Preet Tractors (ME)

TRAINING REPORT

AT

PREET TRACTORS PVT. LTD.

(TRACTOR DIVISION)

NABHA

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Submitted to:

(HOD of Mechanical.)

Submitted by:

Dilbir Singh

ME-5th

90111124341

2

CONTENTS

S. No. Particular

1. Acknowledgement

2. Company Profile

3. Location

4. Technical Specifications f Tractors

5. Quality Policy

6. Engine Assembly

7. Engine Testing

8. Tractor Assembly

9. Engg. Department

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ACKNOWLEDGEMENT

I am highly thankful to Mr.Y.C. AGGARWAL (Managing Director), Mr.RAJINDER

PLA GUPTA (GM HR&A) for permitting me to join the industry & to get useful in

information about the plant.

For full completion of my Industrial Training, Training Report and the help during

the Training Period, I Express my sincere thanks to Mr. SANJEEV SHARMA, Sony

Singh ( Quality assurance, Tractor Assembly )

It is also my pleasure to express my gratitude towards the staff of parts inspection

Department for their full Co-operation and giving me the knowledge of instrument

and project to their best.

To sum up a heavy thanks to all those who through formal and informal way

guided me throughout my project work, I will cherish their support for the years to

come.

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COMPANY PROFILE

PREET is a well known name in the field of agro industries. It was established in

year 1980 by Sh. Hari singh

His hard working efforts and continues improvement in the company has now made it the number one manufacturer in the field of combine manufactureThe development of tractors which started in house in 2001, was materialized in launching manufacturing activities of tractors have started in early 2003. A batch of 21 tractors have been tested (On all the farming operation) through farmers who had the vast experience in agriculture. . Now this company has six improved models of tractor.

1. PREET 3549 DI (35HP ENGINE POWER)

2. PREET 4049 DI (40HP ENGINE POWER)

3. PREET 4549 DI (45HP ENGINE POWER)

4. PREET 5049 DI (50HP ENGINE POWER)

5. PREET 6049 DI (60HP ENGINE POWER)

6. PREET 4X4 (75HP ENGINE POWER)

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PREET is the first Indian company, which has designed 75HP engine. Company's growth is 150% as compare to the last , year. The Daily production is 15 tractors now days. The demand of this tractor is in the northern, southern and central region of India,Sri Lanka,Bangladesh and Pakistan. from the New Year production of the two new models of tractors is starting. Models are of 30HP and 25HP

Turnover of the company during the last year was of Rs. 400 crore. Market image

of this company is increasing day by day.

LOCATION

The factory is located at Nabha a city of Punjab.

PREET TRACTORS is situated on Nabha Patiala Road about 3 KM hardly fifteen

minutes drive from the main Bus stand of Nabha. Preet Combine is a private

concern of India Particularly in state of Punjab. This factory was among first to be

set up in this industrial town.

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TECHNICAL SPECIFICATOINS OF PREET TRACTOR

ENGINE 3549 DI 4049 DI

POWER / CYLINDER 35 H.P. /3 40 H.P. /3

BORE/STROKE 95/110 97/110

MODEL/MAKE DI/PREET DI/PREET

ENGINE (RPM) 2100 2100(RATED)

CAPACITY 2340 CC 2438 CC

TRANSMISSION

CLUCH DRY SINGLE CLUCH DRY SINGLE CLUCH

BRAKES DRY DISC MECH DRY DISC MECH

STEERING WORM & SCREW WORM & SCREW

LIFT SYSTEM HYDRAULIC HYDRAULIC

LIFT CAPACITY 1200 Kgs 1200 Kgs

POWER TAKE OFF

SPLINES SPEED 21,1000RPM 21,1000RPM

TYRE SIZE

FRONT 6.00X16(8PLY) 6.00X16(8PLY)

REAR 13.6X28(12 PLY) 13.6X28(12 PLY)

WEIGHT 1945 Kgs 1945 Kgs

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DIMENSIONS (MM)

LENGTH 3580 3580

WIDTH 1720 1720

GROUND CLEARANCE 400 400

CAPACITY

DIESEL TANK 56 Ltrs 56 Ltrs

ENGINE 6.50 Ltrs 6.50 Ltrs

COOLING SYSTEM 8 Ltrs 8 Ltrs

TRANSMISSION 55 Ltrs 55 Ltrs

PREET

3549 DI

PREET 4049 DI

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TECHNICAL SPECIFICATOINS OF PREET TRACTOR

ENGINE 5049 DI 6049 DI

POWER / CYLINDER 50 H.P. /4 60 H.P. /4

BORE/STROKE 95/110 100/110

MODEL/MAKE DI/PREET DI/PREET

ENGINE (RPM) 2100 RPM 2200 RPM

CAPACITY 3120 CC 3456 CC

TRANSMISSION

CLUCH DRY DUAL CLUCH DRY DUAL CLUCH

BRAKES DRY DISC MECH DRY DISC MECH

STEERING WORM & P0WER WORM & POWER

LIFT SYSTEM HYDRAULIC HYDRAULIC

LIFT CAPACITY 1800 Kgs 1800 Kgs

POWER TAKE OFF

SPLINES SPEED 6 (540 RPM) 6(540RPM)

TYRE SIZE

FRONT 6.00X16(8PLY) 7.50X16(8PLY)

REAR 14.9X28(12 PLY) 16.9X28(12 PLY)

WEIGHT 2150 Kgs 2170 Kgs

DIMENSIONS (MM)

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LENGTH 3740 3820

WIDTH 1795 1900

GROUND CLEARANCE 430 457

CAPACITY

DIESEL TANK 56 Ltrs 56 Ltrs

ENGINE 9 Ltrs 9 Ltrs

COOLING SYSTEM 11 Ltrs 12Ltrs

TRANSMISSION 55 Ltrs 55 Ltrs

PREET 5049 DI PREET 6049DI

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QUALITY POLICY

We at PREET Tractors Ltd. are committed to the total customer delight by:

1. Providing consistent quality of tractors of combines through the best

utilization of the people and technology.

2. Involving all employees in an environment of learning and continuous

improvement.

3. Maintaining a safe and satisfying work culture.

4. Developing committed suppliers.

5. Adhering to Quality management systems based on ISO 9001: 2008 QMS.

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ENGINE ASSEMBLY

DETAILS OF ENGINE ASSEMBLY

STAGE l:

Three lines are present at standard size

a) A Grade tolerance +12 micron.

b) B Grade tolerance +24 micron.

c) C Grade tolerance +36 micron.

The cylinder has two seats: -

1. For water.

2. For oil.

The Grade sign of the liner should be kept toward the camshaft.

Crankshaft Fitting:

First of all bush type liners are inserted into the bearing holes. The liner is provided

with recess to store a minimum amount of oil, which wets as the crankshaft during

storing engine. The bearing cup is opened and crankshaft assembly placed into it.

The bearing cup is tightened again with 10-12 Kg-m torque rod and crankshaft is

checked that it is revolving easily or not

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STAGE2:

Piston Assembly Fitting: -

The piston assembly is filled into the liner and big end is tightened to crankshaft

Line is filled with A grade piston assembly. The grade mark should towards

camshaft. The piston ring cuts should be so adjusted that there should not be in

same line

Piston

Stage 3:

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Lubrication Oil Pump Mounting: -

The lubrication oil pumps connected to crankshaft gear by an idle gear of 2-3

degree. The crankshaft and pump gear has 22 teeth each. The pump is provided

with relief valve [through], which opens at kgf.

In the case of are loading or something injected in main gallery then pressure is

released from their valves.

Rear Cover & Front Cover Mounting: -

The rear cover and front cover are cleaned perfectly with air and filled to engine

with seals in between [mounted].

Stage 4

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Cam Shaft Fitting: -

The camshaft is inserted into the camshaft hole with bearing and bolt ends are

locked by circle. The camshaft is forged from alloy steel or cast iron and is case

hardened.

The one end of the camshaft is provided with gear, which is locked, gear z-50 for

exact timing of the camshaft gear mark is matched with the mark on idle gear.

Another gear pump is attached with idle gear, which serves the purpose of driving

the fuel injection pump.

Cam Shaft

FLYWHEEL MOUNTING

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The flywheel is mounted the crankshaft and bolts are tightened with 11-12 kg-m

force. The F.LP is connected to F.LP gear through the F.LP drive shaft.

The F.LP. drive shaft is specifically designed to advance the time of injection. The

both ends of F.1.P. drive shaft is provided with spline, one side a key is provided

which is locked to timing gear and recess on their side is pushed in to F.LP. slots.

The angle between the key and recess of 18°', thus the fuel injection is advanced by

18° degree.

Fly wheel

Cylinder Head mounting:

The cylinder head assembly is placed on the piston and studs are passed through it.

If the height of the piston at TDC from the surface is more then 0.1 mm than the

gaskets of given thickness are used. If it is 0.1 to 0.5 mm then 1.2mm thick gasket

is used. If it is 0.5 to 0.8 mm then 1.5 mm thick ,gasket is used. The cylinder nuts

are tightened by 17-18 Kg-m forces

Stage 8:

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Fuel Injection Pump Mounting and Setting of Fuel Injection Pump

The gear of F.I.P. is first of all meshed with F.LP. drive shaft and is loosely

tightened to set the timing of gear first of all pointer is tightened on the crankcase

and flywheel us rotated which is meshed for 16 , 18 , 20, 24 angles. The pointer at

set at 18 of flywheel and then the pump is rotated clockwise till one from first

nozzle stop out blowing. At this position a cut mark is made on both the pump and

crankcase for further setting. The pump is tightened properly and pipes are

tightened over nozzle and injectors. The head of position is covered with covers

and the complete engines are sending to engine testing shop. The whole of engine

shop is air-cooled.

Fuel Injection Pump

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ENGINE TESTING

INTRODUCTION

Engine testing is done for checking the performance of newly assembled engine to

found out any assembled fault, their HP, leakage and other fault. Engine testing

shop of the STD is equipped with latest digital control equipment. The engine

testing is done with the help of turbine (Water) or hydro dynamometer is four in

number so that engine is tested at a time. The shop is equipped with heavy-duty oil

filter, which is used to clean the oil from dust or other large particle. The shop has

bush pump tester is measured on the based of S.A.E ratings. The society of

automobile engineer's USA has specified die method of measuring the power

output of the engine for standardized purpose. The engine is run without generator.

TRACTOR TESTING

Tractor testing is done under the international organization for standardization

(ISO). The first tractor with an internal combustion engine was introduced in

American agriculture in the year 1889. The tractor-testing act was passed in U.S.A

in 1920. In India tractor-testing station was finally establish at Budani in 1959 for

tractor testing atmospheric pressure shall not be less than 96.6 Kpa.

The basic task in the design and development of engines is to reduce the cost and

improve the efficiency and the power output. In the order to achieve the above task

the development engineer has to compare the developed engine with the other

engines in terms of its output and efficiency. Towards the end engineer has to test

the engine and mal<e measurements of relevant parameters that reflect the

performance of the engine.

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ENGINE TESTING AT PREET TRACTORS

PURPOSE OF TESTING A TRACTOR ENGINE:

In general purpose of testing an I.C. engine is to determine the following:

1. To determine the rated power output with respect to the fuel combustion in

Kg per Kw hr brake power output.

2. To determine the mechanical and thermal efficiencies of the engine.

3. To see the performance of the engine at different loads.

4. To determine the quantity of lubricating oil required per B.P. Kw-hr. e) To

determine the quantity of cooling water required per B.P. Kw-hr. f) To

determine the overload carrying capacity of the engine.

5. To prepare the heat balance sheet of the engine.

Engine Testing

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SOME IMPORTANT TERMS AS ISI TERMINOLOGY

Speed:

The speed of a engine is the mean speed of its crankshaft in RPM. Except in the

case of free piston engines where the speed is the number of cycles per minute of

the reciprocating components.

Steady Load Speed Band:

It is the maximum total variation in speed expressed as a percentage of the mean

speed, which may occur while there is no change in the external load conditions.

Continuous Power

The power which engine is capable of delivering continuously between the normal

maintenance intervals stated by the manufacturer at the stated speed and under

stated operating conditions.

Indicated Power:

It is the total power developed in the working cylinder by the gases on the

combustion side of the working pistons.

Friction Power:

It is the power consumed in the frictional resistance.

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Brake Power:

It is the total power consumed in frictional resistance.

Fuel Consumption:

It is the quantity of fuel consumed per unit of power per unit of time. It is generally

expressed in grams of fuel consumed per B.H.P.

Mechanical Efficiency:

It may be defined as the ratio of the power obtained at the crank shaft i.e. Brake

power to the Indicated power.

Thus Mechanical Efficiency = Brake power (B.P.) /Indicated power (Z P.)

Thermal Efficiency:

Indicated Thermal Efficiency:

It may be defined as the ratio of heat converted into indicated work to the heat

energy supplied by the fuel, during a specified period of time.

So, Indicated Thermal Efficiency

= Heat equivalent to LP per min. / heat energy supplied by fuel per min. = LP.

* 60 / Mf *CV

Brake Thermal Efficiency:

It may be defined as the ratio of the heat equivalent to Brake power (B.P.) to the

heat energy supplied by the fuel during a specific time.

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So, Brake Power Efficiency

=Heat equivalent to B.P. per min. /Heat supplied by fuel per min. =B.P.

*60/Mf*CV

Preparation for Test:

Test runs shall be made on an engine as being offered to the consumers. Before

starting the engine tests, the engine shall have been thoroughly run in the fuel and

lubricating oil used during the test shall be specified by the engine manufacture.

In general the engine operating temperatures and the lubricating oil pressure during

the test shall be maintained at the values recommended by the manufacturer. In

engine testing we note down the following data:

1. Revolution per minute (R.P.M)

2. Fuel Time

3. Engine Lub. Oil pressure

4. Water outlet temp.

5. Lubricating oil temp.

6. Torque (N-M).

7. Smoke reading with the help of Bosch smoke meter.

8. In case of silencer a noise meter & U-tube manometer for measuring

backpressure.

With the help of the data we calculate following parameters:

1) B.HP = R.P.M *N-Ml Dynamometer Constant Per B.KP per hour. .

(Which are 7023.746 for Dynamometers used at STANDARAD)

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2) In kilowatts = R.P.M *N-M/9549.305

3) Specific fuel consumption (S.F.C) =297000/B.KP*fuel time

Gram per B.H.P per hour

Where 297000= 0.825 * 100 *3600

4) Torque Brake up (T.B. U)

= Max. Torque -Rated Torque / Rated Torque

Dynamometer is the instrument used at STANDARD to measure the engine power

and it must include at least four essential elements:

1. A means for controlling torque.

2. A means for measuring torque.

3. A means for measuring speed.

4. A means for dissipating the power.

Dynamometers are of mainly two types:

Absorption type:

a) Mechanical b) Hydraulic

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TRACTOR ASSEMBLY SHOP

Type of PTO Tractor

There are three types of PTO Tractor:

1. Multi PTO Tractor

2. Ground PTO Tractor

3. Simple PTO Tractor

Multi PTO Tractor:

it can be work in gear at stop position as in at well which help in achieving the

move speed as compare with other tractor. Multi PTO tractor is work at six high

speed & six low speed gears.

Ground PTO Tractor:

It is work in PTO in gear is only when tractor going as thoster and reaper. It can be

given only turo speed.

One directly to PTO and other throw the gear when tractor is going on. It cannot

work in gear when tractor is sleep gear is put through the idle gear.

Simple PTO Tractor:

It is the PTO which can be work at 540 R.P.Iv1 in one speed when the tractor is

stop and going on. Tractor is work in only one speed.

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INTRODUCTION TO ASSEMBLY SHOP

Tractor assembly shop is main shop of preet tractor division. In this shop the

different machining parts, housing and other component, which are machined on

the other department or purchased, from outside are assembled here.

Then assembled components like differential housing, gearbox rear cover, trumpet

housing and other housing are sending to in main line for tractor assembly. In main

tractor assembly line tractors are said to paint shop through overhead endless chain

rotating conveyor.

Following are main phase of assembly.

1. Differential Housing Assembly

2. Rear Cover Assembly

3. Gear Box Assembly

4. Main line Assembly Phase

5. Paint Phase

6. Assembly of accessories and inspection

1.Deferential Housing Assembly :-

It is rear part of the tractor cheesy. The main function of differential in tractor is to

reduce the final and also to turn the drive round at 90 degree. The reduction of the

speed is done in two staged. First stage reduction in tail pinion and crown wheel

meshing and second stage reduction in bull gear meshing with left and rights BP

shaft.

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Assy. Of Differential

It is also consisting the PTO shaft (Power take off shaft), which is used to run the

thrashers, pumps and other accessory components with the help of pulley attached

on it.

Following are the main Parts of Differential Housing: -

Crown Wheel.

Tail Pinion.

Cage assembly with Sun & Planet gears.

P.T.O Shaft.

B.P. Shaft Left & right.

Bull Gears.

Bevel Gear.

Bearings.

Brakes Housing Assembly

Oil Seals,

Gaskets etc.

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Assembly of Crown Wheel:

First of all components are washed with oil to remove the dirty particles. Cage

having two holes in these holes dowels are tight fitted for accurate fitting of crown

so that a11 other holes of the cage and crown are in same line. The crown wheel is

pressed on case with hydraulic press and then tightened by bolts with lock washer,

and then the right bevel gear is placed on their cage seat. The four plant gears are

put on across with washer and then assembly is placed in the cage. Then left bevel

gear is placed. Operator checks the motion of the gear by manual inspection

Tail Pinion Assembly:

In tail pinion assembly the cone for taper roller bearing is pressed with hydraulic

press. The bearing is heated before the tight fit, the tail pinion is inserted inside

bearing. The different size shims are also placed before tightening of rear cover of

cage. Whole assembly is tightened by nuts and bolts.

Rear Axle Assembly:

In rear axle assembly bolts are tight fitted in the holes of hub. Where the rear tire is

tightened with bolts to the whole assembly. Two bearing on either side of the

trumpet housing are tightened at gang drill

Brake Assembly:

Standard Tractors are provided with heavy self energizing water sealed disc brakes

with ventilation pipe, which gives better cooling.

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The ventilated results in reduction of about 30% in pad temperature. Brake housing

cover contains to disc made of asbestos base. The max temp resistance is about 300

degree C. below this is two disc plate a cast iron plate is fixed which is held by

springs. Whenever brakes are applied plate tends to expand. During expanding of

C.I plate the discs strongly mounted on BY left and BY right shaft stops the

movement of differential.

P.T.O Shaft Assembly:

Two bearings, which tight it fit on P.T.O shaft, are firstly places with help of

circles then P.T.O shaft assembly is passed through rear PTO hope of differential

housing.

Following Three Tests are done:

1. Back Lash Testing

2. %Age of contact

3. Pattern Test

BACK LASH TESTING

This test is performed with the help of plunger dial gauge. Back lash in crown

wheel is not more then 20 to 30 micron if it is deviated from this value then

packing is changed on either side (left or side) of cage of bearing housing. But

never change the number of shim. If Backlash is more than 30 micron then shims

from right side is removed and shifted in to left side. IF it is less then 20 micron

then vice versa. Also require run out for crown wheel is OS-l mm.

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2.REAR COVER ASEEMBLY:-

Rear cover assembly is used to cover the differential housing. It contains lift

control system, which is hydraulically operated. Driver seat is fitted on the upper

side of rear cover. The response valve housing (R.V), control valve, ram cylinder

and other component assembly fitted inner and outer side of rear covers assembly.

The main components fitted on rear cover assembly are: -

a) Control valve assembly

b) RN. housing assembly

c) Ram cylinder and piston assembly

d) Operating sector assembly,

e) Sensor tube assembly

f) Gaskets, bolts, nuts

g) Other Components

Ram Cylinder Assembly: -

It contains cylinder with piston inserted inside it. The relief valve assembly is

mounted at top front of cylinder. The connecting rod is placed in piston rear side

and one side is locked with ram arm assembly. Rock arm, spacer and seals are

placed. At the end of rock arm assembly, lift arm assembly is placed & then locked

with bolts on both sides.

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3.Gear Box Assembly:-

In gear box assembly all gears are fit in gear box housing. All scrabs are fit in all

gears. In this main shaft is fit.

Break and gear testing by driving:-

In this test the brakes and gear. At first run a tractor on middle speed and suddenly put the brakes. If tractor is stop correctly then passed it. Minimum speed for change a gear is measure in this.

In break testing paths

ENGINEERING DEPARTMENT

In Engineering Department at preet Tractors the main works are done of making

catalogue, dealing with ISO and project regarding testing of tractor from Central

Farm Machinery Testing & Training Institute (CFMT&TI), Budni (M.P.) and

Automotive Research Association of India (ARAI), Pune.

This department takes responsibility of implementation of system given by ISO. It

also helps to perform Audits.

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In this department, making of service operator of service Manual, Price list and

giving part No. according to requirement of company is being done.

It also takes responsibility to update the Bill of Materials (BOM) for Analyzing the

Cost.

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