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The country, India, is basically an agricultural country where more than 65 % of population enough food has to be produced. This cannot be produced with our conventional bullock drawn implements. So there was need felt to invent such machine which speeds up the agricultural production. Due to this reason the tractor was invented. Before we start, it is necessary to know how the word tractor is derived. Prior to 1900, the machine i. e. tractor is known as traction machine (pulling machine). After 1900, both the words joined by taking tract from traction and tor from motor calling tractor. The tractor is the machine which is used for applying high traction. In our country, tractors were started manufacturing in real sense after independence and at present, we are self-sufficient in meeting demand of countrys requirements for tractors. At present in India, there are different tractor producing factories present like Hindustan machine tools, Punjab tractors, Kirloskar tractors, etc. is directly or indirectly connected to agriculture. Moreover for increasing .
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COMPANY PROFILE
BIRTH OF HMT
In 1949 the idea of public sector tools was commissioned to be a corner stone for the governments industrial development plans. This led to the birth of HINDUSTAN MACHINE TOOLS at Bangalore in 1953 which started a single machine tools factory to produce lathes at Bangalore, in collaboration with M/s Oerlikon of Switzerland. Next, the company widened its product range beyond lathes by entering into technical collaboration with other international leaders in machine tools such as Fritz Werner, Herman Kolb, Errantly Somua, Gildermeister, Liebherr etc. The second machine tool unit was set up in Bangalore in 1961 making use of the Companys own resources. The company diversified itself when, in collaboration with Citizen Watch Company of Japan, the first watch factory was setup in Bangalore in 1962 to produce hand watches. The third machine tool unit was set up in 1963 at Pinjore, Haryana to produce milling machines. In next few years, Machine Tool Units were set up at Kalamessary in Kerala and in Hyderabad. The Printing Machinery division was attached to machine tools factory at Kalamessary to qualities Printing Machine. HMTs tractor business commenced its operations in 1971 in technical collaboration with M/s MOTOKOV, Czechoslovakia because of the priority given to the agriculture in the national development plan and to take advantage of the green revolution. HMT started the operations with the manufacturing of 25 Hp tractors. Over the years, it has developed tractors ranging from 25 75 Hp. The unit in Hyderabad began to make lamps and lamp making machines in 1973 to cater to the growing needs of rural. This was followed by producing automatic watches. A third watches factory was established in Srinagar to manufacture hand wound watches for men. In 1975, the company took over the machine tool corporation of Indias unit in Ajmer, Rajasthan and its name was changed to HMT Limited. In 1975, a separate international scales network called HMT was set up comprising of companys own agencies as well as other sales agents in Australia, Page | 2
Europe and America. This network was to handle the marketing strategy and operations of the company overseas and it also extended its services to the other leading Indians and overseas engineering companies. Since then this international arm of the company has set up the turkey project in Algeria, Indonesia, Iraq, Kenya, Nigeria and Srilanka.
HMTS PRODUCTS
HMT PRODUCTS The main products produced by HMT ltd are Machine tools, Watches, Tractors, Bearings, Printing Machinery, Die Casting Machinery. The divisions of HMT are described below
BANGALORE
It produces lathes (both CNC and Non CNC), milling/ machining centers, grinding machines, gear cutting machineries, simple drilling machines, special purpose machines, die casting and plastic injection moulding. It also produces refurbishing and retrofitting like heavy duty, turret lathe, multi spindle drilling machines and fine boring machines. Page | 3
The other application components include the jigs, fixtures, some radar and transonic components. It also develops hinomerik control system, Hyderabad.
CNC MACHINE
HYDERABAD
It produces the machining centers, CNC, Boring machines, milling machines, die and mould machining centers, presses and brakes. It also produces special purpose machines like CNC tube chamfering machines, cam shaft milling machines, filament winding machines, horizontal and vertical coil winding machines, multi spindle machining centers.
KALAMESSARY
It produces CNC lathes and printing machineries.
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AJMER
It produces grinders and lathes. It also manufactures some application components like hydraulic lift mechanism for tractors, valve devices and oil priming pump.
CNC MACHINE After establishing two machine factories and a watch factory in Bangalore, the Pinjore unit was established as the third machine tool factory. Breaking the ground on 2nd may, 1962, this factory
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TRAINING CENTRE
In training centre, the basic machines are studied such as Lathe Machine, Milling machine, Drilling Machine, etc.
TURNING SECTION
FITTING SECTION
MILLING SECTION
TURNING SECTION
In turning section, we have learnt about the lathe machine which is mother of all machines and play a basic role in mechanical line.
LATHE MACHINE
Lathe is probably the oldest machine tools. The basic idea about turning or lathe machine came out in 17 century. Until 1770, lathes were useless metal cutting because they lacked power and holding device, were not strong enough and accurate enough to guide the tools. For its development to the form in which we know it now, we owe much to Henry Muldsley, who developed the sliding carriage and in 1880 built a screw cutting lathe.
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LATHE MACHINE
FACING
This operation is carried out to produce flat surface at the end of part, which is useful for parts that are attached to other components, or face grooving to produce grooves for O-ring seals.
DRILLING
In this process a drilling of desire diameter is held in the tail stock and the operation of drill is carried out.
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BORING
In this enlargement of hole or cylinder cavity made by previous process is done. It improves accuracy and surface finish.
THREADING
In this operation internal and external threads on the surface are prepared.
KNURLING
In this operation a regularly shaped roughness is prepared on the cylindrical surface for fascinating easy gripping.
FITTING SECTION
Fitting work is very important work in engineering. In fitting shop unwanted material is removed with the help of hand tools. It is done for mating, repair and manufacturing purpose. The person working in fitting shop is called as fitter. Commonly used tools are hacksaw, files, chisels etc.
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MILLING SECTION
Milling machine were basically developed to machine flat surface. But, the present machine can machine flat, countered and helical surfaces, cut gears and do various other jobs. Due to this all milling machine is one of the most useful and necessary machine tools found in the shop and it rank next to the lathe in importance. Milling machine are designed to hold and rotate milling cutter or cutters, hold the work piece and feed the work piece to the milling cutter in one several directions.
MILLING MACHINE
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FOUNDRY MECHANISMS
Since there are certain basic steps in the metal casting process, these may be used as unit of mechanism. Processing steps which lead them to the mechanism are:
FOUNDRY MECHANISM
SAND PREPARATION
CORE MAKING
MELTING
CLEANING
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FOUNDRY SHOP
SAND PLANT SYSTEM SAND HANDLING SYSTEM CORE MAKING AND BAKING SYSTEM MOULDING MAKING AND HANDLING CORE SETTING SYSTEM
TESTING LAB
FETTLING SECTION
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BUCKET ELEVATOR
When sand is to be conveyed vertically upward, a bucket is ideal. There are two pulleys, one at the top and other at the bottom which carry an endless belt. The belt carries number of buckets all around and the whole assembly is enclosed in steel casting which has two openings, one at bottom for feeding and other at top for discharge.
BELT CONVEYOR
It is used for transferring sand from one place to another. It consist of endless belt, two pulleys or idlers for carrying a loaded belt and returning the empty belt, a belt tightening mechanism and the belt cleaner. The angle of inclination should not be exceeding 150 for dry sand.
Cooling time in oven 3 hrs. After baking, the hardness is tested by using hardness meter
CORE MAKING
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MOULD MAKING
MOULD BAKING
Dry sand moulds are to bake to acquire hardness to with sand the pressure produced by the flow of molten metal. These are baked in ovens. Mould baking cycles for ovens 300C for 2 hrs. and Cooling time in oven 3 hrs.
MELTING SECTION
It is having two types of furnace. 1. Electric induction furnace, 2. Copula furnace.
FETTLING
After they are knocked out on vibrator shake, the casting head to be finished by the removal of projections whether they are gets riser or runner that where there as a part of design aspect or the projection which has appeared as a defect like fins or blow holes. The process that involves all these procedure of casting finish is termed as fettling.
Fettling operation is divided into following stages: 1. Knocking out of dry sand cores, Page | 15
2. Removal of gates and risers, 3. Extraction of fins and other projections, 4. Cleaning and smoothing of the surface, 5. Repair casting by filling of the blow holes, straightening the wrap or deformed casting.
MELTED METAL
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BOTTOM MILLING
SLOT MILLING
WASHING
FINAL BORE
TOP MILLING
TAPPING
BOTTOM MILLING
With help of crane we put the work piece on the milling machine (SPM). Bottom milling is done for removing the extra material on the gear box housing.
TOP MILLING
Put the housing on milling machine according to location holes. Top milling done for removing the extra material on the housing.
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SLOT MILLING
In this milling we made the slots for gear forks which used for change the gears. Dimension of slot is 16mm.
BORING
Boring is done for removing extra material from bores to make the bore according to their dimensions.
TAPPING
Tapping is for making the internal thread in to the drilled holes and for joining purpose.
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WASHING
Washing the gear box housing.
INSPECTION
Inspect the housing for defect like blow hole or others.
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MILLING
MARKING M.T HOUSING
BORING FINISH
WASHING
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HORIZONTAL MILLING.
Horizontal milling is done for removing the extra material or allowances according to their drawing
RADIAL DRILLING
Radial drills are used for the made the location holes in the housing and these locations are used for seat the job on the different type of machine.
BORING
In this boring operation we do rough boring of front, left & right bores. Dimensions of bores: Left hand bore: 290mm. Right hand bore: 288& front hand bore: 90mm
BORING FINISH
After horizontal milling we put the housing on the boring machine on their location holes. it is done for finishing purpose.
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WASHING
Washing is done to remove chips and oil. this is done after all the operation.
INSPECTION
Inspection of work piece according to their drawing.
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SPLINE SHAFT
A shaft with longitudinal gear like ridges along its interior or exterior surface is called spline shaft. the function of spline shaft is to transmit the power from flywheel to lay shaft. Material used for spline shaft is low carbon steel.
SPLINE SHAFT
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RAW MATERIAL
CUTTING OF SHAFT
CNC TURNING
FITTING.
GEAR HOBBING.
INSPECTIO N
WASHING.
INSPECTION
GEAR SHAVING.
BENCH DRILLING
After these process spline shaft send to heat treatment plant for hardening process. 1. Gas carburizing & hardening. 2. Tempering 3. Shot blasting. 4. Straightening. 5. Centre grinding. 6. Internal grinding. 7. Fitting. 8. Inspection
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RAW MATERIAL
ANNEALING
TURNING
MATERIAL CUTTING
GAS CARBURIZI NG
CYLINDRICAL GRINDING
FACING
WASHING
THREAD ROLLING
TURNING
FITTING
DRILLING
STRAIGHTENING
INSPECTIO N
GEAR HOBBING
TEMPERING
SHOT BLASTING
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WHEEL SHAFT
Wheel shaft is assembled in axle housing and its transmit torque to wheels.
WHEEL SHAFT
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RAW MATERIAL
FACING DRILLING
RADIAL DRILLING
GEAR HOBBING
INSPECTION
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HEAT TREATMENT
All components (manufactured in LMS) after undergoing machining operation are subjected to heat treatment. It is done so as to improve hardness and strength of these components viz. gears and shafts. Basic operations performed during heat treatment: 1. Hardening, 2. Quenching, 3. Annealing, 4. Tempering, 5. Normalizing, 6. Carburizing. Melting temprature: 6400C, Carburizing media 13- 15 % sodium cyanide + 85 % BaCl + NaCl
HARDENING
For medium carbon steel and high carbon steel 8400C- 8500C For other 770 8200C Hardening is performed on the various metals and its alloys to provide them with strength and wear resistance. It is accomplished by heating the component above its hardening temperature and quenching it in water.
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SHAFT HARDENING
QUENCHING
Emercing hot metal in desired water or oil does quenching. Here transfer of heat is ensured at slow rate so as to remove internal stresses to permissible limit.
QUENCHING MACHINE
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QUENCHING FURNACE
NORMALIZING
In this process, iron alloy casting is heated to 50 600C above critical temperature range. The casting is held for definite time and then allowed to cool in still air. Normalization eliminates casting or cooling strains and resultant casting is easy to machine.
CARBURIZING
Process of adding carbon to surface layer of the component is called carburizing. It is the process of casehardening, which is addition of some elements like carbon, nitrogen to the surface by diffusion for surrounding medium at high temperature the purpose of carburizing is to obtain high surface wear resistance and obtain a hard surface.
TEMPERING
For medium carbon steel and high carbon steel 6700 - 6800 C Page | 31
for fasteners tempering to be done at 3500 4000 C for 1 2 hrs. In tempering long grains formed during quenching are broken into smaller grains so as to improve elasticity of the material. Here heating is done at around 1800 - 2000 C for around 2 hrs. and then cool in air. It reduces internal stress and stabilizes the structure of metal.
ANNEALING
For medium carbon steel and high carbon steel 6800 6900 C.
CASE HARDENING
Carburizing + hardening.
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ENGINE ASSEMBLY
CRANKSHAFT FITTING
First of all bush type liners are inserted into the bearing holes. The liner is provided with recess to store a minimum amount of oil, which wets as the crankshaft during storing engine. The bearing cap is opened and crankshaft assembly is placed into it. The bearing cap is tightened again with 10-12 kg-m torque rod and crankshaft is checked that it is revolving easily or not
CRANK SHAFT
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TIMING GEARS
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CAM SHAFT
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FLYWHEEL MOUNTING
The flywheel is mounted on the crankshaft and bolts are tightened with 11-12 kg-m force. The F.I.P is connected to F.I.P gear through F.I.P shaft The F.I.P drive shaft is specifically designed to advance the time of injection. The both ends of F.I.P drive shaft is provided with spline, One side a key is provided which is locked to timing gear and recess on their side is pushed into F.I.P slots. The angle between the key and recess of 18 degree thus the fuel injection is advanced by 18 degree.
FLYWHEEL
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4. Outlet of F.I. pump is connected to a small pipe to collect the fuel. 5. Now the flywheel is rotated so that piston moves towards the TDC. As we know when piston moves towards the TDC, the plunger in the F.I pump covers the spill port and fuel starts flowing out through the outlet pipe. 6. Now the flywheel is brought to the marked position according to design and then the F.I. pump is tilted, keeping its input shaft fixed so that fuel starts flowing out. 7. Now the FI pump is fastened on the same position.
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ENGINE TESTING
INTRODUCTION
Engine testing is done for checking the performance of newly assembled engine to find out any assembly fault, their HP, leakage and other fault. Engine testing shop of standard is equipped with latest digital control equipment. The engine testing is done with the help of turbine (water) or hydro dynamometer is four in number so that four engines are tested at one time. The shop is equipped with heavy duty oil filter, which is used to clean the oil from dust or other large particles the shop has bush pump tester is measured on the based of S.A.E rating. The society of automobile engineers USA has specified die method of measuring the power output of the engine for standardized purpose. The engine is run without generator.
TRACTOR TESTING
Tractor testing is done under the international organization for standardization (ISO). The first tractor with an internal combustion engine was introduced in American agriculture in the year 1889. The tractor testing act was passed in U.S.A in 1920. In India tractor testing station was finally establish at Budani in 1959 for tractor testing atmospheric pressure shall not be less than 96.6 Kpa. The basic task is design and development of engines is to reduce the cost and improve the efficiency and the power output. In order to achieve the above task the development engineer has to compare the developed engine with the other engines in terms of its output and efficiency. Towards the end, engineer has to test the engine and make measurements of relevant parameters that reflect the performance of the engine
ENGINE TESTING AT STANDARD TRACTORS, PURPOSE OF TESTING A TRACTOR ENGINE In general purpose of testing an I.C engine is to determine the following: 1. To determine the rated power output with respect to the fuel combustion in kg per kw hr brake power output 2. To determine the mechanical and thermal efficiencies of the engine 3. To see the performance of the engine at different loads 4. To determine the quality of lubricating oil required per B.P.Kw-hr. Page | 42
5. To determine the quality of cooling water required per B.P.Kw-hr. 6. To determine the overload carrying capacity of the engine 7. To prepare the heat balance sheet of the engine
CONTINUOUS POWER
The power which engine is capable of delivering continuously between the normal maintenance intervals stated by the manufacturer at the stated speed and under stated operating conditions
INDICATED POWER
It is the total power developed in the working cylinder by the gases on the combustion side of the working pistons
FRICTION POWER
It is the power consumed in friction resistance
BRAKE POWER
It is the total power consumed in friction resistance
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FUEL CONSUMPTION
It is the quantity of fuel consumed per unit power per unit of time. It is general expressed in grams of fuel consumed per B.H.P.
MECHANICAL EFFICIENCY
It is defined as the ratio of the power obtained at crankshaft i.e. brake power to the indicated power. Thus mechanical efficiency = brake power (B.P.) / indicated power (I.P)
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With the help of the data we calculate following parameters 1. B.H.P = R.P.M *N-M / Dynamometer constant 2. IN KILOWATTS = R.P.M *N-M / 9549.305 3. Specific fuel consumption (S.F.C) = 297000 / B.H.P*fuel time
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CAGE ASSEMBLY
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BRAKE ASSEMBLY
Standard tractors are provided with heavy self energizing water sealed disc brakes with ventilation pipe, which gives better cooling. This ventilation results in 30% reduction in pad temp. Brake housing cover contains two discs made up of asbestos base. The max temp resistance is about 300C. Below these discs there are two cast iron disc plates (with steel balls), which are held by springs. Whenever brake is applied, the CI plates rotate and due to presence of balls these plates moves axially 7 press the brake pads against broke housing and differential housing. As the brake pads are mounted on BP left & right, therefore above discussed process results into braking action.
BRAKE ASSEMBLY
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BACKLASH TESTING
This test is performed with the help of plunger dial gauge. Backlash in crown wheel is not allowed more than 20 to30 micron. If it deviates from this value then packing is changed on either side of cage in bearing housing. If it exceeds the 30 micron value then shims are removed from right side and shifted to left side. If it is less than 20 micron then vice versa. Also run out for crown wheel is 0.5-1 mm.
The bull gears are tighten to trumpet housing assembly by lock nut and the whole assembly is also tightened by nut and studs on the outer side of differential housing. Then PTO shaft head cover is tightened to protect its outer teeth. The sliding gear and PTO shifter rod assembly is mounted on differential housing. Two filters are placed inside the differential housing and then whole assembly is sent to main line.
The main components of rear cover assembly are:1. Control valve assembly 2. R.V. assembly 3. Ram cylinder and piston assembly 4. Operating sector assembly 5. Sensors tube assembly 6. Gaskets, Bolts and Nuts 7. Other components
R.V. ASSEMBLY
It contains one response valve, check valve and release valve. It is also connected with control valve through pipe housing. The knob is placed on the top of response valve to close or open the response valve as per requirements. These days R.V housing and control valve are integrated into single unit.
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First of all, rear cover is mounted over the moving trolley and tightened with bolts. Then operating sector assembly is placed at its respective place. A sensor tube is placed at rear side of the rear cover. Earlier R.V. housing was used to fit outside the rear cover which was connected to the control valve through piping in the rear cover housing. But now these days both R.V. housing & control valve are integrated into single piece and it is fitted inside the rear cover. Control valve contains three valves i.e. back measure valve(3-6 kgf), unloading valve and scroll valve. Oil from pump goes to R.V. through pipes, which is further connected to the check valve through inner hole of R.V. housing and back pressure valve of control valve. The operating pressure of check valve is 9-12 kgf and
operating pressure of back pr valve is 3-6 kgf. During un-operated position, the oil flow continues through back pr valve of control valve. During operation of position arm the unloading valve closes the gallery of oil to the back pr valve. Thus the pressure in the R.V. housing builds up which opens the check valve at 9-12 kgf. At this position, the oil goes in the ram cylinder, which further operates the lift arm. For requirement of any position of lift, the knob of response valve of RV housing is rotated which cut the supply of oil and position of ram arm is achieved. Sensor tube works in the field during ploughing of soil with harrow. When harrow deeply dug in soil, draft is set at position through sensor tube. The rocker arm attached to sensor and harrow link, when push the sensor tube inside and automatically controls oil supply.
box are higher mechanical efficiencies and lower noise level due to use of helical gears instead of straight spur gear. It gives the tractor a top speed of 30 kmph and a minimum speed of 2 kmph. There are 5 forward and one reverse gears with a high and low level.
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TRANSMISSION GEARS
CLUTCH ACTUATOR
Clutch actuator assembly contains clutch actuator guide on which bearing is tight fitted and locked with circlip.
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Then lay shaft assembly is inserted into its respective holes and tightened from front of gear box housing by a hexagonal nut. Z-19 gear of input shaft is in constant mesh with Z-49 gear of lay shaft. Then output shaft assembly is placed into the gearbox where its one end is supported over the needle bearing in the input shaft and other one is supported in the gearbox housing. For D.C. models, the intermediate shaft, which is hollow, is placed over the input shaft, but both shafts are free with respect to each other. A gear Z-21 is keyed to this shaft, which is meshed with a gear Z-43. This Z-43 gear is keyed to the shaft which drives the PTO shaft. This particular shaft is passed through the hollow lay shaft and supported on needle bearings in the lay shaft. The four selector rods are placed in the holes with spring loaded ball for each rod. The gear selector forks are inserted into the groove of sliding and then tightened over the gear shifter rods with the help of bolts. Then another selector rod is fitted, which protrude on the back side of gearbox. This rod actuate epicyclic gear train of the high-low shifting assembly. Then the top of gear box is covered with its top mating part and then fastened with the bolts. Then the gear box is sent to the main assembly line.
CLUTCH ASSEMBLY
Clutch is device used to connect and disconnect the tractor engine from the transmission gears and the drive wheels. Clutch transmits power by mean of friction between driving members and driven members. Generally dual clutch is used in the HMT Tractors.
MT HOUSING ASSEMBLY
In this housing the differential unit and the hydraulic pump is fitted also it provide the special arrangement of gears.
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LIFT MOUNTING
After mounting of axle on the differential lift is mounted on the main transmission housing which is used for the load up to 1200 kg and 1400 kg.
ENGINE MOUNTING
After then engine is mounted on gear box and MT housing and portal assembly with the help of bolts.
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GREASING ZONE
Greasing is done all the greasing points with the help of pneumatic gun. The following are the grease points: 1. Front wheel hub 2. Front axle extension 3. Front axle pin 4. Clutch shaft 5. Right hand stud 6. Three point linkage 7. Tie rod end Three free play of foot brake is maintained 2mm.
AIR CLEANER
After fitting the air cleaner radiator is attached with engine. The main purpose of radiator is providing the cooling to the engine i.e. the remove the heat from engine. Water and alcohol is used as coolant in the radiator.
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TYRE MOUNTING
After attached all parts tyre is attached with tractors. After assembly the tyre alignment of wheel is done.
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SPECIFICATIONS
95 110 2100 2300 + 60 14
0.3 0.4
7. 8.
9.
10.
First ring Second ring Third ring 11. 12. 13. Nozzle spray holes H. P. pipe size (mm) Ring colour on injector
0.2 0.4 0.4 0.6 0.25 - 0.5 5 0.2 150 6 1.8 500 Utility green
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MODEL 3022
SPECIFICATIONS
102 110 2100 2300 + 60 22
0.25 0.25
7. 8.
9.
10.
Piston ring end gap (mm) First ring Second ring Third ring 0.35 0.55 0.35 0.5 0.35 - 0.5 4 0.3 160 6 1.5 400 Golden yellow Page | 62
SPECIFICATIONS
95 110 2100 2270 + 60 22
7. 8.
9.
10.
Piston ring end gap (mm) First ring Second ring Third ring 0.2 0.4 0.4 0.6 0.25 - 0.5 4 0.21 150 6 1.5 500 Utility green
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MODEL 4022
SPECIFICATIONS
95 110 2100 2270 + 60 14
0.3 0.4
7. 8.
9.
10.
First ring Second ring Third ring 11. 12. 13. Nozzle spray holes H. P. pipe size (mm) Ring colour on injector
0.2 0.4 0.4 0.6 0.25 - 0.5 4 0.21 150 6 1.5 500 Utility green
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MODEL 4922
SPECIFICATIONS
102 110 2200 2400 + 60 14
0.3 0.4
7. 8.
9.
10.
Piston ring end gap (mm) First ring Second ring Third ring 0.2 0.4 0.4 0.6 0.25 - 0.5 4 0.21 150 6 1.5 450 Golden yellow Page | 66
MODEL 6522
SPECIFICATIONS
102 110 2220 2400 + 60 14
0.3 0.4
7. 8.
9.
10.
Piston ring end gap (mm) First ring Second ring Third ring 0.2 0.4 0.4 0.6 0.25 - 0.5 4 0.25 150 6 1.5 450 Golden yellow
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BIBLIOGRAPHY
1. 2. 3. 4. 5. Daily dairy (H.M.T.) Operator manuals(H.M.T.) Wikipedia http://www.wikipedia.org/ Hmt. Website http://www.hmttractors.co.in/ Google search https://www.google.co.in/
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