Training Report on Standard Tractors

TRAINING REPORT

OF

INDUSTRIAL TRAINING

AT

STANDARD COMBINES PVT. LTD

(TRACTOR DIVISION)

Barnala

Submitted to:

Sh. Sachin Garg

Mechanical Department

B.G.I.E.T., Sangrur

Submitted by:

Maninderjeet Singh

B. Tech (4th Sem) Mechanical Engg)

Roll No. 100111195628

CONTENTS

S. No. Particular Page No.

1. Acknowledgement

2. Company Profile

3. Location

4. Technical Specifications f Tractors

5. Quality Policy

6. Name of Different Departments

7. Research and Development mechanism

8. Personnel Department

9. Material Handling Mechanism

10. Account Department

11. Purchase Department

12. Maintenance Department

13. Store

14. Machine Shop

15. Engine Assembly

16. Engine Testing

17. Tractor Assembly

18. Engg. Department

19. Single Cylinder Engine

ACKNOWLEDGEMENT

First of all I would like to convey thanks to Dr. S.K. Sharma (Principal

R.B.I.E.B.T. Mohali) and Prof. U.S. Koonar Training Incharge of Mech. Engg.

Department in our college.

I am highly thankful to Mr. Nachhatar ingh (Managing Director), Mr. Nirmal

Singh (GM HR&A) and Mr. B.K. Sharma (HR&A Manager) 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. Balkaran Sinqh (Engg.

Deptt.)

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.

Finally I would like to convey thanks to all the workers.

Ravinder Singh

COMPANY PROFILE

STANDARAD is a well known name in the field of automobile industries. It was

established in year 1973 by S. Nachhatar Singh.

His hard working efforts and continues improvement in the company has now

made it the number one manufacturer in the field of combine manufacture. In

1999, S. Nachhatar Singh started anew project named by manufacturing of tractor.

Now this company has five improved models of tractor.

1. SE-335 (35HP ENGINE POWER)

2. SE-345 (45HP ENGINE POWER)

3. SE-450 (SOHP ENGINE POWER)

4. SE-460 (60HP ENGINE POWER)

5. 5E-475 (75HP ENGINE POWER)

6. 5E-124 (24HP ENGINE POWER)

STANDARAD 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 Uttar Pradesh, Rajasthan, Bihar,

Haryana, Karnataka, and Tamilnadu etc. from the New Year production of the two

new models of tractors is starting. Models are of 30HP and 24 HP

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

of this company is increasing day by day. Recently Standard Tractors has got the

second position in All India Tractor Competition held at GB Agriculture

University Pant Nagar organized by All India Tractors Association. Standard has

joined hands with a tractor-manufacturing unit of Italy for the manufacture of

tractor by compromise between the two.

LOCATION

The factory is located at Barnala a district of Punjab.

STANDARAD TRACTORS is situated on Sangrur Bathinda Road about 3 KM

from Barnala city at Handiaya Chowk hardly fifteen minutes drive from the main

Bus stand of Barnala. Standard 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.

TECHNICAL SPECIFICATOINS OF STANDARD TRACTOR

ENGINE 335 345

POWER / CYLINDER 35 H.P. /3 45 H.P. /3

BORE/STROKE 95/110 102/110

MODEL/MAKE SE/STANDARD SE/STANDARD

ENGINE (RPM) 2100(RATED) 2200(RATED)

CAPACITY 2340 CC 2696 CC

TRANSMISSION

CLUCH DRY SINGLE CLUCH DRY DUAL 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 6 6

PTO, ENGINE 540, 1764 540, 1764

TYRE SIZE

FRONT 6/8 PLY 6/8 PLY

REAR 12 PLY 12 PLY

WEIGHT 2096 Kgs 2120 Kgs

DIMENSIONS (MM)

LENGTH 3450 3500

WIDTH 1675 1760

GROUND CLEARANCE 400 435

CAPACITY

DIESEL TANK 68 Ltrs 68 Ltrs

ENGINE 8 Ltrs 8 Ltrs

COOLING SYSTEM 8.5 Ltrs 8.5 Ltrs

TRANSMISSION 47 Ltrs 47 Ltrs

Standard 335DI Standard 345DI

TECHNICAL SPECIFICATOINS OF STANDARD TRACTOR

ENGINE 450 460

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

BORE/STROKE 95/110 100/110

MODEL/MAKE SE/STANDARD SE/STANDARD

ENGINE (RPM) 2200(RATED) 2250(RA'I ED)

CAPACITY 3120 CC 3454 CC

TRANSMISSION

CLUCH DRY DUAL CLUCH DRY DUAL 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 6 6

PTO, ENGINE 540, 1764 540, 1764

TYRE SIZE

FRONT 6/8 PLY 6/8 PLY

REAR 12 PLY 12 PLY

WEIGHT 2158 Kgs 2325 Kgs

DIMENSIONS (MM)

LENGTH 3640 3640

WIDTH 1760 1930

GROUND CLEARANCE 435 490

CAPACITY

DIESEL TANK 68 Ltrs 68 Ltrs

ENGINE 12.5 Ltrs 12.5 Ltrs

COOLING SYSTEM 10 Ltrs 12Ltrs

TRANSMISSION 47 Ltrs 47 Ltrs

Standard 450 DI Standard 460DI

TECHNICAL SPECIFICATOINS OF STANDARD TRACTOR

ENGINE 475

POWER / CYLINDER 70 H.P. /4

BORE/STROKE 105/120

MODEL/MAKE SE/STANDARD

ENGINE (RPM) 2200(RATED)

CAPACITY 4156 CC

TRANSMISSION

CLLJCH DRY DUAL CLUCH

BRAKES DRY DISC MECH

STEERING WORM & SCREW

LIFT SYSTEM HYDRAULIC

LIFT CAPACITY 1500 Kgs

POWER TAKE OFF

SPLINES SPEED 6

PTO, ENGINE 540, 1764

TYRE SIZE

FRONT 6/8 PLY

REAR 12 PLY

WEIGHT 2450 Kgs

DIMENSIONS (MM)

LENGTH 3640

WIDTH 1930

GROUND CLEARANCE 475

CAPACITY

DIESEL TANK 68 Ltrs

ENGINE 11.5 Ltrs

COOLING SYSTEM 12.5 Ltrs

TRANSMISSION 47 Ltrs

Standard 475DI

QUALITY POLICY

We at Standard 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: 2001 QMS.

DIFFERENT DEPARTMENTS

1. Research and Development Department

2. Personel Department

3. Tool Room

4. Accounts Department

5. Purchase Department

6. Maintenance Department

7. Store

8. Machine Shop

9. Engine Testing

10. Tractor Assembly Shop

11. Marketing Department

12. Servicing Department

13. Engineering Department

RESEARCH AND DEVELOPMENT DEPARTMENT

Research and Development is an integral and sustaining department of any

organization which want to sustain its place in the ever- developing industrial

environment. The emphasis on research and development in the Standard Group

proved by a long list of new products that have been introduced and established in

the years ever since the establishment of the Standard Group. Research work is

carried out in this unit and design work is accomplished presently, the research and

development is going on with various new products.

The organization of standard tractor division operates functionally, through a series

of shops and departments. Standard Tractor Division (STD) is undergoing

expansion on large scale. STANDARAD establishes well advanced testing shop

for testing of engines produced in order to maintain strict control. A full fledge

administrative block is produced for effective management and improved work

place. The production of engine is being planned to raise engine per day.

PERSONAL DEPARTMENT

Any industry depends upon human being it has acquired workers and creates an

acceptable environment and rule of practice to encourage the greatest degree of

participation from its employee The Depot. Concerned with this called personnel

Dept. a small concern the owner it self carries on the personnel function where as

in large organization, it is given a maximum individual development; desirable

working conditions and desirable working relationship between employees and

effective molding of human resources for the purpose of contributing to the

organization goals.

AIM OBJECTIVE AND FUNCTION

1. Procurement and maintenance of adequate workforce as regards to both

number and quality of personnel.

2. Education and training of present employees.

3. Maintaining satisfactory personnel contacts &employees relationships.

4. Maintaining satisfactory group relationships by contacting employer's

groups.

5. Maintaining employee’s health.

6. Maintaining employee’s safety.

7. Maintaining employees service activities and employees welfare.

MAINTAINING HANDLING MECHANISM

Material handling involves the movement of material manually or mechanically in

batches or one item with in plant. The movement may be horizontal, vertical or the

combination of both.

The various material handling equipments used in the machine shop of STD;

1. Roller Conveyer

2. Wheel conveyer

3. Screw conveyer

4. Haulage Conveyor

5. Power hoists

6. Trolleys

7. Block and Tackle type hoist

TOOL ROOM

Tool room is essential part of any industry. Tool room takes care of jigs and fixture

makes new ones reshape tool etc. The various function of tool room is

MAKING AND REPAIR OFTOOLING

Tool room makes different tool as per the design given by IE dept. the different

tool include insert setting fixture tendons bushes & many more items Repair of

worn out tool is also done.

ACCOUNTS DEPARTMENT

The main objective if account dept. is to determine, classify and analyze the cost

and income of business enterprise. The account dept has following dept. has

following functions:

1. Sales Accounting

2. Purchase Accounting

3. Labors Accounting

4. Financial Accounting

PURCHASE DEPARTMENT

The department is responsible for purchasing all type material in correct qualities

and at the most economical prices the purchase department occupies a vital and

unique sit-in-a concern because purchasing is one the main nation in the success of

a modern manufacturing concern the purchase function liaison agency which

operates between the factory out side vendors on all matters of procurement the

various objective and function of purchase department are;

1. To procure right material

2. To procure material in right quantity and quality.

3. To procure material economically.

4. Maintain records of reliable sources of supply.

5. Making controls with right sources of supply

6. Revives material specification with an idea of simplifying and standardizing.

7. procure and analyzer quotations.

8. Place and follow up purpose orders.

9. Maintains records of all purchases

10.To prepare purchasing budget.

11.To keep an uninteresting supply of materials

12.To endure that prompt payments are made to the vendors in the interests of

good public relations.

13.To sell material and scrap.

MAINTENANCE DEPARTMENT

In the modern industry, Equipment and machinery are very important part of the

total productive effort. Lot of capital is invested in the plant equipment and

machinery. These are deteriorated by their exposure to environment and working

condition. lf their damage is not checked at proper time, these make the equipment

non-usable. Thus it is very important to maintain, repair and recondition these to

increase their life and make them available for maximum number of operation

hours.

The various objective of maintenance department are:

1. To achieve minimum breakdown.

2. To keep the plant in good working condition at the lowest possible cost.

3. To prevent loss in production services.

4. To maintain the various plant services.

5. To provide plant protection including fire protection.

6. To establish and maintain a suitable state of maintenance of material.

Insurance administration.

7. Overhauling of plant equipment and, machinery.

8. Generation and distribution of power and other facilities.

9. To carry out corrective repairs to alleviate unsatisfactory conditions found

during preventive maintenance inspection.

SOTRE

1. Material and supplies constitutes the most important assets in the majority of

business enterprises The success of the business beside other factor depends

to a large extent on the efficient storage and material control.

2. Material pilferage, deterioration of material and careless handling of stores

leads to produce losses.

STORE MANAGEMENT TAKES CARE

1. That material is never out of stock.

2. That no material is available in much excess than required.

3. There is adequate procedure of receipts and issue of material

4. That there us proper method of keeping store records.

5. Proper storing of materials done.

VARIOUS FUNCTIONS

1. To receive material, goods and equipment's and to check them for

identification.

2. To receive pats and components which have been processed in the factory?

3. To record the receipts of goods.

4. To correct positioning of all materials and supplies in the stores.

5. To maintain stock safety in good condition by taking all precautions to

ensure that they don’t suffer from damage, pilfering deterioration.

6. To initiate purchasing cycle at the appropriate time.

INTRODUCTION TO MACHINE SHOP

The machine shop is major part of any factory all the machining operations which

are to be done on any component is performed in machine shop.

There are two types of machine shops depending on the work to be performed. As:

1. Light Machine Shop

2. Heavy Machine Shop

LIGHT MACHINE SHOP

Introduction

L.M.S. is shop for manufacturing small components of the tractor in Standard

Tractor division this is small shop where light operations on components are

performed on different components for production work.

Main operation performed in L.M.S. is as follows:

1. Drilling

2. Tapping

3. Reaming

4. Milling

5. Facing

6. Turning

7. Boring

8. Grinding

Major machines used in light machine shop are as follows:

LATHE

Lathe is the mother of entire machines & probably the oldest machine tool finds its

great application at STANDARD TRACTORS.

Here in this industry lathes of sizes 6 feet & 8 feet are installed owing to there use.

Lathe removes the undesirable material from the rotating work piece held between

two lathes centers of tail & head stock. The lathes are installed here are centre

lathes.

Major performed on lathes are:

1. Turning

2. Facing

3. Grooving

4. Drilling

5. Boring

6. Reaming

7. Knurling

8. Cutting

Milling Machine:

Milling is the process of removing metal by feeding the work past a rotating multi

point cutter. In milling operation the metal removing rate is high because cutter

rotates at high speed and has many cutting edges. The surface finish is also better

due to multi cutting edges column & knee types milling machine has been installed

in machine shop. In this type of machines three types of motion are possible.

1. Vertical (Up & Down) movement

2. Transverse (In & Out) movement of saddle

3. Longitudinal (Back & Front) movement of table

Shapers

The shapers makes use of the single point tool that transverse the work and feeds

over at the end of each stroke. In body agro industries vertical shapes has been

installed owing to the reason that is used in the formation of the key ways in round

pulleys.

Vertical shaper is proffered over the horizontal type because the thrust acts directly

on table bed, so there is no possibility of deflection of table. Only simple fixtures

needed.

POWER HACKSAW

For cutting of the large sized job reciprocally power hacksaw has been kept in

machine shop Although it is a slow and expensive method of cutting but owing to

its advantage, it is widely suitable. Several bars may be cut at same time and

continuous attention is not needed, since the saw stops automatically when cut is

finished. A lubricant is often used for easier cutting action and longer life of blade.

A crank mechanism is provided to raise the blade on each return stroke, to protect

the teeth of blade while it dragged backward. Average cut is of 3 mm.

GRINDER

It is one of the simple and useful machine required in the industry Grinding is a

process of removing metal by rotating abrasive wheel. Abrasive particles acts as

cutting tool tips.

GRINDER IS USED FOR

1. To remove a very small amount of metal from work space and to achieve

small tolerances.

2. To obtain better surface finish.

3. To sharpen the cutting tools

4. To cut hardened steel.

5. To machine tough surfaces, which are not easy to machine by H.S.S tool or

carbide tool.

HEAVY MACHINE SHOP

Introduction

The heavy machine shop (HMS) is one of the most important shops in the industry

It plays a very important role in the production of the tractor As the name suggests

all the heavy components namely the differential housing, the gearbox housing, the

cage and trumpet are machined here. The shop is called the backbone of the

industry. The Heavuy machine shop is divided into five sections.

1. Differential housing line

2. Trumpet Line

3. Rear Cover Line

4. Crankcase Housing Line

5. Tool Room

All the sections are highly equipped with modern machinery and equipment Each

section has a layout i.e. tile raw material is received at one ends and the finished

component is dispatched from the other. The material received is in form of casting

The machining process is carried out under strict quality norms. There is in the

process inspection at each workstation. The component is made to go through final

inspection before it dispatched for assembly.

The material handling system in the H.M.S shop consists of hydraulic life trucks,

power hoists; roller conveyors, overhead crane, and fork lift trucks. Bins etc. The

shop has well designed network of roller conveyers.

ENGINE ASSEMBLY

DETAILS OF ENGINE ASSEMBLY

STAGE l:

Three lines are present at STANDARD

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

Stage 2:

Timing Gear Fitting: -

The idle shaft is pushed into the crankcase and roller type bearing with lock is

inserted into the shaft. The idle timing gear is then pressed into the bearing. The

timing gear is punched at two places and punched sign has to be matched with

punched mark of [on] crankshaft.

Timing Gear Fitting

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:

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

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.

FLYWHEEL MOUNTING

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.

Flywheel

Stage 5:

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.

Cylinder Head

Stage 6:

Water Body and Pulley Mounting: -

The water body is mounted with thermostat control valve opens at 70° C. the

pulley is mounted on camshaft.

Stage .7:

The assembly is removed from the trolley, is placed on the stationary frame.

Stage 8:

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

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.

ENGINE TESTING AT STANDARD 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

SOME IMPORTANT TERMS AS ISI STANDARD

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.

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.

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)

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

Now mechanical absorption type dynamometers are of further two types:

1. Prony Brake.

2. Rope Brake.

3. Band Brake.

Transmission type:

a) Mechanical b) Electrical

In STANDARD TRACTORS Hydraulic type dynamometer are used for readings

TRACTOR ENGINE TESTING:

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.

INTRODUCTION TO ASSEMBLY SHOP

Tractor assembly shop is main shop of standard 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

Deferential Housing Assembly Phase

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.

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.

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.

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.

%AGE OF CONTACT TEST AND PATTERN TEST

Pattern test and %age contact test is done with the help of yellow paint applied on

teethes of crown wheel. Then rotat8ing crown wheel with hand %age of contact

and pattern of tail pinion is impressed on the teeth of wheel. The %age of contact is

60 % to 70% require. IT can be increase or decrease by using the shims by

fastening it on tail pinion carrier. When increase in number of shims the pattern

goes increase and vice versa.

The bull gear are tighten to trumpet housing assembly by lock nut and the whole

assembly of trumpet housing is also tighten by nut and studs on outer side of

differential housing then PTO shaft head cover is tightened to protect its outer

teeth. The sliding gear and PTO shifter rod assembly is mounted on differential

housing. Two filters are places are inside diff. housing and then whole assembly of

dif£ Housing is sending to the main line.

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.

RV. Housing Assembly: -

It contains one response valve, check valve and release valve. It is also connected

with control valve through pipe housing. The Knob is placed at top of response,

valve to close or open the response valve as per requirements.

Control Sector Assembly: -

It contains the draft control assembly, and position control assembly. Both these

assemblies are connected to their lever. The position control assembly is connected

to black mark level and draft control assembly is connected to red mark lever.

First of all rear cover is mounted on the moving trolley and tightened with bolts.

The control sector assembly is placed at there respecting place. A sensor tube is

placed at rear side of rear cover. The ram cylinder assembly is placed inside rear

cover R.V. housing is placed outside rear cover, which is connected to control

valve through pipes.

Control valve contains three valves i.e. back measure valve and scroll valve. Oil

from pump goes into R.V. housing through pipes, which is further connected, to

the check valve through inner hole of R.V. housing and back presser valve of

control valves. The opening pressure of check valve is 9-12 Kgs and operating

pressure of back pressure is 3-6 Khs. During un-operated position the oil flow is

continues through the backpressure valve of control valve.

During operation of position arm the unloading valve close the gallery of oil to

backpressure valve. Thus the pressure R.V. housing builds up which open the

check valve at 9-12 Kgs. At this position the oil goes in the Ram cylinder, which

further operates the lift arm. For requirement of any position of lift knob of

response valve of R.V. housing is rotated which cut the supply of oil and Ram arm

achieved. Sensor tube works in field during plaughing of soil with harrow. When

harrow deeply dug in soil, draft it set at position through sensor tube.

The rocker arm attached sensor and harrow link, which push the sensor tube inside

and automatically control value control oil supply.

ENGINEERING DEPARTMENT

In Engineering Department at Standard 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.

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.

PROJECT STUDY OF SINGLE CYLINDER DIESEL

ENGINE

Single cylinder diesel engine is that engine which only one cylinder is there. It is

air cooled engine.

Specifications:

Dia of Piston : 114.88

Dia of Liner : 115mm

Stroke : 150mm

Displacement : 1539cc

Type : Single Cylinder Diesel Engine Air Cooled

H.P. : 24

R.P.M. : 1700 rated

No. of fins : 21

Weight of fly wheel : 111Kg

Governor Type : Centrifugal

Diesel Pump : Plunger Type

Lubricating Type : Gear Pump Type

Angle of Fuel injection : 11 degrees before TDC

Air Cleaner : Dry Type

The single cylinder engine which is developed by STANDARD is air cooled. In

this radiator is required, only air fan is used which spread the air in the fins for

cooling the crank case.

There are only two companies who made the single cylinder engine namely

Mahindra and Eicher, Standard is the third company and first in Punjab.

Main advantage is that it is easy to handle. Fewer accessories are required for

cooling, high efficiency.

Setting of Engine:

The setting of engine is done from the pulley. The angle is 11 degrees before TDC.

It means the fuel inject in the cylinder 11 degrees before TDC (before Top Dead

Centre) in power strike. It is done with help of cam gear.

Lubrication System:

For lubrication system 4 liters oil is used. The lubrication is done with the help of

gear pump system, with the gear pump system the oil is put on the crank.

Air Clean System:

It has an Air Cleaner System. First of all Air is passed through the filter.

Crank Case:

Crankcase is made from cast iron. The cylinder is mounted on the crankcase. Shaft

is there, connecting rod is there, cam shaft is fitted to crankcase. On the backside

of crank case Lubrication gear system is fitted. The filter is fitted outside the

crankcase. Crankcase, is placed on the roller bearing because the weight of

crankcase is more.

Single Cylinder Diesel Engine

Inlet Valve:

Length : 149 +.1

Surface Hardness : 600HVM

Tuff tidal depth : 0.01min

Tensile Strength : 90-105 Kg/min

Cam Shaft

Splines

Type : Involute

Pressure Angle : 20 degrees

Module : 2

Material : Mn = 20, Cr = 5

Exhaust cam dia : 31.5

Inlet cam dia : 31