swaraj training report
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a reort on six months training at ptl, mohaliTRANSCRIPT
Six Months Industrial Training Report PUNJAB TRACTORS LIMITED
PROJECT REPORT
ON SIX MONTHS INDUSTRIAL TRAINING (JUNE 2013 to DEC 2013)
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR B.Tech (Mechanical Engineering)
At
PTL, Mohali
SUBMITTED BY: AMRITPAL SINGH
Branch Roll No.: 1410013 Univ. Roll No.: 100031127688
Mechanical Engineering Department AMRITSAR COLLEGE OF ENGINEERING & TECHNOLOGY,
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AMRITSAR, INDIA
PROJECT REPORT
ON SIX MONTHS INDUSTRIAL TRAINING (JUNE 2013 to DEC 2013)
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR B.Tech (Mechanical Engineering)
At
PTL, Mohali
SUBMITTED BY: AMRITPAL SINGH
Branch Roll No.: 1410013 Univ. Roll No.: 100031127688
Mechanical Engineering Department
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AMRITSAR COLLEGE OF ENGINEERING & TECHNOLOGY, AMRITSAR, INDIA ABSTRACT OF THE REPORT
“Training is an investment and hence should be able to get due returns in terms of better quality of
workmen and Engineering for future.”
P.T.L. today is one of the major Tractor Producer Industry, giving their best performing machines to
their customers. As concerned with my Industrial training it is of my best opportunity during my
Engineering to learn many things about Automobile Industry through this Industry.
During my training I learn many things that would pay to me in my near future. I pay thanks to the
training faculty of our college and to staff and operators of P.T.L. Swaraj for their co-operation during
my Industrial Training. Not only did I have chance to learn technical skills but also a lot of good
human qualities have been invested by this training tenure. Once again thanks to head of deptt. and
faculty members for giving us this prime opportunity to let us make most of this time which in turns is
like gold-dust for us.
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ACKNOWLEDGEMENT
I am highly grateful to Dr. MS Aujla, Principal, Amritsar College of Engineering and Technology, Amritsar for providing this opportunity to carry out the six month industrial training at Punjab tractors limited (PTL), Mohali.The constant guidance and encouragement received from Er Gaurav Tejpal (Head, Mechanical Engg. Deptt) and training Coordinator Er. S. B. S. Kalsi (Associate Professor) has been of great help in carrying out the project work and is acknowledged with reverential thanks. I would like to express a deep sense of gratitude and thanks profusely to Mr. S.S. Mangat (Manager Assembly Deptt.). Without the wise counsel and able guidance, it would have been impossible to complete the report in this manner. The help rendered by ER. Tarun Honda ( Assistant Manager Assembly Deptt.). for experimentation is greatly acknowledged. I express gratitude to other faculty members of Mechanical Engineering Department, Amritsar College of Engineering & Technology, Amritsar for their intellectual support throughout the course of this work. Name of student & SignatureAMRITPAL SINGH
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Contents
S.No. TOPIC Page no.. 1. INTRODUCTION TO COMPANY 2. COMPANY’S PROFILE 3. PRODUCT PORTFOLIO’S 4. SWARAJ ENGINES LIMITED 5. DEPARTMENTS 1. Production planning and control
2. Quality engineering
3. Industrial engineering
4. Personal department
5. Accounts department
6. Purchase department
7. Machine shop
8. Assembly shop
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9. Maintenance
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INTRODUCTION
TO PUNJAB
TRACTORS
LIMITED
HISTORY
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In the mid-sixties, with the Green Revolution triggering large-scale tractor usage, there was a need for the country to build sufficient indigenous capacity to meet this growing demand.
In 1965, the Central Mechanical Engineering Research Institute (CMERI), Durgapur initiated design and development of Swaraj Tractor based on indigenous know how. That is how the idea for development of what was to become Swaraj was initiated. The first prototype was ready in May 1967 and by April 1970, field experience of over 1,500 hours had been gained. At that point, it was decided to christen a name for the product – signifying Indian, easy to pronounce and signifying power and grace. The name `Swaraj', was approved by the then Prime Minister, Mrs Indira Gandhi.
In 1970, the Government of Punjab acquired the Swaraj tractor's design and established Punjab Tractors Limited (PTL). The tractors were produced and sold under the brand name of Swaraj. In 2007, Mahindra & Mahindra Ltd. acquired majority stake in PTL, and in Feb 2009, it was merged into M&M as the Swaraj Division of Mahindra & Mahindra.
OVERVIEW
Swaraj has become synonymous with tractors that are powerful and reliable because of their long
term expertise in delivering such products consistently. We have been manufacturing tractors that
serve the need of our buyers in agricultural as well as commercial operations. Our product range
starting from a 22 HP category tractor to a 72 HP category tractor straddles every HP category
requirement. customers.
The brand enjoys a strong equity in the market and commands a market share of close to 12%.
The brand is known for producing tractors that are powerful and reliable. Presently, there are more
than 7,00,000 satisfied customers of Swaraj in the country. Swaraj tractors are also exported
to various countries including Bangladesh, Nepal, Sri Lanka, Nigeria, Ghana, Gambia,
Zimbabwe, Zambia, Tanzania and the USA.
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“ORIGIN OF THE WORD “SWARAJ”
In Hindi, the word “SWARAJ” means “Freedom from Bondage”. Since P.T.L. was
the only first largest tractor project in India, moreover fully based upon Indian technology. So
“SWARAJ” was appropriately chosen as its brand name. SWARAJ GROUP sells its product under
this brand name.
POSITION OF SWARAJ PRODUCTS IN MARKET
With more than 2 lacs of tractors & harvester combines operating in Indian farms,
SWARAJ are now a well-established brand name in country. SWARAJ is now an internationally
recognized name in the developing world. The products of SWARAJ are not only restricted to
Indian market but they had entered in international market. SWARAJ tractors find an important
place in developing countries like Ghana, Tanzania, Zambia, Kenya, Sudan, Uganda, Indonesia &
Malaysia, etc. they are also sending their combines to South Korea having first A.C. cabin
combine in India. Long way back, they had also transported the machined rims to Japan, a project
millions of dollars.
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OBJECTIVES
1. The main objective of the company is to bring the latest technology of high quality and cost
advantage to its customers. By having a strong R&D and the fully computerized manufacturing
facility, SEL ensures a non-stop supply of quality tractors.
2. 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 department is to
have the best in product development with maximum utilization of the human resources
available.
3. To achieve international standards of excellence in all aspects of agriculture and diversified business with focus on costumer delight.
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COMPANY’S PROFILE
SWARAJ HISTORY
The Indian Tractor Industries, as it is now, is a major segment of its engineering industry.
However till 1974, Indian firms assembling semi knocked down (SKD) kits in collaboration with
foreign manufactures met the tractor requirements of the country largely through imports & partly.
Though the first Tractor Company was set up in India in 1960, but the growth in real terms started
from 1974, when the government banned the import of tractors. Today India is the largest tractor
producing and consuming country. In an effort to reduce imports & develop indigenous technology,
the government, permitted setting up of the major manufacturing companies.
1. Eicher Good Earth 1960
2. TAFE 1964
3. International Tractors 1965
4. Escorts Tractors 1966
5. Ford Tractors 1971
6. HMT 1973
7. Punjab Tractors 1974
8. Kirloskar 1974
9. Harsha 1975
10. Auto Tractors 1981
11. Universal Tractor 1982
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THE INDIAN MARKET DIMENSION
GEOGRAPHICALLY
TERRITORY %age of Domestic Sales
North (Punjab, Haryana & Uttar Pradesh) 32%
Central (Madhya Pradesh & Rajasthan) 26%
East (Bihar, West Bengal, Orissa & Assam) 10%
West (Gujarat & Maharashtra) 12%
South (Andhra Pradesh, Tamil Nadu, Karnataka & Kerala) 20%
SEGMENTWISE
HP Range %age of Total Sale
Up to 30 HP 19%
31-40 HP 51%
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Above 40 HP 30%
INTRODUCTION
PTL ’S BIRTH
Keeping in mind Punjab agrarian economy it was decided by Punjab Govt. to
encourage the growth of industries which complements Punjab’s agricultural growth. This task
was entrusted to P.S.I.D.C. and with dual objective of industrial and agricultural growth; PTL was
established on 27th June 1974.
INDUSTRY BASICS
The Indian tractor market is dominated by low price, rugged, versatile and low to
medium powered tractors; the main reason being the inability of farmers to invest in farm
mechanization. Tractors are categorized on the basis of horse power (HP) of the engine. In India, the
popular range of tractors is 20-40 HP compared to 60 HP in Europe and 90 HP in the USA. Though
large tractors were economically unviable in India, there has been an increasing demand for high-
powered tractors due to soil conditions, particularly in states of MP, Gujarat and Maharashtra. But
more recently, higher-powered tractors are also being sold in states like Punjab where it is considered
as a status symbol. Tractors available in India are 1/4th of the prices of similar powered tractors
internationally or in developed countries. Availability of credit is the most crucial factor impacting
tractor demand, as in India 90% of the tractors are financed by bank credit at concessional rates.
Increased use of irrigation facilities, shift towards multi-cropping, consolidation of lands holdings,
promotion of co-operatives and higher investment in agriculture also contributes to higher tractor
demand. The tractor segment comprises players like Eicher, Escorts, HMT, Punjab Tractors, M&M,
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TAFE, Sonalika, which control about 98% market share. India is the world’s largest market in tractors
since 1996. A few international players like Case New Holland, John Deere have also set up facilities
in India. Punjab Tractors is promoted mainly by Punjab State Industrial Development Corporation
Limited and has acquired the second highest market share in the tractor segment from 9.1% in 1975. In
1970, PTL had major competition from other companies like Eicher, Tractors and Farm Equipment
(TAFE), Mahindra & Mahindra (M&M), Escorts and HMT. PTL is one of the leaders in its business
and has put up a heady performance in contrast to other private sector players. Punjab Tractor is the
only major tractor company, which entered this business without any foreign collaboration. The
company has beefed up its R&D capabilities in the last two to three years. PTL’s Swaraj-735 is in a
class of its own and has been benchmarked by its competitors to which 16 new features have been
added. PTL has single – mindedly focused on increasing its market share in tractors.
Current Scenario
During the first half of 2001-02 PTL increased its market share from 18.5% to
21.4%. With the total industry volumes plummeting by 16.6% the sales of PTL fell only a trifle
3.1%. Under these circumstances, though the revenue has fallen by a 0.38% the operating
profitability has risen by 1.03%. PTL garnered the operating margins of 19.4% in the first half of
FY2001-02, while the lead players like M&M, Escorts and Eicher have reported operating margins
of 4.4%, 0.7% and 2.9% respectively. The Net Profit has increased by 1.4% to Rs.564 million and
the contribution of 40-50HP tractors has increased by 30%, which indicates higher margins from
bigger tractors due to a strong foothold in Punjab and Haryana markets.
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SWARAJ’S YEARLY PROGRESS
1965:- Govt. of India's research institute (CMERI) at Durgapur initiates design and development
of SWARAJ tractor based on indigenous know-how.
1970:- Punjab Govt. through PSIDC acquires SWARAJ tractor's design from CMERI and
establishes Punjab Tractors Ltd. (PTL) for its commercialization.
1971-73:- PTL sets up SWARAJ Project for 5,000 tractors per annum at a capital outlay of Rs.
37.0 million with an equity base of Rs 11.0 million.
1974:- Swaraj 724 (26.5 HP) tractor commercially introduced.
1975:- 2nd tractor model SWARAJ 735(39 HP) developed by own R&D, commercially
introduced.
1978:- 3rd Tractor model SWARAJ 720 (19.5 HP) developed by own R&D, commercially
introduced. Maiden equity divided declared.
1980:- Guided by social concerns and responsibility, PTL takes over PSIDC's scooters unit -
Punjab Scooters Ltd. (subsequently renamed as SWARAJ Automotives Ltd.) India's first Self
propelled Harvester Combine - SWARAJ 8100 developed by own R&D, commercially introduced.
SWARAJ Foundry Division set up in backward area.
1983:- 4th Tractor Model - SWARAJ 855 (55 HP) developed by own R&D, commercially
introduced. Expansion of annual capacity to 12,000 tractors per annum at Plant 1.
1984:- SWARAJ MAZDA Ltd. promoted in technical and financial collaboration with Mazda Motor Corps. & Sumitomo Corp. Japan for manufacture of Light Commercial Vehicles. PTL's equity participation is Rs. 30.4 million (29%) and that of Mazda and Sumitomo's Rs. 27.0 million (26%).
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1985:- SWARAJ Industrial Forklift Trucks developed by own R&D, commercially introduced.
1986:- SWARAJ ENGINES Ltd. promoted in technical and financial collaboration with
Kirloskar Oil Engines Ltd.(KOEL) for manufacture of diesel engines. PTL's equity participation is
Rs. 6.9 million (33%) and that of KOEL's Rs 3.6 million (17%).
1995:- Setup of tractor Plant II at Village Chappercheri with annual capacity of 12,000 per annum.
1998:- Commencement of expansion to 60,000 tractors (30,000 at each plant). Capital outlay of Rs
1000 million, funded mainly through internal accruals.
1999:- 5th and 6th tractor models - SWARAJ 733 (34 HP) & SWARAJ 744 (48 HP) developed by
own R&D, commercially introduced.
2000:- Expansion of annual tractor capacity to 60,000 completed.
2001:- PTL won National Championship trophy in competition organized by All India
Management Association (AIMA) for young managers. Economic times and Boston Consulting
Group selects PTL as one of the India's finest 10 companies out of Economic times top 500
Companies.
2002:- Cumulative tractor sales crosses 5,00,000/-.
2003:- PSIDC's disinvestment of its entire Equity holding (23.49%) in PTL in favour of CDC
Financial Services (Mauritius) Ltd. With this, total holding of CDC & its associates in PTL stands
at 28.48%.
2004:- 7th & 8th tractor models - Swaraj 939 (41 HP) & Swarj 834 (34 HP) developed by own
R&D, commercially introduced.
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2005:- PTL disinvested 15,73,000 equity shares of Rs. 10/- each of Swaraj Mazda Ltd.
(constituting approx. 15% of SML's paid up capital) in favour of Sumitomo Corporation, Japan, a
joint venture partner in Swaraj Mazda Ltd. at a total consideration of Rs. 629.2 million.
2007:- CDC/Actis Group and Burman Family's disinvestment of their Equity holding in PTL (43.3%) in favour of Mahindra Group (M&M).
2008:- Swaraj 3 Tonne Battery forklift, designed and developed by in-house R&D, commercially launched
Punjab Tractors Ltd. (PTL) has commercially launched another model - Swaraj 939 FE at a
function in Indore.101 units of this new generation tractor were delivered to farmers from all over
Madhya Pradesh and Chhattisgarh, by Mr. R.Gopalan, Managing Director, State Bank of Indore in
the presence of PTL's Mr. Yash Mahajan (VC & MD) and Mr. A.M. Sawhney (SVP-Mktg).
Powered by a future ready, fuel - efficient 41 HP SAE, three-cylinder water-cooled diesel engine,
Swaraj 939 FE has a constant mesh gear box, diaphragm clutch and neutral safety switch.
Upgraded variants of this model can also be supplied as per customer needs/requirements.
M&M made open offer to shareholders for another 20% equity of the Company.
Mahindra Group's equity holding in the Company stands at 64.6%
Cumulative Tractor Sales cross 600,000.
Swaraj Track Type Combine designed and developed by in-house R&D, commercially launched.
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INTERNATIONAL AND NATIONAL COLLABORATION OF SWARAJ GROUP
Swaraj group has entered into technical and financial collaborations with various national and
international companies.
Swaraj Mazda Limited was set with technical and financial collaborations with Mazda Motors
Corporation of Japan.
Swaraj Combine Division was entered into with Komatsu Forklift Company of Japan for
manufacturing fork lifters.
Swaraj Engines Limited was set up in technical and financial collaboration with Kirloskar Oil
Engines Limited, Pune for manufacturing diesel engines.
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MILESTONES
1970 Establishment of PTL for making Swaraj brand of tractors
1974 Commercial production started with 2 models: 724 FE & 735 FE
1980 Swaraj 8100, India’s first self-propelled combine harvester launched
1983 Swaraj 855 launched in the 50 hp category
1995 Establish of the 2nd plant for manufacturing Swaraj tractors in Chhaparchhedi
1999 Launch of Swaraj 744
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2002 Cummulative sales of Swaraj tractors (till date) touches 5,00,000
2007 Swaraj 724 FE Orchard and Swaraj 978 launched
2007 M&M (the leaders in domestic tractor industry) acquires majority stake in PTL
2009 Merger of PTL into M&M and subsequent transformation as the Swaraj Division of
Mahindra & Mahindra Ltd.
2009 Launch of 735 XM – the first of the XM series of models
2009 Launch of 843XM – building on the XM series
2011Rated Highest In Industry for Customer Satisfaction Index (CSI), Sales Satisfaction Index (SSI) &
CaPS
2011 Swaraj Division achieved Stage-5 in MQW Assessment
2012 Launch of 825XM, 841XM, 744XM, 855XM - strengthening the product portfolio with XM Series
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2012 Swaraj becomes the second tractor company in the world to win the prestigious DEMING Prize
2012 Rated Highest In Industry for Customer Satisfaction Index (CSI)
2013 Swaraj Division Plant 1 and Plant 2 Won TPM Excellence Award From JIPM
INTRODUCTION TO SWARAJ GROUP
Swaraj Engines Ltd., situated at Phase 9, Industrial Area Mohali was established in
technical and financial collaboration with Kirloskar oil Engines Ltd. For manufacturing diesel
engines for Swaraj Tractor Division Phase 4, Industrial Area, Mohali. During the few years of its
existence, it has not only increased its product range but also increased its production from 345 in
the first year more than 18000 engines now. These engines are sent to the Swaraj Tractor Division
where they are fitted on various Tractors.
Swaraj group came into existence with the establishment of Punjab Tractor Limited on 27 th June,
1974. The company was India’s first large scale based on totally indigenous design & technology, was
promoted by Punjab State Industrial Development Corporation (PSIDC) with the help of Govt. of
India & Public financial institutions.
VARIOUS DIVISIONS OF SWARAJ GROUP
Swaraj consists of six divisions:
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1) Swaraj Tractors Division.
2) Swaraj Mazda Ltd.
3) Swaraj Automotives Ltd.
4) Swaraj Engines Ltd.
5) Swaraj Foundry Ltd.
6) Swaraj Combine Division.
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MERGER WITH MAHINDRA&MAHINDRA IN YEAR 2007
M&M’s president (farm equipment sector) Anjani kumar Choudhari, who took charge as PTL’s
chairman over the weekend, told ET: “Swaraj has tremendous brand value in many northern
markets and we are going to exploit it fully. M&M bagged the bid at about Rs 360 per share, and
is acquiring about 43 per cent stake in the Chandigarh-based tractor firm for close to Rs 1,000
crore in an all-cash deal.
The 43 per cent stake includes 29 per cent owned by private equity firm Actis and 14.2 per cent by the Delhi-based Burman family. It was the second largest tractor company a few years ago and we would be promoting Swaraj aggressively to regain its lost market share. Some price improvements in the product are also being planned, which would be followed by a publicity campaign. While both the tractor brands would exist independently, a synergy in production and other back-end operations has been planned. M&M would utilize the low-cost vendors of PTL for its own tractors and eventually have a common vendor base for both the products. “We are planning major capital investment for modernization and expansion of foundry operations. There is a huge shortage of casting capacity in the market, so a major integration of the PTL’s foundry business with M&M operations is being planned. The company is also planning an expansion of PTL’s combined harvester (mechanized harvesting vehicle) manufacturing facility. “Iran Tractor Manufacturing Company, our business partners in Iran, has shown keen interest in the combined harvesting facility. Officials of the company have visited the PTL factory and are looking for exports of these machines.
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SWARAJ TRACTORS DIVISION:-
It is located in Phase-IV, SAS Nagar. The construction work of PTL was started in March 1972 and
the first batch rolled out on 14th November 1973. It started with an annual capacity of 5000 tractors
with a capital of Rs. 37 million. In 1974 it went into commercial production with Swaraj 724 26.5
BHP tractors as its first model. During its 22 year of production, it has not only expanded its
manufacturing capacity to more than 24000 tractors per annum but adds more products into its
manufacturing range. Its product range includes the following.
PRODUCT PORTFOLIO
Less than 30 hp
724 XM
SPECIFICATIONS
Engine Brakes Electricals
Transmission Steering Weight & Dimensions
Gear Speeds Hydraulics Warranty
PTO Speed Tyres Features
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ENGINE
Model RV-2 XM + 3A
HP Category 25-30 HP
Type 4 Stroke, Direct injection, Diesel engine
No. of Cylinders 2
Bore and Stroke 100 X 116 mm
Displacement 1824 cc
Rated Engine Speed 1800 rev/min
Air Cleaner 3- Stage Oil Bath Type
Cooling System Water Cooled with No loss tank
Transmission
ClutchStandard Single dry disc friction plate
Optional NA
No. of gears 8 Forward, 2 Reverse speeds
Gear Speeds (Km/hr) With 6.00 * 16 front & 12.4*28 rear type
Forward 2.19 to 27.78
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Reverse 2.74 & 10.77
PTO Speed
PTO SpeedStandard 1000 rpm
Optional 540 rpm
Brakes
Brake typeStandard Dry Disc type Brakes
Optional NA
Steering Type
Steering typeStandard
Mechanical Steering with Heavy Duty single drop arm for better manoeuvrability & comfort to operator
Optional NA
Hydraulics
Hydraulics
Live Hydraulics • Position control: To hold lower links at any desired height • Automatic draft control:To maintain uniform draft• Mix Control: For optimum field output
Lifting CapacityStandard 1000 Kgf at lower link ends
Optional NA
Linkage 3 point linkage Category-I suitable for Category-II type implement pins.
Tyres
Front Standard 6.00 x 16
Rear Standard 12.4 x 28
Front/Rear Optional NA
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Electricals
Electricals12 Volt, 88 Ah. BatteryStarter motor & Alternator
InstrumentsEngine rpm cum hour meter with direction indicators, Fuel Gauge, Ammeter, and Water Temp. Gauge & Oil Pressure Indicator
Weight & Dimensions
O.A.Length 3320 mm
O.A.Width 1675 mm
O.A.Height 2270 mm
Wheel Base 1935 mm
Min.ground Clearance
375 mm
Weight of Tractor 1750 kgs
Wheel trackFront :1300 mm
Rear :1350 mm (with 12.4*28 tyre size)
Features
• More fuel efficient engine meeting with Bharat Trem -IIIA norms• Concealed lockable battery near starter• 11" clutch for easy gear engagement & longer life• Telescopic stabilizers bars for easy adjustment and better implement stability• Live Hydraulics• 1000 Kgf Hydraulic lifting Capacity• Adjustable P.U sliding seat for operator comfort• Mobile cum carrier charger• Neutral safety switch• Transparent water separator for easy access & timely drainage of water from fuel system• Quick release coupler with tap off pipe for tipping trailer application
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• Steering lock – Safety from theft• Higher capacity 88AH battery for easy start & longer life
724 XM ORCHARD
SPECIFICATIONS
Engine Brakes Electricals
Transmission Steering Weight & Dimensions
Gear Speeds Hydraulics Warranty
PTO Speed Tyres Features
Engine
Model RV-2 XM + 3A
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HP Category 25-30 HP
Type 4 Stroke, Direct injection, Diesel engine
No. of Cylinders 2
Bore and Stroke 100 X 116 mm
Displacement 1824 cc
Rated Engine Speed
1800 rev/min
Air Cleaner Dry type, Dual element with dust unloader
Cooling System Water Cooled with No loss tank
Transmission
ClutchStandard Single dry disc friction plate
Optional NA
No. of gears 6 Forward, 2 Reverse speeds
Gear Speeds (Km/hr) with 5.00 x 15 front & 11.2 x 24 rear type
Forward 2.29 to 24.22
Reverse 2.28 & 09.02
PTO Speed
PTO SpeedStandard 1000 rpm
Optional NA
Brakes
Brake typeStandard Oil Immersed Brakes
Optional NA
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Steering Type
Steering typeStandard
Mechanical Steering with Heavy Duty single drop arm for better manoeuvrability & comfort to operator.
Optional NA
Hydraulics
Hydraulics
Live Hydraulics • Position control: To hold lower links at any desired height • Automatic draft control:To maintain uniform draft• Mix Control: For optimum field output
Lifting CapacityStandard 1000 Kgf at lower link ends
Optional NA
Linkage 3 point linkage Category-I suitable for Category-II type implement pins
Tyres
Front Standard 5.00 x 15
Rear Standard 11.2 x 24
Front/Rear Optional NA
Electricals
Electricals12 Volt, 75 Ah. BatteryStarter motor & Alternator
InstrumentsEngine rpm cum hour meter with direction indicators, Fuel Gauge, Ammeter, and Water Temp. Gauge & Oil Pressure Indicator
Weight & Dimensions
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O.A.Length 2800 mm
O.A.Width 1440 mm
O.A.Height 1450 mm
Wheel Base 1575 mm
Min.ground Clearance
240 mm
Weight of Tractor 1400 kgs
Wheel trackFront :1060 mm
Rear :1034 mm (with 11.2*24 tyre size)
Features
• More fuel efficient engine meeting with Bharat Trem -IIIA norms. • Concealed lockable battery near starter• Live Hydraulics• Hydraulic lifting Capacity -1000 Kgf • Oil Immersed Brakes• Adjustable P.U sliding seat for operator comfort • Dry type air cleaner with dual element with dust collector• Side draft downward draft silencer for orchard application• Rear track (1034mm) width suitable for inter cultivation crops• Better wheel traction for farm operations• Transparent water separator for easy access & timely drainage of water from fuel system• Tap off connection for tipping trailer application
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30-40 HP
834 XM
SPECIFICATIONS
Engine Brakes Electricals
Transmission Steering Weight & Dimensions
Gear Speeds Hydraulics Warranty
PTO Speed Tyres Features
Engine
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Model RV-3 XM + 3A
HP Category 30-35 HP
Type 4 Stroke, Direct injection, Diesel engine
No. of Cylinders 3
Bore and Stroke 100 X 110 mm
Displacement 2592 cc
Rated Engine Speed
1800 rev/min
Air Cleaner 3- Stage Oil Bath Type
Cooling System Water Cooled with No loss tank
Transmission
ClutchStandard Single dry disc friction plate - 280 mm dia. (11")
Optional NA
No. of gears 8 Forward, 2 Reverse speeds
Gear Speeds (Km/hr) With 6.00 * 16 front & 12.4*28 rear type
Forward 2.14 to 27.78
Reverse 2.68 & 10.52
PTO Speed
PTO SpeedStandard 1000 rpm
Optional 540 rpm
Brakes
Brake typeStandard Dry Disc type Brakes
Optional Oil Immersed Brakes
Steering Type
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Steering typeStandard
Mechanical Steering with Heavy Duty single drop arm for better manoeuvrability & comfort to operator
Optional NA
Hydraulics
Hydraulics
Live Hydraulics • Position control: To hold lower links at any desired height • Automatic draft control:To maintain uniform draft• Mix Control: For optimum field output
Lifting CapacityStandard 1000 Kgf at lower link ends
Optional NA
Linkage 3 point linkage Category-I suitable for Category-II type implement pins.
Tyres
Front Standard 6.00 x 16
Rear Standard 12.4 x 28
Front/Rear Optional NA
Electricals
Electricals12 Volt, 88 Ah. BatteryStarter motor & Alternator
InstrumentsEngine rpm cum hour meter with direction indicators, Fuel Gauge, Ammeter, and Water Temp. Gauge & Oil Pressure Indicator
Weight & Dimensions
O.A.Length 3475 mm
O.A.Width 1705 mm
O.A.Height 2250 mm
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Wheel Base 1930 mm
Min.ground Clearance
380 mm
Weight of Tractor 1845 kgs
Wheel trackFront :1300 mm
Rear :1350 mm (with 12.4*28 tyre size)
Features
• More fuel efficient engine meeting with Bharat Trem -IIIA norms. • Concealed lockable battery near starter• Oil Immersed Brakes*• Telescopic stabilizers bars for easy adjustment and better implement stability• Live Hydraulics• 1000 Kgf Hydraulic lifting Capacity• Adjustable P.U sliding seat for operator comfort• Mobile cum carrier charger• Neutral safety switch• Transparent water separator for easy access & timely drainage of water from fuel system• Tap off connection for tipping trailer application • Steering lock – Safety from theft• Higher capacity 88AH battery for easy start & longer life
735 XM
Engine
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Model RV-3 XM + 3A
HP Category 35-40 HP
Type 4 Stroke, Direct injection, Diesel engine
No. of Cylinders 3
Bore and Stroke 100 X 116 mm
Displacement 2734 cc
Rated Engine Speed
1800 rev/min
Air Cleaner 3- Stage Oil Bath Type
Cooling System Water Cooled with No loss tank
Transmission
ClutchStandard Single dry disc friction plate - 280 mm dia. (11")
Optional NA
No. of gears 8 Forward, 2 Reverse speeds
Gear Speeds (Km/hr) With 6.00 * 16 front & 12.4*28 rear type
Forward 2.30 to 27.80
Reverse 2.73 & 10.74
PTO Speed
PTO SpeedStandard 1000 rpm
Optional 540 rpm
Brakes
Brake typeStandard Dry Disc type Brakes
Optional Oil Immersed Brakes
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Steering Type
Steering typeStandard
Mechanical Steering with Heavy Duty single drop arm for better manoeuvrability & comfort to operator
Optional Power steering
Hydraulics
Hydraulics
Live Hydraulics • Position control: To hold lower links at any desired height • Automatic draft control:To maintain uniform draft• Mix Control: For optimum field output
Lifting CapacityStandard 1000 Kgf at lower link ends
Optional NA
Linkage 3 point linkage Category-I suitable for Category-II type implement pins.
Tyres
Front Standard 6.00 x 16
Rear Standard 12.4 x 28
Front/Rear Optional 6.00 x 16 / 13.6 X 28
Electricals
Electricals12 Volt, 88 Ah. BatteryStarter motor & Alternator
InstrumentsEngine rpm cum hour meter with direction indicators, Fuel Gauge, Ammeter, and Water Temp. Gauge & Oil Pressure Indicator
Weight & Dimensions
O.A.Length 3470 mm
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O.A.Width 1695 mm
O.A.Height 2255 mm
Wheel Base 1950 mm
Min.ground Clearance
395 mm
Weight of Tractor 1895 kgs
Wheel trackFront :1300 mm
Rear :1350 mm (with 12.4*28 tyre size)
Features
• More fuel efficient engine meeting with Bharat Trem -IIIA norms. • Single piece front tilting bonnet for ease of maintenance • Concealed lockable battery near starter• Oil Immersed Brakes* • Power Steering* • Bigger Rear Tyre - 13.6 x28 * • Telescopic stabilizers bars for easy adjustment and better implement stability• Live Hydraulics• 1000 Kgf Hydraulic lifting Capacity• Adjustable P.U sliding seat for operator comfort• Mobile cum carrier charger• Neutral safety switch• Transparent water separator for easy access & timely drainage of water from fuel system• Tap off connection for tipping trailer application • Steering lock - Safety from theft
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40-50 HP
841 XM
Engine
Model MDI 2385 S - 3A
HP Category 40-42 HP
Type 4 Stroke, Direct Injection, Diesel Engine
No. of Cylinders 4
Bore and Stroke 88.9 x 110 mm
Displacement 2730 cc
Rated Engine Speed
1900 rev/min
Air Cleaner 3- Stage Oil Bath Type
Cooling System Water Cooled with No loss tank
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Transmission
ClutchStandard Single dry disc friction plate - 280 mm dia. (11")
Optional NA
No. of gears 8 Forward, 2 Reverse speeds
Gear Speeds (Km/hr) With 6.00 * 16 front & 12.4*28 rear type
Forward 2.3 to 29.3
Reverse 2.8 to 10.9
PTO Speed
PTO SpeedStandard 540 rpm
Optional NA
Steering Type
Steering typeStandard
Mechanical Steering with Heavy Duty single drop arm for better manoeuvrability & comfort to operator
Optional NA
Hydraulics
Hydraulics
Live Hydraulics - SENSILIFT Hydraulics for better operations in Loose & Sandy Soil • Position control: To hold lower links at any desired height • Automatic draft control:To maintain uniform draft• Mix Control: For optimum field output• Sensilift Hydraulics: For better operations in loose &sandy soil
Lifting CapacityStandard 1200 Kgf at lower link ends
Optional NA
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Linkage 3 point linkage Category-I suitable for Category-II type implement pins.
Tyres
Front Standard 6.00 x 16
Rear Standard 12.4 x 28
Front/Rear Optional 6.00 x 16 / 13.6 x 28
Electricals
Electricals12 Volt, 88 Ah. BatteryStarter motor & Alternator
InstrumentsEngine rpm cum hour meter with direction indicators, Fuel Gauge, Ammeter, and Water Temp. Gauge & Oil Pressure Indicator
Weight & Dimensions
O.A.Length 3390 mm
O.A.Width 1680 mm
O.A.Height 2200 mm
Wheel Base 1935 mm
Min.ground Clearance
370 mm
Weight of Tractor 1820 kgs
Wheel trackFront 1330 mm
Rear 1350 mm (with 12.4*28 tyre size)
Features
• More fuel efficient engine meeting with Bharat Trem -IIIA norms. • Compact design with new attractive decals • Live Hydraulics
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• Sensilift Hydraulics - for smooth operation with seed drill & cultivator in sandy soil • 1200 Kgf Hydraulic lifting Capacity • Transport lock • Isolator valve for auxillary application • Oil Immersed Brakes • Telescopic stabilizers bars for easy adjustment and better implement stability• Adjustable P.U sliding seat for operator comfort• Mobile cum carrier charger
SWARAJ ENGINES LIMITED
Swaraj Engines Ltd., situated at Phase 9, Industrial Area Mohali was established in technical
and financial collaboration with Kirloskar oil Engines Ltd. For manufacturing diesel engines for
Swaraj Tractor Division Phase 4, Industrial Area, Mohali. During the few years of its existence, it
has not only increased its product range but also increased its production from 345 in the first year
more than 18000 engines now. These engines are sent to the Swaraj Tractor Division where they
are fitted on various Tractors. The foundation stone of the Swaraj Engine was laid by the governor
of Punjab Mr. S. S. Ray on 29th December, 1987 and the production started from 28th December,
1988.
SEL is spread over an area of 12.72 acres. Having built covered area for manufacturing block is
13500 sq.mtrs & administration block is 1600 sq.mtrs. & Canteen blocks covers about 1300
sq.mtrs Investment on plant, machining, tooling etc 52 Crores. Machine shop houses 151 machines
out of 29 are computerized numerical control machines.
All components, before assy. are thoroughly cleaned by special purpose washing
machines. Cleanliness level of components is regularly monitored. Great emphasis is laid on
general hygiene of the plant, machinery & components offered for assy. The engines are assembled
in air pressurized shops, where ambient temperature during summer is maintained at 32°C with 30
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air changes per hour. Each test cell is sound proof & air pressurized; where 130 air changes take
place/ hr. Engines are tested as per the latest norms laid out by ARAI. Tested engines are
dispatched to tractor or Combine Division the very next day.
In addition to components for tractor engine we are having a dedicated machine shop, which
is manufacturing & supplying 100% Cylinder Blocks & Con Rods required by SML, on day to day
basis. Supply of SML cylinder head is also made from here.
The various engine models being produced at SEL are:
1. S-15, Single Cylinder:
2. RV-2, Two Cylinder:
Engine Specifications
Model : RV-2 xm KIRLOSKAR
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Engine Specifications
Model : S-15 ; Swaraj
HP : 24.5 S.A.E.
Tractor : SWARAJ 722
Type : 4 - Stroke, Direct Injection, Diesel Engine
Bore and Stroke : 120 X 126 mm
Displacement : 1425 cc
Rated Engine Speed : 1900 rev/min
Cooling System : Water Cooled
Six Months Industrial Training Report PUNJAB TRACTORS LIMITED
HP : 26.5 S.A.E.
Tractor : SWARAJ 724 FE
Type : 4 - Stroke, Direct Injection, Diesel Engine
Bore and Stroke : 100 X 110 mm
Displacement : 1728 cc
Rated Engine Speed : 2000 rev/min
Cooling System : Water Cooled
3. RV-3, Three Cylinder :
Engine Specifications
Model : RV-3 xm KIRLOSKAR
HP : 39 S.A.E.
Tractor : SWARAJ 735 FE
Type : 4 - Stroke, Direct Injection, Diesel Engine
Bore and Stroke : 100 X 110 mm
Displacement : 2592 cc
Rated Engine Speed : 2000 rev/min
Cooling System : Water Cooled.
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Engine Specifications
Model : RB-30 xm KIRLOSKAR
HP : 48 S.A.E.
Tractor : SWARAJ 744 FE
Type : 4 - Stroke, Direct Injection, Diesel Engine
Bore and Stroke : 110 X 110 mm
Displacement : 3136 cc
Rated Engine Speed : 2000 rev/min
Cooling System : Water Cooled with Oil Cooler for engine oil.
5, RB-33, Three Cylinder:
Engine Specifications
Model : RB-33 xm KIRLOSKAR
HP : 50 S.A.E.
Tractor : SWARAJ 855 FE
Type : 4 - Stroke, Direct Injection, Diesel Engine
Bore and Stroke : 100 X 116 mm
Displacement : 3308 cc
Rated Engine Speed : 2000 rev/min
Cooling System : Water Cooled with Oil Cooler for engine oil.
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These engines are sent to the Swaraj Tractor Division where these are fitted on various
model tractors. The S-15 engines are manufactured in the Swaraj Combine Division and fitted on
Swaraj 922 model tractors. But now S-15 engines are also manufacture by Swaraj engines and
soon its full production will started in Swaraj engines.SEL manufactures diesel engines for Swaraj
Tractor Division.
DEPARTMENTS:
Department is the breaking down an enterprise into various departments. Grouping of activities into
department is very essential because it limits the number of subordinates to supervise by a manager.
The various departments in SEL are:
10. Business Excellence (ISO department)
11. Production planning and control
12. Quality engineering
13. Standards room
14. Industrial engineering
15. Personal department
16. Accounts department
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17. Purchase department
18. Machine shop
19. Assembly shop
20. Tool room
21. Stores
22. Maintenance
DETAILS OF ALL THESE DEPARTMENTS:
1.) PRODUCTION PLANNING AND CONTROL (PPC)
The PPC at SEL is in charge of maintaining the inventory status, of arranging receipt and dispatch of
components and of follow up. It also supervises transfer of components from the machine shop and
stores to the assembly area and maintains the shop floor status of the components. PPC indicates two
functions:
Production planning is the function concerned with the planning, Directing and controlling of the
methods to be used to make products and the way in which the production facilities etc. should be laid
out in the space available for production.
Production Control is the function of the management, which plans, directs and controls the material
supply and processing activities of an enterprise. So that specified products are produced by specific
methods to meet and approved sales program.
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2.) QUALITY ENGINEERING DEPARTMENT
Another important part of the plant is the Quality Shop. With the increasing competition in the
market it is desired by the company to produce such a quality product so as to satisfy the various
needs of the customer and the level of quality of the product. This work is done by the quality
department. Quality seeks on every minute defects and smallest of dimension that could bring
much risk of poor quality, defects and line reject.
The quality shop is 24 by 7 hours running. By this you can yourself judge how much the company
is putting in to maintain the quality of the products and also that their customers get the best
quality product every time. It is the shear responsibility of the quality shop only that the materials
within the maintained dimensions are being transferred on to the machines so that it doesn’t causes
any further problems and also to minimize line rejection losses. Also it is the responsibility of the
quality department to put various materials on rework if they cause problem like line rejection.
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The quality shop comprised of three main parts:-
Quality Receiving Department
Coordinate Measuring Machine Room
Standard Room
Before I begin explaining about various parts within the quality shop, it is important to know that
all its branches work towards the ultimate goal of maintaining quality only.
Quality is relative term and is generally explained with reference to the product. Quality can be
defined as fitness for purpose.
The Quality engineering department at SEL is divided into four sections.
These are
Quality engineering [receipt]
Quality engineering [Machine shop]
Quality engineering [Assembly]
Quality engineering [Testing]
3.) INDUSTRIAL ENGINEERING DEPARTMENT
Industrial Engineering (I.E.) is concerned with the design, improvement and installation of integrated
system of people, materials, equipment and energy. It draws upon specialized knowledge and skill in
the mathematical, physical and social sciences together with principles and methods of engineering
analysis and design to specify predict and evaluate the results to be obtained from such system.
I.E. is engineering approach to detailed analysis of the use and cost of resources of an organization.
The main resources are men , money , materials , equipment and machinery. The industrial
Engineer carries out such analysis in order to achieve the objectives (to increase productivity or
profits etc.) and policies of the organization. An Industrial Engineer’s technique is too go beyond
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the mechanical cost factor. He is associated with organization structure, administrative techniques,
and labour problems and at the same time he understands the relationship between efficiency and
consent (of the working group). Essentially the industrial engineer is engaged in the design of a
system and his function is primarily that of management. If he is to focus on only one concept to
describe his field of interest and objectives, it would have to be productivity improvement.
The mission of I.E. would be try to produce more to serve better without increasing the resources
being consumed.
3.1 OBJECTIVES OF I.E.
Industrial engineers are concerned with two basic objectives: improving efficiency and reducing
wastage. Efficiency is improved on resources employed such as men, material, machine
management and money. It therefore, means improving efficiency in manufacturing process,
methods, capital investment and efficiency of plant. In practical 100% efficiency is impossible to
achieve.
The second objective of I.E. is to reduce wastage. Since the two objectives are of universal
application, the area of operation of Industrial Engineering is also very wide
3.3 ROLE OF INDUSTRIAL ENGINEERING IN SEL
The most important and result oriented dept. in the terms of production planning, designing,
optimization of methods etc. is the industrial engineering dept. It is the backbone of all types of
process industries. The various functions of the I. E. dept are the following:
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PROCESS PLANING: - It deals with process capabilities of various machines, and constantly
works on projects for productivity improvements, optimum layouts, Programming of CNC
Machine, Productivity Improvement Studies, Optimum Utilization of material resources etc.
TOOL CONTROL CELL: - It deals with tooling, jigs, and fixtures being used throughout. It
also does inventory control, dealing in various cutting materials available and their respective
usage, different types of cutting tools, tool-holders etc; their nomenclature and corresponding
applications.
TOOL DESIGN: - It deals with the designing aspect of equipment, sets various standards for
QE etc. for designing the different parts of engines.
ASSEMBLY/PROJECTS: - Its deals with the process of Engine Assembly shop, Conducting
Trials for different tooling required in Assembly, Implementing any design change in Engine as
recommendation from R&D , Project related work like new machine installation, Civil related works
in plant etc.
4. PERSONNEL
Any industry depends upon human beings. It has to acquire workers and it creates an acceptable
and rule of practice to encourage the greatest degree of participation from its employees. The
department concerned with this called personnel department.
The personnel function exists in every enterprise regardless of its size & irrespective of the fact
whether or not there is personnel department. In small concern, the owner itself carries on the
personnel function whereas a large organization it is given a maximum individual development,
desirable working condition and desirable working relationship between employees and employers
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and between groups of employees and effective moulding of human resources for the purpose of
contributing to the organizational goals.
5.) ACCOUNTS
The main objective of the accounts department is to determine, classify and analyze the cost and
income of the business enterprise. Accounts department provides information for the following:
Cost control through accumulation and utilization of cost data
Profitability of products
Budgeting
Standard costing
Continuation of business
Proper matching of cost with revenues
Control of material and supplies
Wages and overhead costs
Determining expansion and contraction policies
6.) PURCHASE
The purchase department is responsible is responsible for purchasing all types of materials in
correct qualities and at the most economical prices.
The purchase department occupies a vital and unique position in a concern because purchasing is
one of the main functions in the success of a modern manufacturing concern. The purchasing
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function acts as a liaison agency, which operates between the factory and the outside vendors on
all matters of procurement delivery of the articles in accordance with terms of purchase agreement.
7.) MACHINE SHOP
Facilities at this shop include equipment for drilling, boring, fine boring, grinding, lapping etc.
Machining to components, cylinder heads, connecting rods, cylinder blocks, crank case and gear
casing is done in this shop.
The various functions of this shop are:
1. Machining of cylinder, cylinder heads, crank cases, gear casing etc. of the entire engine models
being manufactured at SEL
2. Assembly of cylinder heads
3. Machining & assembly of connecting rods of RV engine models.
4. Machining & assembly of connecting rods of SM
Some of the operations being carried out for the processes being performed at the SEL m/c
Shop for machining the different components are:
Grinding
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Drilling
Boring
Turning
Semi finish boring
Finish Boring
Tapping
Milling
Chamfering
Reaming
Lapping
Washing
MACHINES USED IN MACHINE SHOP:
Vertical milling machine
Horizontal milling machine
Radial drilling machine
Gang milling machine
Rough boring machine
Semi-finish boring machine
Finish boring machine
Honing machine
Gun drilling machine
Washing machine
Rotary grinder
Rough milling machine
XLO valve lapping machine
Line boring machine
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MACHINING PROCESS OF VARIOUS COMPONENTS:
CRANK CASE
CYINDER HEAD
GEAR CASING
CYLINDER BLOCK
SML CYLINDER BLOCK
SML CYLINDER HEAD
CONNECTING ROD
CRANK-CASE
Crank–case is the housing for accommodating crank shaft and cam shaft. In SWARAJ
tractors, crank case is cast separately and attached to cylinder block. The bottom face of crank case
walls is flanged to strengthen the casing and to provide a machined joint face for sump to be
attached. Crank-shaft is supported in the crank case through a number of bearings called main
bearings. The construction of the crank case has to be such as to provide very high rigidity because
it must provide reactions for the heavy forces set up to gas pressure in the cylinders. The cylinder
block is mounted above the crank case. At the top of the cylinder block is attached the cylinder
head. Attached to crank case is sump, flywheel, gear casing, fuel filter, water separator etc.
The material of crank case is cast iron because it has following advantages:-
1. Good foundry material
2. High machinability
3. It does not warp under high temp. & pressure developed in cylinders
4. It is slightly porous nature as it retains better lubricant oil film
5. It does not wear too much
6. Sound damping properties
7. Low coefficient of thermal expansion
8. It is relatively cheap
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CYLINDER HEAD
Cylinder head is attached to the top of the cylinder block by means of studs fixed to the block. The
gaskets are used to provide a tight leak proof joint at the interface of the head and the block. The
cylinder head forms a combustion chamfer above each cylinder. It also contains injector holes and
cooling water jackets. Besides valve openings are provided in the head. Upon which is also
mounted the complete value operation mechanism. In all the cylinder heads of swaraj engines, the
inlet and exhaust manifolds are placed on different sides of the cylinder head, it is called offset
cross-flow type. Detachable head type has many other advantages over the integral construction.
1. From production point of view, the cylinder block casting with open bore for the detachable
type head, is much more simplified.
2. Operations like de carbonizing and value grinding are simplified
3. The comp. ratio can be changed slightly by changing the thickness of gasket used between
the block and the head. The material used for cylinder head is cast – iron
There are separate sets of pipes attached to the cylinder head which carry the air and the exhaust
gases. These are called manifolds.
The cylinder has the nozzle bore in which the injector is inserted. The function of injector is to
inject the fuel in the cylinder in properly atomized from and in proper quality. The cylinder head
apart from having the inlet and exhaust manifolds (attached to cylinder head) has a water outlet
manifold. On the top of cylinder head, is mounted the rocker arm, rockers shaft, push rods, springs
rocker cover etc. The cylinder head also contains the inlet and exhaust valves.
There is a water jacket in the cylinder head for the circulation of cooling water. The lubrication oil
for the lubrication of rocker assembly enters from Rocker supply hole. Where it enters through
rocker supply hole where it enters through rocker supply pipe from crank-case. RV2 and RV3 have
the same cylinder head while RB30 and RB33 have the same. The S-15 has completely different
cylinder head.
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1. WATER GALLERY TESTING MACHINE:
After above operations water gallery is tested by passing pressed air from water exhaust while
water inlet is closed by on arrangement and then dipped in coolant for checking any leakage in
plugs or blow holes in valve holes.
2. VALVE SEAT LAPPING:
1. Apply lapping paste on valves periphery and insert in valve seats
2. Hold the valves by rubber lapper.
3. Start the machine and lap the valves
4. Stop machine and release the job
5. Clean the seats- Valves with cloth properly
6. Place the comp. with top side up on washing unit.
7. Clamp cylinder head and start machine cycle.
8. Tap 1-hole M 10 ×1.5 and 15 deep.
9. Rotate camp and place on fixture to bring inlet side on top.
10. Tap 1-hole M 10×1.5 and 10 deep.
11. Feed the comp. in the washing booth
12. Remove the comp from booth after washing
13. Clean the comp with air Jet and cloth.
14. Alloy lockset on care plug holes
15. Fit case plugs in core holes by hammer and punch
3. PRESSURE TESTING MACHINE
1. Place and clamp are cylinder head on the unit.
2. Clamp cylinder head pneumatically and dip ass in tank
3. Start air and check for any air bubble. Lift the head and release the job pneumatically
and kept cylinder Head on conveyor.
4. Drain out excess coolant clean with cloth and put rubber stamp with CuSO4.
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4. LEAKAGE TESTING AND FINAL ASSEMBLY:
1. Remove cylinder head from washing unit and clean residuals with clean and dry cloth
as per shop practice.
2. Insert valves from bottom side and place cylinder head on base plate.
3. Place the cylinder head on table put valve cup in the valves from top side.
4. Place 2 no. of valve springs with the help of fixture on inlet valve. Side and exhaust
valve side.
5. Press cups along with springs with the help of fixture on inlet valve. Side and exhaust
valve side.
6. Insert collets pairs to take the proper seat with valve cup.
7. Test for leakage on valve leakage testing machine at air pressure of 4 kg/cm2
8. Re-lap the seats is leakage appears
The emery paste is used in lapping process which acts as a grinder and grinder both
valve and valve seat.
5. FINAL INSPECTION:
After leakage test and final assembly, final inspection of cylinder head is done. In this
inspection the tap of holes and valve seats and valve guides are inspected by a quality
inspector and then pieces are moved to assembly shop.
GEAR CASING
As the name suggests, gear casing is the casing for gears. It encloses the crank shaft gear, cam
shaft gear, idler gear, FIP driving gear, lubricating oil pump assembly. It has following faces.
1. covering face or oil filler body mating face
2. crank- case mounting face
3. sump mating face
4. lubricating oil filter mating face
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5. Plate face
6. Water pump mounting face
Covering face: On this face, timing setter, tension lever, and pulley for driving
crankshaft are mounted.
Crank case mounting face: It is a face which meets with the gear end face of crank
case.
Sump face: On this face, sump is mounted.
On water mounting face, water pump is mounted in RV2&RV3. but in case of
RB30&RB33, the water pump is mounted on cylinder block. On this face alternator
bracket is mounted in RV2&RV3. But in case of RB30&RB33, it is mounted on
cylinder block
MACHINING PROCESS OF GEAR CASING:
1. VMC-40:
FIRST SET UP:
This is a machine made by Kirloskar, on this machine, the operations on the crank case
mounting face are done. There are two machines on which same operations are done on this
face.
Dowel holes accommodates dowel pins so that the gear casing can be easily supported during
fitting as these pins gets fitted into dowel holes on the gear end side of crank- case
4 drilled holes of Ø 5mm are around bearing hole. Here plate is mounted
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4 drilled holes of Ø 8.4 around FIP mating hole. Here FIP is mounted. Through FIP mating
hole the FIP shaft passes on which adapter flange is mounted. With this adapter flange, the FIP
driving gear is tightened
Bearing hole accommodates bearing.
The extended portion of gear casing where the plate is mounted accommodates the gear. This
gear transmits motion to the hydraulic pump which is used for operating the lift hydraulic
pump.
SECOND SET UP: set-up is also done on a V.M.C.-40 machine. On this machine the
following operations are done on the oil filler body mating face. Here also two machines are
used for same operation.
Oil seal hole accommodates the end of shaft where oil seal is mounted which prevents the oil
to come out of gear casing. On this end of crank- shaft, the pulley for giving a drive to it is
mounted.
2. HMC-500
Third set-up of gear casing is done on H.M.C. machine. This machine is used for operations done
on lubricating oil mating face, sump face, plate face and top face are done . Operations done are
drilling chamfering & tapping .
3. FLEXIARM :
The tapping of all faces are done on this machine by clamping in fixture specially designed for
this operation& also side drilling is done.
4. WASHING MACHINE:
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After oil gallery drilling washing of gear casing is done on washing machine with coolant.
Washing is done to remove chips and other components from oil galleries and other drilled holes.
After washing cleaning of gear casing is done with air jet and de burring of gear casing is done.
5. LEAKAGE TESTING AND INSPECTION:
After washing oil gallery leakage test is done. First gear casing is dipped in coolant and air passed
through oil gallery. If bubbles appear then there is leakage in oil gallery otherwise there is leakage
in gear casing. After this final inspection of gear casing is done and then send to assembly shop.
8.) ASSEMBLY SHOP
Most of the products are formed from a large no. of single parts produced at different times by
various production processes. All these may not be made at a single place but procured from
different sources. The objective of assembly is to combine individual components into a useful
product of higher value.
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The assembly shop at SEL assembles the engines of various models. Assembly is done manually in
which workers perform various assembly operations by using dexterity, sense organs and
intelligence using various tools and fixtures. Different components are brought from the stores and
the machine shop and engines are assembled from these components. After the assembly of engine,
their testing is done. Engine testing is also part of assembly shop.
The Assembly at SWARAJ TRACTOR DIVISION deals with the assembly of tractor models
722, 724, 733, 735, 744, and 834. Assembly is the joining of various constituents to form a final
product. The assembly process is carried out on the main line, which has various sub assemblies
along its length. Assembly shop can be divided in two main areas: -
1) Before paint area
2) After paint area.
BEFORE PAINT AREA: -
The area before painting can further be divided into sub assemblies/ loops namely
Differential loop.
Gearbox loop.
Rear cover loop.
Engine assembly loop.
DIFFERENTIAL LOOP:-
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Differential casting mounted on trolley after washing.
Bull pinion Shaft left and right fitted.
Cage assembly fitted.
It consists of:
1. Crown wheel.
2. Tail pinion assembly.
3. Roller bearing.
4. Bevel wheels.
5. PTO shaft fitted.
6. Rear axle/trumpet is fitted.
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7. PTO shifter assembly fitted.
8. Gearbox assembly is lifted.
9. Rear cover assembly fitted.
10. Brakes are fitted.
11.Parking brake.
12.Suction pipe
13.PTO cover
14. Trailer hook is fitted.
15. Angle bracket is fitted.
16. Rocket link is fitted.
17. Footboard is fitted.
18. Clutch pedal is fitted.
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GEAR BOX LOOP:-
Gearbox housing mounted on trolley.
Drive shaft & input shaft assembly.
Output shaft assembly.
Lay shaft and connecting shaft assembly.
Shifter rod assembly.
Steering assembly.
GEAR BOX:-
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The gearbox used in the tractors being manufactured by the P.T.L. is of the “SLIDING
MESH TYPE”. This is the simplest type of gearbox. The power comes from the engine to the
clutch shaft and hence to the clutch gear which is always in mesh with a gear on the lay shaft. All
the gears on the lay shaft are fixed to it and as such they are all the time rotating when the engine is
running. The clutch is engaged three direct and one reverse speed are attained on suitably moving
the gear on the main shaft by means of selector mechanism.
REAR COVER LOOP:-
Rear cover mounted on trolley.
Control valve and response valve assembly.
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Ram assembly. (This consists of cylinder, piston and piston rods.)
Testing of hydraulic lift.
ENGINE ASSEMBLY LOOP
Engine mounted on trolley
Dynamo is fitted.
Self-motor is fitted.
Oil pump is fitted.
Front axle beam and bracket is fitted.
Clutch plate is fitted.
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After that the chassis is carried to the next level by the lift where the engine & the 3-point
assembly of the tractor along with the other components are fixed. The parts fitted here are:
3-point linkage which contains the following parts:
Bracket.
Lower link fitted at the left side.
Leveling rod fitted at the right side.
Stabilizer stainer.
Draw bar.
Top link.
Battery frame.
Front frame.
Tie rod attached with the drop arm of the steering system.
Accelerator link.
Delievery pipe.
Engine attachement The engine is attached with the chassis system in this level of assembly. The engine is also
carried to this level with the help of the lift crane, which lifts the engine assembly & delievers it to
this level. Shlug is applied at the corneror we can say at rhe circumference of the gearbox where
engine is attached with studs & bolts. Shlugs works as gaskets or seals & avoid the oil leakage &
water mixing in the engine. the engine, which is suplied to this level of assemble where the engine
is attached contain the following parts attached on it:
Front axle.
Extension in the front axle used for the setting of the wheels.
K.P.S.A. (King Pin Shaft Axle) with the wheel disc & nuts fitted in there for the fitting of
the wheels.
Drop arms.
Tie rods.
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Bucket.
Clutch plates
Alternator.
Self starter.
Fuel pump.
The above parts are already fitted with the engine when it comes to the engine chassis
assembly. The make of the engine is KIRLOSKOR or SWARAJ KIRLOSKOR depending upon
the model as 3-cylinder, 2-cylinder or 1-cylinder. The engine was imported from this company
from Pune. SWARAJ also has its own engine plant where the engines are assembled. After
assembling the chassis & engine arrangement, the fitments are checked by the workmen appointed
there at this level & if there is some part missing, it is attached here. Then the whole assembly is
mounted over the conveyor, which takes that piece to different chambers of washing, drying,
primering, baking, painting & again baking.
After painting the conveyor takes the assembled piece to the DISMOUNTING STAGE where
different parts & components are fitted on the tractor & the tractor was completed. After that the
testing of the tractor is done. A tractor has to pass through different tests to claim itselfs to be as
perfect & if there is some problem coming out in this stage, the tractor is send to the recovery
shop, where the problem of the tractor is recovered. After the recovery the tractor is again
tested & after passing the test the tractor finally send to the yard from where it is send to the R &
D Complex for further tests. Now we shall discuss the DIFFERENTIAL, GEAR BOX, REAR
COVER AND DISMOUNTING STAGE in detail.
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GEAR BOX
The power, which the engine develops, is transmitted to the wheels of the tractor by certain
essential parts. The application of engine power to the driving wheels through these parts is called
“POWER TRANSMISSION”. These parts are clutching, gear box, differential and rear axles.
To start a tractor from rest, the inertia of its whole weight must be overcome. Diesel engine
does not develop its full power at low speed. It has to run at fairly high speed before it develops
maximum power and torque.
Since much power is needed in starting, climbing uneven land and in pulling varying loads,
a provision must be made to permit the engine to run at high speed while the wheels run at lower
speed. This is achieved by a system called “GEAR BOX”.
With the help of gearbox we can achieve this and pulling power of the tractor can be
increased or decreased by varying the speed of tractor. For these tractors gearbox used is of the
type of “SLIDING MESH GEAR” type.
TYPES OF GEAR BOX:
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Selective gearbox.
a. Sliding mesh type
b. Constant mesh type.
c. Synchronous type.
Planetary gear transmission.
Automatic gearbox
WORKING IN GEAR BOX
The Constant Mesh (CM) gear is rigidly fixed to the input shaft or clutch shaft. It
remains always connected to the drive gear (also CM gear) of the lay shaft. Three other gears
are also rigidly fixed to the layshaft. They are the second speed gear, first speed gear and
reverse speed gear. Two gears are mounted on the splined main shaft or output shaft (also
known as intermediate shaft) which can be slided by the shifter fork when the shaft lever is
operated. These gears are the second speed gear and first and reverse speed gear. They can be
connected to the corresponding gears of the layshaft and always remains connected to the
reverse gear of the layshaft.
Gears in neutral: When the engine is running and clutch is engaged, the CM gear
drives the layshaft gears. The layshaft rotates opposite in direction of the clutch shaft. Note that
in neutral position, only the CM gear is connected to the CM gear of the layshaft. Other gears
are free, and hence the transmission intermediate shaft is not turning. The vehicle is stationary.
First or low speed gear: By operating the gear shift lever, the larger gear on the
intermediate shaft is moved along the shaft to mesh in the first gear of the layshaft. The
intermediate shaft turns in the same direction as the input shaft. Since the smaller layshaft gear
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is engaged with the larger intermediate shaft gear, a gear reduction of approximately 3:1 if
obtained. That is, the input shaft turns three times for each revolution of the input shaft. Further
gear reduction in the differential at the rear wheels produces a still higher gear ratio,
approximately 12:1, between the engine crankshaft and the wheels.
Second speed gear: By operating the gearshift lever, the larger gear of the
intermediate shaft is demeshed from the first gear of the layshaft and then the smaller gear of
the input shaft is meshed with the second gear of the layshaft. The intermediate shaft turns in
the same direction as the input shaft. A gear reduction of approximately 2:1 is obtained. The
differential gear reduction increases this gear ratio to approximately 8:1.
Third, top or high speed gear: By operating the gear shaft lever, the second gear of
the intermediate shaft and layshaft are demeshed, and then the second and top gear of the input
shaft is forced axially against the CM gear of the input shaft. External teeth on the input shaft
gear mesh with the internal teeth in the second and top gear. The intermediate shaft turns with
the input shaft and the gear ratio of 1:1 is obtained. The differential reduction reduces a gear
ratio of about 4:1 between the engine crankshaft and the wheels.
Reverse gear: by operating the gear shaft lever, the larger gear of the intermediate
shaft is meshed with the lever idler gear. The reverse idler gear is always in mesh with the
layshaft reverse gear. Interposing the idler gear between the layshaft reverse gear and
intermediate shaft bigger gear, the intermediate shaft turns in the direction opposite to that of
the input shaft. This reverses the rotation of the wheels so that the vehicle backs.
High/Low Gear: High/low gear shifter enables to achieve either high torque-low
speed or low torque-high speed with the help of planet gear & carrier assembly.
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High Gear: Low torque-high speed is achieved when hi-lo shifter is shifted in high
gear position. Coupling intermediate shaft and output shaft with the help of sleeve transmits
the power.
LOW GEAR: High torque-low speed is achieved when hi-lo shifter is shifted in low
gear position. The power is transmitted to output shaft from intermediate shaft, planet gear and
carrier assembly and sleeve. The planet gear & carrier assembly reduces the high speed and
subsequently torque is increased.
LUBRICATION OF GEAR BOX
Proper lubrication of gear box is extremely important. The transmission gears operate in a bath
if lubricant. The fear box should always remain filled with lubricant. It prevents metal to metal
contact which would generate so much heat that the gear teeth would be burned away. It
lubricates bearing if the fear box.
Special Tools Used In Gear Box Assembly:
1. Dowel Pressing Tool used for internal gear.
2. Planet Pin Fitting used for planet carrier.
3. Base for Planet Carrier.
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4. Pin aligning tool used for planet gear.
5. Extraction tool used for planet carrier.
6. Needle bush used for Input shaft and intermediate shaft.
DIFFERENTIAL SYSTEM
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If the car travels in a straight line, the two rear wheels turn on the road exactly at the same speed.
There is no relative movement between the two rear wheels. The propeller shaft may be geared
rigidly, in the case, with the rear axle to rotate the rear wheel together. But when the car takes the
turn, the outer wheel travels on the longer radius than the inner wheels. The outer wheel turns
faster than the inner wheel, i.e., there is the relative movement between the two rear wheel. If the
two rear wheels are rigidly fixed to a rear axle, the inner wheel will slip which will cause:-
Rapid tyre wear.
Steering difficulties.
Poor road holding.
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Therefore, there must be some devices to provide relative movement to the two rear wheels when
the car takes a turn. And here comes the purpose of differential.
The differential is a device that splits the engine torque two ways, allowing each output
to spin at a different speed.
The differential is found on all modern cars and trucks, and also in many all-wheel-
drive (full-time four-wheel-drive) vehicles. These all-wheel-drive vehicles need a differential
between each set of drive wheels, and they need one between the front and the back wheels as
well, because the front wheels travel a different distance through a turn than the rear wheels.
Part-time four-wheel-drive systems don't have a differential between the front and
rear wheels; instead, they are locked together so that the front and rear wheels have to turn at the
same average speed. This is why these vehicles are hard to turn on concrete when the four-wheel-
drive system is engaged.
The differential has three jobs:
To aim the engine power at the wheels
To act as the final gear reduction in the vehicle, slowing the rotational speed of
the transmission one final time before it hits the wheels
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To transmit the power to the wheels while allowing them to rotate at different
speeds (This is the one that earned the differential its name.)
WORKING of DIFFERENTIAL:
The engine drives the crown wheel mounted on the cage assembly through tail pinion.
Four bevel pinions are mounted on the cross, which is fitted in the cage assembly. Cross-moves
along with the cage assembly and bevel pinions are free to rotate on the cross. Two bevel gears are
mounted on the splined bull pinion shafts lt. and rt., which are supported on the taper roller
bearings in the differential housing. These taper roller bearings give rigid support to cage
assembly.
CASE-1:
On straight roads, the cage moves along with the crown wheel carrying the bevel
pinions and bevel gears without any relative motion among them. At this time bevel pinions do not
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revolve around the cross but act as a key between bevel gears lt. and rt. causing the bull pinion
shafts to rotate at the same speed.
CASE-2:
Now consider that if the tractor is moving and the bull pinion shaft rt. is being held
stationary by applying the brake for a shorter turn in the field, due to this bevel gear rt. cannot
rotate while cage assembly is still rotating in the same direction. As bevel gear rt. is stationary,
bevel pinions will roll over bevel gear rt., or we can say it will walk along bevel gear rt. while
revolving around its own axis. On the other hand bevel gear lt. will move two times faster. The
reason for the faster speed of bevel gear lt. is that while it is rotating on its axis due to the speed of
cage assembly in the same direction an additional speed has been added due to the relative motion
between bevel pinions and bevel gear lt.
CASE-3:
As soon as any of the rear wheels of tractor come across a loose/wet soil where
resistance to both the wheels is not equal or when the tractor is on a turn (say right turn), unequal
resistance will come across both wheels, causing speed reduction of rt. wheel & rt. bull pinion
shaft. But the cage assembly will keep on rotating at the same speed & in same direction. Now
bevel pinions will roll over bevel gear rt. at a slower speed. Hence bull pinion shaft lt. will rotate at
slightly higher speed due to the speed of cage assembly and the additional speed given to bevel
gear lt. by bevel pinions. This is the working principle of the differential system. On the straight
roads the speed of both rear axles remains same and on turns, the inner wheel is subjected to more
resistance and hence it moves at a slower speed and outer wheel moves faster.
The DIFFERENTIAL SYSTEM is very useful in the automobiles. This help in
the turning of the vehicle. As already discussed in the above cases that how the vehicle differential
works while the vehicle takes the turn. During the turning, the inner speed of the vehicle reduces &
the outer wheel moves faster than the inner wheel. The differential on the vehicle distributes the
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vehicle moves easily. Steering system is used for the turning of the vehicle. The following is the
layout of the differential assembly, which helps in understanding the things in easy way:
Differential Trouble Shooting
1. Noisy Differential:
a. Less lubricating oil in the differential housing.
b. Low viscosity oil or use of poor quality oil.
c. Wrong adjustment of Crown Wheel and pinion teeth.
d. Wrong out hub bearing.
e. Worn out or broken teeth of Crown Wheel or Tail Pinion.
f. Less Backlash of Crown Wheel and pinion teeth.
g. Worn out bearing of Crown Wheel or Pinion.
h. Crown Wheel misaligning on cage.
i. Loose star Pinion.
j. Broken or worn out thrust washers of star pinion or bevel gear.
2. Vehicle does not move when put in gear:
a. Broken axle shaft.
b. Broken pinion flange key.
c. Broken teeth of crown wheel and pinion.
d. Broken cross or star pinion.
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DISMOUNTING STAGE
INTRODUCTION:
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DISMOUNTING means the removing of the complete assembled tractor piece from the
conveyor. The conveyor is a long rail like carrier system, which carries the tractor chassis & engine
assembly through the different chambers of washing, drying, primering, baking & then to the
dismounting stage.
After the attachment of the complete assemblies of differential housing, gearbox &
engine fitting, the assembled piece is mounted on the conveyor which takes the assembled piece to the
different chambers of washing, drying, primering, baking & then further to the dismounting stage.
First of all the chassis & engine part is washed in the washing chamber. After washing the assemble
piece is dried with the blowers in the drying chamber. After that the assembled piece is coated with the
primer in the primering chamber. A primer makes a thin layer on the assembled piece, which helps the
paint to be attached to the assembled piece. After the primering the assembled piece is dried out. Then
the assembled piece travels to the painting chamber & paint is sprayed on the assembled piece of the
tractor containing the chassis & the engine. After the paint section, the assembled piece travel to the
baking chamber. In this the paint dried out & fixed on the assembled piece. Then at last the assembled
pieces reaches to the dismounting stage. In this stage the wiring, sheet metal work attachment & other
parts of the tractors like radiator, steering, fuel tank, etc. is fitted. When the fitting of the parts of the
tractor is complete the tractor piece is removed from the conveyor called the DISMOUNTING of the
tractor. Then the further test like road testing, rig test, engine test, etc. is done.
After the dismounting stage, we get the complete tractor but without testing. So testing
of the tractor is done after dismounting & after passing the tests, the tractor is sent to the yard from
where it is supplied to R & D COMPLEX. Here further testing of the tractors is done on the engine &
other parts like lifting, etc. & improvement or development is done in the tractor for better
performance. After all this procedures of testing etc., the tractor is ready to be supplied to the market.
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DISMOUNTING STAGE:
After the processes of washing, drying, painting, baking, the assembled
piece is finally arrived to the DISMOUNTING STAGE through conveyor. This dismounting stage is
further divided into different small stages & in each stage, 2 persons works at a time, on an assembled
piece of chassis & engine. The work is divided between these 2 men at the different stages. The
dismounting stage is divided into 5 different stages in which the parts of the tractor are fitted on the
assembled piece of chassis & engine & in every 6 minutes, we got a complete tractor, which is
removed from the conveyor of the dismounting stage.
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STAGE 1:
Alternator connection
Horn
Brake rod
Brake switch connection
Fan belt
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STAGE 2:
Speedometer wire
Rear frame
Fuel tank
Overflow pipes
Felt pads
STAGE 3:
Fan
Radiator
Hose pipes
Dash board (it mainly has instrumental panel which contains engine oil meter, fuel
gauge, ampere meter, temperature gauge, speedometer)
Dash board cover
Number plate
STAGE 4:
Battery
Steering wheel
Head lights
Clutch connection
Hooks and side panel
Knobs and covers
Sealings
STAGE 5:
Seat
Sheet metal covers (side panel covers, side shield, bonnet, front grill)
Fenders
Tyres fixing
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Batter cover
Torque checking
Engine oil pouring and greasing
Charts and stickers
After completing all the above stages the tractor reaches the point where it is removed
from the conveyor, which is known as the DISMOUNTING STAGE of the tractor. A platform is
there & when the tractor reaches the platform the conveyor is removed & the tractor is free. After that
the tractor slides down the platform & reaches the stage, which is the final stage after the dismounting
of the tractor. This stage comes before the testing of the tractor. In this following functions &
equipments are fitted on the tractor:
Air cleaner
Exhaust
Front tyres distance check and adjust.
TOOL ROOM
In industry various types of tools are used. The tool room caters to the needs for manufacturing of gigs, fixtures, gauges, dies, etc. During machining wear & tear of the tool takes place. The tool room is provided in order to re-sharpen these tools.
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FUNCTIONS OF TOOL ROOM
RE-SHARPENING OF THE TOOLS- whose wear & tear has taken place. This ensures that there is no delay in production due to blunt tools.
NEW JIGS & FIXTURES- In order to improve the production rate & quality of the work & to decrease the job setting time, new jigs & fixtures are developed in the tool room.
MAINTENANCE OF OLD JIGS & FIXTURES- Old jigs & fixtures that lose their accuracy due to breakage or wear & tear are repaired in the tool room.
NEW DEVELOPMENT WORK- Any modification & development work is carried out in tool room, for e.g. a new component is to be installed in a tractor, its die assembly is developed in the tool room.
MANUFACTURING OF MEASURING TOOLS- Certain measuring tools used in the metrology lab for quality check are manufactured in the tool room.
MAINTENANCE DEPARTMENT
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Maintenance is another very important factor, which influences the productivity; there are different kinds of maintenance practices like:
1. Scheduled Maintenance.2. Breakdown Maintenance.3. Preventive Maintenance.4. Predictive Maintenance.
Its importance is mainly due to the fact that it reduces breakdown time and health is achieving production targets at low costs
It caters to repairing replacing, and adjustment or modification of parts used in various machines.
Each machine has a symbol, which indicates whether maintenance has to be on daily basis, weekly basis, quarterly basis or monthly basis. The maintenance scheduled is maintained for each month after consultation with the shop in charge.
CHECK POINTS AT ENGINE TESTING
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1. Engine load at rated RPM
2. SFC at rated RPM
3. Oil Pressure at Idle RPM & NLFT
4. Engine Idle RPM & NLFT
5. FIP Hunting
6. FIP model
7. Engine Number & Code
8. Lubricating Oil Level
9. Check for Unusual noise of Compression Leakage
a. Tappet Noise
b. Gear Noise
c. Head Noise
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e. Humming Noise
10. Water leakage Al. Bend / Adaptors / Water manifolds / Hose pipe
11. Water Leakage from water Pump mtg. / pump seal
12. Water leakage from Thermostat Assembly
13. Lubricating oil leakage LO. Filter / Pipes
14. Lubricating oil Leakage from Joint for Gov. hsg.
15. Lubricating oil Leakage from Joint for Oil sump
16. Lubricating oil Leakage from GES / FWES Seal / FAB Studs
17. Fuel Leakage from Fuel connections / Sed. Bowl
18. Fuel Leakage from Feed pump / Banjo
19. Water mixing in Engine oil
20. Fuel supply noise at 1400 RPM No Load (Any erratic noise)
21. Seating of rubber bush bottom (Push rod Tube) in RV Engines
Leakage check points
1. Injector Leak off Pipe
2. Rocker Cover
3. Water Inlet Manifold
4. Water Hose Pipes
5. Lubricating Oil Cooler Pipe
6. Water Pump
7. Water Separator
8. Diesel Filter
9. Gear Casing Mounting Studs
10. Lubricating Oil Filter
11. Rocker Supply Pipe
12. Crank Case
13. Oil Seal Housing
14. Oil Sump
15. Cylinder Head
16. Cylinder Block
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CHECK POINTS AT ENGINE DESPATCH
1. Tested OK Sticker
2. Engine code & FIP code
3. Engine No. Punching
4. Engine Flywheel & Hsg. As per code / model
5. FIP & Fuel Filter seals
6. Missing Components
7. Lubricating. Oil in sump with colour (For Water Mix).
8. Completion of Engine with all Parts
9. Dipstick in dipstick guide. Loose / tight
10. Crank Nut for tightening
11. Protrusion of M14 Cyl. Head studs & FAB studs
12. Tightening & Positioning of Rubber Pipes & Polymer Thermostat hsgs.
13. Tightening of Rocker covers
14. Tightening of FIP mtg. Nuts
15. Water Pump as per model
16. Fuel cut - off Lever spring- leakage & Tension
17. Threading for Tachometer in Oil filler Body
18. Threading in Flywheel hsg.
19. Any Dent on L.O. Sump (Sheet metal)
20. Oil Leakage from drain plug
21. GES / FWES Main Oil seal leakage
22. Casting Finish / Fettling marks on Crank Case, Gear Casing
23. Breather tube Seating
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