Professional Documents
Culture Documents
International Tractors Training
International Tractors Training
International Tractors Training
ACKNOW
ACKNOWLEDGE
LEDGEMENT
I take this opportunity to express my gratitude to the person, who has directly & indirectly
helped to complete this training with a positive note.
I am greatly indebted to Mr. Gurvinder Singh (Training-In-charge) for his inputs &
guidance throughout the training. I also express my thanks to Mr. Manoj for his timely
inputs on the scope & presentation of the study. I am also thankful to the Training
Department of International Tractors Limited, Hoshiarpur.
Last but not the least, I would like to thank all my friends who have helped me in the study
by providing critical examination of the training & very co-operative behaviour.
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DECLARATION
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Signature of Student
Title
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Company profile
Introduction to Tractors
Basic Terminologies used
Working of an Engine
Main Parts of an Engine
Engine Performance
Fuel System
Engine Cooling
Process of Engine Assembly
Engine Trouble and Remedy
Decodification
Electrical Trouble and Remedies
Braking System
Lubrication
Transmission
5S Formula
Procedure of Final Assembly
Practical Work During Training
Bibliography
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10-12
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17-18
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20-21
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CONTENT
COMPANY PROFILE
We are pleased to introduce ourselves as one of the largest Manufacturer and Exporters of
agricultural Tractors, implements and equipments in India.
SONALIKA has a current turnover of approx. Six hundred million USD with activities
spread in various fields including Tractors and Automobiles; Hydraulic Systems; Engines;
Forgings; Brake Systems; Component Manufacturing, etc.
Established 1969, Sonalika Group has been contributing towards green revolution since its
inception. Sonalika Groups flagship company International Tractors Ltd is one of the
largest tractor manufacturing companies in India manufacturing tractors in the range of 2090Hp.
International Tractors Limited with brand name Sonalika ventured into production of
tractors in 1995 and has emerged as the fastest growing Tractors Company having sold
more than 32,000 Tractors last year and counted among the Top Three-Tractor
Manufacturers in India.
Product Range Tractors ranging from 30HP to 90HP in 2WD and 4WD, Tractor
Mounted Combine Harvesters, Multi Crop Threshers, Harvesting Attachments. Ploughs,
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SONALIKA | HIGHLIGHTS
2010
2009
Grand Launch of technical advanced Worldtrac series of tractors. The series comprises
of tractors with advanced features.
Developed in-house unique DIESEL SAVER UNIT FOR SONALIKA Tractors.
Became only Company in India To Produce 90 Hp Tractors.
2008
2007
Joint Venture between International Tractors Ltd. and Magma Shrachi Finance.
2006
Successfully Developed Four Wheel Drive front axles and Transmission of tractor for
Yanmar.
2005
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2001
INTRODUCTION TO TRACTOR
TRACTOR: The word TRACTOR has been derived from traction which means
pulling. A tractor is required to pull or haul an equipment, implement or trolley, which are
coupled to the tractor chassis through suitable linkage. A tractor can also be used as a
prime mover as it has a power outlet source which is also called Power Take Off or P.T.O.
shaft.
The use of tractor in India was established with the help of Czechoslovakia. Then tractors
were imported from European countries.
But after knowing the use of it, the demand increased dynamically. So many industries
started its production in India to compel with demand.
CLASSIFICATION OF TRACTORS
TRACTORS:
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2. According to capacity:
(a) Light tractor
(b) Medium tractor
(c) Heavy tractor
1. According to wheels:
(a) Three wheeler
(b) Four wheeler
(c) Chain wheel(track type)
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CONSTRUCTION OF A TRACTOR
1. Power Unit:
Unit: Engine and all accessories necessary for its operation such as ignition, fuel
supply, cooling, lubrication, governing , starting and lightning system.
2. Transmission System:
System: Clutch, gear box, differential, drive mechanism, belt pulley,
power take off, power lift and control.
3. Chassis:
Chassis: Frame, wheel and steering mechanism. It does not have body.
1. Radiator
2. Water pump and fan
3. Front axle
4. Front and Rear tires.
5. Engine and Engine sump
6. Clutch and Gear Box
7. P.T.O. shaft
8. Differential
9. Lift lower link
10. Sensing spring
12. Steering box
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11. BRAKE HORSE POWER: Actual horse power produced on fly wheel is known as
brake horse power.
12. FRICTIONAL HORSE POWER: Actual horse power produced on fly wheel is
known as brake horse power.
13. MECHANICAL EFFICIENCY OF IC ENGINE: It is the ratio of brake horse power
to indicated horse power. It varies from 65 to 90 percent.
14. THERMAL EFFICIENCY:
EFFICIENCY: It determines how efficiently fuel is utilized in the engine.
15. INDICATED THERMAL EFFICIENCY: It is the ratio of heat to work done by the
gases in the cylinder to the total heat energy supplied by the combustion of fuel in the
same time.
16. BRAKE THERMAL EFFICIENCY: It is the ratio of heat to work done by the gases in
the cylinder to the total heat supplied by the fuel in the same time.
17. CRANK THROW: This is the distance between the center of crank pin and main
bearing of the crank shaft. This distance is equal to the stroke length.
18. IDLE RPM: Revolution per minute at no load and no acceleration.
19. MAXIMUM RPM: Revolution per minute at no load and full accelerator.
20. RATED RPM: Revolution per minute at full load and full accelerator, where engine
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b) Inlet: 0.3 mm
In four stroke diesel engine all events taking place inside the cylinder completed with four
stroke of piston. Each cylinder has two valves for inlet and outlet. The opening and
closing of valves are controlling by cam shaft. It is driven by crank shaft with the help of
suitable gears. The cam shaft runs at half speed of crank shaft.
3. POWER STROKE:
STROKE During power stroke the high pressure is developed due to
combustion of fuel causing the piston to move forward or backward at regular intervals.
Both valves remains closed during the stroke.
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4. EXHAUST STROKE: During exhaust stroke the exhaust gases go out to exhaust and
valve and the cylinder becomes ready to receive fresh air. The inlet valve is closed and
exhaust valve remains open during this stroke.
19. Exhaust manifold and inlet manifold: Cast iron and aluminum alloy.
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ENGINE PERFORMANCE :
INTRODUCTION:
INTRODUCTION This topic describes different terms relating to engine
measurement and performance such as cylinder diameter, length of piston stroke,
cylinder volume and so on but also the engine rating, efficiency, head balance etc.
WORK:
WORK When an object is moved by the application of force, work is set to be done. It
is measured by the product of the distance. The body moves and the force applied on
it.
ENERGY:
ENERGY Energy is the ability or capacity to do work. When the work is done on
object, energy is stored in that object.
POWER: Power is the rate of doing work. The work can be done slowly or rapidly.
The rate at which work is done is measured in term of power.
HORSE POWER:
POWER A horse power is the power of horse, or a measure of the rate at
which horse can work.
TORQUE: Torque is twisting or turning effort. The torque is equal to the product of
the force and its perpendicular distance to the point of rotation.
COMPRESSION RATIO:
RATIO It is the ratio of the volume of the charge in the cylinder
above the piston at Bottom Dead Center and the volume of charge when the piston is at
Top Dead Center.
r = clearance volume + displacement volume
clearance volume
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1 FUEL FEED PUMP: It is a pump which transfers fuel from the fuel line to the fuel
injection pump. It is mounted on the body of fuel injection pump.
2 FUEL INJECTION PUMP: It is a pump which delivers metered quantity of fuel to
each cylinder at appropriate time under high pressure.
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3 FUEL FILTER: It is device to remove dirt from fuel. Usually two filter primary and
secondary filter are used in diesel engine.
ENGINE COOLING:
Properties of an efficient cooling system: An efficient cooling system removes 30 to 35% of
the heat generated in the combustion chamber. Too much removed of the heat decrease
thermal efficiency of the engine.
Method of cooling:
(1) Air cooling
(2) Water cooling
1) Water cooling:
cooling In this method of cooling, the water is circulated though water jackets
around each of the combustion chamber and cylinder valve stem. The circulating
water when passes through the engine jacket in the block it takes heat. When it
passes through the radiator, it is cooled by air drawn through the radiator.
2) Air cooling:
cooling In this method of cooling, the heat is decreased directly to the air after
being conducted through the cylinder wall.
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3) Thermostat:
Thermostat A thermostat valve is used in water cooling system to regulate the
circulation of water in system to maintain the normal working temperature of the
engine part during the different operating condition.
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7) Cooling
Cooling Fan:
Fan Cooling fan sucks in fresh cool air through the radiator, thus cooling
the hot water.
Crankcase washing
Crankshaft assembly
Cylinder head
assembly & engine
belt pulley fitment
Rocker arm
assembly, push rod
fitment
Engine testing
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Dispatch
Remedy
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Remedy
Check and set time
Adjust
Investigate cause and correct
Cylinder and piston worn, replace on
earliest opportunity
Regrind journals, fit replacements
shells
Remedy
Stop engine and allow cooling off,
remove dirt
Clean
Replace
Remove throttle plate
Reduce load
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Remedy
Remove bowl and empty excess
Replace pump and have it repaired
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Probable cause
Air cleaner oil bowel overfilled
Injection pump faulty
3 Three Cylinder
100 Bore diameter in mm
F Fuel Efficient Engine
L Extra Length of Stroke (118 mm)
Remedy
Find fault and correct
Have coil replaced
Correct fault
Remedy
Replace alternator
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Probable causes
Rectifier faulty
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Remedy
Tighten pulley nut
Have bearing replaced
battery
wire
Remedy
Clean
Remedy
Stop engine and immediately open
earth switch (or disconnect wire from
battery terminals) correct fault
Trouble: Starter
Starter fails to crank engine :
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Remedy
Find fault and correct
Charge the battery
Clean thoroughly
Check and tighten
Clean
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Probable causes
Engine at fault
Battery low
Commutator or brushes dirty
Poor connection in starter circuit
Solenoid contacts burnt
BRAKING SYSTEM:
SYSTEM:
Brakes are used to stop, stand or to turn tractor. There is different brake for every
wheel. It is known as a mechanism to stop the moving vehicle in shortest time and in
shortest distance.
FUNCIONS OF BRAKE:
1) It helps operator to decrease the speed of machine.
2) It also helps during turn.
3) It helps in control in heavy traffic.
4) To stop a machine.
TYPES
TYPES OF BRAKES:
1) Mechanical brake
2) Hydraulic brake
3) Disk brake
Mechanical brake: This is an internal expanding brake when the brake paddle is pressed
the cam revolves with help of cable and link. It force the brake shoe, because of this force
they expand and start to friction with brake drum, makes them slow and ultimately stop
them with braking power. When the force is removed from paddle it is reset.
Important parts in mechanical brake
1) Brake paddle
4) Brake drum
5) Brake paddle
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2) Brake shoe
Hydraulic
Hydraulic brake:
brake The hydraulic brake is an arrangement of braking mechanism which
uses brake fluid, typically containing ethylene glycol, to transfer pressure from the
controlling unit, which is usually near the operator of the vehicle, to the actual brake
mechanism, which is usually at or near the wheel of the vehicle.
Disk brake:
brake The disc brake is a wheel brake which slows rotation of the wheel by the
friction caused by pushing brake pads against a brake disc with a set of calipers. The brake
disc (or rotor in American English) is usually made of cast iron, but may in some cases be
made of composites such as reinforced carboncarbon or ceramic matrix composites.
This is connected to the wheel and/or the axle. To stop the wheel, friction material in the
form of brake pads, mounted on a device called a brake caliper, is forced mechanically,
hydraulically,
pneumatically
or
electromagnetically
disc. Friction causes the disc and attached wheel to slow or stop. Brakes convert motion to
heat, and if the brakes get too hot, they become less effective, a phenomenon known
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as brake fade.
LUBRICATION :
Lubrication is essentially, required in tractor maintenance. To supply the lubricating
oil between the moving parts is simply termed as lubricating. Lubrication of all
moving parts is essential to reduce friction, wear and to prevent seizure.
Properties of lubricants:
1) Viscosity
2) Flash points
3) Fire point
4) Cloud point
Viscosity:
Viscosity Viscosity is a measure of the resistance to flow or the internal friction of
oil.
Flash points:
points The flash point has been defined as the lowest temperature at which
the lubricating oil will flash when a small flame is passed across its surface.
Fire point:
point If the oil is heated further after flash point has been reached. The
lowest temperature at which the oil will burn continuously is called fire point.
Cloud point:
point The oil changes from liquid state to a plastic or solid state when
subjected to low temperature. In some cases the oil solidifying which makes it to
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appear cloudily. The temperature at which this take place is called cloud point.
TYPE OF LUBRICANTS:
LUBRICANTS:
There are three types of lubricants:
1) Solid: Graphite, mica, soap stone, or steatite.
2) Semi solid: Grease
3) Liquid: Mineral oil, vegetable oil, animal oil etc.
LUBRICATION SYSTEM FAULTS :
Trouble: Low oil pressure :
Probable cause
Oil pressure gauge faulty
Oil pump intake strainer clogged
Oil pressure relief valve clogged
Unauthorized grade of engine oil
Crank shaft bearing worn
Remedy
Check gauge, replace if necessary.
Look for oil leaks, stop if any.
Wash
Wash
Change to authorized oil
Required journals fit replacements
shells
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Remedy
Replace
Replace or piston if necessary
Replace worn parts
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Probable cause
Piston rings worn out or stuck
Piston rings side clearance large
Large intake valve stem clearance in
guide
TRANSMISSION:
TRANSMISSION:
We know that the horse power, the rear wheel depends upon the turning effort and the
speed of rotation. We need different torque and speed for different application at the
rear wheel but engine speed and torque are between engine and rear wheel, which gives
variable torque and speed. This mechanism is known gear box. Any combination of
gear wheels by which power is transmitted one shaft to another shaft is called gear train.
The direction of rotation of driver gear will be opposite to that of driving gear.
TYPE OF GEAR BOXES:
There are mainly two types of gear boxes. These are as under:
Sliding mesh gear box: In this type of gear box one moving gear is pulled out and
pushed to mesh another gear.
Constant mesh gear box: In constant mesh gear box, the gears on main and
counter shaft are always in engaged position. In this the splined sleeve is made to
shift to mesh with the gear to right and left or kept in neutral position.
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CLUTCH :
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other components. The main motive of clutch is to make gearing easily and quick. It is
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The clutch is fitted in engine to connect and disconnect power stream in gear box and
CLUTCH ASSEMBLY:
ASSEMBLY:
There are following parts in clutch assembly
1) Clutch lining
2) Cushion spring
5) Hub flange
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4) Rivet
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3) Torsion spring
5 S FORMULAS:FORMULAS:1. Seiri
2. Seiton
3. Seiso
4. Seiketsu
5. Shitsuke
2s
SEITON
3s
SEISO
4s
SEIKETSU
5s
SHITSUKE
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1s
JAPANESE MEANING
WORD
SEIRI
Sorting out, clearing, segregation, proper selection and remove the
waste
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S. No.
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Project:
Project: Time Study at Differential Loop assembly and Gear box Assembly
Time Study:
Time study is the process to establish a time for a qualified worker to perform specified
work under stated conditions and at a defined rate of working.
Average Cycle Time:
Time:
Average Cycle Time is defined as the mean of the different durations taken to complete
one cycle of an operation.
Part 1
1 Differential Time Study
Function of differential:
A differential is used between the back tyres of the tractor.
Its basic function is to provide different rotation to both the back gears during turning.
Various parts used in differential assembly are:
are: Trumpet
Spur ,helical gears
Cage
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Gasket
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Break
Dropping the
housing on
trolley
B.P Shaft
fitment (crown
gear)
P.T.O Shaft
fitment
OIB drum
fitment on
both sides
Bull gear
placing
Punching
Chasis No.
Pinion Fitment
Crown Gear
preloading
check
Trumpet
Fitment
P.T.O Shifter
Fitment
Brake Lever
fitment
Lifted by
overhead
crane
Suction pipe
fitment
.2 - .3 mm
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v Backlash Testing:
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35
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Gearbox housing
on trolley
Intermediate Shaft
fitment
Bottom plate
fitment
Steering &
accelerator fitment
Lifted by overhead
crane
Recommendations:
v Mismanagement among workers.
v Mandrel tools are not placed at right place
v More involvement of man then machine.
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BIBLIOGRAPHY
1. www.sonalika .com
2. Search Engines
Engines (Google and
and Yahoo)
3. Sonalika Library material.
4. I. C. Engines book by V. Ganesan
Ganesan
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THANK YOU