Swaraj training report

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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http://www.mahindraswaraj.com/files/portfolio_30hp_724XM.htm#features

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM.htm#tyres

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM.htm#pto

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM.htm#warranty

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM.htm#hydraulics

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM.htm#speed

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM.htm#dimensions

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM.htm#steering

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM.htm#transmission

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM.htm#electricals

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM.htm#brakes

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM.htm#engine


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

Model RV-2 XM + 3A

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http://www.mahindraswaraj.com/files/portfolio_30hp_724XM_Orchard.htm#features

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM_Orchard.htm#tyres

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM_Orchard.htm#pto

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM_Orchard.htm#warranty

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM_Orchard.htm#hydraulics

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM_Orchard.htm#speed

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM_Orchard.htm#dimensions

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM_Orchard.htm#steering

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM_Orchard.htm#transmission

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM_Orchard.htm#electricals

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM_Orchard.htm#brakes

http://www.mahindraswaraj.com/files/portfolio_30hp_724XM_Orchard.htm#engine




No. of Cylinders 2



Rated Engine Speed

1800 rev/min

Air Cleaner Dry type, Dual element with dust unloader


Transmission

ClutchStandard Single dry disc friction plate

Optional NA


Gear Speeds (Km/hr) with 5.00 x 15 front & 11.2 x 24 rear type


Reverse 2.28 & 09.02

PTO Speed


Optional NA

Brakes

Brake typeStandard Oil Immersed Brakes

Optional NA

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Steering Type


Mechanical Steering with Heavy Duty single drop arm for better manoeuvrability & comfort to operator.

Optional NA

Hydraulics

Hydraulics



Optional NA

Linkage 3 point linkage Category-I suitable for Category-II type implement pins

Tyres




Electricals



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


240 mm




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

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http://www.mahindraswaraj.com/files/portfolio_30-40hp_834XM.htm#features

http://www.mahindraswaraj.com/files/portfolio_30-40hp_834XM.htm#tyres

http://www.mahindraswaraj.com/files/portfolio_30-40hp_834XM.htm#pto

http://www.mahindraswaraj.com/files/portfolio_30-40hp_834XM.htm#warranty

http://www.mahindraswaraj.com/files/portfolio_30-40hp_834XM.htm#hydraulics

http://www.mahindraswaraj.com/files/portfolio_30-40hp_834XM.htm#speed

http://www.mahindraswaraj.com/files/portfolio_30-40hp_834XM.htm#dimensions

http://www.mahindraswaraj.com/files/portfolio_30-40hp_834XM.htm#steering

http://www.mahindraswaraj.com/files/portfolio_30-40hp_834XM.htm#transmission

http://www.mahindraswaraj.com/files/portfolio_30-40hp_834XM.htm#electricals

http://www.mahindraswaraj.com/files/portfolio_30-40hp_834XM.htm#brakes

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Model RV-3 XM + 3A



No. of Cylinders 3



Rated Engine Speed

1800 rev/min



Transmission

ClutchStandard Single dry disc friction plate - 280 mm dia. (11")

Optional NA




Reverse 2.68 & 10.52

PTO Speed


Optional 540 rpm

Brakes


Optional Oil Immersed Brakes

Steering Type

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Optional NA

Hydraulics

Hydraulics



Optional NA


Tyres




Electricals



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


380 mm




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



No. of Cylinders 3



Rated Engine Speed

1800 rev/min



Transmission


Optional NA




Reverse 2.73 & 10.74

PTO Speed


Optional 540 rpm

Brakes


Optional Oil Immersed Brakes

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Steering Type



Optional Power steering

Hydraulics

Hydraulics



Optional NA


Tyres



Front/Rear Optional 6.00 x 16 / 13.6 X 28

Electricals



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


395 mm




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


Type 4 Stroke, Direct Injection, Diesel Engine

No. of Cylinders 4

Bore and Stroke 88.9 x 110 mm


Rated Engine Speed

1900 rev/min



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Transmission


Optional NA



Forward 2.3 to 29.3

Reverse 2.8 to 10.9

PTO Speed


Optional NA

Steering Type



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


Optional NA

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Tyres



Front/Rear Optional 6.00 x 16 / 13.6 x 28

Electricals



Weight & Dimensions

O.A.Length 3390 mm

O.A.Width 1680 mm

O.A.Height 2200 mm

Wheel Base 1935 mm


370 mm


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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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


HP : 26.5 S.A.E.

Tractor : SWARAJ 724 FE





Cooling System : Water Cooled

3. RV-3, Three Cylinder :


Model : RV-3 xm KIRLOSKAR

HP : 39 S.A.E.






Cooling System : Water Cooled.

4. RB-30, Three Cylinder: 45 | P a g e



Model : RB-30 xm KIRLOSKAR

HP : 48 S.A.E.






Cooling System : Water Cooled with Oil Cooler for engine oil.

5, RB-33, Three Cylinder:


Model : RB-33 xm KIRLOSKAR

HP : 50 S.A.E.






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 crankshaft, 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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http://www.howstuffworks.com/four-wheel-drive.htm

http://www.howstuffworks.com/fpte3.htm


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

power between the two wheels by giving the less power to the inner wheel then the outer one & the 79 | P a g e


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

d. Valve Touch Noise89 | P a g e


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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Swaraj training report

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Transcript of Swaraj training report