A Project Report on reverse gear

Mechanism

Under the Guidance of

Mr. N.K Yadav

(Deputy Manager)

Engine assembly

In
Scooters India Limited, Lucknow

Submitted by
Prinsu Kumar
Amity University Lucknow







CONTENTS

Certificate

Acknowledgement

Vision Mission

Quality Policy

About Scooter India Ltd.

Products

Departments

About Machine Shop

About Line No. 7

Machine Used in Line No. 7

Manufactured Component of Line No. 7

Main Project



DECLARATION



I certify that Mr. Prinsu Kumar, a student of amity
university lucknow, Mechanical & Automation
Engineering 3rd year has completed a project on "reverse
gear mechanism" under my guidance. I certify the
originality of the project report. I wish a bright future for
him.
Date:
Mr. N.K yadav
(Deputy Manager) engine assembly S.I.L. Lucknow
























VISION OF THE ORGANISATION

To grow into global company constantly striving meet the
changing needs of customer through constantly improving existing
product adding new products and opting new technology and
expanding the customer base.

CORPORATE MISSION

To fulfill customer needs for economical and staff made of road
transport and quality engineering product through contemporary
technology.

QUALITY POLICY OF S.I.L.

We are committed to meet the customer requirements andcontinuou
sly improve our quality management system. The company sales
and services quality objective within the frame work of this policy.

ABOUT SCOOTERS INDIA

Incorporated in 1972, Scooters India Limited is an ISO
9001:2000and ISO 14001 Company, situated at 16 Km mile stone,
South-west of
Lucknow, the capital of Uttar Pradesh on NH No 25 and is well-
connected by road, rail and air. It is a totally integrated automobile
plant, engaged in designing,
developing, manufacturing and marketing a broad spectrum of conv
entional and non-conventional fuel driven 3-wheelers.Companys
plant owes its origin to M/s. Innocenti of Italy from which it bought
over the plant and machinery, design, documentation, copyright etc.
The company also possesses the world right of the trade name
LAMBRETTA / LAMBRO. In 1975, company started its
commercial production of Scooters
under the brand name of Vijai Super for domestic market &
Lambretta for overseas market. It added one more wheel to its
product.range and introduced three wheelers under the brand name
of VIKRAM/LAMBRO. However, in 1997, strategically, the comp
any discontinued its two-
wheeler production and concentrated only on manufacturing and
marketing of 3 wheelers. These three wheelers have become more
relevant in the present socio-economic environment as it transports
goods and passengers at least cost. The company has its own
marketing network of Regional Sales Offices all over India, catering
to customers requirements in the areas of sales and services.

DESIGN AND DEVELOPMENT DEPARTMENT

Design & Development has become the prime mover for theorganis
ation. The business today is customer driven. The department
remains in constant touch with the customers to transplant their
needs and thinking on the drawing board - nay on the computer
screen. The department serves the internal customers
through design, development, standardization, value engineering,
defect removal etc. Equipped with computer aided design
lab ( CAD lab ), AdvancedInstrumentation, testing rigs prototype m
anufacturing facilities andinternet, the company's D & D is
recognized by the Ministry of Science and Technology, Govt. of
India. It has the distinction of the developing first zero pollution
electric three wheelers in the world. Company besides its own in-
house R&D; also works in association with leading
ResearchAssociations & Educational Institution like I.I.T 's. Kanpur
; I.I.T., Dehradun; A.R.A.I. Pune; T.C.I.R.D. Patiala etc

Computer Aided Design Laboratory

The CAD laboratory provides a wide range of facilities. The
versatility of brains combines with the flavor of new creation to
evolve quality product. All the designing & drafting process moulds
into a shape in this well equipped environment
of CAD laboratory. Which includes FE analysis, Working model
simulation & designing through Auto-Cad 14.




























ASSEMBLY DEPARTMENT

The components manufactured in plant as well as those bought
have to be finally assembled to make the product three wheelers. In
the.process many sub assemblies, too, are involved. However, two
mainassemblies worth mentioning are engine assembly and vehicle
assembly. Both are conveyorised. Every 5 minutes a three wheeler
rolls down the conveyor. The vehicle conveyor has 23 stations.
Speed can be adjusted to meet increasing demand.

DIE CASTING SHOP

The biggest die casting shop in this part of the country handles both
Aluminum and Zinc alloys. Equipped with pressure die casting
machines of 160, 250, 400 and 1,000 tons locking pressure, the
metal is fed to machines from individual holding furnaces of 75 /150
kg., which in turn are fed by mother melting furnace of 500 kg.
aluminum.capacity. The shop based on projected area, is capable of
producing aluminum die casting up to 5 kg. in weight. The shop is
backed by chemical and metallurgical labs as also with a die
maintenance section. The well-equipped machineries are used in this
department in single shift, except two machines that are used in two
shifts; that produce all the accessories required by this organization.
The die casting of various
type of components like Gear box housing, Crank case, Front wheel
drum, Rear wheel drum, Bell housing, Magneto flange, Cylinder
head, lower and upper Handle bar, Levers, Differential housing
cover, Brake shoe etc are undertaken.
Die casting some components for fulfilling customers'
requirement are also taken up. Some of our customers are BHEL,
Bhopal; Greaves India Limited, Aurangabad to whom supplying the
Gear boxes and 422 cc aluminum Engine are supplied.



FABRICATION DEPARTMENT

The fabrication operations are carried out in Two departments viz.
Press Shop and Welding Shop. The Press Shop is equipped with 20
presses ranging from 10tons to 550 tons. Presses are fed by sheets
cut to size on shearing machines of 3000x6 & 2500x3 mm. size.
Components ranging from washer to cabin roof and door
(1000x1200 mm.) are being processed in this shop. The Welding
Shop is equipped with battery of Spot welding, MIG welding, Seam
welding as well as Arc welding machines. CO2 welding
is extensively used for getting close tolerance on welded structures.
The department has its own auxiliary shop for maintenance of
tools and dies.

FOUNDRY LAB

The foundry, most modern in this part of the country, canproduce
all grades of grey cast iron as well as S. G. iron. In fact, it had been
innovative to find new processes of modulisation, for which it was
granted 2 patents. Equipped with an Induction Melting furnace,
Shell Molding Machines & Core Shooters, Green Sand Molding
facilities,.Isothermal Heat Treatment Furnace, one sand muller mach
ine, twoshot blasting machine, two set jolting machines for green sa
ndmoulding, fettling and shot blasting equipments, its normal range
of production weighs upto 8 Kgs. on a pattern plate of 450x600 mm.
However, foundry men are trained to make casting even of 1 ton
weight if emergent requirement
arises. The foundry is not fully loaded with its captive requirement.S
pare capacity is utilised for producing sophisticated castings of prest
igious customers like BHEL, Indian Railways, Aerospace, Brakes
India Limited, Crompton Greaves limited. The induction furnace
has a capacity of 1.3 tons. The two types of molding is been done
here. 1. Shell molding 2. Green sand molding. The foundry can
manufacture a wide range of products namely Differential
housing, Differential cages, Power transmission wheel, Crankcase
flange, Magneto motor,
Engineoutput flange, Adapter plate for electric vehicle, Cylinder for
bothVikram 410 petrol version and Vikram 750 diesel version.

ABOUT MACHINE SHOP
Machine shop has a wide variety of machines like General purpose
machine, Special purpose machine, Multispindle automatic machine
, Single spindle automatic machine etc; which are mainly working
onsingle shift through eight different lines. Line no 2 is basicallyma
chining the aluminium components. Crank shaft and cylindermachin
ing is usually done on line no 3. Line no. 4 is the Grinding
line where the grinding process is done. Heat treatment is performed
in line no. 5, while different turning of shafts and gear shaping and
shaving are
carried on line no 6.Line no. 7 includes the functioning of gearmanu
facture process mainly broaching, hobbing, finish turning, gears
having etc. Machining of different levers, centre less grinding of
tubes and shafts, serration / thread rolling operations is achieved in
line no. 8& lastly different components are fed in two other lines by
line no. 9.Blank Turing of gear and machining of parts is done on
multi spindle and single spindle automatic machine. Engine
components and some vehicle component are the prime production.


PAINT SHOP

Paint shop includes three sections namely Paints section,
sprayphosphating section, pickling.Paint section includes two conve
ntionpainting spray booth & one electrostatic painting plant. The
first one is called conventional primer where mainly frame paintings
are done. The equipments used for conventional painting are
Bellows 230 spray gun and pressure fit tanks (we prepare paints).
The various types of frames like Diesel 750, Mini petrol, Mini
diesel, Diesel floor mounting,
DieselNepal, Diesel scrubber, Electric vehicle are painted here. The
otherconventional booth is known as conventional finish booth.
Here the frame accessories like cabin front, roof top, front fork, axle
housing are
painted. In electrostatic plant the accessories of the frame, the
component of lighter weight and minimum size like silencer, pillar
and various brackets are painted here. In spray phosphate the main
work is to clean the components before painting or to make surface
according to paint requirement. After phosphate the products goes to
passivation for converting ferrous to ferric for paintings need. The
products come from welding shop, press shop and machine shop to
phosphate, and after the process is being done the products go to
vehicle assembly. The pickling department is mainly for
maintaining the surface of heavily corroded materials.




TOOL ROOM

The tool room is a cell where brain combines with versatility to
evoke the new era of invention. The designs of tool coming from
maintool planning departments are implemented here. The tool roo
m isfurnished with well equipped machineries namely, CNC machin
e(Taiwan), Jig Boring machine (Czech Republic), Jig Grinding
machine(Switzerland), Profile Grinding machine (Germany), Die sh
ieldingmachine (Czech Republic), EDM (USA), Schaublin machine
(Switzerland). Tool room evoke a high performance output,
consisting almost99.9% of company's requirement : one die casting
die per year, 1-10press tools per month, 8-10 jigs per month, 10-12
gauges per month and 400 C.T. tools per month These machines are
efficiently used to manufacture different tools and dies like Jigs &
fixture,Gauges,Cuttingtools, Forging dies, Die casting dies, Develop
ment items etc. The different activities like turning, milling different
shapes, grinding, heat treatment, jig boring, jig grinding, checking in
the standard room, heat treatment according to the job requirement,
final inspection are undertaken in the tool room.


DEPARTMENTS

The.organisation has various departments to perform differentactivit
ies competently. SIL has an organized system to control
differentactivities. Personnel & administration department looks afte
r theemployees welfare, medical benefits, conveyance facilities, mai
ntainstheir personal records and controls their regularity. It also take
care.of the security for the organization. Marketing & services
department. Looks after the marketing of the products, provide
services to the customer and regulates the activities in its various
regional offices. Materials controls the purchasing of the raw
material, keep
aneye on the cost of the material in the market, store the different
materials and products and establishes a company-vendor
relationship. Workshop manufactures different products
in steps in different lines. Design & development is the prime
creative unit for the organization. It brings out some brilliant design
with.modern.technologies.Finance.&.accounts section keeps track o
n the financial growth and the maintenance of various types of
accounts.

PRODUCTS OF S.I.L.

Scooters India Limited makes various & versatile types of
three wheelers: Vikram 450D, Vikram 410G, Vikram 600G, Vikram
750D,Vikram 750D (WC), Vikram EV. The products have a high
payload capacity and efficiency. These are specially designed and
developed for local transportation. However, the generation of
Vikram runs successfully in different countries also. Our product is
very demanding in various countries all over the world
.Germany, Italy, Sudan, Nigeria, Nepal, Bangladesh are few of thec
ountries. For product details click on the product options.

MACHINES USED IN LINE NO. 7


Broaching Machines

1. Internal Splines Broaching 4976
2. Oil groove broaching machine 3505
3. Bore Broaching 2021
4. Bore Broaching 3271
5. Bore Broaching 2997


Hobbing Machines

1. Semi Automatic Hobbing Machine 10488
2. Semi Automatic Hobbing Machine 10576
3. Semi Automatic Hobbing Machine 10120
4. Tag Teeth Hobbing 2014
5. Semi Automatic Hobbing Machine 10290
6. Eight Head Shaft Hobbing Machine 2586
7. Eight Head Shaft Hobbing Machine 2585

Hydraulic Press & Turning
Facing, Chamfering Machines

1 . Fresh turning, facing & bore chamfering Machine 2148
2. Hydraulic Press 392
3. Fresh Turning, Facing & Bore Chamfering 10489
4. Hydraulic Press 728
5. Turning 3249
6. Hydraulic Press 2773
7. Turning 296
8. Turning 10498
9. Hydraulic Press 383
10. Turning Machine 10490
11. Turning Machine 10387

Shaving Machines
1. Teeth Shaving 4817
2. Teeth Shaving 4102
3. Speed Gear Teeth Shaving 4395

Milling Machines

1. Milling Machine 10466
2. Horizontal Milling Machine 2732
3. Horizontal Milling Machine 10621
4. Cam Milling 10388
5. Cam Milling 91
6. Cam Milling 513
7. Cam Milling 511
Lathe Machine

1. Central Lathe Machine 441

Drilling Machines

1. Portable Drilling Machine 2419
2. Portable Drilling Machine 5035

Teeth Chamfering Machine

1. Teeth Chamfering Machine 2168
2. Teeth Chamfering Machine 2992
3. Teeth Chamfering Machine 10623

Bench Grinding Machine for Deburring

COMPONENTS MADE IN LINE NO. 7
1. Ring Nut
2. Speed Gears (I, II, III & IV)
3. Primary Transmission Wheel
4. Engine output Gear
5. Reverse Gears
6. Spline Sleeve
7. Transmission Shafts
8. Big Sprockets
9. Couplings
10. Sliding Dog11.Reverse Gear Sprockets
12. Central Lug

ABOUT LINE NO. 7

Broaching:-

Broaches tools for cutting metal, comprising a plain pilot portion, a
tapered toothed portion and a plain shank engaging with the pulling
head on a broaching machine. The teeth have normally single
cuttingedges and on a circular broaches run in series round the taper
edportion, gradually increasing in cross section as they near the
shank. They are either pushed or pulled mechanically through a
previously cored or drilled round, square, rectangular or hexagonal
hole to produce the current form. They will also finish flat surfaces,
irregularity formed holes and open grooves such as key ways in
hubs. Another application is to the forming of teeth in internal gears
and rackets, splines in shafts etc. They are usually made of a tough,
hard, sound, non distorting
steel alloy, high carbon and case hardening types, the precise steelde
pending on the service life required, the material to be cut, and the
length and form of the broached areas. Relatively few are made
of.casecarburizing steel and hardened high speed steel is now the m
ostpopular material for the cutting teeth of solid and some other
broaches. The tools have to be heat treated and ground and the heat
treatment is extremely important. Broaches for finishing internal
holes differ from those for finishing the external surface of a
component. Those to be pushed through the work are shorter than
those to be pulled through. For internal work the.tools are usually
solid, unless their diameter is so great as to render distortion in heat
treatment probable and serious. The teeth are of size and form for
the operation and if the broach is more than
3inches.How it is often made as a composite consisting of a tough
centralportion of carbon steel, conically ground, on to which cutting
segments of nickel or high speed steel are mounted in the form of
toothed rings set one over the other until the cutting portion is
adequate for the job. This makes its possible tomorrow a segment or
ring when pulled or worm and insert a replacement each ring then
move up one this costs for less than replacing the entire broach.
Hobbing:-
In this process, the gear bank is rolled with a rotating cutter called
hob. A majority of involutes gears are produced by this method. . A
gear hob looks like a worm, but carries a number of straight flutes
(gashes), cut all around, parallel to its axis. This results in theproduc
tion of separate cutting teeth and cutting edges, as shown. In
operation, the hob is rotated at a suitable speed and fed into the gear
blank. The blank also rotates simultaneously. The speeds of the two
are so synchronized that the bank rotates through one pitch distance
for each complete revolution of the hob. There is no intermittent
motion of any of the two and the generating motion continues
steadily. The hob teeth are just like screw threads, i.e. having a
definite helix angle. The hob is, therefore titled to its own helix
angle while cutting the gear so that its teeth are square with the
blank and produces a true involutes shape. Spur, helical and
herringbone gears and many other shapes like spindles and gear
sprockets etc. can be cut by hobbing process. Each cutting tooth of
the hob is provided relief at its back to enable clearance. In portion,
the hob can be conceived as a cylindrical body, around which the
teeth of a long rack are wrapped along a helical path and provided
with straight flutes at regular intervals, parallel to the axis of the
cylinder. Cross section of every tooth across the helix resembles that
of the rack teeth.

Types of Hobbing:-
This hobbing process is classified into different types according to
the directions of feeding the hob for gear cutting. This classification
is as follows: 1.Hobbing with axial feed.2.Hobbing with radical
feed3.Hobbing with tangential feed.
Shaving:
It is a process of finishing gear teeth by running the gear at high
speed in mesh with a. Gear shaving tool which is in the form of a
rack or pinion. The teeth of the shaving tool are hardened, accurately
ground and their faces are provided with serration.
These serrations form the cutting edges which actually provide a
sort of scraping operation on the mating faces of the gear teeth to be
finished. The gear is pressed into contact with the shaving tool and
the latter rotated at high speed.
The.gear also rotates in mesh with the tool and is also reciprocated
simultaneously. The shaving tool carries a little inclined teeth so that
their axes can be crossed as the two come in contact. This prevents
the jamming of the two. The above relative motion of the gear and
the shaving tool results in a highly finished surface on the gear teeth.
When a rack type tool is used, the gear is mounted on a
reciprocating arbor and is brought in mesh with a horizontal rack
situated under it. The rack is reciprocated longitudinally at high
speed and the gear across it. The lengthwise movement of the rack
type tool also rotates the gear.
Shaving with rack.type tool, however, suits only small gears. Thesha
ving tools, although costly, have a fairly long life.

Drilling:
Drilling is an operation through which holes are produced in a solid
metal by means of a revolving tool called drill.
Since it is not possible to produce a perfectly true hole by drilling, it
is considered as. a
roughing operation. Obviously, therefore, where a very close
dimensional accuracy is to be maintained, this forms only the basic
operation. For such holes, drilling is followed by another operationc
alled reaming, in which the required dimensional accuracy and fine
surface finish is obtained by means of a multi-tooth resolving tool
called reamer
Boring
It is the operation employed for enlarging an existing hole. The hole
may be previously drilled, cast, punched or produced through any
other suitable operation. In line no. 7 there are portable drilling
machine are used. It is very small, compact and self-contained unit
carrying a small electric-motor inside it. It is very commonly used
for drilling holes in such components that cannot be transported to
the shop due to their
size or weight or where lack of space does not permit their
transportation to the bigger type of drilling machine. In such cases,
the operation is performed on the site by means of the portable
electric drill. Portable drills are fairly light in weight so that they can
be easily handled by one or two men only. They are manufactured in
different sizes and capacities, thus being suitable for a wide range of
whole sizes. Also, on account of the high speeds available, a
considerable saving in time is affected by their use. Another
advantage is that the holes can be drilled by means of them at any
desired inclination. Usually they are made to hold drills up
to a maximum diameter of 12 mm. However, portable drills of up to
18 mm. dia. capacity are available.


Milling:
Milling is the same given to the machining process in which there
movable of metal takes place due to the cutting action of a revolving
cutter when the work is fed past it. The revolving cutter is held on a
spindle or arbor and the work, clamped on the machine table, fed
part the same. In doing so, the teeth of the cutter remove the metal,
in the form of chips, for the surface of the work to produce the
desired.shape.Milling machine has acquired an indispensible positio
n in allmodern production workshops. Its specific significance lies i
n itscapability to perform a large number of operations which no
other single machine tool can perform. At the same time, it gives
production at
afairly high rate and within very close machine tools like shapers,
planers, slotters etc., but for small and medium size jobs only; as it
willprove to be too slow for machining very long jobs. For small an
dmedium jobs, the milling machine gives probably the fastest
production with very high accuracy. For this reason, it has gained a
very wide application in mass production work. Obviously,
therefore, it is very versatile machine tool. In line no. 7 there are
horizontal milling machine are used. In housing for electrical, the
main drive, spindle bearings, etc. The knee acts as a support for the
saddle, worktable and other accessories like indexing head etc.
Over arm provides support for the yoke which in turn, supports the
free end of the arbor. The arbor carrying the cutter rotates about a
horizontal.axis. The table can be given straight motions in three
directions:

Longitudinal, cross and vertical up and down but cannot be
swiveled. For giving vertical movement to the table the knee itself,
together with the whole unit above it, slides up and down along the
ways provided in front of the column. For giving cross movement to
the table, the saddle is moved towards or away from the column
along with the whole unit above it. A brace is employed to provide
additional support and rigidly to the arbor when a long arbor is used.
Both hand and power feeds can be employed for the work.

Cam Milling:
The constant rise and fall cams can easily be cut on a universal
milling machine, equipped with a universal dividing head and as
witching type vertical milling attachment. The dividing head is
geared to the table feed scare in the same way as for spiral milling.
end milling cutters are usually employed in this operation. If the
table is moved towards right, the blank approaches nearer to the
cutter.Also,becauseof the gearing at the back, the dividing head spin
dle revolvessimultaneously. The combination of these two
movements. I.e. the table movement and the spindle rotation,
enables milling of cam on the blank fitted on the dividing
head spindle. Both, the cutter as well as the dividing head spindle,
should be inclined at the same angle. Steeper the angle of inclination
quicker will be the approach of the blank to the cutter. Alternatively,
we can have the cam axis above and the cutter axis below. In that
case, we will be required to move the table towards the left for
feeding the blank against the cutter.



Plain Step And Fresh Turning Between Centers:

When the work is held between centers for any sort of turning
operation, one end (left hand end) is firmly gripped in a table dog
and then the same end is supported on the tip of the live centre. Tail
of the dog engages with the driving plate and the other end (right
hand end) of the job is supported on the dead centre fitted in the tail
stock. Work revolves during the operation and the tool is fed against
the job. Enough care should be taken while starting the operating,
particularly.by.abeginner. Speed of spindle and its direction of rotati
on should bechecked and suitably adjusted. Rough cuts in the
beginning.should.befollowed by finishing cuts for which the spindle
speed should beincreased and depth of cut reduced. Check
the controls and practice hand feeds which, in due course, can be
followed by power feeds. For taking any sort of measurement
always stop the machine. In this first the tail stock is moved and
brought near the head stock to ensure a true alignment of dead and
live centers by sighting along the axes of the two. Work is then held
between centers and revolved. A chalk is held in hand gently against
the revolving work and marks made near both the ends. Continuity
of these marks indicates the trueness of the marked.
Centers, otherwise the chalk marks will be found only on elevated
portions of the periphery of the work. Once the larger part of the
excess material has been removed through rough turning, it is
followed by

Finish turning:-
Operation in order to bring the job to correct size and provide a fine
surface finish on it. The amount of excess material to be removed
through this operation is very less and, therefore, lighter feed and
smaller depth of cut are used and the heavier tool is replaced by a
finish turning too.

Facing:-
It is an operation which enables the production of a flat surface
through machining at the end of a job. In this operation the tool is
fed at right angles to the axis of the job. Since no longitudinal feed
is needed, the carriage is usually clamped to the bed so that it
remains stationary during the operation. Feed to the tool is provided
by moving the cross-slide by hand. Depending upon the diameter of
the work piece the power feed can also be used. Two methods of
holding the tools are usually employed. One is to set the tool slightly
inclined to the exact right angle position so that only the tip of the
cutting edge remains in contact with the job face and the remainder
of the tool is free of the job. Another method is to set the tool
parallel to the axis of the job. This is done when the job is held in a
chuck or a face plate. In both the cases the tool can either be fed
outwards, i.e., away from the centre. Normally the selection of any
one to these methods is according to convenience; still the latter
method is more commonly employed. The facing operation is
usually performed in two steps. In the first step a rough facing
operation is done by using a heavy cross of the order of 0.5 to 0.7
mm and a deeper cut up to 5 mm (maximum). It is followed by a
finer cross feed of 0.1 to 0.3 mm and a smaller depth of cut of about
0.5 mm. In the first step the idea is to remove major part of excess
material while in the second step a fine finish is provided to the
surface.








MAIN PROJECT

Reverse gear mechanism
The implementation of the reverse gear is usually different,
implemented in the following way to reduce the cost of the
transmission. Reverse is also a pair of gears: one gear on the
countershaft and one on the output shaft. However, whereas all the
forward gears are always meshed together, there is a gap between
the reverse gears. Moreover, they are both attached to their shafts:
neither one rotates freely about the shaft. When reverse is selected a
small gear, called a, reverse idler is slid between them. The idler has
teeth which mesh with both gears, and thus it couples these gears.
In other words, when reverse gear is selected, it is in fact actual gear
teeth that are being meshed, with no aid from a synchronization
mechanism. For this reason, the output shaft must not be rotating
when reverse is selected: the car must be stopped. In order that
reverse can be selected without grinding even if the input shaft is
spinning initially, there may be a mechanism to stop the input shaft
from spinning. The driver brings the vehicle to a stop, and selects
reverse. As that selection is made, some mechanism in the
transmission stops the input shaft. Both gears are stopped and the
idler can be inserted between them. There is a clear description of
such a mechanism in the scooters India limited Service Manual,
which refers to it as a "reverse gear mechanism":
Whenever the clutch paddle is depressed to shift into reverse, the
main shaft continues to rotate because of its inertia. The resulting
speed difference between main shaft and reverse idler gear produces
gear noise. The reverse gear noise reduction system employs a cam
plate which was added to the reverse shift holder. When shifting
into reverse, the 5th/reverse shift piece, connected to the shift lever,
rotates the cam plate. This causes the 5th synchro set to stop the
rotating main shaft.
A reverse gear implemented this way makes a loud whining sound,
which is not normally heard in the forward gears. The teeth on the
forward gears of scooters India limited are spur gear cut. When the
spur gears rotate, there is constant contact between gears, which
results in quiet operation. In spite of all forward gears being always
meshed, they do not make a sound that can be easily heard above
the engine noise. By contrast, most reverse gears are spur gears,
meaning that they have straight teeth, in order to allow for the
sliding engagement of the idler, which is difficult with helical gears.
The teeth of spur gears clatter together when the gears spin,
generating a characteristic whine.
It is clear that the spur gear design of reverse gear represents some
compromises (less robust, unsynchronized engagement and loud
noise) which are acceptable due to the relatively small amount of
driving that takes place in reverse. The gearbox of 450D/750D is a
notable example of a gearbox with a spur reverse gear engaged in
the same synchronized manner as the described above.










GEAR ASSEMBLY

The assembly of gear has been done in different stages at assembly
line:-

Station no.1

Gearbox hosing loading assembly.
Inner lever.
G.C Shaft.

Station no.2

Lay shaft.
Lay shaft spacer.
Dowel pin.







Station no.3

Gear set.
G.B. flange.
Seam clearance (0.07 to 0.3 mm).



Station no.4

P.T. wheel.
Clutch bell.
Umbrella flange.

Station no.5

Clutch assembly.
Bell housing.


Station no.6

Reverse gear.
Push rod, selector, T.O.P shaft & reverse gear complete assembly.
Torque Lay shaft tighten 8.50 to 9.00 kgmtr.





Station no.7

Top cover gas kit.
Top cover.
O-ring.
Nut, washer & bolt assembly.


Station no.8

Companion flange & nut assembly.
O-ring, spring, R.G lever assembly.


Station no.9

Mounting pad, nut tighten.
On loading gear box.