Project report of Industrial

training
Of six month
In
Sonalika
International Ltd
Duration: - 2nd January to
30thJune2006

Submitted to: - Submitted by:-

Mr. Manjinder Singh Amrit pal Singh
S.B.S.C.E.T, FZR

1
 Contents

Acknowledgement………………… 3

Preface……………………………… 4

Company Profile…………………… 5

Project 1……………………………… 12

Project 2……………………………… 27

Project 3……………………………… 53

Project 4……………………………… 65

Project 5………………………………l 85

Biblography…………………………… 91

Acknowledgement

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It is a matter of immense pride for me to present report of industrial
training undertaken at International Tractors Limited from January 2006
to June 2006. I am grateful to I.T.L. to give me this opportunity. I am
grateful to Mr. L.D.Mittal (Chairman), Mr.A.S.Mittal (Vice Chairman) &
Mr.D.Mittal (Managing Director) and HRD who allowed me to get training
in I.T.L .I am thankful of all engineers, officers & all workers who provide
me knowledge. I also express my sincere thanks to Principle
Mr.H.B.Sharda principal of S.B.S.C.E.T. Ferozepur & the teachers of
Mechanical department for their matured guidance and encouragement
in the accomplishment of training.

With Thanks.

Amrit Pal singh

S.B.S.C.E.T , FZR

3
 PREFACE OF TRAINING
According to the curriculum after the completion of 3rd year or the 6th
semester there is a six Months industrial to help the students understand
the industrial culture or industrial atmosphere and have a in hand
practical training in the industry in the industry. I have done my training
in International tractors limited which is a joint venture of Sonalika
international and Renault a M.N.C. (Muti National Company) which
makes tractors. It is a leading company in tractor making and is a very
fast growing company after only nine years in tractor making it is number
three in India in this field. I chose this company because I have great
interest in automobiles and there is a great future prospect after wording
in such a big and fast growing firm. My project was to study working
hydraulic lift. The main purpose of Tractor is in Agriculture field like
ploughing fields etc. It is only possible because there is Hydraulic lift
attached to the Differential Housing Assembly. All the main parts of
Hydraulic Lift are mounted in the Rear Cover of Differential Housing. In
our project we studied about the machining and working of various parts
of tractors which I have explained below.

4
 Introduction to the company

Company profile

Sonalika Group Introduction

Sonalika Group is contributing to green revolution in India Since 1969. Initially
it started with Farm Equipments and Machinery. Brand name of the group
products is "SONALIKA". Market share in Farm Equipments is 80 % in India.
Group turnover is 220 Million USD (INR 1000 Crores). Sonalika Group is one
of the top five tractor manufacturers in India. Apart from tractors its product
line includes multi utility vehicles, three wheelers, engines , Hydraulic
Systems , Casting , Forging , Brake System , Automotive components
manufacturing and various farm equipments and implements. 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
art manufacturing facilities, spread in acres, located in the pollution free
suburbs of Punjab and HimachalPradesh.

Sonalika is also an environmentally responsible corporate citizen and has

developed in-house, the vehicle engines that confirm to Bharat II Norms. It is
now in the process of developing the Bharat III engines for its advanced
products. No wonder Sonalika products have created a niche for themselves not
only in India but also in foreign markets. An average growth rate of 30% makes
it one of the fastest growing corporate in India. It also happens to be one of the
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 9001:2000 and
ISO 14001.

5
There tie ups: -
Venture with Renault France
The Company's authorized Capital = Rs.56 million (As on 31/03/2001)
Issued, subscribed and Paid up Capital = Rs.50 Million (As on
31/03/2000)
Shareholding:
Sonalika Group = 80%
Renault Agriculture = 20%
Annual Turnover = Rs.2098 Million approx. (As on 31/03/2003)
Group Turnover
The Group Turnover for the Current Fiscal Year is 1000 Crore INR (Indian
Rupees)

Group Units::

International Tractors LTD Sonalika Agriculture Industries

Sonalika Capital Ltd. Punjab Agriculture Industries
Casting Corporation of India International Cars & Motors Ltd

International tractor Ltd. was established on 1996 - 1997. Now in

JUNE2003, the production rate of tractor is 60 per day. The total no of
employees working in ITL is 1200.The total no of dealers of ITL in India
& neighboring countries are 548. ITL have introduced 15 models of
tractors. There are 5 regional offices in India, which are at DELHI,
PATNA, AHMEDABAD, MANIPUR and BHOPAL. Turn over of ITL if
400/crore. Company got ISO 9001 Certificate in April 1999 BY ICL.
Company is also running its own agriculture equipment making
industries, which is producing thrasher, disk harrow, wheat harvester
etc. They have got collaboration with RENAULT AGRICULTURE LTD.
FRANCE in February 1999. Renault Agriculture provided state of the
art technology and latest designs.
The Company And Its Tie Up With Renault
The company has recently signed a tie with Renault of France who is
the world leaders in the field of tractor manufacturing and was rated as
world’s number one tractor company at the year’s award in Italy. ITL has
signed an MOU with Renault Agriculture, a 100% subsidiary of Renault
group of France to manufacture and market tractors of Renault
Agriculture design in India and neighboring countries. Renault
Agriculture designs manufactures & distributes tractors and agricultural
machinery in 1998; it recorded a scale of more than $ 600 million. It has

6
three factories and 1883 people working for it and is represented in 52
countries across the globe. The MOU signed by ITL with Renault
Agriculture is a three-pronged collaboration, Technical, Financial and
Commercial. Major highlight of agreement is that Renault will open the
European and Asian markets for Sonalika. The world leader will jointly
participate in the inter-national marketing strategies and efforts to market
products of both the companies. Another special feature of the
agreement is that Renault Agriculture will take minority equity stake of
20% in present ITL that will remain under its management control. By
joining hands with the market leaders in France, the world’s biggest
European tractors market, Sonalika is sure to go a long way.
ITL went into collaboration with Renault agriculture of France in July
2000.
Renault Agriculture is a subsidiary of the Renault Group with 51% stake
owned by CLAAS, Germany. Renault Agriculture is the largest tractor
manufacturing company in Europe. It produces tractors in the range of
50-250 HP, having worldwide distribution ands sales network.

Renault Agriculture - ITL agreement results in the production of Ceres

and Solis tractor under Sonalika brand name.

With a turnover of more than € 637 billion (2002), Renault is one of the
30 largest companies in the world. Each year Renault produces over two
million vehicles and employs over 140,000 people. Renault has alliance
with NISSAN to complement the financial and technical strengths
bringing in synergic growth.

7
Mission: -
International Tractors Ltd. offer quality product with distinctive features
at reasonable price .The company ensure better than the best after sale
service for the satisfaction of the customer .The firm is ranked as best in
terms of its quality and production front. Company is exporting its
tractors to different Asian as well as African countries.

Memorandum Of Understandings
The Indian tractor market is dominated by low price, no frills, rugged,
versatile and low to medium powered tractors. Tractors have an integral
part of farm mechanization and have a crucial role to play in increasing
productivity. In India 90% of the tractors are financed by bank credits at
concession rates. ITL has signed MoUs with various banks all over the
country for tractor retail finance, which is giving a special impetus to
company. It has resulted in easy availability of loans to farmers coupled
with quick disposal of cases. The payment rotations have also become
faster from the dealers to the company, which helps cost cutting.

Work culture

The I.T.L. Seeks to create a culture where each employee, vendor, and
dealer feels himself responsible and integral part of the enterprises. The
work culture at I.T.L. Is open & participative. Learning is encouraged in
the company. Every member respects 5 F formulas
1. Fast 2. Focused
3. Fair 4. Friendly.
5. Fun
This governs its approach to business and relationships within the
organization. It has designed its management structure in response to
the needs of quick decision-making and operational flexibility even
through hierarchies and designation does exit. It is a highly informal
organization where communication moves in all direction, decision-
making is quick and to a large extent delegated.

Future plans: -
1. To provide superior quality tractors over all world with new
technology at reasonable rates, and to become no. 1 in
automobile industry within five years.

8
 2. Itl have plans to market 25,000 tractors during current financial
year.
skills through training. The company believes in developing human
excellence.

ACHIEVEMENTS: -
1. Company, which has shown about 127% increase in turnover
within a period of 3 years.
2. Company has produced smoke free diesel engine.
3. Company has increased its production of diesel engines up to 60
engines a day.
4. The company has obtained iso 9001 certification.
5. Sonalika tractors have made rapid strides in indian tractor industry
by having sold 13496 tractors during 2000-2001 achieving over
50% growth vis-à-vis industry drop to the tune of 10% as
compared to preceding year.
6. Itl has a network of around 514 dealers all over india.

Objective of the company: -

The main objective of the company is to bring the latest technology of
high quality and cost advantage to its consumers. By having a strong r &
d with help of its technological partner Renault agriculture, the fully
computerization manufacturing facility ensures a non-stop supply of
quality tractors. Apart from the general objective every departments
have their own objectives. Which are in tune with the main objective of
the company? In that sense the main objective of personnel department
is maximum utilization and development of the human resources
available keeping all the aspect of human being in view? The personnel
department of itl, ensures the welfare of the employees at the maximum
level, and keeps morale of the company at high.

Corporate mission : -
1. To achieve international standards of excellence in all aspects of
agriculture and diversified business with focus on customer delight
through value of products and services and cost reduction.

9
2. To maximize creation of wealthy value and satisfaction for the
shareholders.
3. To attain leadership in developing, adopting and assimilating state
of the art technology for competitive advantage.
4. To provide technology and services through sustained research
and development.
5. To faster a culture of participation and innovation for employees
growth and conditions.
6. To cultivate high standards of business ethics and total quality
management for a strong corporate identity and brand quality.
7. To help enrich the quality of life of the community and preserve
ecological balance and heritage through a strong environment
conscience.
8. Hence the vision of the company can be described as providing
latest technology advanced tractors to the consumers. Maintaining
standards of quality and customers. Maintaining standards of
quality and customers satisfaction. Constantly increasing profits by
achieving higher growth rate. The company had achieved an
impressive over 30% growth rate during last year when the entire
industry was reeling under economic recession.

10
 Production of Tractors

Sr. no. Financial years Production(nos)

1. 1996-1997 396
2. 1997-1998 2808
3. 1998-1999 6375
4. 1999-2000 6493
5. 2000-2001 13502
6. 2001-2002 16931
7. 2002-2003 16627
8. 2003-2004 19616
9. 2004-2005 26855
10. 2005-2006 32741
11. 2006-2007 37841

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 Project 1
Study of the entire machine present in Heavy machinery shop.

Introduction to machines: -

The heavy machinery shop is one of the most important shops of the
industry. It plays a very important role in the production of the tractor. As
the name suggests all the heavy components namely the differential
housing, gearbox housing, crankcase housing, cage and the trumpet are
machine here. The shop is called the backbone pf the industry. The
heavy machine shop divided into five sections:

(1)Differential housing line

(2)Gearbox housing line
(3)Cage & trumpet line
(4)Crankcase housing line

All the sections are highly equipped with modern machinery.

Each section has a process layout i.e. the raw material is received at the
end and the finished component is dispatched from the other. The
machining process is carried out under the strict quality norms. There is
in process inspection at each workstation. The
Component is made to go through final inspection before it is dispatched
for the assembly. The material handling system in HMS shop consists of
hydraulic lifts truck, power hoists, roller conveyors, overhead crane, fork
lift trucks, bins etc. the shop has well designed network of roller
conveyors. The castings from the trucks are loaded onto these
conveyors and the material goes to the respective section. At the end of
each conveyor a section for the inspection has been made so as to
make the component through inspection process. Each workstation is
provided with a power hoist of 500 kg. These are used to pick the
casting from the conveyor and load onto the machine and vice versa.

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Instruments for heavy machinery shop:-

Sr .no Instruments Size Components

1 Vernier calliper 0-100 Diff. Housing,

cage assembly
2 Vernier calliper 0-400 Gearbox
Housing
3 Vernier calliper 0-600 Trumpet
Housing
4 Micrometer 0-25 Gearbox
Housing
5 Micrometer 25-50 Diff Housing
6 Micrometer 50-75 Gearbox
Housing
7 Micrometer 75-100 Trumpet
Housing
8 Micrometer 100-125 Trumpet, diff.
Housing
9 Micrometer 125-150 Diff. Housing
10 Micrometer 150-175 Cage
assembly
11 Depth Vernier 0-200 Trumpet
Housing
12 Bore gauge 10-18 Gearbox
Housing
13 Bore gauge 18-35 Diff & gear
Housing
14 Bore gauge 35-60 Rear cover

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 Machines in HMS
Differential housing line
The differential is the major component of the tractor. Without the
differential we cannot give the tractors the relative movement between
the tyres during the turns. For that we have various machines for there
machining.
These machines are: -

(1) Vertical machining centre-1

(2) Vertical machining centre-2

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 (3) Duplex milling machine-1
(4) Duplex milling machine-2
(5) Rough boring machine
(6) Two way boring m/c
(7) Drilling S.P.M
(8) Fine boring machine-1
(9) Fine boring machine-2
(10) Multispindle drilling machine
(11) Radial drilling machine
(12) Flexi arm (Tapping machine)

(1) Vertical Machining Center :-

The machine is called vertical milling center because in this the tool is
perpendicular to the axis of the job. VMC is a fully automatic and highly
precision machine. The machine is controlled by the computer, which
regulates the feed and the rpm of the tool and also the movement of the
job. In this machine the tool is stationary and the arm moves in z-
direction and the job moves horizontally in x-direction & y-direction.
The operation performed on the VMC is: -
(1)Face milling
(2)Chamfering
(3)Rough milling
(4)Reaming
(5)Fine milling
(6)Boring
(7)Drilling
(8)Doweling

The basic specification of that machine is: -

Standard features of that machine is

Control system: - Siemens 830 GA3 CNC control, With simodrive 6C1
drive system

Axis transverse: -

Longitudinal (x-axis) 1200 mm

Transverse (y-axis) 560 mm
Vertical (z-axis) 560 mm

15
Table size: - 1000*500 mm
Tool change capacity 24

Feed: -
Variable feed 1TO 6000 mm/rev
Rapid transverse 16000 mm/rev

Spindle: -
Nose taper BT-50
Power 5 KW
Speed range 50-6000 rpm

Hydraulic & lubrication system: -

Oil used hydraulic oil 32 Grade

Hydraulic system Tuken
Lubrication system centralized lubrication system

(2) Duplex milling machine : -

It is the hydraulically controlled milling machine. On this machine the

milling can be performed on both faces of the differential housing. The
machine is fitted two circular cutters having 64 inserts and one wiper
each. The 64 inserts are for rough milling and wiper is for the finishing.
The job is fed between these two cutters. Movement of job is in x-axis
only and the movement of cutters is in the y-direction. The machine is
highly précised and we can get the high degree of surface finish.

Standard features of that machine: -

Control system: - Messung XMP-8PLC control system

Basic machine data :-

Type of machine : - Duplex milling machine

No. of milling spindle : - 2
Size of saddle : - 1000*2500 mm
Stroke of saddle: - 1200 mm
Overall dimension: - 5400*5000*2500
Loading height: - 1100 mm
Component clamping: - Hydraulic clamping

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Feed: -
Feed rate 480/240 mm/min
Rapid transverse 9000 mm/rev

Spindle: -
Spindle speed 85 rpm
Power 22*2 KW

Hydraulic & lubrication system: -

Oil used Hyd. Oil 68 Grade

Hydraulic system Tuken
Sump oil capacity 300
Lubrication system centralized lubrication system
Within 220 grade lubrication oil

(3) Rough boring machine: -

It is hydraulically controlled boring machine. In this machine we can bore

the hole for brake housing of dia 109 mm Lt& Rt on the differential
housing and also on bore the hole for trumpet housing of dia 129 mm Lt
& Rt on the differential housing. This machine is used to enlarge the
diameter of various components. Boring machine can be of two types
(1) One way boring machine
(2) Two way boring machine.
In one way boring machine we can bore the component from one side &
in two ways we can bore the component from both of the sides. Both of
those machines are hydraulically operated. In that tool arm is parallel to

17
the component. If we are going for the boring of PTO face or TP carrier
face & it is perpendicular when we bore the trumpet or BP shaft face.

Two way Multispindle boring drilling (SPM): -

It is a special purpose machine. In this machine bore the fine hole for
T.P. carrier and also drill the hole for mounting the T.P. carrier and the
PTO shaft cover and the other accessory on the back side of the
differential housing.

Fine Boring Machine :-

It is also a hydraulic controlled boring machine. In this machine we can

bore the hole of dia 130 mm for the trumpet mounting and break housing
mounting of dia 110 mm simultaneously by fixing the fixture with this
machine. The clamping device is also hydraulic. Boring machine is of
two types
(1) The machine which can fine the bore on the left & right face
(2) The machine which can fine the bore on the rear face & front
face.
These machines are used according to the component whether it is
gearbox or differential.
In differential we use both type of machine because we have to fine the
bore on the right face & the left on machine & in second on for the
finishing operations on PTO & tail pinion bore. In gearbox we use one of
those kinds. We can perform the operation on the input shaft face & the
pump face.

(4) Radial drill machine : -

This machine is move in a radial direction of the job. In this machine we
can perform the operation like tapping and drilling.
The position of the operation on the different component is: -
(a) We can tap various holes like drain plug on the top side of differential &
make many operation on the hole which are made through the VMC like
chamfering etc
(b) We can drill various holes on the rear end where we can fit the shifter
rods in assembly.

The specification of that machine: -

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Control system: - Electromechanical controls

Capacity: -

Drilling in solis 60 mm
Tapping metric fine 70*2 mm

Working range: -

Drilling Radius: -
Max 1500 mm
Min 530 mm

Sleeve diameter : - 350

Sleeve to spindle distance : -

Max 1325 mm
Min 355 mm

Spindle transverse: - 325 mm

Base to spindle distance:-

Max 1420 mm
Min 355 mm

Variable feed : - 0.125 to 1.25 mm/rev

Working surface of base: -

Length 1490 mm
Width 910 mm

Spindle : -
Nose taper MT5
Power 3.6/4.5 KW
Speed 40-180 rpm

Lubrication: -
Oil used Hydraulic oil 68 Grade
Lubrication system Forced lubrication system

19
On that machine we can change the position of the component if we
want to drill hole on the other side of the component by the help of lifter.

Multispindle drill machine: -

Multispindle drilling machine is used to drill the hole at the various
positions of the component. There are two types of machine: -
(1) Which can drill the hole on the trumpet & BP shaft face
(2) Which can drill the hole on filter mounting face & front face of
the component?
This can machine can increase the production of the component by
using the number of operations at one time. The tool that we using in
that machine are present in no. of quantity depend upon the number of
holes which we have to drill as per the drawing.

Flexi arm (tapping machine)

This machine is used to tap the various holes on the rear cover & the
front side as well on the bottom side the top face of the component of
various diameters as per the position that are mention in the drawing.

Gearbox housing line

Fowling is the machine in the gearbox hosing line: -

1. Rough boring machine

2. Fine boring machine
3. Heavy-duty lathe
4. Radial drilling machine
5. HMC 1200 (horizontal) milling machine.

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(1) Rough boring machine: -

This machine is basically used to make the bores in which the

intermediate shaft and the lay shaft are passed. This machine is used to
bore the pump face and the PTO bore face on both the side of the
gearbox. The PTO bore in the gear must of the same diameter when we
bore them. These two bore are in opposite to each other but in the same
alignment or in same line. In rough boring machine we also perform the
operation of chamfering at one position & turning at the middle of the
PTO face. This machine increases the diameter of the various faces by
4 to 5mm.

(2) Fine boring machine: -

In this machine we can fine the bore to limit, which are mentioned in
drawing. The machining of the component is done up to 1mm or +0.005
& -0.00 i.e. is the bilateral limit more than the dimension acquired by
rough boring machine.

(3) Heavy-duty lathe: -

In this machine facing of front face of the gearbox housing up to dia.

418mm and then take the thickness up to 15mm and total length up to
416 mm is done. By using that machine we can perform the various
operations like turning on the inner side of the gear face upon which
facing can be done.

(4) Radial drilling machine: -

This machine is used to drill the component for making the holes for the
shifter fork rods up to the total length of the gearbox i.e.416mm after the
fine boring or the various operations can be done. All the specification of
the radial machines is throughout same in HMS shop.

(5) Horizontal machining center: -

This machine is basically a CNC machine in which we can use various

machine codes and l codes to perform the various operations. On
horizontal machine center we perform the operation of rough milling, fine
milling, drilling of various diameters, chamfering, boring dowelling etc. by

21
using single machine. This machine can increase the production of the
particular component by large scale. This machine is computer numeric
machine in which we can feed the program and the operation. In this
machine we can clamp the component on the bed of the machine and
this bed can move according the required parameter, which is feeded
into the control panel. The machine is controlled by the computer, which
regulates the feed and the rpm of the tool and also the movement of the
job. In this machine the tool is stationary and rotate about its axis & the
arm moves in y-direction and the job moves horizontally in x-direction &
z-direction. The operations which are performing on the gearbox on
HMC are: -
(1) Rough cutting
(2) Final cutting
(3) Drilling of dia 10.2
(4) Drilling of dia 12 i.e. Dowell
(5) Boring of Dowell pin
(6) Chamfering of holes
(7) Reaming of holes.

The specification of that machine is: -

Standard features : -
Control : - simens
Axis transverse : -

Longitudinal 630 mm
Transverse 560 mm
Vertical head 500 mm
Rotary 360°

Table size: - 500*500 mm

Automatic tool changer: -

Capacity 32

Feed
Variable feed ITO 6000
Rapid transverse 32000 mm/min
Spindle
Nose taper BT-50
Power 11/15 KW

22
Speed range 60-6000 rpm

Hydraulic & lubrication system

Oil used 32 Grade

Hydraulic system YUKEN
Lubrication system centralized lubrication system.

Trumpet housing line

Following are the various machines in the trumpet housing line:

1. Lathe (4 jaw chuck, 3 jaw chuck)

2. Multispindle drilling machine
3. Boring machine
4. CNC milling machine.

Lathe (4 jaw chuck, 3 jaw chuck): -

Lathe is basically used for the turning and facing operation manually
without any program feed into the machine. In this machine, we set the
rpm of the chuck along which we can clamp the component on one side
and on the other side we can clamp through tailstock. After we can
perform the various operations like facing, turning etc as per the
requirement.

Multispindle drilling machine: -

Multispindle drilling machine is basically used to make multiple holes at

one time. This machine is used to increase the production of one
component that requires lot of drilling operation on one component. In
this machine we can make the hole of different dia like on front side of
the trumpet it is dia 10.2 mm & on the rear side it is of dia 13 mm. We
can make multiple holes of that of same dia on the periphery of that
component as per drawing.

Boring machine: -

This machine is used to bore the hole of various dia on both the side of
the trumpet at the same time. We can also perform the operation of

23
grooving on that machine. In this machine we can clamp the component
on the bed and the operation can be performed automatically as per the
program feed into the machine control panel. Their cutting bits contain
three edges we can approximately cut 60-65 pieces of the component
with one edge.

CNC Milling Machine: -

This machine can be used to make the facing operation on the topside
of high low gear housing. In this machine we can clamp the component
on the machine. In this machine we can clamp the component at certain
angle so that we can get the smooth surface at some angle as required
in assembly. Then we feed the program on the control panel as per the
drawing like at what angle the cut has to be performed. In this machine
the component can move x direction and the tool can move in y
direction. The control we are using in that machine is Fanuc control. This
machine is completely operated by the codes, which can perform the
operation.

24
 Crank case housing line

This line contains various types of machine

(1)Vertical machining center (VMC 1200)

(2)Gang milling machine
(3)Rough milling horizontal machine
(4)Face milling horizontal machine

Crankcase is of various types like

(1)Two cylinder crankcase

(2)Three cylinder crankcase
(3)Four cylinder crankcase

All of that crankcase require different fixture for them for machining. For
that we are using five vertical machining centers. In this three VMC
contains the fixture of three cal crankcase and one contains the fixture of
two cylinder & four cylinder engine. It can be interchanged as per the
production or requirement of the component.

Vertical Machining Center (VMC 1200)

The machine is called vertical milling center because in this the tool is
perpendicular to the axis of the job. VMC is a fully automatic and highly
precision machine. The machine is controlled by the computer, which
regulates the feed and the rpm of the tool and also the movement of the
job. In this machine the tool is stationary and the arm moves in z-
direction and the job moves horizontally in x-direction & y-direction.

The operations performed on the VMC are: -

(1)face milling
(2)chamfering
(3)rough milling
(4)reaming
(5)fine milling
(6)boring
(7)drilling
(8)doweling

25
In this machine we can machine the component two times. Firstly on the
top side then secondly on the bottom side.
The operation, which we are performed on the topside, is: -
(1)rough milling on cylindrical face
(2)rough milling on the pump face
(3)fine milling on the cylindrical face
(4)fine milling on the pump face
(5) Drilling of dia 6.8 on the pump face.
(6)Drilling of holes of dia 14 on the cyl surface

The operations performed on the bottom side are: -

(1)rough milling on bottom face
(2)rough milling on the bearing cap face
(3)fine milling of the bottom face
(4)fine milling on the bearing face
(5)drill of dia 6.8
It depends upon the number of passes of the cutter on the component
for machining of the piece.
After doing the operation on the component we can pass the component
to these can pass the component to the rough milling horizontal to do
the further operation.

Rough milling horizontal

This machine is basically used to machine the both the faces, which are
perpendicular to the bottom side face. This machine is the Multispindle
machine, which can perform the operation on the different positions,
which cannot be done the single machine. It is hydraulic machine
through which we can perform the operation. This can deplete the layer
by 4.5 mm to get the required dimensions as per the requirement. The
bit we can use in this machine is 3 edges.

Gang milling machine

Gang milling machine is multi cutter machine which are fixed on the
abhor which can be rotated by the spindle at particular rpm. By that
machine we can perform two operations i.e.
(1)Rib milling
(2)Notching

26
The abhor contain ten cutters of same dia from left to right and contains
five notching cutters which perform the operations. These cutter can
rotate circumferentially and deplete the later of bearing from both side by
3mm on which bearing cap can rest and also an the other bearing ends.
The bits we can use in the cutters are three-edged shape. In between
the cutters there are notching cutters, which can perform the notching
operation in the component. It may be of 5 mm in dimensions on both
the ends of the crankcase on which last bearing cap rest. This machine
is hydraulically operated. Through pressurized system we can
performed the operation like up and down movement of the abhor and
the bed on which the component can clamp.

Face milling horizontal

This machine is used to face the component along y-direction in which

the bed can move. This machine is hydraulically operated by that thing
we can move the bed and the tool cutters along the x-direction to the
bed. In face milling, the cutters can move circumferentially along the
pump face, starter face, tender face and deplete the layer of the
boundary lining by 2-3 mm to get the proper adjustment in the assembly.
There tolerance can vary in microns. The cutters we are using are four
in number.

Radial drilling machine

Radial drilling machine is used to drill the component or taping of the

holes, which are made during the process on the various machines at
different positions on the bottom face and on the cylinder face of various
diameters.These are all the brief review of all the machines, which are
present in Heavy machinery shop.

27
 Project 2
Study of the tool life & the parameter that effect the tool profile.

Tools are of various types depending upon the operation that we have top perform
or on what type of machine we are using for the operation.

There are various types of machines which are used in the industry are

(1) CNC machine

(2) Duplex machines
(3) Manually operated machine

These types of machine requires the different tools for there operations
• For CNC & Duplex machines we require small tools
• For manually operated machines like radial drill we require big tools

CNC Machines

CNC mainly consists of two forms: -

(1) Vertical machining center
(2) Horizontal Machining Center

For CNC machines, the tool profiles are as per the machining of any component are
of

(a) Triangular type

(b) Hexagonal type
(c) Rhombus type
(d) Octahedral type
These profiles are depend upon the operation perform on the component. Whether
we have to perform the rough cut or the final cut. In CNC the rough cut requires the
tool, which are of hexagonal form. Which have more number of edges as compare to
the other tool. In rough-cut the rpm of the machine is more and the feed is less as
compare to the final cut. In rough cut the depth of cut is more than 4.5 mm. In final
cut the rpm is more and the feed is little bit more as compare to the rough cut. The
same tool or the tool having a square geometry can be used for the final cut.

Duplex Machine

Duplex machines are of two types: -

(1) The machine that can perform the operation the Left and right side of the
component.
(2) The machine that can perform the operation on the front and the rear side
of the component.

28
For duplex machines, the tool profiles are of different shapes. In duplex machine we
use big tool cutters on which tool are fixed in their particular position and then we
screwed it with the help of device which can check the accuracy of the tool whether
the tool is screwed at a proper angle or not. The tools are in 60 to 64 in number. All
these tools are embedded in the circular disc.

Duplex machines are use for the side facing which cannot be done by the CNC
vertical machining center. In these machines, tools moves around the left & right
hand side periphery & made a cut depend upon the rough cut and final cut
dimensions to be achieved. In rough cut, the feed of the cutter is low and the depth
of the cut is more near about 4 to 5mm. In final cut, the feed is more and the depth
of cut is near about 0.5mm to 1mm. For these types of machines we require the
tools of square geometry or the rhombus geometry.

Manually Operated machines

Manually operated machines are of different type: -

(1) Rough Boring machines
(2) Fine boring machines
(3) Radial drill machines
(4) Multispindle drilling machines.

Rough Boring Machine

In Rough boring machines, we always use low rpm and high feed. These machines
are used to bore the different diameters depend upon the drawing of the component.
In these machines we use the tools of triangular form, which are small and big in
size. These tools are placed on the arms of the tool cutter that is fixed to the
headstock and operated by the spindle. The arms of the tool cutters are in various
lengths depend upon the bore position from the headstock. These machines have
headstocks on both the sides, which can perform the operation as per drawing.
These machines are used for rough cut only which can increase the diameter of the
component.

Fine Boring Machine

In fine boring machine we use the tool that are also of triangular form but small in
size as compare to the Rough boring. In this rpm are high and the feed is also more.

Radial Drilling Machine

In radial drill machine, we can perform those operations of drill that cannot be done
by the VMC i.e. is drilling on the front and the rear side of the component. The tools
that we used are ob bigger in length but are thick in size & having a circular profile.

29
Multispindle Drilling Machine

In these types of machine used various drill of various diameters as per drawing. In
that type of machine there are more than 10 spindles on the both the
headstock. These machines have high feed and rpm as compare to the
other machine.

PROJECT NO. 3

Study of the Differential Line that includes the machining of the

component from first stage to the last stage: -

In that project we can see the various stages that are performing on the differential
housing of various tractors.

There are three type of tractor differential model that are used by the industry that
are: -
(1) CRD model
(2) Solis-3 model
(3) Normal model

These components are machine at different machines because e the fixtures are of
different lengths & breaths.

These differentials are made according to the production. If we need the more
production of any model we can fix the fixtures on the machine & done the
operations. These entire models housings have different dimension along their
length, breaths& their circumferential diameter.

Machining of Differential Housing

There are different types of machines that are used for the machining of differential
housings are: -

(1) Vertical machining center

(2) Duplex milling machine

(3) Window milling machine

30
 (4) Rough boring machines

(5) Fine boring machines

(6) Drilling machine (spm)

(7) Multispindle drilling machine

(8) Radial drilling machine.

(9) Tapping

(a) Machining of CRD Model

CRD model have different dimensions related to other models so it has different
fixtures than the other.

How the machining can be done on CRD, Normal and Solis-3 differential: -
The machines that come in the sequence of the machining is in that way: -

(1) Vertical machining center

For the machining of differential the first machine come is the VMC.
In this we can perform the various operations on the differential as per the drawing.

The operations that we perform on the various side of differential is

(1) Rough milling (B.S)

(2) Drilling drain
(3) Chamfer
(4) Final milling
(5) Rough milling (R.S)
(6) Drilling dia 10.2
(7) Chamfer
(8) Boring dia 11.7
(9) Final cut
(10)Reamer

For the machining of that component we can place the component on the bed of the
machine & mark the reference. Reference the major point in the machining of any
component. From that point we can move to the other directions to perform the
different operations on the various side of differential.
For the machining of the differential we mark the reference as (0,560,560) along X,
Y, Z-axis. From that point we can move to the operations.

31
The operation can be done on the bottom side of differential. In this we can make
the reference & perform the rough cut on the

(1) Vertical machining center (MCH-56)

This machine is used for the CRD & Solis models. In that machine we have to place
the component on the bed of the machine & done the various operation on the
component like milling, drilling, & dowelling on the rear cover side & on the top side.

The sequence of the operations is as follows: -

• Drilling on (rear cover mounting hole)

• Boring for dowelling
• Reaming for dowel hole
• Chamfering
• Milling finish (top side)
• Bottom face milling (rough)
• Drain plug drilling
• Milling finish (bottom side)

By taking the reference we can perform the operations.

(1) Top face milling (rough)

This is the first operation come in the machining of the differential. This operation is
used to remove the layer of material by 5mm form the rear cover face. In this
operation we can fix the component on bottom side by the use of dowel pin that is
near to the drain plug. For the CRD model it reduces the layer by 5mm from 478 mm
to 473 mm & For the Solis model it reduce the layer by 2.4 mm from 468.2 mm to
465.8 mm. In this operation the tool perform the operation the outer periphery of the
component.

(2) Drilling on the top side

In this case dowel have a particular position because the tool always start at the
dowel position and close at dowel position after making one loop.
For the CRD model: -
This is the operation that we can perform on the component after rough milling. In
this operation we can drill 20 holes of dia 10.2 having a depth 26-mm on the outer
periphery of the component on the rear cover side.
For the normal model we can drill 21 holes of dia 10.2 mm on the rear cover side.

(3) Doweling: -

32
This is the major operation that we perform on the particular component because if
the is any error in that particular position the component is rejected. By making that
operation we can form the dowel that is used in the further operations on different
machines.
This component has different dowel position depend upon the model
For the normal model it is 120 mm with the tolerance of 0.20 mm from the left face
on the rear side.
For the CRD model it is at 284 mm with the tolerance of 0.1 mm from the right face
on the rear side.

(4) Reaming of dowel hole: -

This process is used for enlarging the diameter of the dowel to dia 12 with the depth
of 18 mm with a unilateral limit of +0.018 mm this dimensions is same for the
different models. Reaming is done upto 15mm down the z-axis for all the models.

(5) Chamfering: -

This operation is used to chamfer the hole by 45°with 1 mm down along the z-axis.
The chamfering is performing on all the holes that we made on the component
during operation.

(7) Milling finish: -

By that operation we can make a fine cut on the topside of the component & deplete
the layer by 1mm.

After the milling operation the dimensions of the normal is 445± 0.5 mm & for the
CRD is 469 approximately

(8) Milling on the bottom side: -

This operation is used to deplete the layer by 5mm from the two side of the broke
hole & from the drain plug.

(9) Drilling on the sides: -

This operation is performing on the two sides to drill dia 10.2 on the two sides& for
the solis model it is of dia 7 and having a depth of 13 mm.

(10) Drilling drain plug:-

This process is used to drill a hole of 22.5 mm on the drain plug down the z-axis.

33
(11) Milling fine:-

This operation is used to perform to deplete the layer by 1mm on the two sides & on
the drain plug.

DETAILS OF CUTTING TOOL PARAMETER: -

Operation Cutting tool Rpm Feed Life/edge

Rough milling Face mill 700 900.02 26
cutter
Drilling S/c drill 22.5 1120 330.00 1000-2000
Chamfer Chamfering 2000 800.02 60
insert
Final cutter Face mill 750 1500.03 51
cutter
Rough cutter Face mill 700 700.01 26
cutter
Drilling S/c drill 10.2 2000 500.011 500
Boring Boring head 1600 115.00 1000-1100
Final cutter Face mill 750 2000.05 50
cutter
Reamer Carbide 420 90.00 550
reamer dia 12

TIME CYCLE OF ALL THE OPERATIONS: -

Sequence of operation Machine used Cycle time

Rough milling MCH-56 31sec
Drilling drain MCH-56 10 sec
Chamfer MCH-56 11 sec
Final cutter bottom MCH-56 25 sec
Rough cutter (R.C) MCH-56 3 min 34 sec
Drilling dia 10.2 MCH-56 1 min 54 sec
Chamfer MCH-56 16 sec
Boring MCH-56 39 sec
Final cutter MCH-56 1 min 32 sec
Reamer MCH-56 37 sec
These are the various operations & the time cycle of the operation, which can be
done on the machine MCH-56.

Inprocess inspection

34
After doing the machining we can go for the inprocess inspection in which we can
calculate the various dimensions formed by the machine.
The major dimension we can check is the distance between the top face & the
bottom face.
For the CRD model it is 473 mm approximately
For the solis model it is 468.2 mm approximately

(2) Vertical machining center (MCH 57)

This machine is used for the normal model. In that machine we have to place the
component on the bed of the machine & done the various operation on the
component like milling, drilling, & dowelling on the rear cover side & on the top side
as same as the machine MCH 56.
This machine is basically used for the various operations on the rear cover side i.e.
the topside.
The sequence of the operations is as follows: - on the topside
(1) Milling rough
(2) Drilling dia 10.2
(3) Boring for doweling
(4) Chamfering
(5) Milling finish
(6) Reaming for the dowel hole
By taking reference we can perform the operation as same as the machine MCH 56.
The operations are as follows

(1) Milling operations: - In this we can machine the component from the top & also
from the bottom side by performing the milling operations on that faces.
Milling operations are of two kinds
(a) Milling rough: - this is the first operations which we can start the machining. By
this we can deplete the layer by 4 mm from the topside & the bottom side. In dims
between the top face & the bottom face is 448.5 mm after machining.
(b) Milling finish: - this is the fifth operation on the component. In this we can deplete
the layer by app 2mm from the topside. After machining the component the dims are
445.5-mm. These operations give the smooth finish over the topside & bottom side.

(2) Drilling of dia 10.2: - by that operation we can drill 21 holes on the periphery of
the topside that is of depth 26 mm. By that operation we can first drill the dowel.

(3) Boring for doweling: - in this operation we can increase the dia of the one hole
i.e. the dowel hole. After boring the dims of the hole is 11.7 mm on the two faces on
the differential.

(4) Chamfering: - This operation is used to chamfer the hole by 45°with 1 mm down
along the z-axis. The chamfering is performing on all the holes that we made on the
component during operation.

35
(5) Reaming for the dowel hole: - this process is used to increase the dia of the
dowel pin hole from 10.2 mm to 12 mm with the accuracy of + 0.018 mm.
These are operations which we can perform on the differential on MCH 57.
Inprocess inspection: -
After doing the machining, we can check the dimensions between the top face &
bottom face. It must be 445.5-448.5 mm.

DETAIL OF CUTTING TOOL PARAMETER: -

Operation Cutting tool Rpm Feed Life/edge

Rough milling Face mill 700 1100.02 26
cutter
Drill dia 22.5 S/c drill dia 1020 330 500
22.5
Chamfer Chamfer 1600 800 60
insert
Drill dia 12 S/ drill dia 1700 450.01 520
10.2
Final cut (B) Face mill 750 2700.07 26
cutter
Drill dia 10.2 S/c drill dia 2000 500.01 500
10.2
Boring Boring head 1600 115.00 1000-1100
Final cut Face mill 750 3000.07 28
cutter
Reamer Carbide 420 90 550
reamer

CYCLE TIME FOR THE OPERATIONS: -

Operation Machine used Time

Rough milling bottom MCH 57 56 sec
Drilling drain MCH 57 10 sec
Chamfer MCH 57 36 sec
Final cut bottom MCH 57 49 sec
Rough cutter top MCH 57 2 min 34 sec
Drilling 10.2 MCH 57 2 min 9 sec
Boring 11.7 MCH 57 34 sec
Final cut top MCH 57 60 sec
Reamer MCH 57 41 sec
Drilling 12 MCH 57 48 sec

Duplex milling machine

36
There are two duplex machines that have two different fixtures on them. By that we
can perform different operations on the differential housing.
The machines are: -
(1) DMH-58
(2) DMH-59
Both that machine is used for same operations but on the different sides.
DMH 58: - That machine is use for the machining of the normal model differential. In
that machine we can perform two operations that is
(1) Milling first cut
(2) Milling final cut
In this machine we can rest the component on the topside by the help of dowel pin
that are made from vertical machining center. In that machine we face two sides that
is front side & rear side of the differential. The position of the dowel is 20 mm from
the dowel center one along the right face & another on the left face. On that dowels
we can firmly place the component and stat the operations. In this machine the
cutter are along the ± x-axis
& We can place the differential in the fixture via Y-axis. The two cutters move
towards each other & perform the operations.
DMH 59: - That machine is use for the machining of the CRD model differential. In
that machine we can perform one operations that is
(1) Milling cut
In this machine we can rest the component on the topside by the help of dowel pin
that are made from vertical machining center. In that machine we face two sides that
is left face & right face where we can assemble the breaks on the differential. The
position of the dowel is 284± 0.1 mm from the right face one along the rear end
along left face .On that dowels we can firmly place the component and stat the
operations. In this machine the cutter are along the ± y-axis & we can place the
differential in the fixture via x-axis. The two cutters move towards each other &
perform the operations.

Cutting tool parameter for DMH 58

Operation Cutting tool Rpm Feed Life/edge

Face mill
Milling first cutter left
Face mill 85 480/240 63
cutter right
Face mill
Milling cutter left
Second Face mill 85 480/240 63
cutter right

Cycle time for the operations for DMH 58

Operation Machine used Time

Milling first DMH 58 2 min 34 sec

37
Milling final DMH 58 2 min 15 sec

Cutting tool parameter for DMH 59

Operation Cutting tool Rpm Feed Life/edge

Face mill
Milling first cutter left
Face mill 85 480/240 63
cutter right
Face mill
Milling cutter left
Second Face mill 85 480/240 63
cutter right

Cycle time for DMH 59

Operation Machine used Time

Milling cut DMH 59 6 min 40 sec

After doing the operations then inprocess inspection come in which we can check
the distance between the two faces i.e. is left & right.

Rough boring machine

Rough boring machine is basically used for the boring operation. This machine can
bore along the different directions of the component. This is hydraulically operated
machine. In that machine the tool that we can use of triangular profile.
RBH-20-21-22-110: - these are the different machines on which we can perform the
work.
RBH-20 is used to bore the normal tractor differential. It is used to bore the PTO
fixed face. The dimensions before the machining is 105 approximately but after
machining it becomes of dia 114 mm. It can also perform the other operation facing
rough in which it can form the dimensions of 367.5 mm between the front face the
intermediate face.
RBH-22 is used for the operation on the normal differential. In this operation the
component is rest on the machine on the rear cover side. In that machine the
operation is performed on the left & the right side of the component. Before perusing
for the operation the dims is dia 123 on the trumpet face & dia 100 0n the brake
house face. After machining its dims changes from 123 to 129 app on the trumpet
face & 109 on the brake housing face. This operation is performing on the both the
faces of the differential.
RBH-21 is used for the operation on the CRD model differential. In this operation the
component is rest on the machine on the rear cover side. In that machine the
operation is performed on the PTO bore faces of the component. Before perusing for
the operation the dims on the inner face is dia 72 & 73.5 & dia 72 on the outer face.
After machining its dims changes to dia 79 & 73.5 mm on the inner face & dia 79

38
mm on the outer face of the component. This operation is perform on the both the
rear & the intermediate faces of the differential.
RBH-110 is used for the operation on the CRD model differential. In this operation
the component is rest on the machine on the rear cover side. In that machine the
operation is performed on the left & the right side of the component. Before perusing
for the operation the dims is dia 128 on the trumpet face & dia 104.71 on the brake
house face. After machining its dims changes from to 134 mm app on the trumpet
face & 111.70 mm on the brake housing face. This operation is performing on the
both the faces of the differential i.e. left & right.

INPROCESS INSPECTION

After doing the operations inprocess inspection comes. In which they can check the
bore by the pressure gauge. if the reading on the pressure gauge goes in + the
component is machined accurate if in – it id defective.

Detail of cutting tool & their cycle time

For RBH-21

Operation Cutting tool Life /edge Cycle time

Boring rough inner Boring carbide 150 4 min 53 sec
Boring rough outer Boring carbide 150 4 min 4 sec

For RBH-110

Operation Cutting tool Life/edge Cycle time

Bore bar unit 1 Boring carbide 150 4 min 40 sec
Bore bar unit 2 Boring carbide 150 3 min 35 sec
Drill on break S/c drill dia 30 1000 ( multiple 2 min
pedal face edge)

RBH-20

Operation Machine used Cycle time

Boring dia 109 RBH-20 3 min 34 sec

Window milling machine

Window milling machine is used for the machining on the widow that is present on
the right & left face near the front side. In that machine the component is placed
along the front side in the down direction.

39
In this machine the two operations are performed on the component i.e. the window
milling on left side & boss milling on the right side. In that machine both the
operations done at the same time.

When the operation is performed the dimension of the right face from the center is
153± 0.1 mm & having a perpendicularity of 0.10 and along the left face its distance
is 143± 0.1mm from the center of the component.

INPROCESS INSPECTION

After the operation we can check the distance between the window face & the boss
face. It must be of dimension 286± 0.2 mm.

Parameter of that machine: -

Operation Cutting tool Life/edge Cycle time

Milling rough Face mill cutter 150 6 min 28 sec
Milling fine Face mill cutter 150 6 min 10 sec

Fine boring machine: -

This machine is use to perform a final operation on the component. That operation
is fine boring that is made upon the hole by the rough boring. It depletes 1mm from
the various sections of the component on which the rough boring is performed.
There are various machines for the operation to be performed.
FBH-108-109
FBH 108is used for the CRD model. In that machine various operations are
performed like TPC face, inner & outer face & facing & grooving on the rear end
bore. After the machining TPC has a dimension of dia 120± 0.035 mm. Boring inner
& outer have dimension dia 80+0.035 accuracy & on the outer it is dia 80 +0.035.
Grooving is done on the PTO face at distance of 196.45 mm from the bp shaft face
to the intermediate face. The grove is of dimension 3.18 mm from one face of the
differential & having a dia of 83.5 mm.
FBH-109 is used for the operation on the CRD model differential. In this operation
the component is rest on the machine on the rear cover side. In that machine the
operation is performed on the left & the right side of the component. Before perusing
for the operation the dims is dia 134 on the trumpet face & dia 111.70 on the brake
house face. After machining its dims changes from to 135± 0.04 mm app on the
trumpet face & 112.712± 0.035 mm on the BP shaft face. This operation is done on
the both the faces of the component.

Operation Cutting tool Rpm Feed Life/edge

Boring Fine boring 280/240 3000 60
unit

40
 Boring in Face boring 280/140 3000 60
unit
Boring out Face boring 280/140 3000 60
unit
Facing STGCRION11 280/140 3000 34
Grooving Grooving tool 280/140 3000 70

After that the component that is machined goes to the threading machine where we
can make tapping on all the sides of the component.
After the machining& the inprocess inspection the process comes final inspection.
For the final inspection TRIMOS is use that can calculate the CD of the component
from the different sides. With this instrument we can take one surface as a base or
the reference after that we can get the various figures that we need as prescribed in
the drawing.

PROJECT-4
THE STUDY OF TRACTOR ASSEMBLY SHOP

Process chart of tractor assembly line

Diff. Sub. Trumpet Gear box Rear

assy Hsg. Assy. sub assy. cover
assy.

Diff. Hsg. Trumpet Gear box Rear cover Oil

Loading on assy. Mtg. assy. Mtg. assy Mtg. filling
line

41
Engine
Primer Dry-up Chasis Front axle assy Mtg.
zone zone washing assy. Mtg.
 Front axle Engine assy
& related & related
components component

INTRODUCTION

Tractor assembly shop is main shop of ITL. In this shop the different machined parts,
housing and other components which are 'finished or machined in other departments
of the industry and other component which are purchased from vendors are
assembled here. Then assembled components like differential housing, gearbox,
rear cover, Trumpet housing and other housing are send to main line for Tractor
assembly. In main Tractor assembly line tractors are send to paint shop through
overhead endless chain rotating conveyor. It is supported from ceiling and has a
fixed path to travel which saves valuable floor space. The arrangement is such that
lifting mechanism (with help of hook) lowers down for loading and unloading of
tractors.

42
Following are main phase of assembly:

1) Differential housing assembly.

2) Gearbox assembly.

3) Rear cover assembly.

4) Main line assembly phase.

5) Paint phase.

6) Assembly of accessories and inspection.

1) DIFFERENTIA HOUSING LINE

43
 Process chart of differential assembly

P.T.O. shaft sub

assy.

Clean the casting & Load the casting Fit the drain plugs Fit the P.T.O.
punch the serial no. On on the working with the washer & shaft in the
the casting trolley tight it. casting

Cage & B.P. shaft assy.

44
 Cage & B.P.
shaft sub assy.

Insert the left B.P. shaft on the left side Fit the thrust Wash the cage &
of casting & cage & insert the right bearing cone on the B.P. shaft sub assy.
B.P. shaft into the cage from the right left side of casting In washing machine
side of casting with little hammering

If backlash is more than

0.3mm move shim from
right to left

Fit the seal carrier on Preloading (12kg) Fit the T.P. carrier Apply yellow paint
B.P. shaft with shim is done to check with shim (0.2- to check backlash &
(0.2-0.5mm) &tight it the No. Of shim 0.5mm) & tight it setting of teeth
temporary & bearing setting temporary.
If backlash is less
than 0.2mm move
Brake housing sub shim Rt. to Lt.
assy. Trumpet sub. Assy.

Fit the Brake Fit the link plate Fit the trumpet Tight the seal
housing on the & P.T.O. shaft assy & bull gear carrier & T.P.
spline of B.P. cover. in Diff. Housing. carrier tightly
shaft.

Oil filter & P.T.O

shifter sub assy.

Fit the plain cover

with oil filter & Fit the sliding Fit the Fit the
Fit the rocker link
P.T.O. shifter sub & fixed Chain
angle Bkt.
assy. P.T.O. gear

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.

45
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)

• Shims

• Gaskets

• Fasteners

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.

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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.

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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 – loading is 8 kgf.
and crown wheel pre - loading is 12 kgf. Crown wheel run out is 0.05 - 0.1 mm and
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.

By assembling the different devices we can from the differential

Differential that we assemble on the line are different in there sizes. It depends upon
what model which we assembling. Every model has their specification.
The different views of the differential are: -
Top view full assembly of differential PTO fixed & sliding

GEAR BOX ASSEMBLY

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

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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.

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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

The different views of gearbox are: -

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 (lay shaft) (Shifter forks)

(Intermediate shaft) (Front view of normal Model gearbox)

(Rear view) (Clutch disengage)

The basic diagram of gearbox with the attachment with the differential is show
below: -

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52
 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

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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 9-12kgf. 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.
The top view views of the rear cover assembly: -

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The basic component that describe in the figure is
(1) Rock shaft
(2) Ram cylinder
(3) Coupler assembly
(4) Spool arrangement
(5) Relief & pressure valve
(6) Rear cover housing

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The views of the part of rear cover assembly: -

(Sensor tube)

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 LINE ASSEMBLY PHASE

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. The way we can work on the tractor on the assembly line is
shown below: -

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