ABOUT HMT

HMT (HINDUSTAN MACHINE TOOLS) LIMITED was established in 1953 in Bangalore. And this is oldest manufacturing unit of the HMT. The main product of the Company was Machine Tools, Metal forming presses and press brakes, pressure die, casting machines and automatic plastic injection moulding machines, Automatic plastic injection moulding machines, Paper cutting machines, Automatic plastic injection moulding machines, Paper cutting machines, Tractors, Lamps and Lamp making machines, Printing Machinery, Watches. The 3rd unit of HMT LIMITED was established at Pinjore in 1963 with two divisions: Machine Tools division Tractor division. In addition to its units at Bangalore and Pinjore, HMT has many divisions in different states as below: HMT LIMITED, BANGALORE. HMT LIMITED, PINJORE. HMT LIMITED, KALAMASSERY HMT LIMITED, HYDERABAD. HMT LIMITED, AJMER. HMT LIMITED, SRINAGAR HMT LIMITED, RANIBAGH HMT also has an international Marketing division (HMTI) having its offices in different countries. HMT collaborated with reputed firms of other countries to develop its products. HMT manufactures different types of tractor. And their ranges varies from model to model and horse power. The tractors manufactured by HMT are following: 2522 (Orchard Special FX, DX). 3522 (FX, DX). 4022 (FX, AC). 4922 (FX, AC). 5022 (FX, DX). 6522 (FX, DX). 7522 (FX, DX). There are different models and the horse power of each tractor is secret in its name. 1st two digits show horse power of tractor. And last two digits are standard of HMT. 2522 has two cylinders and its horse power is 25 HP. Similarly, 3522, 4022, 4922, 5022, are different modals are three cylinder and they are of 35 HP, 40HP, 49HP, 50 HP respectively. And 6522 & 7522 has four cylinder and they are of 65 HP, and 75 HP respectively. Orchard is a special modal of HMT and is used to harvest grape crops. All the tractors of the HMT are EDI (efficient direct injection) engine.

2 WHY TO CHOOSE HMT TRACTORS! All the tractors are EDI i.e. direct injection gives much more power than any other tractor. There are different cylinder heads for each cylinder i.e. if one of the cylinder head got damaged only single cylinder head needs to replace. Consumption of lubricant is approximately nil. Spare parts are easily available in the market due to which we can repair any where. Each engine is so well designed and tested. Transmission box has provided an ideal gear that helps in reversing the tractor as well as we can also run attachments (tharesor) etc in reverse direction whenever they got stuck. If we need to increase the speed of the tharesor in other tractor we need to increase the speed of the tractor due to this the fuel consumption is get increases. But in HMT tractors, due the availability of the ideal shaft we can increase the speed of the attached equipments in step by shifting the gear. Due to this the fuel consumption become low and efficiency get increases

TRACTOR PARTS
below:1. Engine/crank case 2. Gear box. 3. Housing box 4. Lift 5. Front axel. 6. Manual steering/ power steering. 7. Electrical section.

It is really very tough to explain any machine in just a single part. So for the easiness of study, manufacturing, repairing, assembly etc. all machines are divided in different parts. Similarly, a tractor is also divided into different parts which is mentioned

R&D DEPARTMENT

R & D (Research and development) department is very important department in any industry. As its name is showing its function, that it is the only department which is responsible for research and development, upgradation of drawings, and to change the features of tractor as per requirements, or market demands to satisfy the customers. During our training period we met Mr. Sham lal who is manager in the R&D department. He told us more about this department and took us for a visit of this department. Those industries which are fast growing need revise of their design and range of products. This department is also necessary to face the rivals. And this is only possible by changing the design and upgrade of products on right time. There are so many companies in the market to challenge the company like HMT. Aims of R &D department: Research and design. Upgrade the design. Test the engine and get together with market conditions. Looks on costumers feedback. Make the design better than all the available design of tractor in the market. Work on the future projects in advance. Brought new technologies for high production and new design.

FOUNDRY SHOP
operation is performed in all the other operations.

The foundry shop is very important shop in an industry. It is that place where very 1st

Foundry is that place where metals are formed in different forms by molding and casting. In foundry shop process is started with melting of metal in furnace. An induction furnace is used for melting of metal In HMT ltd. The induction furnaces are available in range of 2 ton -3 ton. And operating temperature is 900 c 1400 C. Operation time is 3 hours to 3 hours. Process is initiated by melting small amount of metal in induction furnace. This temperature is near about 900C when this metal is completely melted; more metal is added in the furnace to get correct volume of melted metal (i.e. 3 ton). Metal is dropped into the furnace with the help of crane. This crane has an electro-magnet. In which metal piece in hold and dropped in the furnace. And it takes 3 hours to 3 hour to complete this process. When the metal is completely melted its temperature reached 1260C to 1400 C, it depends on the size of job which is being melted (i.e. if the thickness of job is more then it would take more time and if the thickness is less then it will take less time).

TESTING: - testing means to calculate the exact proportion of carbon and silicon in molten metal.

Carbon cup

Metal wire Platinumrhodium tube

Fig:-CARBON CUP

A carbon-cup is used to measure the percentage of carbon and silicon. It is made up of sand and consists of a glass tube of platinum-rhodium. It passes from the center of cup having high melting temperature (i.e. it does not melt at 1200C temperature). When the material is completely melted. it is taken out from the furnace with the help of a small container and filled into the carbon cup . And placed on CE apparatus. And left at least 5 minutes over it. As the metal cool down. It gives exact reading of carbon and silicon presence. Readings noted during the operation are following:-

Boiling temperature of metal

: 1202C

7 Percentage of carbon in metal,C Percentage of silicon in metal, si Percentage of phosphorus in metal : 3.16 : 1.94 : 0.03(constant)

These readings can be clearly seen on the screen of CE apparatus.total percentage of carbon, silicon and phosphorus is 3.82%. These values can also be checked theoretically by the formula:Total percentage of carbon, silicon and phosphorus = Percentage age of carbon + (percentage age of silicon/3) +percentage age of phosphorus =3.16+ (1.94/3)+0.03 =3.16+0.646+0.03 =3.83 %( Ans.)

CELL CORE MAKING MACHINE

Cell core making machine is a machine which is used to make core by using sand under high pressure and heat. Cell core making machine are operated by two types of fuel here in HMT LTD, which are: Liquid petroleum gas cell core making machine. Electrically controlled cell core making machine.

Both machines are used to manufacture the cores. The sand which is used for this purpose is composite sand (i.e. mixture of sand and resins). Initially die is heated at 240C and this temperature remains constant for all time till the machine remains ON or (dies are being manufactured). After this sand is press into the die under high pressure. And the volume of sand is regulated by control valve and this selection of volume of sand depends on the shape and size of die which we want to manufacture. This process takes 40 sec to complete this process and temperature range is 240 C260C. Working: - initially the hydraulically operated pallet turns up and the composite mixture of sand and resin is filled into the die under high pressure. The LPG gas is switch on to heat the die. And temperature starts rising. This rise in temperature roasts the core. Because of this core become hard. After this core is taken out from the machine and left for the cooling.

LIGHT MACHINE SHOP

Light machine shop is that area where small and light weight parts are machined. All kind of machining operations are done here such as turning, milling, slotting, threading, gear manufacturing, welding, finishing. The parts produced are gear shifting fork, front axle pivot, steering shaft, front axel pins, P.T. shaft (power transmission shaft), D.P. shaft (differential shaft),all kinds of gears, rear axel, crown wheel and pinion etc. Crown wheel and pinion is prepared on SPIRMATIC MACHINE this machine is made of Switzerland. it is similar like lathe machine. Its tool post is mkounted on the head of the machine and tool post is replaced by chuck (work holding device). This machine has made to produce spiral bevel gears only as its name is showing. Its tool post can rotate on its axis in opposite directions. Its chuck also rotates as usual. Initially, tool travels in linear direction to attain the depth of gear tooth and then ideal rotation of head stock is started. And all the teeth are formed in spiral shape. The circular head stock has readings on it. This is set according to the length of tooth. Pressure angle used for this kind of gearing is 30. Some years ago, pressure angle was used 20 in HMT. But now a day, it is 20.

10

Tool post

Rotating tool post

Tools

chuck

Spiromatic spiral bevel gear cutting machine

The light machine shop has lot of machines in this department for higher production purposes. and each machine has its own work. The machines available in the HMT are different kind of gear cutting machines, single and multi spindle drilling machines, coping lathes, hobbing machines, reciprocating gear cutting machines. Internal & external grinders etc.

11 All small parts of tractor are manufactured here. and all machining operations are done here such as drilling boring, tapping, gear forming, gear finishing, slotting, straighten, welding, turning and facing etc.

The parts created in the light machine shop are:(1) Gear shifting fork. (2) Front axel. (3) Rear axel. (4) Steering shaft. (5) Pivots. (6) Front axel pins. (7) P.T. shaft (power transmission shaft). (8) D.P. shaft (differential shaft). (9) All kind of gears (i.e. spur and helical). (10) Crown wheels and pinions. (11) Sun and planet gears. (12) Planet pins etc.

12

HEAVY MACHINE SHOP

Machine shop is that section where all the parts of the tractor are machined. All the machines are special purpose machine in the workshop i.e. each machine is planted in the industry to do only one kind of work or processes. For this process machine shop is divided into different areas or lines. o Cylinder head machining line o Crank case machining line. o Cam shaft machining line. o Gear box machining line. o Differential machining line etc. And other parts are also manufactured on different machines such as fly wheel, tappet valves etc. Gear box (1) MARKING:Gear box very firstly entered into the machine shop and marking is done with the help of vernier caliper and try square. The vernier caliper has the capacity to measure the specimens of sizes at least 500mm. marking include the following steps. o Mount the gear box/differential on working table. o Set the specimen at 90. o Find out the center of the bore of the gear box. On front and rear side of it.

13 o Match them. But if these points are not in level (i.e. one point in below side and another one is right. Then shift the lower point up and then do the marking.) A gear box is manufacture by passing it through different stages and from different machines. This detail is mentioned below:(2) HORIZONTAL MILLING MACHINE: - on this machine bottom side of the gear box is machined and excess material is removed from the specimen. And then dispatched for further process to the next machine through the crane. (3) RADIAL DRILLING MACHINE: - on this machine two location holes are drilled in the bottom side of the gear box (4) VERTICAL MILLING MACHINE:-. On this machine upper portion of the gear box is machined and excess material is removed form the specimen. (5) DUPLEX MILLING: - on this stage, rough finishing of the font and the rear side of the gear box is done. (6) DUPLEX MILLING MACHINE: - gear box is machined from its right and left side. (7) HORIZONTAL MILLING: - on this stage, slots are made on the upper portion of the gear box. These slots work as a guide for the gear lever during gear shifting. (8) BORING MACHINE: - on this machine two ways boring is done. This machine contains two tools on its both side of the machine. One tool bores two holes on each side. Thats mean a gear box has four holes on each side of it. (9) VERTICAL MILLING MACHINE: - here, the slots which are made on the upper side of the gear box in before process is divided across the length of the gear box. (10) TWO WAY BORING MACHINE: - it is that machine where holes of the upper Sides are bored from the front and rear side of the gear box. And each Tool on each side of the gear box do two holes. (11) TWO WAY BORING MACHINE: - on this machine lower side of the gear Box. The boring process is done from the front and rear side of the gear box. (12) ANGLE BORING MACHINE: - angle boring machine is a special

14 Purpose machine. And it is designed to enlarge the hole at an angle as its name is showing. This machine is used to bore steering holes on the Gear box. (13) MULTI TOOL DRILLING MACHINE:- it is a multi purposes machine. And HMT Use it as drilling machine for right and left side of the gear box. This Has capacity to hold multiple tools together and each tool rotates About its own axis as like as drilling machine. This is used for high Production. (14)SPECIAL PURPOSE DRILLING MACHINE: - front and rear sides of the gear box are drilled on this machine.10 and 12 holes are drilled on front and rear side respectively. (15) RADIAL DRILLING MACHINE:-the holes are drilled on the top, bottom, left and right sides of the gear box in further operations. 16 holes on top side, 20 holes on bottom side, 10 holes on front side and 20 holes on rear side are developed. (16) WASHING MACHINE: - washing process do on the gear box so that dust particles, oil and the fine scraps are removed from the gear box. These dust particles are deposited on the surface of the gear box during machining operations. So it becomes compulsory to remove these dust particles. Otherwise they may cause serious accident during working of the tractor. Water is allowed to flow inside the machine at high pressure. The machine is divided into two compartments. Soapy water is poured in one compartment to wash away the oil, and dust etc. and plain water is poured in other compartment to clean the soap from the surface. And after this process, the gear box is send to the tractor assembly shop, where further operations do according to the process schedule.

DIFFERENTIAL BOX
Differential box is a very important part of an engine or machine system. The main purpose of differential is to differentiate the power on rear wheels when vehicle is taking turn on the curves. Differential is only a part of machine which

15 make possible to the automobiles to turn the radii on the road. It consists of a crown wheel, hydraulic pump, gear wheels. The crown wheel consists of two sun wheels, two planet pins, four planet gears, two flange nuts, and cover and bolts with four strips. The differential box is dispatched from the heavy machine shop. And then all the parts are mounted inside the differential. Like gear box, first of all marking is done on the differential. This marking ensures that how much material is going to be removed from the differential box. After the marking it goes on:(13) DUPLEX MILLING MACHINE:-bottom and top face are machined. (14) machined. (15) are machined (16) (17) (18) milling operations. (19) (20) (21) and left side. (22) RADIAL DRILLING MACHINE: - drilling and tapping is done on front, rear, left and right sides. (23) WASHING MACHINE: - finally box is washed and stored and dispatched to the assembly shop on demands. Fly wheel, brake disc, and other small parts are also produced here. Milling, turning, and finishing operations are also done DOUBLE ENDED BORING MACHINE: - two bores RADIAL DRILLING MACHINE :-Top tapping. 3-WAY BORING MACHINE: - final finishing on right are drilled in front and rear side. 3-WAY BORING MACHINE: - right and left face are MULTI SPINDLE DRILLING MACHINE: - holes are FM3:- It is special purpose machine and used for vertical DUPLEX MILLING MACHINE:- front and rear faces RADIAL DRILLING MACHINE: - location holes are

machined and facing is also done. drilled on front and rear side and also on top and bottom side.

16

HEAT TREATMENT
Heat treatment shop is that shop where physical and chemical properties of the materials are changed by heating or cooling it. Various properties of the material are changed by annealing, quenching, hardening, and carburizing etc. heat treatment basically done to improve the toughness, strength, remove the stresses etc from the work pieces. Forged gears imported to heat treatment department from the metallurgy shop. And then annealing or carburizing is done as per requirements. ANNEALING: - The process is done as stated below: Close the press gas inlet i.e. air and the LPG at the flow meter. Bring the heating chamber temperature 800C. Open the rear door and confirm that the gas in the furnace is burnt off. Shut off rear curtain burner flame manually by closing air and LPG valves. Lock the rear doors with the pins to keep it open always till next running. a) Open the front door of heating chamber. b) Confirm that the gas has been completely burnt out and discharged by combustion c) Open the intermediate door. When the carbon soot burn sparks can be seen and the temperature rises above 900C stop this operation to prevent

17 the damage to the refectories and radiant tubes. d) Close the intermediate door and the front door for 10 minutes to drop temperature to 850C. e) Re-open the front and the rear door to burn the carbon. And repeat it 4 to 5 times at an interval of 10 minutes for the satisfactory burn out of carbon. a) Extinguish the pilot burner of the rear door. b) Close main valve of the LPG. c) Switch off the furnace heater. d) Let the furnace to be cool down with front and the intermediate door closed ( keep the rear door open). e) The fan should be switched off only when the temperature of the furnace is below 300C. f) Open both front and the intermediate doors. g) Forced cooling is to be done when temperature of the power supply from the control panel. CARBURIZING: - carburizing is the method of introducing extra carbon into the surface of the steel. In this case by heating the metal in a furnace into gas this is rich in gas such as methane, propane, and butane. Initially, when the material such as gears, crown wheels etc are brought into the industry it has low hardness i.e. material remains soft. So it becomes very necessary to improve the hardness. It is only done by increasing carbon content in it. For this, metal is heated in the furnace in the presence of gas. Carbon contents are deposited in the metal by doing so. Methane gas is used in the HMT to do this process. Metal in placed in the furnace and its temperature in increased to 950C and left for a sufficient time. During this process methane gas is passes from the furnace. And its carbon is deposited on the metal

18

NEW ENGINE SHOP

New engine shop is that place where all the engine parts are machined like cam shaft, cylinder head, tappets, crank case, etc. Like the heavy machine shop it is also divided into different sections i.e. crank case is machined in a row and the cam is another row, cylinder heads are being machined in another row according to their processes. New engine shop deals in manufacturing of:(1) cylinder head. (2) Crank case. (1) cylinder head :Cylinder head is very important part of an engine as it covers the sleeve and enables the power to develop in the sleeve (or over the piston head). Cylinder head is produced by the casting processes so it needs to be machined for proper shape, size and finishing. The purpose of machining is also to open water jacket and to make holes for tighten it on the crankcase, to make holes for injector and also to provide relief valves. A relief valve provides safety to the engine when high pressure developed inside the cylinder of the engine. A cylinder head has to pass through many stages for finalizing. A different machine has some special works and each machine has designed to do only that works. (As I already has discussed about it) initially, a stock of cylinder head is imported from the

19 foundry shop and stored in the new engine shop temporarily. And the pieces are machined according to the demands. The pieces go for different operations on different machines are:Machines (1) VERTICAL MILLING MACHINE (2) HORIZONTAL MILLING MACHINE (3) ROTATORY INDEXING DRILLING MACHINE Ratatory indexing drilling machine is a special purpose drilling machine. And it is used for high production. it has a rotatory bed which rotates at 360. And it also has 12 steps for single operations. Numbers of specimen pieces are mounted on the pallet and then pallet is feed inside the machine. And process begins. Each piece passes through 12 steps and each step does separate operation. And the process accomplished as roratory table rotates one rotation. (4) SNC-800 (5) RADIAL DRILLING MACHINE (6) VTC- 800 (7) DT- 40 (8) Washing machine (9) RELIEF VALVE/ DIS-PLUG FITTING MACHINE (10) LEAKAGE TESTING MACHINE to test leakage and blow Hole. This machine is used top test the leakage of the cylinder head. 3 kg/cm of air pressure is filled into the cylinder head through its all openings. And the specimen dipped into the water and leakage or blow holes are easily recognized by this. If there is any leakage in the cylinder head air bubbles seen coming out from that place. The core sand got break at 3 kg/cm of air pressure and blow hole got opened. These blow holes generated during the casting of the cylinder head when some sand particle left in the casting during pouring of the metal. (11) GUN RIMMING MACHINE makes valve way. drill washing operations relief valves are fitted. final milling on the bottom Face drilling operations drilling and tapping. operations top & bottom face machined left & right faces, front and Rear face machined drilling, rimming, tapping.

20 The gun rimming machine is used to enlarge the holes of the valve. For this oil coolant passes through the hole and tool also reciprocates in the holes. (12) DIGITAL HEIGHT GAUGE the dimensions and the properties of the specimen. inspection Digital height gauge is an instrument which is used to check all

ENGINE ASSEMBLY
An engine assembly consists of following sections and each section has its own specified work. That is the section will do only that work for which it is specialized. Crank case. Crank shaft and crank cup with thrust bearing. Lubrication plug and punching. Gear fitting Piston Lubrication pump assembly. Front and rear cover assembly. Flywheel assembly. Cylinder head mounting. Water pump and filter assembly. Rocker arms assembly. Fuel injection pump mounting.

21 Injection timing. Magneto starter and alternator mounting. Fan and radiator mounting. Air filter mounting. Air compressor mounting.

1) CRANK CASE:Crank case in a very important part of engine. It contains crank shaft cam shaft, pistons and connecting rods etc in it. It is made of cast iron. Crank case is main body of an engine because all the parts are mounted inside and outside of this case. Crank case Crank caps

Crank shaft place Sump side

Crank case

22

2) CRANK SHAFT AND CRANK CUP WITH THRUST BEARING. Crank shaft is a shaft which converts the reciprocating motion into rotatory motion. Web

Balancing weight

Crank shaft 3) LUBRICATION PLUG AND PUNCHING. Lubricating plug are mounted in crank shaft for lubrication purposes for all engines and punching are done to mark the engine number etc. 4) GEAR FITTING In this section all the gears are fitted and set for their timing and better response Lubrication pump

23 Helical gears Crank shaft Lubricating oil pipe

Crank case

(5) PISTON: -

Gear fitting

Piston and connecting rod assembly Pistons are very important parts in all internal combustion engines. They are generally made up of aluminum alloys. Main function of pistons is to compress the air in the sleeve during the compression stroke and to provide required power in power stroke to the transmission system. (6) LUBRICATION PUMP ASSEMBLY: -

24 Inlet pipe

Helical gear

Fuel feed pump Gear type pumps are used in tractors. It contains two gears inside it. And both the gear is meshed with each other. The pump has one inlet port and an outlet port. Inlet port is connected to inlet tube which is dipped in the sump. And outlet port is connected to the internally built oil ways through which lubricating oil reaches to all the parts of the engines. And it is mounted after the crank shaft over it. (7) FRONT AND REAR COVER ASSEMBLY. These are just a cover made up of the cast iron to cover front and rear portion of the engine. (8) FLYWHEEL ASSEMBLY: -

Flywheel is a wheel which is used to store the energy in it. It stores the energy during power store and releases it during all remaining stroke. The size of

25 flywheel depends upon the size of engines and it cylinders. Size of the flywheel decreases as the number of the cylinder increases. (9) CYLINDER HEAD MOUNTING. Inlet and outlet valves

Inlet port

cylinder head Cylinder heads are very important part of all the engines. They contains inlet and outlet valves, spark plugs or injectors, inlet and outlet valves are tensioned with the help of open coil spring. Rocker arms are used to open and close the inlet and outlet ports. (10) WATER PUMP AND FILTER ASSEMBLY: Pulley

Fan Inlet port

Rotary type water PUMP

26 Water pumps are compulsory in the internal combustion engine to circulate the water in water jackets of the engine. They are always mounted on the top section of the engine and controlled by belt and pulley arrangement. (11) CAM SHAFT: Cams

Cam shaft: for 3 cylinder engine Cam shafts are the common shafts having cam like structure on it. Cam shafts are used to convert rotatory motion into reciprocating motions. cams shafts are mostly used in engines to open and close the valves. (12) ROCKER ARMS ASSEMBLY: -

Rocker arms Rocker pin

Bolts

Rocker arm Rocker arm consists of a rocker main body, two arms, circlips, and a pin. Rocker arms are always used to open and close the inlet and outlet valves. The rocker

27 arms are operated by push rods which are directly mounted on cam shaft. And push rod is supported by tappets. (13) FUEL INJECTION PUMP MOUNTING: -

Fuel injection pump Fuel injection pumps are used in engine to supply the fuel at very high pressure. It is because of the reason that is the fuel is supplied at low pressure it will not burn properly and produces smoke. Therefore efficiency of the engine will reduces. To remove these problems fuel is supplied at very high pressure. Hence, fuel injection pump is necessary. (14) INJECTION TIMING: Injection timing plays a very important role in an engine.. Because this is the only factor which is responsible for the supply of the proper amount of the fuel inside the cylinder. The operator has a manometer type tube. Which is mounted on the FI pump and the very 1st thing is to remove the air from the pump and this is done by loosing and tightens the nut of the FI pump. And once air is removed from pump then it is checked that fuel pump is pumping the fuel at right time or not. And this done by rotating the flywheel. HMT has its own standard that is fuel pump must pump the fuel at 14. And the tolerance is taken as 1-2. (15) MAGNETO STARTER AND ALTERNATOR MOUNTING: -

28

Starter is always used in an engine to start it and it is mounted on the flywheel.

The Alternator is a device which is used to charge the battery which has discharged during the starting the engine. (16) FAN AND RADIATOR MOUNTING :-

Fan and radiator is mounted on an engine to cool down the hot water of the water Jacket of the engine. The fan provides Sufficient air to pass through the radiator. And a radiator is made up of the very small tube or we can say it is cluster of the tube through which water Passes. When air blow from these tube it cools the tube, because of which temperature of water goes down. And this process repeated till the engine works. (17) AIR FILTER MOUNTING: -

29 Paper filter

Outer case

Paper / sponge type Air filter Air filter mounting is very important mounting on the engine. Air filter is used to purify the air which is being used by the engine. The air filter arrangement helps to keep impurities away from the engine if air filter is not mounted on the engine the impurities will enter into the engine and cease it.

(18) AIR COMPRESSOR MOUNTING: Air compressor is used to compress the air. And this compressor arrangement in the tractor provides very important role in different situations when the farmer is working in the field. When:1) Tire got puncture. 2) Pneumatic pressure is required. 3) Using air he can clean his tractor. 4) Can paint his tractor by mounting paint gun. 5) Can fill air in the tires etc.

30

ENGINE TESTING DEPARTMENT

Engine testing department is that department which deals in testing of engines. Procedures of testing of all the modals of engine are same. A water brake dynamometer is used to test the engine. Stated below:o While running the engine at ideal. check the following2) Lubrication of rocker arms. 3) Rotation of push rods. 4) Leakage of fuel oil and water. o Loading of engines (1) Check and record the water temperature.

31 (2) Oil pressure after completion of every specimen. (3) Tighten cylinder head bolts.] (4) Re-adjustment valve clearance and lock the adjusting nuts. Mostly clearance in given 0.03mm for inlet valves and 0.04mm for outlet valves. o Check and record the fuel time for 100CC at rated rpm and full load. o Check and record the fly up rpm. o Total cycle time of engine testing is 1 hour 50 minutes (110 minutes). o Check the oil pressure after completion of the process and oil pressure in the engine is 2kg/m for ideal running and 4 kg/m for rated rpm. Correct power = {load (N-M)*RPM}/7023.74 S.NO. 1 2 3 4 5 6 7 RUNING TIME (IN MINUTES) 10 20 30 30 10 5 5 RPM 700 1000 1400 1700 1600 1800 RATED LOAD (%) NIL 20 50 75 75 100 100

2100/2200 While testing an engine many problems occurs in engine. Then these problems are treated by repairing or replacing the parts. The problem arises during testing are listed below:o Leakage problems o Blow holes in crank cases. o Injector problems. o Fuel injection pump not work properly. o Rocker arm problems. o Compressor problems.

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TRACTOR ASSEMBLY
Tractor assembly shop is that place where complete machine is prepared. Big, small, and very small all the parts are assembled to complete a full working machine (tractor). And this assembly process started from the gear box .initially, stud, nut and bolts tighten on the required places, before keeping the gear box on the conveyor. Now the gear box is mounted on the conveyor, and parts are assembled step by steps: MTH lift gear box mounting.

33 Mechanical brake assembly. Portal/direct axel mounting. Lift mounting. 3-point linkage assembly. Engine mounting. Front axel mounting. Steering mounting. Housing brake mounting floor assembly. Master cylinder and floor sub assembly. Channel plate, trolley hook mounting. Torsion hooks mounting. Greasing and brake binding. Air cleaner and radiator mounting Fuel tank and steering wheel mounted. Radiator water filling Tire mounting. Wheel alignment. Bridge out. Mudguard assembly. Bonnet assembly. Electrical works.

(1)

MTH GEAR BOX MOUNTING: - MTH stand for main transmission housing. MTH consists of gear and differential box. First of all, gears are fitted in the gear box and then differential is mounted on its rear side. The gear box consists of CM (constant mess) gears.

(2)

MECHANICAL BRAKE ASSEMBLY: - here, the brakes are mounted on the left and right sides of the differential box. it consists of brake shoe and main housing of the brake.

34 (3) REAR AXLE MOUNTING: - rear axle is mounted on the left and right side of the differential. The rear wheels are mounted on the rear axles. (4) LIFT MOUNTING: - lift contains a piston and cylinder arrangement in it which mostly used to pick up the load. (5) 3- POINT LINKAGE ASSEMBLY: - these links used behind the tractor engine and helps in lifting the load or trolley etc. two struts are also mounted here. These struts help in raising and lowering the link. And then clutch is mounted in the front side of the transmission box. Clutch assembly consist of (6) Clutch release shaft. Clutch bearing Rectangular key Two open coil spring. Grease nipple.

ENGINE MOUNTING: - now the heart of the tractor is mounted on the transmission system. It provides sufficient power to the tractor to work in the fields and on the roads.

(7)

FRONT AXEL MOUNTING: - front axel consists of hub assembly (tapered bearing, bearing sheets, shim, and castle nut). Now the hub assembly is mounted over the pivots. Pivot is an axel over which hub rotates. This assembly makes a set for one wheel. These kinds of two sets hub assembly and pivots are used to make front axel of the one tractor. Now 2 steering arms, extension, and a pin is mounted on the hub assembly. Which is further fitted with the bracket and tube with the help of cylindrical pin. And front axel assembly is completed. And this assembly is exported to the tractor assembly. Where it is assembled with the tractor. (8) STEERING MOUNTING:- steering assembly consist of steering shaft, 2 ST blocks, nut and screw, left and right side bush, drop arm with washer and castle nut, steering column and hand acceleration pipe or clamp. The steering nut and screw contain 77 round balls in it.

35 (9) HOUSING BRAKE MOUNTING FLOOR ASSEMBLY (10) MASTER CYLINDER AND FLOOR SUB ASSEMBLY: - master

cylinder is mounted on this step. This master cylinder contains fluid in it. This helps in applying the brakes. (11) CHANNEL PLATES AND TROLLEY HOOK MOUNTING:- channel plates support the trolley hook .which further helps to attach trolley and other adjustment behind the tractor. (12) GREASING AND BRAKE BINDING:-on this stage, grease is applied to all required parts and brake is tighten. (13) AIR CLEANER AND RADIATOR MOUNTING: - air cleaner and radiator play a very important role in all automobiles as it clean the air. And radiator cools down the temperature which is flowing in water jacket of engine. These air cleaner and radiator are imported from outside. (14) FUEL TANK AND STEERING WHEEL MOUNTED: - here the fuel tank and the steering are mounted on the tractor.

(15) RADIATOR WATER FILLING: - water is filled in the radiator. (16) TIRE MOUNTING: - the front and the rear tires are mounted on the axels of the tractor. As usual, front tires are small as compare to the rear tires. Rear tires of all the tractors always kept larger so that high amount of torque can be applied to the rear wheel. (17) WHEEL ALIGNMENT: -Wheel alignment is part of standard automobile maintenance that consists of adjusting the angles of the wheels. The purpose of these adjustments is to reduce tire wear, and to ensure that vehicle travel is straight and true (without "pulling" to one side). Alignment angles can also be

36 altered beyond the maker's specifications to obtain a specific handling characteristic (18) MUDGUARD ASSEMBLY: - mud guard work as safety guard in tractors. (19) BONNET ASSEMBLY: - its engine is cover by the bonnet. (20) ELECTRICAL WORKS:-battery is placed in the battery box. And all wiring is done. Front, rear, and indicator lights are fixed on tractor.

PAINT SHOP
Paint shop always plays a very important role in an automobile company. It is very useful in giving attractive look to the machine, automobile or any thing on which it is painted. Every car, bike, or any automobile owner loves his vehicle like his bride. In

37 more right words, paint is like cloth of the vehicle. A beautiful color attracts the peoples. The Beautiful colors show the quality and reputation of company and its products etc. But this beautiful attraction does not come easily. It has to cross through lot of treatments and steps. These treatments are done so that the part gets ability to withstand in all kind of weathers and also wear the attacks of the acid; detergents etc. and these properties are attained by crossing the unit through various processes which are mentioned below:-

PRE-TREATMENT
(1) (2) MATERIAL FROM INSULARLY UNIT: - Material is imported from the outside. And then stored in paint shop. These parts are release as per demands of it. PHOSPHATING: - it is very 1st operation done on the specimens. In these steps rust and dust are removed by dipping it in well maintained solution. This operation is performed in a huge tank. This tank is divided into five parts. And each container does following operation in Following steps DECREASING, RASING, DERUSTING, RASIN. Decreasing comes very 1st in this operation. And the dust, rust and the other impurities are removed from the specimen by simply dipping the specimen into the solution. After the dipping it is rinsed in 2nd tank and then dipped in another tank for DERuSTING and then again rinsed. (3) (4) DERUSTING: - DERUSTING process is done in carbo-bond acid. Its temperature is maintained at 65C. And it takes 12 minutes in completion. ACTIVATION: -for this process a GARDOLANE Z solution is used. and the process is done under the maintained temperature at 35C-40C. And it takes 5 minutes in completion. (5) PHOSPHATING: - the work piece is dipped in zinc chromate solution (GARDOBOND-159) under the maintained temperature at 60C. And it takes 10 minutes 15 minutes in completion. This is the only place where black color coating is done to protect the specimen from the atmospheric effects. (6) PASIVATION: - here some kind of process is done so that rust do not occur again due to atmospheric effects.

PAINTING

38 (1) WASHING: - Before painting washing is done t remove the dust particles from the surface of the specimen. This is a compulsory process because if any dust left behind the process the the specimen will loose its shining effect. And it will look so unattractive. (2) CLEANING: - After the washing cleaning is done. Tag rag cloth is used for this process. This tag rag cloth has a quality; it can absorb the dust particle and resist the spreading of the dust particles over the surfaces of the specimens. (3) (4) (5) (6) SURFACER: - This is used for cleaning purpose. This process is used to remove PAINTING: - Here, paint is applied on the specimens. After painting the OVEN: - Oven is used to dry the paint. The process is done under the maintained DRY SANDING: - This is the only process where dot like impurities and finger residues left after cleaning. specimen is sent to the oven. temperature at 120C-150C. And this process is accomplished within 45 minutes. prints are removed from the article or specimen. This process is done by using a sand paper (no. 180). (7) (8) (9) WET SANDING: - The process is similar as dry sanding. The process is done by OVEN: - Oven is used to dry the paint. The process is done under the maintained CLEANING: - Tag rag cloth is used for this process. This tag rag cloth has a using sand paper (no. 220). temperature at 120C-150C. And this process is accomplished within 45 minutes. quality; it can absorb the dust particle and resist the spreading of the dust particles over the surfaces of the specimens. (10) (11) FINAL PAINTING: - final coating of paint is applied on the article. Stoving OVEN: - Oven is used to dry the paint. The process is done under the maintained This is the last operation of painting department after this the painted article are exported to the tractor assembly shop. Here these parts are mounted over the tractor. paint is used for final painting. temperature at 120C-150C. And this process is accomplished within 45 minutes.

39

TOOL ROOM
As its name is showing that it is that place where tool are been stored. In other sense, it is that place where repairing, making and storing of the tools and dies, jig and fixture are done. Thats mean; tools are manufactured or repaired and then stored here (in this department). And dispatched to different department as per requirement.

40 This improved sense of production gives very high output of the products. If the requirement of an items or products is low then it can be manufactured in the tool room or in the machine shop by single worker. But if mass production is required then tool and dies & jig and fixture are designed in the tool room to the very high accuracy. And then it is used as the master piece in the work shop. All the pieces are manufactured according to the size and accuracy of this piece. Example: - suppose some holes are to be made on a specimen on some particular distances. Then it is done 1st time on any drilling or milling machine. But if lots of similar pieces are there to manufacture. Then its production cost is increased and output will be reduced. Tool room is designed to figure out these problems. A jig or fixture is manufactured here which guide and hold the work piece. And neglect the continuous setting of the machines. Thats why tool room is necessary in all the industries.