A VOCATIONAL TRAINING REPORT

OF

SIX WEEKS INDUSTRIAL TRAINING, UNDERTAKEN

AT

INTERNATIONAL TRACTORS LIMITED

HOSHIARPUR

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS

FOR THE AWARD OF THE DEGREE OF

BACHELOR OF ENGINEERING IN MECHANICAL ENGINEERING

SUBMITTED TO: SUBMITTED BY:

ER. ABHISHEK CHAUHAN ANKIT SEHRAWAT

ER. GAURAV SAINI SG-14910

DEPARTMENT OF MECHANICAL ENGINEERING

UIET, PUSSGRC HOSHIARPUR

 PREFACE

Industrial Training is a most important part of study curriculum in engineering education

field . I am a student of B.E in Mechanical Engineering at Panjab University SSG Regional
Centre, Hoshiarpur and had underwent industrial training for SIX WEEKS in
SONALIKA International Tractors Limited.

So for the industrial training I have preferred Tractors Industries

because of its bright future. INTERNATIONAL TRACTORS LTD. vill.Chackgujran,
Hoshiarpur is one of the best firm , which has got ISO 9001 certificate in just two years
of its establishment. The firm has acquired the state of the art technology from Renault
Agriculture Ltd. France with whom they have collaborated. Now company has joint venture
with Yanmar, Japan. The profits and growth of company is amazingly superb. In just three
years of establishment the company is ranked in top positions. The Research &
Development center of firm is completely modern with latest technology. The work force of
company is highly skilled at the top level as well as at the floor level. At the same time
the fresh graduates bring in the fresh ideas.

The company is contributing its maximum to agricultural sector

of country in terms of tractor & its implements. The second unit of company is
engaged in making tractor implements which is again have strong hold in market. So I
have preferred to join INTERNATIONAL TRACTORS LIMITED for SIX WEEKS
training.

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 ACKNOWLEDGEMENT

I am grateful to International Tractors Limited, for providing me with an opportunity

to work with them and undertake a project of such importance. This training and
experience has not only enriched me with technical knowledge but has also imparted the
maturity of thought and vision, the attributes required to be a successful mechanical
professional. Sincere thanks to all my colleagues at ITL for their support and assistance
through out the project.

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 CONTENTS
Topic.

1. Preface

2. Acknowledgement

3. Contents

4.Company Profile

5.Tractor

6.Engine assembly
Introduction
Connecting rod & Piston Assembly
Head assembly
Main assembly
Engine specification
Engine testing

7.Gear and Heat treatment

8.Light machine shop (LMS)

9.Heavy machine shop (HMS)

10. Engine testing

11.Research & Development centre

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 INTERNATIONAL TRACTORS LIMITED
(SONALIKA)
COMPANY PROFILE

Sonalika group started its journey of success during 1976 with foundation of small unit to
fabricate and assemble wheat-harvesting machines. With the passage of time this small
initiative taken by Mittals in 1976 turned into a great success due to the undaunted
efforts of its promoters and thousands of employees who worked unaltered throughout.
The great success provided further motivation ultimately resulting in setting up a new
plant in the name of International Tractors Limited for the production of tractors as the
demand and requirement of which was growing at a good pace. The plant which was set
up at village Chak Gujran, Hoshiarpur and is spread over an area of 65 acres (approx.)
And obtained the certificate of incorporation on 26th, February 1996. Now Sonalika
group consists of 3 companies:
1. SONALIKA AGRICULTURE INDUSTRIES
2. INTERNATIONAL TRACTORS LIMITED
3. INTERNATIONAL CARS AND MOTORS LIMITED
International tractor ltd was incorporated on October 17,1995.It was established on 1996 -
1997. Now in Feb-March, the production rate of tractor is 100-125 per day. The total no
of employees working in ITL is more than 3000.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.
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.
The main head office of ITL is at Mauritius.
THE COMPANY AND ITS TIE UP WITH YANMAR:
The company had signed a tie-up with Yanmar, Japan. The MOU signed by ITL with
Yanmar, Japan is a three-pronged collaboration, technical, financial and commercial

5
GLOBAL PRESENCE
A key element of ITLs growth is its strong commitment to the global marketplace. We
constantly align our production platform in response to customer demand. As a result the
company is making its presence felt in more than 80 countries across all continents and its
international opportunities and pursuits are growing. The global recognition of ITLs
growth has been highlighted by strategic investment into the Group by leading international
brands like Yanmar of Japan and Private Equity Partner, Black Stone of Singapore.
Through world class integrated manufacturing facility, a well-equipped research and
development center, a robust dealership network, consistency in our quality of products and
services and our customer centric approach, we are aiming to become a well-respected global
player.

MISSION:
International tractors ltd. Offer quality product with distinctive features atreasonable 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.

ISO CERTIFIED COMPANY:

Recently the company has also obtained the ISO 9001:2000 certifications thereby
becoming the only tractor company in Punjab to obtain such certification.

RECRUITMENT: -
Diploma/graduate engineers are recruited through
Campus interview
Employment exchange
Advertisement
Also the candidates up to particular level have to undergo a better of compulsory
selection tests, which include Personality, aptitude test & a series of functional tests, by

6
which competence of the candidates at the cognitive level is assured. Important factor
considered while selecting an individual are the set of aptitude and values an
individual possess , as this determines the ultimate adjustments between organization
and employee. Many times vacancies are also filled by circulating the requirement
internally, for e.g. the scheme of fast track to managerial carriers. Candidates
with the necessary aptitude under goes a selection test programmers based
assessment center methodology. Those who are successful can jump almost four
grades.

TRAINING AND LEARNING:-

All classes of employee are trained. Non skilled are trained to become skilled worker
and skilled worker are trained to acquire multiple skills. Diploma and graduates
engineers are trained for one year. There are special managements programmers
andclasses. In addition to the job related training all employee attend self-development
programmes.

WORK CULTURE:
The ITL Seeks to create a culture where each employee, vendor, and dealer feels
himself responsible and integral part of the enterprises. The work culture at ITL is
open & participative. Learning is encouraged in the company. Every member
respects 5 S formulas.
1.Seiri 2. Seiton 3.Seiso 4.Seiketsu 5.Shitsuke

5s stands for the first five letters of the Japanese words:

JAPANESE
S.No. MEANING
WORD
Sorting out, clearing, segregation, proper selection and remove the
1s SEIRI
waste
Systematic arrangement, keeping things at proper place.
2s SEITON
A place for every thing and every thing in its place.
Cleaning. Keep all the work place area, equipment clean
3s SEISO
Standardizing, environment, cleanliness. Light, noise, punctuality.
4s SEIKETSU
(Order and save time)
Maintain discipline and standards
5s SHITSUKE
To maintain above 4s,respect the rules.

7
The 5s also helps to develop and maintain a good organizational behavior. This
program started in ITL from December 2000. The ultimate goal of house keeping
through 5s is to reduce the cost of product by increasing productivity and
contributing to total quality.
OBJECTIVES OF COMPANY
1. 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 and the
fully computerized manufacturing facility, ITL ensures a non-stop supply of
quality tractors. Apart from the general objective, every department has their own
objectives, which are in tune with the main objective of the company. In that
sense the main objective of R&D department is to have the best in product
development with maximum utilization of the human resources available.

2. CORPORATE MISSION OF THE COMPANY

To achieve international standards of excellence in all aspects of agriculture and
diversified business with focus on customer delight
To maximize creation of wealthy value and satisfaction for the shareholders.
To attain leadership in developing, adopting and assimilating state of the art
technology for competitive advantage.
To provide technology and services through sustained research and development.
To faster a culture of participation and innovation for employees growth and
conditions.
To cultivate high standards of business ethics and total quality management for a
strong corporate identity and brand quality

8
OUR BRAND

The company represents two types of brand, namely:

Sonalika
Solis
SONALIKA

The brand logo depicts a rising sun and a growing crop. The yellow colour of rising sun
symbolizes cheerfulness and good health.

Sonalika was a special variety of wheat seed that was responsible for ushering green
revolution in India. The brand logo depicts a rising sun and a growing crop. The yellow
colour of rising sun symbolizes cheerfulness and good health. The green crop
symbolizes fertility, growth and harmony that our brand aims to spread around the
world. The blue signifies stability, power, elegance and formality which Sonalika aims
to bring in farmers life. The color red signifies strength, and has been used to depict
our product strength. It depends on the vision one looks at the logo. It can also be
seen as the yellow gear symbolizing togetherness and collective growth. We at
Sonalika believe in taking our partners along in terms of aggrandizement and
prosperity

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 The word SOLIS is a Spanish name derived from the Latin sol SOLIS, literally meaning
sun. The blue used in logo associates with stability, power, elegance and formality

The word SOLIS is a Spanish name derived from the Latin sol SOLIS, literally meaning sun.
The blue used in logo associates with stability, power, elegance and formality. Just like the
sun is important for sustaining human life on earth, similarly our brand aims to be equally
important in farmers life to sustain production. The cursive font depicts consistency, and the
outline embraces the strength ensuring quality and consistency in our product

10
VARIOUS MODELS
INTERNATIONAL TRACTORS LIMITED THE COMPANY
As the name suggests, the company is related with the production of tractors and started
its commercial production on October 14th, 1996. At present, the company is producing
different models of tractors, which are: -
DI-730 DI-35 DI-740 DI- 55 DI-750 DI-750III
DI-745 DI-745III DI-750-1 DI-750-III DI-60 DI-75
DI- 90 Etc.

11
12
The monthly production rate of tractors is 3000 to 3800 tractors. The assembly shop is
designed such as to assemble 140 tractors per day. The tractors manufactured by the
company have secured a special place in the market because of their maximum pulling
power and minimum fuel consumption and have achieved a reputation for performance
and quality.
At present the company has a strong nationwide network of more than 528 dealers.
This distribution of dealer network has helped the company to provide sales and services
to its customers. The company is catering to the market throughout not only India but also
various other countries like Nepal, Sri Lanka and South Africa, Nigeria, Zimbabwe.

Tractor-A brief introduction

A wheeled, self-propelled vehicle for hauling other vehicles or equipment and for
operating the towed implements; also, a crawler, which runs on an endless, self-laid track
and performs similar functions.

A farm tractor is a multipurpose power unit. It has a drawbar for drawing tillage tools and
a power takeoff device for driving implements or operating a belt pulley. The acreage to

be worked, type of crops grown, and the terrain all impose their requirements on tractor
design. Accordingly, models vary in such details as power generated, weight, ground
clearance, turning radius, and facilities for operating equipment. All models can,
however, be grouped under four general types: four-wheel, row-crop or high-wheel,
tricycle, and crawler.

Tractors are rated by their horsepower they deliver at the drawbar and at the belt. On
small models, the drawbar and belt horsepower may run as low as 10 (7.5 kW); on large
models the drawbar horsepower runs as high as 132 (98 kW), while belt horsepower
reaches about 144 (107 kW).

The major components are engine, clutch, and transmission. These components are
intimately related and designed to work in conjunction with each other to accomplish
specific work. Tractor engines are relatively low-speed; their maximum horsepower is
generated at crankshaft speeds in the neighborhood of 2000 rpm. These engines have one,
two, three, four, six, or eight cylinders and operate on gasoline, kerosene, liquid
petroleum gas, or diesel fuel. They are of the spark-ignition or diesel type, operating on
the four-stroke-cycle principle, and are cooled by water or air.

Power is transmitted to the rear wheels or to all four wheels. Drive to the front wheels is
mechanical or hydrostatic, its purpose being to increase drawbar pull at the will of the
operator. Transmissions have 3, 4, 5, 6, 8, 10, or 12 forward speeds and one or two
reverse gears. Clutch less hydraulic transmissions are also used, making it possible to
shift gears while in motion. Vehicle speeds are low, ranging from slightly more than 1
mi/h (1.6 km/s) to about 18 mi/h (28 km/h) in high gear.

The basic design of an industrial tractor for hauling and for operating construction
equipment departs little from that of a farm tractor, and differences in design of models fit
the vehicle to its intended work. Because high ground clearance is not needed for
industrial work
ENGINE ASSEMBLY SHOP

INTRODUCTION:-Engine can be called as heart of automobile. Engines are used for

different purposes. The engine used in INTERNATIONAL TRACTORS is of these
types. The engine fitted in 740 DI is made by SYMPSONS, which are imported. The
engine in 740 & 760 models are assembled in the engine assembly shop. The engine
in 50 & 60 H.P. are of two types one is standard model and its design is taken from
ZETOR of Checkosolavia and other is fuel efficient model in which crank case and
head design is taken from AVL (Auto Vehicle Ltd.0 of Austria). Due to better
performance of F.E. model engines the production of standard engines is stopped now.
The engine shop of INTERNATIONAL TRACTOR LTD. is well furnished with
latest fitting and checking instruments. . The workers in this shop are of high skill
level and have lot of experience. The production of shop is about 50 engines per day
and can be increased if required. All the component of engines except crankcase is
brought from outsides. The shop is having latest engine testing shop and having latest
equipment. In testing shop engine is checked for efficiency, specific fuel
consumption, power, torque, leakage, rpm and other faults.

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CONNECTING ROD &PISTON ASSEMBLY
In this assembly we have to take four identical connecting rods are taken whose
weight isnt differing by 10 grams. For that every connecting rod is weight and group
of same weight connecting rod are kept separately. If there is difference in weights
(more than 10gms) then it may cause vibration and stress over gudgeon pin. The four
connecting rods are marked with identical marks. The piston is assembled to
connecting rod with piston pin and locked with the cir-clip. The problem that may
occur is that piston pin may not go easily. This problem can be removed by rubbing
the pin by sand paper. Three rings are used in piston. Two top rings are used to
maintain the compression and third is required for lubrication. The lubrication rings is
having a groove in its center and spring is inserted into it. The spring acts as reservoir
of lubrication and continuously applies oil to sleeves.

15
HEAD ASSEMBLY
Wash the cylinder head block with diesel and dry it with air. Put the cylinder head on
fixture and press injector holder bush into it with the help of hydraulic press. Check
the leaking of water jacket around injector bush with the help of pressurized air. Valve
lapping is done with the help of valve lapping compound called as silicon carbide .The
machine automatically prepare the seats. Pouring diesel into the seats checks the valve
seats. If there is leakage then again valve lapping is done with inlet and outlet valve is
position locate the valve inner spring and lock it. Similarly the outer spring is loaded
and locked it, after this cylinder pins are pressed and rocker arm support stud are
reserved. Oil seal is put in the counter proved in water hole. This prevents the water
leakage into head assembly.

MAIN ASSEMBLY
The crankcase from H.M.S. is first of all cleared with water .The
washing machine is rotary type which revolve the crankcase along with it and water
nozzles from all direction clear any rust and chips. The washed cylinder is then dried
in the same procedure in which instead of water nozzles, hot air is blown. The washed
and dried crankcase is than loaded on to the trolley. The trolley is special made on
bearing which can rotate the engine at any angle and engine can be fixed at any place.

The assembly of engine is done in stage that is described as below: -

STAGE: -1
1.LOADING OF CRANKCASE AND AIR BLOWING
2.CYLINDER LINER FITTING: The liners available in I.T.L.. are of three grades
i.e. A, B & C grades. The A grade liner has dimension of +12 microns, B grade
has dimension of +24 microns and C grade has dimension of +36 microns. The
cylinder lining has 2 seats one is for oil and other is for water. The grade sign of liner
should be kept toward camshaft.
3.CRANK SHAFT FITTING: -First of all bush type liner are inserted into the bearing
holes. The linear is provided with recess to store a minimum amount of oil, which
wets the crankshaft during starting of engine. The bearing cup is opened and

16
crankshaft assembly is placed into it. The bearing cup is tightened again with 10-12-
kgm torques and crankshaft is checked, that it is revolving easily.

STAGE: -2
1.TIMING GEAR FITTING: -The idler gear shaft is pushed into the crankcase and
roller type bearing with lock is inserted into the shaft. The idler timing gear is then
pressed into the bearing. The timing gear is punched at two places and punched sign
has to be matched with the punched mark on crankshaft PISTON ASSEMBLY
FITTING: -The piston assembly is fitted into the linear and big end is tightened to the
crankshaft with 8-10 kgm torques. The pistons are also grade as A, B, C has same that
A-grade line is fitted with A-grade piston assembly. the grade mark should be towards
camshaft. The piston ring cuts should be so adjusted that there should not be in same
line.

STAGE: -3
1.LUBRICATING OIL PUMP MOUNTING: -The lubrication oil pumps connected to
crank shaft gear by an idler gear of 2-3 degree. The crankshaft gear and pump gear are
of 22 teeths each. The pump is provided with a relief valve that opens at 4 kgf forces.
In case there is over loading or some thing injected in main oil gallery then pressure is
released from this valve.
2.REAR COVER AND FRONT CAVER MOUNTING: -The rear cover and front
cover are cleaned properly with air and then fitted to engine with seals in between.

STAGE: -4
1.CAM SHAFT FITTING: -The camshaft is inserted into the camshaft hole with be-
baring and bolt ends are locked by circlip. The crankshaft is forged from alloy steel or
cast from hardened cast iron and is case hardened. The one end of camshaft is
provided with gear, which is linked with idler gear Z-50. for exact-ct timing the
camshaft gear mark is matched with mark on ideal gear.
2.PUMP AND FLYWHEEL MOUNTING: -The flywheel is mounted the crankshaft
and bolts are tightened with 11-12 kgm force. The F.I. pump is connected to the F.I.P.
gear through the F.I.P. drive shaft. The F.I.P. drive shaft is special designed to
advance the timing of injection. The both ends of F.I.P. drive shaft is provided with
spline on one side a key is provide which is locked to timing gear and recess on other

17
side is pushed into the the F.I.pump slots. The angle between the key and recess is of
18 degree. Thus the fuel injection is advanced by 18 degree

STAGE: -5
1.CYLINDER HEAD MOUNTING: -The cylinder head assembly is placed on the
piston and studs are passed through it. If the height of piston at T.D.C. from the
surface is more than 0.1mm than the gaskets of given thickness are used. If it is
0.1mm to 0.5mm than 1.2mm thick gasket is used. If it is 0.5mm to 0.8mm than
1.5mm thick gasket is used. Cylinder head nuts are tightened by 17-18 kg forces.

STAGE: -6
1.WATER BODY AND PULLEY MOUNTING: -The water body is mounted with
thermostat control valve. The valves open at 70 Celsius. Thus engine is kept at
correct temperature. The pulley is mounted on crankshaft.
2.WATER RETURN LINE EXHAUST FLANGE AND INLET MANIFOLD
MOUNTING.

STAGE: -7
1.To complete the engine removes it from the trolley. Before removing the engine
from trolley the base plate, filters and other accessories are properly tightened. Then
the engine is removed to roller stand.

STAGE: -8
1.KEEP THE ENGINE ON STATIONARY FRAME.
2.ROCKER ARM FITTING: -The rocker arms with spherical followers are inserted
into galleries and connected to the rockers arm. To compensate for thermal expansion
the gap between inlet rocker arm and valve is adjusted to 0.2mm. The gap between
exhaust valve and exhaust rocker arm is 0.25mm.
3.SELF-STARTED AND DYNAMO MOUNTING.
4.FUEL INJECTION PUMP MOUNTING AND SET FUEL INJECTION PUMP.
The
gear of F.I.P. is first of all meshed with the F.I.P. drive shaft (with recess) and is
loosely tightened. To set the timing of gear first of all pointer is tighten on the
crankcase and flywheel is rotated which is mashed for (6, 18, 20 & 24) angles. The
pointer is set at 18 degree of flywheel and then the pump is rotated clockwise till the
18
 oil from first nozzles stop out flowing. At this position a cut mark is made on both the
pump and crankcase for future settings. The pump is tightened properly and pipes are
tightened over nozzles and injectors. The head of engine is covered with the covers
and the complete engine is send to the engine testing shop.

Gear and heat treatment

Having World Class manufacturing facilities to deliver best quality of transmission gears, shafts
& assemblies for automobile and tractor applications. The Facility delivers all types of gears &
shafts like Main Shafts, Lay shafts, Input Shafts, Synchromesh Gears, Gears with Dog Teeth,
Shifter Sleeves, Synchro Hubs & Cones.

Manufacturing Facilities include

CNC Turnings, CNC Hobbings, CNC Shavings, CNC Multi-Axis

Grinders, Gear Shapers, Broaching, Roofings, Swaging and Tooth
Rounding machines.
Heat Treatment Sealed Quench Furnaces with CNC control, Gas Carburizing
Furnaces, Rotary Furnace, Plug Quenching, Vibratory Debburing, Shot
Blasting, Shot Peening and straightening Presses.

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Light Machine Shop
Light Machine Shop is where we manufacture sophisticated Control Valves for high
pressure (200 Bar) Tractor applications with Hardened (60HRC) Bush and Spools for
prolonged service life. This infrastructure have capabilities to Design, Develop and
Manufacture complete Hydraulic Assemblies for Tractor applications of Lift Capacity
Up to 3000 Kgs and Flow rates up to 45 LPM.

Components Manufactures in Light Machine Shop

Control Valve
Composite Valve
Feathering Valve
Relief Valve
Release Valve
Hardened Alloy Steel Bush & Spool Assemblies.

Heavy machine shop

In Heavy Machine Shop all major components of Tractors are machined. These are

Crank Case
Differential housing
Gear Box Housing
Clutch Housing
Trumpet Housing

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This infrastructure is equipped with the advanced CNC Machining Centers, Special Purpose and
General
Purpose Machines.
All the components are thoroughly checked and inspected for its Geometrical
accuracy on the imported 3D Coordinate Measuring Machine.

Press shop
Stamping facility is equipped with Ultra modern presses from internationally
renowned suppliers. This facility delivers all type of sheet metal components i.e. Skin
Panels, Inner panels, Floor Panels, Pillars, Reinforcements, Cross Members, Oil Pans,
Fuel tanks etc. It includes

21
Presses

Hyd. Press 1200T with bolster size of 4x2.5 Mtrs. 1

Nos.

Hyd. Press 1000T with bolster size of 4x2.5 Mtrs. 1

Nos.

Mech. Press 630T with bolster size of 2.6x2 Mtrs. 1

Nos.

Mech. Press 400T with bolster size of 3.5x2 Mtrs. 2

Nos.

Mech. Press 400T with bolster size of 3.25x1 .8 Mtrs. 1

Nos.

Mech. Press 250T 1

Nos.

Mech. Press 100T 3 Nos.

Mech. Press 75T 5 Nos.

Mech. Press 20T 3 Nos.

Mech. Press 10T 1 Nos.

Mechanical Press IOT- 250T Multiple

Fork lifters (5T& 3T) 1 each.

E.O.T(S.W.L.) 30T 1 Nos.

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ENGINE SPECIFICATION
TYPE 4 CYLINDERS, 4 STROKES
COMBUSTION DIRECT INJECTION
BORE 100 mm
STROKE 110 mm
CYLINDER DISPLACEMENT 3456 cc
COMPRESSION RATIO 17:1
FIRING ORDER 1-3-4-2
ATOMISING SETTING PRESSURE 205 5 kgf/cm
INJECTING TIMING 25 + 1 B.T.D.C
FUEL INJECTION PUMP Inline Type With Mechanical
Governor
INLET VALVE OPENS 26 B.T.D.C
EXHAUST VALVE OPEN 10 A.T.D.C
TOTAL INLET OPEN PERIOD 236
TOTAL OUTLET PERIOD 236
LUB OIL PRESSURE 2-5 kgf/cm (2200 RPM AT
80 CELSIUS)
AIR CLEANER Two Stage With Oil Filling
COOLING Water Cooled With
Thermostat
Control
CAPACITY OF FUEL 73 LIT
FILLING OF OIL SUMP 12 LIT
FILLING OF F.I.P. 0.6 LIT (MICO SYSTEM)
CLUTCH Dry, Double Clutch Plate,
Actuation, Through Heavy Duty
Spring Ensuring. Longer Clutch
Life At Constant Operating
Pressure.
ALTERNATOR 12 V/44 amp
STARTER 12 V/4 H.P.

23
ENGINE TESTING
Engine testing is done for checking the performance of newly assembled engine to
found out any assemble fault, their H.P., leakage and other faults. Engine testing shop
of the I.T.L. is equipped with latest digital control equipments. The engine testing is
done with help of turbine (water) or hydro dynamometer. The
hydrodynamometer are four in number so that four engine is tested at a time. The shop
is equipped with heavy-duty oil filter, which is used to clean the oil from dust or other
large particle. The shop has bush pump tester, which is used to test the pump if there
are any fault. The engine power is measured on the bases of S.A.E. ratings. The society
of automobile engineers U.S.A has specified the method of measuring the power
output of the engine for standardized purpose. The engine is run without generator, air
cleaner, cooling fan etc. However standard circulating pump, fuel pump is fitted to the
engine. The horsepower of the engine is measured with dynamometer and measured
values are then corrected for the standard pressure, ampere and humidity condition
prescribed.

TESTING: -
Before starting the engine the, lubricating oil is filled into the engine and then engine
is mounted on the fixture. The flywheel is directly attached to turbine through
connecting shaft and engine is started. The engine is made to run for three hours to
check the engines leakage and if there is any leakage then that fault is found out and
again put into the testing and if again there is any fault then that engine is rejected.
After minute running the tappet clearance is checked. Tappet clearance is to be kept
.25.005. The clearance is necessary otherwise the thermal expansion of valve will
alter the opening or closing of valve angles. After that engine is run at 2400 r p.m. m.
for 2.30 hours and then the engine is run at various r.p.m. and loads to calculate the
power, b.h.p. and s.f.c. . If the engine is seen to emitting too much smoke than smoke
level is also checked.

POWER OUTPUT: -
The engine shop is having latest technology and all the information is available
digitally. The load can be increased or decreased r.p.m. or s.f.c. can be changed from
within the electronic cabin. Power test is done on 2200 r.p.m. (Maximum r.p.m. of
engine is 2400) where torque is rated and is indicated on digital meter. The alteration
24
in r.p.m. is made by varying the load and fuel supply is kept constant.
The power is calculated as follows
POWER = (R.P.MTORQUE)/(7023.746) H.P.
If the power calculated from above formula comes lower than prescribed limit than
usually fuel timing is altered. The fuel timing is altered with the help of F.I. pump.
Usually the engine is tested on 18 Celsius advancement .By revolving the pump
away from engine the timing is reduced and by revolving F.I.P. toward the engine
thetime is advanced. The advancement usually lower down the power, so timing is
reduced into possible limit to increase the power.

3.6.3 S.F.C: -
It is one of the most important parameter for engine comparing. It is defined as the
ratio of amount of kg of fuel used per hour by the engine to power produced by the
engine.
S.F.C. = (297000) / (POWERTIME) Gm/B.H.P/Hr.
Constant = fuel gravity volume of oil (100 cc)
time
= 0.825 100 3600
= 297000

TORQUE BACKUP TEST: -

It is capacity of engine for maximum load that after the engine r.p.m will decrease
to zero.
TORQUE (backup) = {T (max) T (rated)} / {T (rated)} 100
T (rated) is displayed by meter on 2200 50 r.p.m. and T (max) is
displayed by meter at 1500 + 100 r.p.m. T (max) is found by loss of r.p.m and
increased of torque. The engine is loaded till torque is max and after which the loaded
cause drop in torque.

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Research & Development Department
Research & Development department is playing most important role in growing of
the company. Research & development centre is further divided into following three
main parts:
R&D (Design)
R & D (Protoshop)
R & D (Testing)

R&D (Design): This department deals with designing and modification of the
components, which will be subjected to testing. The designed components are
developed and forwarded to Protoshop for fitment of components on tractor.

R&D (Protoshop): This department deals with the fitment of the components,
which are designed by R&D (Design). Tractors with new fitted components are given
to testing department for testing purpose.

R&D (Testing): This department deals with the testing of the newly developed
components, simulation of field failures in the test labs and in the field.

This department has huge circle of different activities, which lead

to customer satisfaction by providing them best product quality.

Following type of testing is done in this

department: - 1.) Static component testing

2.) Dynamic component testing

Both of testing fields consist of three types of testing: -

Performance testing
Endurance testing
Reliability testing

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The testing department is equipped with latest instruments & test set-ups.
Brief introduction to these set-ups is given below: -
Lab Test Set ups:
Transmission Test Bench
1 Transmission Test
Bench 2Marry Go
Round setup

P.T.O. Test setup

Shock Test setup
Hydraulic break valve test setup
Hydraulic Lift Performance test setup
Fender & operator seat test setup

Field Testing:
Field performance for Bench marking
Comparative field trials
Fuel consumption trials
Haulage trials
Puddling test

Rotavation test

Endurance test

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