Sukhpal Chap.2.docx

1

Contents I. Introduction 1.1 History of mahindra Tractor 1.2 Company profile 1.2.1 Factory layout of mahindra 1.2.2 Market position 1.2.3 Award taken by mahindra 1.2.4 Main market areas 1.3 Technical development 1.4 Productivity 1.5 Different department in mahindra 1.6 Location of mahindra Plant 1.7 Total turnover of mahindra Tractors

II. About Institute III. Products of mahindra tractors IV.Engine 4.1 Introduction 4.1.1 Types of Engine 4.1.2 2-Stroke of Engine 4.1.3 Main system of Engine 4.2 Standard Value of Engine settings 4.3

Engine parts 2

4.4

Engine models of mahindra Tractors 4.4.1

115NCET III –A

4.4.2

398 ED

4.4.3

S – 325 ( SYMPSONS)

4.4.4

S – 320 DED (SYMPSONS)

4.4.5

Engine Trouble shooting and their solution

V. Transmission 5.1

Gears 3.1.1 Types of Gear box 3.1.2 Gear Model in Eicher Tractors 3.1.3 Sliding mesh gear box 3.1.4 Synchromesh gear box 3.1.5 Hydrometric NT gear box

5.2

Differential 3.2.1 Function of differential

Conclusions

3

Chapter 1

I.

Introduction

1.1 History of mahindra tractors development of mahindra Forstern and Dingolfing factories. These pioneers made several tests and carried out a patient work of clarification. The first evolution was marked by the construction of an automatic mower and a three-wheeled tractor. The brothers Joseph and Albert mahindra were born and grew up in an agricultural part of Germany. Their personal taste for agriculture favored the development of ideas which led to the manufacturing of machines and modern devices. In 1949, their manufacture of the first farm tractor with an engine with air cooling allowed to rank among the most important manufacturers of tractors. In 1959, mahindra set up the mahindra Tractor Corporation of India Private Ltd., along with the Goodearth Company of New Delhi, India, and began production in 1960 of Indian-built mahindra tractors. Since 1965, mahindra has been completely owned by Indian share holders. The German mahindra was part of Massey Ferguson from 1970 when MF bought 30% of the company, eventually buying out the German company 1973. Tractors were manufactured first under the mahindra Goodearth name, and then mahindra, mahindra Valtra and Euro power. In 2005, mahindra Motors ltd. Sold the Tractors and Engines business to TAFE (tractor and farm equipment), of Chennai, India, which set up a new subsidiary called TAFE MOTORS AND TRACTORS LIMITED for Eicher In the small village, Forstern near Munich, in Bavaria, Germany, the first mahindra tractor was made, in the 1930s, by Joseph and Albert mahindra. It was the beginning of considerable

II.

COMPANY PROFILE

 Profile of mahindra Motors 4

mahindra Motors Ltd is one of the leading manufacturers of commercial vehicles in India. Their principal activity is manufacturing and selling of commercial vehicles, two wheelers and gears. They are having their manufacturing facilities at Pithampur and Dewas in Madhya Pradesh, Chennai in Tamil Nadu, Thane in Maharashtra and Gurgaon in Haryana. Eicher Motors Ltd was incorporated in the year 1982. The company in technical collaboration agreement with Mitsubishi Motor Corporation of Japan produced the Light Commercial Vehicle in India. The commercial production was commenced in their plant at Pithampur in Madhya Pradesh, with the launch of Canter truck in June 1986. The agreement with Mitsubishi ended in March 1994 after successful transfer of technology and achieving total Indigenization. The demerger of Tractors, TwoWheelers, Engines and Gears businesses from mahindra Ltd was transferred to the company with effect from April 1, 2003. In May 25, 2005, the company acquired 100% of the shares of Design Intent Engineering Inc, USA, which is engaged in the business of providing computer aided engineering & design services for a consideration of USD 2.5 million. The company's Tractor division at Mandideep, Gears division at Parwanoo and Engines division at Alwar had been sold to TAFE Motors and Tractors Ltd, a wholly owned subsidiary of Tractors and Farm Equipment Ltd, for a consideration of Rs 310 crore with effect from June 1, 2005. The company acquired a transmission gear manufacturing plant at Dewas having a gear cutting capacity of 5 lacs gears per annum with effect form November 1, 2006. During the year 2006-07, the company acquired the 100% equity shares of Hoff and Associates (Hoff), Plymouth, Michigan (USA) along with Hoff's two wholly owned subsidiaries in Beijing and Shanghai, China for a consideration of USD 3.5 million. In order to synergize the activities between the two subsidiary companies in USA, Hoff and Associates merged with Design Intent Engineering Inc with effect from January 1, 2008 and the name of Design Intent Engineering Inc was changed to Eicher Engineering Solutions Inc. In May 2008, the company signed a definitive agreement with Aktiebolaget Volvo, Sweden for a formation of a joint venture company through transfer of the existing Commercial Vehicle Business along with related Components and Design Services Business. In August 2008, they transferred the Components and Design Services Business to VECV, the joint venture company with effect from July 01, 200

III.

FACTORY LAYOUT

WASTAGE PRODUCT YARD RESEARCH AND DEVELOPMENT DEP. IV. MARKET

PARKING AREA OF TRACTORS

POSITION OF MAHINDRA

Vikram Lal-promoted mahindra group on Wednesday concluded an agreement to sell its tractor, engine and gear businesses to Chennai-based Tractor and Farm Equipment (Tafe) for Rs 310 crore. The mahindra group also announced plans to acquire a US-based engineeringQUALITY firm for $2.5 million (around Rs 11 crore) asMANUFACTURING part of its future growth plans. DEPART UNIT MENT

The combined venture - with a turnover of Rs 1,700 crore in 2004-05 - will become the second largest tractor maker in the country with a 22% market share. The deal will give Tafe a toe-hold GR in some key north and central Indian states such as Uttar Pradesh, Haryana and Rajasthan. OU ND

5

ACADEMIC

CANTEEN

Tafe will conclude the acquisition through a wholly-owned special purpose vehicle Tafe Motors, Tafe director Mallika Srinivasan said. "We hope to record a combined turnover of over Rs 2,000 crore this fiscal... We will retain the mahindra brand on the tractors and try to grow the brand,"she said. The deal will be financed through a mix of internal accruals and debt. "The definitive agreement for the purchase will be signed shortly,"she added. Shares in Eicher rose 10.8% to Rs 357 soon after the announcement of the deal. Under the deal, Tafe will buy mahindra tractor division at Mandideep (Madhya Pradesh), gears division at Parwanoo (Himachal Pradesh) and engine division at Alwar (Rajasthan). The deal will mark mahindra exit from the tractor market, and is part of the group's plan to focus on the high growth commercial vehicle and motorcycle segments. mahindra Motors said the decision to disinvest the three ventures is based on a review of its business portfolio which identified commercial vehicles as a major growth driver. "This is in line with the company's strategy of focusing on select businesses in which it could attain a strong market position," mahindra group chairman S Sandilya said.

V.  

AWARD TAKEN BY MAHINDRA

IN 1990 – 1991 best tractors award The company has received award from national productivity council for the best performance in production

VI.

LOCATION OF MAHINDRA TRACTORS  mahindra ENGINE , Itarana road ,Alwar Rajasthan, India Pin 301001 Call – 0144 270 2470

VII.

DEPARTMENT IN MAHINDRA ENGINE i. Research & development ii. Production iii. Quality & maintenance iv. Sales and service

VIII. TOTAL TURN OVEROF MAHINDRA Tractors and farm equipment limited (TAFE) IS a tractor majaor incorporated in 1960 at Chennai , with an annual turnover INR 96 BILLION (2013-14) TEFE wields 25% market share of the Indian tractor industry with sale of over 17000000.

6

Chapter II

PRODUCTS OF COMPANY(model) i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii. xiii. xiv. xv. xvi. xvii. xviii. xix. xx. xxi. xxii. xxiii. xxiv. xxv. xxvi.

MAHINDRA YUVO 475 DI MAHINDRA YUVO 575 DI MAHINDRA 475 DI MAHINDRA 575 DI MAHINDRA 585 DI MAHINDRA 595 DI ARJUN 555 DI ARJUN NOVO 605 DI-MS Mahindra YUVO 575 DI 4WD ARJUN NOVO 605 DI-i ARJUN NOVO 605 DI-PS ARJUN INTERNATIONAL MAHINDRA 555 DI POWER PLUS ARJUN NOVO 605 DI–i-4WD ARJUN NOVO 605 DI-i-WITH AC CABIN MAHINDRA YUVO 265 DI MAHINDRA YUVO 275 DI MAHINDRA YUVO 415 DI MAHINDRA 265 DI POWER PLUS MAHINDRA 275 DI ECO MAHINDRA 275 DI TU MAHINDRA 415 DI MAHINDRA JIVO 245 DI 4WD MAHINDRA 255 DI Power Plus MAHINDRA 265 DI MAHINDRA 245 DI Orchard

 Mahindra Gen-set

7

8

9

II. ENGINE A.

Introduction

It is a type of machine that converts heat or chemical energy in mechanical energy. Heat is a type of energy that travelled in low temperature region from high temperature region. It is known as heart of any vehical because any movement starts from engine working. It is power plant of any vehicle where from the power is meet to vehicle.

B.

Types of engine

Internal combustion engine

external combustion engine

Reciprocating engine

rotary engine

Spark ignition engine (petrol engine)

compression ignition engine (diesel

engine) 2-stroke engine

4-

stroke engine Air

cool

engine

water cool engine 4-stroke engine compression engine:-when the engine complete all cycle in two revolutions or 720o of crankshaft or 180o rotation in each stroke.

C. i. ii. iii. iv.

STROKE IN ENGINE Suction stroke Compression stroke Power stroke Exhaust stroke a. It is assumed that the piston is at TDC and both valves are closed in initial position or engine starting.

Suction stroke:i. ii. iii. iv. v. vi.

At TDC inlet valve open and exhaust valve is closed. filtered air enter in combustion chamber. travelling of piston from TDC to BDC. 0 to 180o rotation of crankshaft from initial position. First time stroke length is complete when piston approach to BDC. At BDC inlet valve become close and exhaust valve remain closed.

Compression stroke:i.

At BDC Closed inlet and exhaust valve. 10

ii. iii. iv. v. vi. vii.

Compression of air is starts . Travelling of piston from BDC to TDC. 180orotation of crankshaft from inlet stroke completion or 180o to 360o rotation of crankshaft from initial position of crank shaft. Second time stroke length is complete when piston approach to TDC. The injection of fuel is enter in between this stroke at a certain angle before from TDC position(for example 9o angle BTDC for 241/242 tractor model of EICHER). The combustion in proper or effective way approach when piston approach to TDC position.

Power stroke:i. At initial of this stroke inlate and exhaust valve remain in closed position. ii. Due to burnt fuel high pressure of combustion blast produce pressure on pistion so sufficient that can move to piston position easily. iii. Complete burning of mixture is take place here as well as proper utilization of their pressure also too.. iv. Travelling of piston from TDC to BDC. v. 180o rotation of crankshaft from compression stroke end or360o to 540o rotation of crankshaft from initial position of crank shaft. vi. Third time stroke length is complete when piston approach to BDC. Exhaust stroke:1. At initial of this stroke inlet valve is open and exhaust valve is closed. i. Exhaust of burnt/combusted gasses. ii. Travelling of piston from TDC to BDC. iii. 180o rotation of crankshaft from power stroke end or 540o-720o rotation of crankshaft from initial position. iv. Fourth time stroke length is complete when piston approach to TDC. i. For further keep continuous of engine processing repeating of this stroke is take place maintains .

D.

Main systems in engine

Following are system of engine that is consists with a. Combustion system:ii. Piston, Cylinder , piston rings, connecting rod, flywheel, crank gear, decompression lever, starter/solenoid. a. Exhaust and intake system:iii. Cylinder head ,inflate and exhaust valve , push rod , rocker arm , cam shaft ,cam ,air cleaner, gear , guide lifter , intake manifold , exhaust manifold ,silencer . a. Lubrication system:iv. Lubrication oil(15W40) , sump , oil pump , suction tube and screen , filter element , safety valve , pressure gauge , oil nozzle , front bush , crankshaft ,rear bush , rear bearing housing ,big end bush , capered oil hole in crankshaft ,lubrication gear, idler gear. a. Cooling system:11

v. vi.

vii.

viii. ix.

Air cooled system: - Blower fan, blower fan arm, fins, cover, v-belt, pulley, temperature sensor. Water cooled system:- Coolant(water) , radiator , thermostat valve , temperature sensor , water pump body , fan , fan belt etc. a. Fuel system:Diesel tank , fuel supply pipe , fuel valve , fuel filter(primary and secondary filter element) ,fuel pump(inline-mico-lubricates by lubrication oil have more clearance, rotary-TVslubricates by diesel oil have less clearance ) , fuel gear , water separator , pressure pipe , nozzle/fuel injector , over flow pipe , solenoids , lock nut. a. Governing system:Governor assay- weight , sleeve , shaft , bearing, fork , accelerator lever. a. Breathing system:Air filter, pipe extension pipe, and strip.

E.

Standard setting for engine

Tractor model

241/2 42

278

312/364 368/485 548

333

380/4 80

5150

Engine model

115N CET III-A 1557

298E 27

298ED D/ED

398ED D/ED

398E 49

S324

S320D 320D 325F4 ED ED

1960

1960

2945

2945

2400

S325E 1/E2 2500

3298

3298

Bore / 115/1 stroke 50

100/ 125

100/ 125

100/ 125

100/ 125

88.9/ 127

91.44/ 91.44/ 108/ 127 127 120

108/ 120

Horse power

24

25

30/35

36/45

48

33

38/ 42

47

50

50

Sump oil cap(ltr) Air cleaner oil capacity (ltr.) Tapp et (IV) clear ance (EV)

5.5

6.5

6.5

8

8

8

8

8

10.4

10.4

1.1

1.1

1.1

1.1

1.1

1.1

1.1

1.1

1.1

1.1

0.1

0.1

0.1

0.1

0.1

0.3

0.3

0.3

0.35

0.35

0.15

-

-

-

-

-

-

-

-

-

0.1

0.1

0.1

0.1

0.3

0.3

0.3

0.35

0.35

Actual c.c.

12

2500

5660

557

Bumpin g clearanc e Nozzle pressure Fuel timing angle(B TDC) Compre ssion pressure Liner piston clearanc e Cranksh aft free end play Idle speed Rated speed Full speed Oil pressure idle conditio n Oil pressure rated

1.1 1.2

0.750.85

0.75 0.85

0.75 0.85

0.75 0.85

0.1

0.1

0.1

0.030.08

0.030.08

260+8 240+ 8 90 130

240+8

240+8 130/ 140

240+ 8 130

240+ 8 130

260

130

240+ 8 160

100

270+ 8 14.50

270+ 8 14.50

30 32 0.11 0.12

30 31 0.10 .011

30 31 0.10 0.11

30 32 0.10 0.11

30 32 0.10 0.11

30 31 0.06 0.08

30 32 0.06 0.08

30 32 0.06 0.08

28 30 0.11 0.16

28 30 0.11 0.16

0.2 0.5 470+4 0 1600

0.1 0.35 600+ 100 2150

0.1 0.35 600+10 0 2150

0.1 0.35 625+10 0 2150

0.1 -0.35

0.05 0.38 625

0.05 0.38 625

2150

2150

0.05 0.38 600+ 200 2250

0.1 0.35 600+ 200 2150

0.1 0.35 600+ 200 2150

1780+ 2300 20 +50 1.5 1.8

2300+5 0 1.8

2300+5 0 1.8

2300 +50 1.8

2375

2375

2.1

2.1

2350 +-100 2.1

2350 +-50 1.5

2350 +-50 1.5

3.4

3.5/4

3.4

3.4

4.2

4.2

4.2

3.5

3.5

3.4

625+ 100 2150

F.

Engine models 1. 115NCET III-A :i. This engine is air cooled is manufactured by MAHINDRA Company. ii. Engine uses in 241/242 tractor models of MAHINDRA company. iii. In starting 1 is denoting to no. of cylinder. iv. 115 stay for bore dia. Of cylinder. v. By eliminate first 1 from 115 and putting 0(zero) in remain code denotes to stroke I mean the digits become 150 denote to stroke length of cylinder. vi. By eliminate first digit from 115 and putting 00(double zero) in end of remain digits than it show to cubic capacity of that engine. 13

vii. viii.

Here it is equal to 1500 c.c. NCET-new combustion engine tractor III-A norms (III-B norms and III-C norms also in emission rules)

2. 298 E27/EDD/ED:i. This engine is air cooled is manufactured by MAHINDRA Company. ii. This engine models are uses in 278/312/364 tractor models of company. iii. From 298 starting first digit stay for no. of cylinder Here :- 2 no. of cylinder. iv. After eliminate to first digit and by putting 0(zero) in end of remain digits than generated digit denote to cubic capacity of single cylinder v. Here cubic capacity of cylinder:- 980 c.c. vi. For complete engine:- 2×980=1960 c.c. 3. 398EDD/ED/49:i. This engine is air cooled is manufactured by MAHINDRA Company. ii. This engine models are use in 368/485/548 tractor models of company. iii. From 398 starting first digit stay for no. of cyl. Here:-3 no. of cyl. iv. After eliminate to first digit and by putting 0(zero) in end of remain digits than generated digit denote to cubic capacity of single cylinder v. Here cubic capacity of cylinder:-980 c.c. vi. For complete engine:- 3×980=2940 c.c. 4. S-324/S-325E1/S-325E2/S-325F4:i. This is water cooled type engine. ii. Here for engine model ‘S’ stay for Simpson company manufacturing of engine. iii. This engine models are uses in 333/380/480/5150 tractor models of company. iv. The tractor model 5150 is uses rotary fuel pump. v. In numerical digits first digit stay for no. of cylinder in engine . For here no. of cylinder=3. vi. Remain two last digits show to engine c.c. by putting 00(double zero) in end of remain digits. For here cubic capacity of engine is=2400/2500 c.c . 5. 320DED:i. This engine are power deration model of ultra engine that is launches by company in 1998 as uro 6100 in tractor is power of 61 hp. ii. This engine model is manufactures by MAHINDRA is design of Finland SISU DIESEL company. iii. This engine models are use in 5660/557 tractor models of company. iv. This is special engine have high close tolerance is apply. This engine is design most carefully. v. In numerical digits specification first digit denotes to no. of cylinder=3 and end of 320 we put a zero than it show the c.c. of engine=3200 c.c. vi. This tractor have ultra engine is not most sales due to their unavailability of skilled mechanic in local market. vii. This ultra engine is most dashed so that designed tractor is so covered in fully time and so compact that identification of part opening is not too easy. viii. The 5660 is mostly design for farm utility. ix. The 557 is mostly design for commercial utility 14

Engine-398 Ed Assay:i. Suction screen(3kg-cm) ii. Crank gear bush iii. Thrust washer(2.3kg-cm) iv. Crankshaft v. Bearing housing(2.1kg-cm) vi. Rear oil seal(2.1kg-cm) vii. Thrust washer viii. Crank shaft end play ix. Crank gear x. Flywheel(55kg) xi. Flywheel nut(75kg-cm) xii. Crankshaft weight(10kg-cm) xiii. Cam gear xiv. Idle gear xv. Fuel gear xvi. Pump gear xvii. Timing cover xviii. Pulley(30kg-cm) xix. Liner-piston-ring-connecting rod setting xx. Piston-connecting rod fitting xxi. Liner-piston fitting xxii. Connecting-crankshaft fitting(7kg-cm) xxiii. Lifter(intake/exhaust valve) xxiv. Air blower xxv. Window xxvi. Fan xxvii. Cylinder head setting and fitting(8kg-cm) xxviii. Pushrod sleeve xxix. Inlate manifold xxx. Exhaust manifold xxxi. Inlate and exhaust valve xxxii. Tappet clearance xxxiii. Tappet cover(3.5kg-cm) xxxiv. Filter(1.5kg-cm) xxxv. Fuel pump, delivery valve(7kg-cm) Tappet Clearance For inlet valve Exhaust valve Mention method are applicable:

= =

0.1mm 0.1mm

=

0.75-0.85 mm

Bumping Clearance Clearance

15

The clearance is check by dial indicator if clearance is not correct than it is adjust by putting gasket/ sims So company provide 7-sims to adjust clearance. i. 0.55 mm ii. 0.65 mm iii. 0.75 mm iv. 0.85 mm v. 0.95 mm vi. 1.05 mm vii. 1.15 mm Valve –Head Clearance Clearance = 1.80-1.90 mm It also measures by dial indicator If it is not in above range than the valve sheet and valve is required to turning or to replace.

Compression spring free length :Valve leak checking In simple way this test is doing by putting oil on valve and than the air is insert in intake manifold if air booble is in presence than valves are leak otherwise valve are not leak. Or Enter the oil from intake and exhaust manifold if oil leak than oil come out from valves. Lubrication system i. Oil is collect in sump. ii. Oil is suck by oil pump through suction screen and suction pipe. iii. Oil come out from oil pump. iv. The oil come out is passes through pressure valve. v. And go in filter. vi. Oil come out from filter and go in crank shaft as well as in cam gear by gallery that is provides in block in between crank bush and filter. vii. Oil goes crank bush to bush oil gallery pipe. A hole also provides in btw front bush and pipe that supply oil to head by pipe supply. a. Oil come head in oil is lubricates to rockers and valves and go in push rod sleeve to guid lifter to cam os cam shaft to sump. viii. Oil come in pipe provies next to head pipe hole is supply oil to second and third bush housing through it oil go in big end bush to lubricates crankshaft as wellas to piston cooling nozzle to lubricates to piston and liner through spraying.

16

Gear timing system

8-9th 6th

Crank gear(35) 398 cooling gear

3-4th fuel gear(41)

cam gear(70)

idler gear(41)

fuel gear(41)298 4-5th 11TH

Fuel Injection Time Setting In this tractor model inline fuel pump is uses that consists governor fuel cams And other fuel relates control systems For this model injection angel is:- 14.50 To set fuel timing : i. Check the timing is correct or not. ii. For check we open a pressure pipe line. iii. And leave out delivery valve from pump. iv. Another pipe line which is in J-joint with bolt of fuel pump connecting. v. By rotate engine and observing BTDC and TDC position with timing stopper we can say fuel timing is correct or not. vi. When engine is retard than the loose the fuel pump and push them in direction of engine than tight pump and check timing by changing pump position with nut of its tighten can make its correct timing. vii. When engine is advance than the pump is pushes far away putting them in nut. viii. When the timing is correct then tight them.

17

Engine S-325

Assay :i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii. xiii. xiv. xv. xvi. xvii. xviii. xix. xx. xxi. xxii. xxiii. xxiv. xxv. xxvi. xxvii. xxviii. xxix. xxx. xxxi. xxxii. xxxiii. xxxiv. xxxv. xxxvi. xxxvii. xxxviii. xxxix. xl. xli.

Engine block Main journal bush housing is places(washing +oil) Thrust washer in rear bush outer and inner(grease) Crankshaft setting(dia. , oil running clearance , fillet radius , hole campered )+fitting(washing +oil) Crankshaft fitting(crank gear-25 teeth) Other remain journal housing fitting(washing +oil) Piston dimension checking Piston ring fitting Piston-connecting rod assay(oil) Piston fitting in liner Connecting rod(oil) and crankshaft fitting(8.2 kg) Oil pump setting Oil pump fitting(13-2.5/19) Idler gear(21 teeth , oil on idler gear shaft) Idler gear C-lock Timing case gasket fitting(grease) Gear timing case Idler gear(90 teeth) Cam gear(50 teeth) Fuel gear(50 teeth) Sump joint gasket fitting on gasket Sump gasket Sump fitting Flywheel housing gasket Flywheel housing case Aluminium Seal housing Flywheel(11.8) Timing gear setting Timing cover(3) Filter body(4.5) Water body setting/fitting Head gasket Head setting(valve leak/ height below head surface/valve gasket/guider height/removing scaling of calsium) Head fitting(10.00) Tappet fitting(washing+oil) Head oil pipe fitting(washing+oil) Head gasket Head cover fitting(washing+oil) Pulley fitting Outer oil pipe line fitting Fuel supply pipe fitting

18

PROBLEMS EVENTS IN LINER i. Truncating/taperness in liner i. Temperature on head of piston, ii. Lower lubrication of piston head so large friction area is face by liner, iii. Wrong ring material.

1.

Ovelity of liner generally in wet type liner, more side thrust application in wet liner region,

2.

Scratch/lining on liner Piston-liner clearance, Oversize of ring/large end gape in spring/large groove clearance, Wrong oil grade Improper lubrication Wrong ring alignment of rings

19

3.

liner material cutting One side Bending of connecting rod, Wrong alignment of rings, overloading of engine.

TROUBLE SHOUTINGS AND THEIR REASON Reason behind engine overheating i. Service timing period. ii. Engine over loading. iii. Way of vehicle driving. iv. Oil grade mix-up or improper standard oil using. v. Loosening of fan belt/brokering of fan blade/wrong blade positioning of air motion. vi. Dust in fins. vii. Wrong measurement of sensor/fault in sensor/problem in pointer of indicator. viii. Brake position with wheel. ix. Radiator gasket leaking/improper coolant level. x. Chocking of radiator/damaging of radiator fins. xi. Chocking of cooling pipe gallery of radiator fins. xii. Leaking of water from pump body/broken impeller/slipping of impeller. xiii. Improper Working of thermostat valve. xiv. Improper locking/packing of head cover. xv. Nozzle of oil(piston cooling). xvi. Wrong Tappet clearance setting. xvii. Lowering of Bumping clearance from minimum tolerance. xviii. Advancing of fuel pump timing.

Reason behind loading problem in engine i. Service timing ii. Overloading of implement iii. Loosen clutch setting/engagement iv. Clutch surface is become wet v. Oil leakage from rear oil seal vi. Retardation of fuel pump vii. Large bumping clearance viii. Ring are out of validity condition ix. Fuel pump/filter chocking x. Improper Lubrication 20

xi. xii.

Piston/liner have scratches Incorrect crankshaft free end play

Reason behind more fuel consumption in engine i. Service time duration ii. Over load iii. Bumping clearance iv. Fuel pump retardation v. Improper lubrication/cooling a. Reason behind oil consumption in engine vi. Service time duration vii. Breather system problem viii. Bearing housing/rear bush housing seal is leak or cutted ix. Rings clearance is out of standard x. Valve oil stem seal/gasket is leak xi. Front seal is leak xii. Grade of oil

III. Transmission/gear box:i. ii. iii. iv. v. vi.

Reduce engine r.p.m. Increase torque by reducing r.p.m High- low speed according to field condition. Control on tractor. Help to control tractor. To task as reduction unit.

Type of transmission:-

According to speed:i.

High speed gear box a. This kind of gears uses in speedy vehicles so in pulling such kind of gear are not good perfomer.

ii.

Low speed gear box a. This kind of gears uses in high torque vehicle so they have good pulling power.

iii.

Sliding mesh gear box i. Constant mesh gear box ii. Syncromesh gear box

Sliding mesh gear box:When the engagement of gear in transmission is take place by making main shaft gear sliding on lay shaft gear. Constant mesh gear box:21

When the gear of main and lay shaft always remain in meshing and main shaft gear kept free than the transmission is only take place by fixing the main gear fixing by attaching collar to main shaft. Syncromesh gear box:When the main shaft free gear remain in mesh with lay shaft fix gear than the transmission is take place by syncro units. Sliding Mesh Gear Box Advantages :i. Low maintainance required. ii. Easy service availability. iii. Easy design. iv. Oil change requirement can manage for more than the time. Disadvantages:i. High force requirement for shifting of gear. ii. High noise and clashing. iii. For engagement equal speed of both gear is necessary. iv. Differential It is a mechanical device that is most useful for auto system. It is a combination of gears and gear train that is work as reduction unit as well as stability/control of vehicle. Function of differential i. Equal speed in both wheel when vehicle is running in straight path. ii. When vehicle is in turn than the speed of inner wheel lower by some amount and the outer wheel speed is increase by reduced amount. iii. It works to transfer power at 900 / right angle. iv. Reduction unit. v. When one wheel is in stop than the complete power is transmit to free wheel.

Gear transmission models in Mahindra tractors:1. GT-51(5+1):-241/242 2. Syncro 755:-485/548/5660/557/380 3. GT-80(8+2):1. PTO>1000 r.p.m.:-242/312/333/364 2. PTO 540 STD r.p.m :-312/364/368/485/548/333/5150/5660 3. Hydromatic NT:-242/278/312/364/368/485/333/380/480

Tractor model 241 242

Oil capacity(ltr.) 9.5 11.5

Tripping(ltr.) 12 14 22

Power steering (ltr.) -

278 312/364 368/485 548 333 380/480 5150 5660 557

28 11.5/34 34/36 42 36 36 44 45 38

25 11.5/34 34/36 42 36 36 44 45 38

40 45 36 40 50 52 38

T-shooting in transmission:i. Slip of gear ii. Noise in only one gear iii. Clashing in all gear iv. Huming noise in gear box v. Gear not become neutral vi. Gear shifting problem vii. Noise in gear box only in duration of engagement viii. Noise from differential ix. Noise in neutral

Parts of gear box:g-2 g-1 Flywheel houshing

Flywheel housing:i. Clutch assay ii. Release bearing iii. Fork iv. Sleeve v. Clutch pedal shaft vi. Primary shaft vii. Top shaft g-1 :i. Gear lever attached to top plate ii. Gear shifting fork iii. Gear & box (rail, bolt & spring) iv. Main shaft v. Sliding gear 23

vi. vii. viii. ix. x. xi.

Lay/counter shaft Spur gear/constant mesh gear/clutch gear High-low sliding gear High-low lever and fork Reverse gear Idler gear

g-2 :i. ii. iii. iv. v. vi. vii. viii. ix.

Crown pinion shaft Differential assay housing Star and sun star gear FD pinion Bool gear Rear axle and axle tube PTO shaft rear PTO shifting lever Brake assay

1. Crown wheel

Sliding contact gear in mahindra:This is mostly using transmission system in vehicles because their low cost, easy repair /part availability, lower care etc. In this system the power coming at clutch gear is engages with CM gear so the fixed gear on lay shaft is move off. The main shaft consists of gear so that the can slide on it in any position. whenever gear is changes than the main shaft gear are engage with lay shaft gear so the main shaft starts moves off and power is transmits to differential from where the power is devides according signal of steering on wheels.

GT-51(5+1) Main settings in gt-51:i. ii.

iii.

Backless in star and sun star gear :- 0.10-0.35 mm Backless in CP shaft and crown wheel :- 0.10-0.35 mm Mounting distance of CP shaft :- as per required sims are inserts Assay of GT-51:i. Idler (reverse)gear ii. Rear lay roller bearing(506820) iii. Lay shaft + gear setting iv. Lay shaft + front bearing(6202) v. PTO lever setting(outer side setting is possible) vi. Differential housing vii. Star gear + rod+ crown wheel 24

viii. ix. x. xi. xii. xiii. xiv. xv. xvi. xvii. xviii. xix. xx. xxi. xxii. xxiii. xxiv.

Sun gear Sun-star backless setting Bearing(621363) Left + right plate Crown pinion Crown pinion and crown wheel backless setting Gear box() Gears of main shaft Dog housing Dogs Capsules Bolls Springs Cylinder Cover Lever Level guage

main settings is:i. Sun-star gears backless setting:- 0.1- 0.25 mm ii. CP gear and crown wheel backless setting:- 0.10- 0.35 mm iii. CP gear mid distance setting according to sims requirement. iv. Preloading of CP pinion taper roller bearing:-2.0 – 2.5 kg load.

GT 80 >1000 1. Double axle 2. Cut axle 3. Portal axle 4. Reducing axle

wheel Brake Reducing housing 4

5 25

5

A A

4 3

2 3

6 1 Main shaft 6

2 1

Lay shaft

GT – 80 540 STD PTO

26

GT – 80 MS PTO 540

Syncromesh Transmission

It is special kind of gear mechanism utility for gear engaging and shifting. In this different kind of syncro unites are uses to transmit power one gear to another and to differential. In this arrangement the power is come at clutch/primary shaft gear than this power is transmites to CM gear that is fixed on lay shaft so the power is come in lay shaft than lay shaft consists 3 other fixed gear which is live in engagement with main shaft 3 gear that are free on main shaft. So the power is come in all main gear. The syncro units hace inner tooth splines is kept on the spline of main shaft they are in better meshing. When the syncro unit sleeve have internal tooth is shift fork on the gear have external tooth of main shaft than the syncro unit also rotate with rotation of free gear as we know that the syncro unit spline is fitted on main shaft so the power is comes to main shaft that rotates to main shaft.

Advantages:i. ii.

Gear shifting is smoothen. No noise and clashing in gears. 27

iii. iv. v. vi. vii. viii.

Lower load is requires for shifting of gear. Wear and tear of gear is neglects. Life of gear is rises. Lower gear shifting headache for driver. High speed gear shifting facility. Lower maintainance is requires (time to time service requires).

Disadvantages:i. ii. iii. iv. v. vi.

Skilled mechanic requires for repairing. Parts of it is costly so part availability in market is a big problem. Interchangeability in this is not possible with other gears. Service is more recommended for long life. Design is compact and critical. Manufacturing cost is high.

VI.HYDRULLIC AND CLUTCH Hydraulic system This word is born in Itly , this word consist of hydro means a type of liquid and lic means tube or pipe. The complete hydraulic system is following to the law of Paskal. According to Paskal law if any liquid is filed in a close container than that liquid exerts equal force at every internal point of container in perpendicular direction when the force exert by liquid on every internal point is beyond to tolerable force than the liquid is starts leak from container. Function :i. lift, stay and stop to emplement at required position and adjust to implement automatically to make them is safe working. ii. Draft control iii. External circuit making. Draft :Draft is a resistance due to soil that make safe to tractor as well to emplement. Eicher tractor starts ADDC in their product from 1980 is designed by Itly. ADDC system:Automatic Depth And Draft Control System Company uses 4 type of hydraulic in his product till now.

1. Non mix mode:i. ii. iii.

Company use it 1982-1998. No repair. More hunting. 28

iv.

No any external circuit for trolley tripping.

2. Mix mode:i. ii. iii. iv. v. vi. vii. viii.

1998-till now in use Reduced hunting. Available in repairing mode. Low cost. The external port exist in it for external joining improper on draft utility. Draft lever is work properly in defined rang beyond it it gets overload. Position of stay is at defined movement of draft lever. Jamming of spool lever.

3. Position sensitivity:i. ii. iii. iv.

2005-till now in use Draft overloading is eliminate almost. Stay positions are more in available. Design of mode selector is improve for easy setting.

4. Hydromatic NT:a. 2007-till now in use

Main hydraulic system Hydraulic pump:-

i.

o



ii.

iii. iv.

80-120 kg/cm2

PRV:i. Divide/control on pressure according to lever signal ii. Work as mind of hydraulic iii. It opens ports of oil functioning Lever/shield assay:a. Position control /yellow lever:i. It lift, stay and down the emplements ii. Depth in field iii. Tripping trolley operation b. Finger tip/draft/black lever:i. It manage the load on empliment ii. Safe mode can easily updates c. Location/red lever:i. Lock to draft lever Mechanical linkage:Using linkage the signal is send to PRV as requires. Ram cylinder assay:The oil in pressure enter in cylinder and press to piston to move him as the piston is moves the arms are rotates and lifts to tri linkage.

PRV(pressure release valve) Assay 29

2.Differential valve

1.main spool 3 6.mode selector

4.check valve

5.cylinder safety valve

1. Main spool lever:Lift, stay and down Retainer, spring, 3mm spacer , spool lock valve, spool, sleeve, o-ring etc. 2. Differential lever:This lever work according to path selected by spool lever. Valve, spring, retainer, o-ring etc . 3. Pump safety valve:This valve safe to PRV if the pressure is more then the tolerance by bypassing oil in ADDC housing. Sheet/poppet valve, o-ring, back up ring(white) o-ring, valve, spring, retainer, adjusting screw, o-ring, cap etc. 4. Check valve:-unary valve Oil is enter only through it not exits through it. 30

Same parts as pump safety valve. 5. Cylinder safety valve:This is safe to cylinder to work only in sustainable load beyond sustainable pressure the pressure release valve is open and maintain safety of cylinder. Valve, backup o-ring, o-ring, ball, spring, retainer, o-ring, cap etc. 6. Mode selector valve :By loosen it. it works for emplements. By tight it. it works for external tripping.

CLUTCH-

Clutch is a device for gradual engagement and disengagement of power between the engine and rest of the transmission. It is a coupling used for connecting or disconnecting the engine power to gear box. The clutch is field between engine and gear box. A clutch is a machine membrane used to connect the driving shaft. A clutch thus provides an interruptible connection between two rotating shafts.

FUNCTION OF CLUTCH ASSEMBLYi. To engage or disengage the engine power from gear box as and when required. ii. To allow the engine to take up the load gradually without shock. iii. It should have higher capacity to transmit maximum power without slipping. iv. The control should be easy and require little pedal pressure to operate. v. It should be easy to adjust. 31

vi.

It should have good ability of taking load smoothly without dragging and chattering.

FOLLOWING TYPE OF CLUTCH’s USED FOR MAHINDRA TRACTOR Type of clutch

Tractor model

1.Single clutch plate (with 9.5 inch)

241/242

2. Single clutch plate (with 11 inch)

321/333/380/480/368/364/485/278

3. Single diaphragm clutch plate ( with 11 inch) 4. Duel clutch plate (with 11 inch)

485/480/380/368/333/312/364/5660

333/380/368/485/480/5150/5660/548/557 MAIN SETTING FOR CLUTCH ASSEMBLY i.

Clutch pedal free play- 20 to 25 mm.

ii.

Single clutch plate (with 9.5 inch) finger setting a. Single plate hub to finger distance 33.5 ± 5 mm.

iii.

Single clutch plate (with 11 inch) finger setting a. Clutch plate hub to finger distance 17.5 mm

iv.

Dual clutch plate finger setting a. i.Mainfinger of PTO clutch plate of hub to main finger distance-22.8 or 23mm. b. ii.PTO clutch plate hub to finger distance -14.8 or 15 mm

v.

No setting for single diaphragm clutch plate only clutch free play setting 20 to 25 mm.

TROUBLE SHOOTING1. clutch slippage A. B. C. D.

Oil /grease on the lining Lack of the clutch free play Weak pressure spring Worn out lining

to clean with the petrol /replace. Adjust. fit new set of spring. replace. 32

2. Clutch noises

A. Weak pressure spring replace affected spring. B. Excessive worn splines on the shaft and clutch plate C. Worn/dry release bearings replace affected parts.

replace affected part.

CLUTCH ADJUSTMENT i. Due to long time use, the clutch facing gets worn out. Similarly when the clutch has been used wrongly, facing get worn out quickly. ii. Hence the distance between pressure plate and flywheel reduces, this results in increase in distance between release bearing and fingers. iii. Under this circumstance when the clutch pedal is pressed the release bearing can not press the fingers to the required distance, hence the clutch pedal does not disengaged properly. Hence clutch adjustment essential. iv. The only normal adjustment required throughout the life of clutch friction lining is to readjust the free movement of the clutch pedal periodically i.e. movement of pedal before release bearing comes in contact with the fingers. v. The clutch free play is related with the clearance between the release bearing and fingers. vi. On some tractor, this clearance is adjusted by linkage, whereas on others it is adjusted by moving clutch release shaft.

 CONCLUSION:-

i. ii. iii. iv. v. vi. vii. viii. ix. x.

We studied every product of engine, transmission, hydraulic of Mahindra Tractors. The training was based on product detail and its concept of every system. We assembled and dissembled of five engine ,three types transmission, two types hydraulic. We had best facility by the company. Every work we had to done by our self. We also took theoretical as well as practical classes. Safety and precaution classes were also given by company. Our faculty who took our classes was cleared our every confusion. We enjoyed our summer training program. We visited plant also each department.

33

 REFERENCES:a. www.wikipedia.org for history and award. b. www.mahindra.in c. www.TAFE.com d. Also from notes which was we wrote in the training classes

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