER TESTING:

Before the roller testing front wheels are aligned out side.
Toe of the wheel is checked.
Check the water level of radiator.
Check the Oil level of various parts.
i)

Differential

ii)

Fuel injection pump

iii)

engine sump

iv)

Air cleaner

v)

Check the gauges of tractor.

Wheel alignment, run out etc.

Hydraulic testing. lift capacity.

Noises of various parts.

i.

Gear box

ii.

Differential

iii.

Engine

iv.

Any other part

8. Brake adjustment.
9. Any Type of leakage.
10. Proper stop of engine at desire acceleration.
Roller testing is that process in which correctness & capacity of tractor
is inspected closely in regard of any or more defects or manufacturing of
any part in it.