training report

Six Weeks Industrial Training Project
Report
Submitted in the partial fulfilment of the requirement for the award of
degree of
Bachelor of Technology
in
Mechanical Engineering
Batch
(2013-2017)
Submitted to: Submitted by:
Department of Mechanical
Engg.
DEPARTMENT OF MECHANICAL ENGINEERING
DAV UNIVERSITY
JALANDHAR-PATHANKOT NATIONAL HIGHWAY, NH 44,
SARMASTPUR, PUNJAB.
144012

Industrial training project report of six weeks in
Sonalika International Tractors Ltd.
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ACKNOWLEDGEMENT
I express my gratitude to all those who helped us in various stages of the development of
this project. Firstly, I would like to express my sincere gratitude indebtedness to Dr.
Naresh Sahajpal (Dean Acadamics) and Er. M.P. Garg (Coordinator, Department of
Mechanical Engineering) DAV University for allowing me to undergo the summer
training of six weeks at Sonalika International Tractors limited(ITL),Hoshiarpur.
It is always said that efficient work is nothing but mutual coordination between two or
more people. For me, it was a very difficult real time project without the help of people
surrounding me.
I am also thankful to all faculty members of Department of Mechanical Engineering, for
their true help, inspiration and for helping me for the preparation of the final report and
presentation. Furthermore I would like pay my sincere thanks and gratitude to all the
Staff Members of Sonalika International Tractors limited(ITL),Hoshiarpur. for their
support and for making our training valuable and fruitful.
Finally, I thankful to all of them who directly or indirectly helped me in the completion
of the report successfully, for without their help, this project would not have seen the
“LIGHT OF THE DAY…”.

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DECLARATION
I, **********hereby declare that the work which is being presented in this training by
me, in partial fulfilment of the requirements for the award of Bachelor of Technology
(B.Tech) Degree in “Mechanical Engineering” is an authentic record of my own work
carried out under the guidance of Mr. Sunil Gupta
To the best of my knowledge, the matter embodied in this report has not been submitted
to any other University/ Institute for the award of any degree or diploma.
Date: 21th, Nov, 2016
INDEX
 ACKNOWLEDGEMENT 2
 DECLARATION 3
 INTRODUCTION 6-18
 HISTORY
 LOGO RATIONALE
 MILESTONE
 COMPANY UNITS

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 TRACTOR SHOP 19-38
 INTRODUCTION
 DIFFERENTIAL HOUSING ASSEMBLY
 GEARBOX ASSEMBLY
 REAR COVER ASSEMBLY
 MAIN LINE ASSEMBLY PHASE
 PAINT PHASE.
 ASSEMBLY OF ACCESSORIES AND INSPECTION
 CONCULSION 39
 BIBLOGRAPHY 40
 APPENDIX 41

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INTRODUCTION TO THE COMPANY
 HISTORY OF SONALIKA GROUP
FOUNDER – Mr. L.D.Mittal
Sonalika Group - Sonalika group is one of the top automobile and agriculture
machinery manufacturers in India. Apart from tractors its product line includes multi
utility vehicles, three wheelers, engines and various farm equipments and implements.
Established in 1969, Sonalika group since the inception has tried to understand customer
need to be facilitating them with its value for money products. The Company has a state
of art manufacturing facilities, spread in acres, located in the free shrubs of Punjab and
Himachal Pradesh.
Sonalika is the one of the top 3 tractor manufacturing companies in India, other products
include of, Multi utility vehicles, engines and various farm equipments. Today the group
stands tall with an approximate turnover of 5000 Crore INR. An average growth of 30%
makes it one of the fastest growing corporate in India. It is also one of the few debt free
companies. Group has strength of about 2000 employee technocrats. The company
works on the maxims of low production cost and clean and safe environment. Such
efforts have fetched the company the accreditation like ISO 9001 and ISO 14001.
History reveals that innovation is the key to continued progress and

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when applied to technology that touches human life, it can unfold a whole new economic
phenomenon that has the power to change the world. With unique initiatives like the
Thought leadership Forum, Leadership Forum, we have been able to create a unique
platform for learning through success stories of industry leaders. The success saga of
Sonalika Group a business conglomerate having prime interest in agricultural & auto
machinery goes back to nearly 5 decades. The corporate philosophy embedded in trust,
quality and commitment has helped the group to carve out a niche for itself in the highly
competitive world of Machinery. Sonalika is the fastest growing tractor company
registering growth over growth since its inception has crossed 1.80 lac merely in 10
years & has attained one of the position in top three in India
Sonalika group’s products exist in various international markets. Company’s product
exported to Algeria, Angola, Armenia, Australia, Bangladesh, Cameroon, Ethiopia,
Ghana, Ivory Coast, Malawi, Malaysia, Mauritius, Mozambique, Nepal, Oman, Republic
of Benin, Senegal, South Africa, Srilanka, Sudan, Canada, Zambia, Syria, Togo, Tunisia,
Ukraine, and Zimbabwe.
 MISSION & VISION
VISION STATEMENT:-The dream Project of Sonalika group is to cater the
agricultural and auto industry with quality abrasive products through untiring
dedication and leadership.
MISSION STATEMENT:- we pay personal attention to customers so that, we
can build products they need, and not merely sell the products we build.
 CORE VALUES
To accomplish our mission, the ownership, staff, and management go to great
lengths to treat each customer like a member of the family and provide them with
the best choice of products and highest quality of service in the industry.

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 ETHO STATEMENT OR LOGO RATIONALE
 Red - symbolizes the strength, power, determination, and desire of
company.
 Yellow - surrounding the Sonalika produces a warming effect, arouses
cheerfulness, stimulates mental activity, and generates the same.
 Green Leaf - in the centre symbolizes growth, harmony, freshness, and
fertility. Black underlining the logo associates with power, elegance, and
formality.
 Orange - surroundings the complete logo represents enthusiasm,
fascination, happiness, creativity, encouragement, and stimulation. All this
permutation of persona represents the Sonalika group as an asset in the
industry.

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 Details of top executives
1. Chairman- Mr. L.D. Mittal
2. Vice Chairman- Mr. A.S. Mittal
3. Managing Director- Mr. Deepak Mittal
4. Finance Head- Mr.Rajnesh Jain
5. Production Head- Mr. Ashok Kapoor
6. Marketing Head- Mr.L.R.Yadav (CEO)
7. R&D Head- Mr. Ashwani Malik
 Turnover
The total turnover of the group stands for 3200crore INR. An average growth of
30% makes it one of the fastest growing corporate in India. It is also one of the
few debt free companies.

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 SONALIKA GROUP –MILESTONE
 1969, Modest beginning into farm equipment and machine manufacture and earning
name and fame over all these year.
 1995 Diversification into manufacture of tractor over whelming response from the
market.
 1996 Roll out of first tractor from ITL.
 2000 Enter into joint venture with Renault Agriculture France for tractor
manufacture in India.
 2000 Started in house manuf. Of engine for tractor application.
 2002 Started export of tractor to Africa, Asian sub continental.
 2004 Started Roll out of 100000 Tractors
 2004 Started establishment of ICML.
 2005 Become the fourth largest tractor manuf. In India.
 2005, Roll out of first vehicle from ICML facility.
 2005 Joint venture with Yanmar Agriculture of Japan.
 2006 Successfully developed 4 wheels drive front Axles and transmission of tractors
for Yanmar.
 2006 Rollout of 100000th tractor engine.
 2006 Become 3rd largest manufacture of tractor in India.
 2006 Market launch of Rhino (MUV) and establish dealer’s network.

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 SONALIKA GROUP UNITS
Sonalika group divided into four companies. .Sonalika group units are as follow:
SONALIKA
GROUP
INTERNATIONAL
TRACTOR
LIMITED
INTERNATIONAL
CARS AND MOTOR
LIMITED
INTERNATIONAL
AUTOTRAC
FINANCE LIMITED
SONALIKA AGRO
INDUSTRIES

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 INTERNATIONAL TRACTORS LIMITED
International Tractors Limited was incorporate on October 17, 1995 for the
manufacture of Tractors and has since then built a distinct position for itself in the
Tractor industry. ITL is manufacturing various Tractors of Sonalika brand between
30 H.P to 90 H.P, and CLASS brand between 70 hp to 90hp. The tractors
manufactured by company have secured a reputation of performance, quality and
reliability in the market because of their maximum pulling power, minimum fuel
consumption and low emission. All this makes ITL one of the top five tractor selling
companies in India. These tractors are also exported to various countries including
South Africa, Australia, Zimbabwe, Sri Lanka, Canada, Bangladesh, Algeria,
Zambia, Senegal, Ghana etc.
ITL has entered into strategic alliance with YANMAR of Japan for joint
manufacturing tractors in India. ITL has a marketing arrangement with TATA
International for development of selected South American and African market. The
company’s marketing efforts are promoted by dealer network of 600, and 450 sub
dealers. Such a networking has enabled the company to grow like a well-knit family
whose roots lie in its customers, who have providing constant feedback and support
to allow the company to turn their dreams into products.
They are also manufacturing tractors, meeting norms of Smoke & Mass Emission,
Tested and certified by ARAI, Pune. United States Environmental Norms Agency,
Washington DC has also certified our Engines. These certifications enabled
SONALIKA Tractors to enter into world Market. All the Models of Tractors and
Combines Harvesters manufactured by us are tested & approved by central Farm
Machinery and Tractors Training & Testing Institute, Bundi (MP) India, (the
Government of India Institute authorized for issuing test reports).
Address- International Tractors Limited Jalandhar Road, Hoshiarpur (Pb.)
Pin-146001 (India)

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 INTERNATIONAL CARS AND MOTOR LIMITED
International Cars & Motors Limited (ICML) is a Group Company of the Rs 1200
Crores SONALIKA Group. The Company is promoted by Mr. L.D.Mittal
(Chairman), Mr. A.S.Mittal(Vice Chairman) & Mr. Deepak Mittal, Managing
Director, who are having vast experience in manufacturing of tractors, Farm
machines & Automobiles.
ICML is a project of its kind and is the ‘Pride of Himachal Pradesh’. The Company is
having its state-of-the-art production facility, with centrally air-conditioned, dust &
pollution free environment, to manufacture multi-utility vehicles / sports – utility
vehicles, in Amb, Himachal Pradesh. The Company is a ‘Mother Unit’ as its
establishment shall attract many other ancillary & small units for meeting the raw
material requirements yielding manifold employment avenues, revenue &
industrialization in the state.
The Company has entered into Technical Collaboration Agreement with MG
Rover of UK, with the technical know – how from MG Rover, UK. The Company
has manufactured MUV with the name of RHINO RX & the same MUV boasts of
Rover engines. The company is in-process of developing its own Common Rail
Direct injection (CRDi) engines.
The company has the installed capacity to manufacture 2000 MUVs in a month
i.e., 24000 MUVs in a year. In the first full year of production in 2006-2007, ICML is
aiming to churn out about 5000 MUVs & expects to achieve a turnover of 250
Crores. The Company, besides catering to the domestic market, also has an eye on
exports & exports to Malaysia, Nepal, Bangladesh & Indonesia are also in an
advanced stage. It will also offload the product in African continent soon. The
Company is eligible for the Central & State Govt. Tax sops, exemption from the

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excise duty & income tax for 10 years, which shall add to its viability & future
expansion.
Sonalika Group intends to inject Rs. 1000 Crores in Himachal Pradesh over the next 2
-3 years in the upcoming ICML plant & ICML has an ambitious plan to play a major
role in the Indian Automobile Industry. International cars & motors ltd, car plant is
located in foothills of Shivalik Range and surrounded by natural greenery of
Himalayas at AMB (HP) a tax-free zone. The total area of plant is 93,000 Sq. M. out
of which 42,000 Sq. M. is covered area. Plant capacity is to produce 24000 cars in a
year.
Address:-Amb Distt. , Himachal Pradesh.{Tax Free Zone}
 INTERNATIONAL AUTOTRAC FINANCE LIMITED
International Autotrac Finance Limited is a non banking finance company
approved by RBI. IAFL provide finance to customers of International cars & motors
limited in rural & semi urban areas across India through customer friendly schemes.
Its parent company Sonalika Group ranks among the largest tractor & farm
equipment manufacturer in India
Business Plans of IAFL
First Phase: In the first phase, the area of operations will be in the state of Punjab,
Haryana, Jammu, H.P (Done).
Second Phase: In the second phase, the area of operations will be extended to other
parts of Northern India.
Third Phase: In the third phase, the area of operations will be extended to whole
India.

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 SONALIKA AGRO INDUSTRIES CORPORATION
Sonalika Agro was established in 1971 to support the Indian farmers with
mechanization technology to facilitate persistence of green revolution. Sonalika Agro
Industries Corporation, the group’s maiden venture is one of the foremost Farm
equipments and implements manufacturing companies in India with 80% share in
threshers alone. Its product line includes Combine Harvesters, Tractor/Self Driven
straw reapers, Potato Planters, Maize sheller cum Dehuskers, Seed Cum Fertilizers
Drills, various kinds of threshers, etc.; Sonalika Agro is a pioneer in manufacturing
tractors mounted combine harvester, which is not popular in India, but also in various
others countries across the globe. Today, the company is supporting the farmers with
world class farming equipment to ease the process of making the Green Revolution
II, a dream come true. In the light of the company's mission, highly qualified and
experienced staff is working as a family in the manufacturing facility at Hoshiarpur
(Pb).
 THE VARIOUS DEPARTMENTS OF ITL:
1. MATERIALS
2. Q. C.
3. PURCHASE -
4. STORE
5. FINANCE
6. PAINT SHOP
7. ASSEMBLY
8. HEAVY MACHINE SHOP
9. LIGHT MACHINE SHOP
10. ENGINE DIVISION
11. R & D

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 CERTIFICATIONS
 ISO – 9001:- ITL has got ISO-9001 quality system certified by International
Certification Ltd. It is for use when conformance to specified requirements is to be
assured by supplier during several stages which may include design, development,
production, installation & servicing.
Sonalika has arranged collaboration with French Renaults for technical know-how and
marketing. With the help of this collaboration SONALIKA will develop its own DI-740
Tractor engine which will help it to reduce its cost.
 ISO 14001:2004Environment ManagementSystem

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5 S FORMULAS:-
1. Seiri
2. Seiton
3. Seiso
4. Seiketsu
5. Shitsuke
S. NO. JAPANESE MEANING
WORD
1S SEIRI Sorting out, clearing, segregation, proper selection and remove the
Waste
2S SEITON Systematic arrangement, keeping things at proper place. A place
for everything and everything in its place.
3S SEISO Cleaning. Keep all the work place area, equipment clean
4S SEIKETSU Standardizing, environment, cleanliness. Light, noise, punctuality.
(Order and save time)
5S SHITSUKE Maintain discipline and standards To maintain above 4s,respect the
rules.

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 WHY 5 “S” LAY-OUT NECESSARY:
 For increasing the out-put of the existing products.
 For introduction of new product & diversification.
 For switching-over to technological advancements in machinery,
materials, Processes, product design, fuel & energy etc.
 For elimination of wastes.
 For environment, discipline and safety.
 FACTORS AFFECTING 5 “S” LAY-OUT (PITFALLS):
 Area, location
 Type of work
 Work environment
 Repairs & maintenance
 Changes in part drawing/ models.
 Management job is to continually improve the system in terms of design,
material, method, maintenance, machine capability and training etc

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 INTRODUCTION TO TRACTOR
A wheeled, self-propelled vehicle for hauling other vehicles or equipment and for
operating the towed implements; also, a crawler, which runs on an endless, self-laid
track and performs similar functions.
A farm tractor is a multipurpose power unit. It has a drawbar for drawing tillage tools
and a power takeoff device for driving implements or operating a belt pulley. The
acreage to be worked, type of crops grown, and the terrain all impose their requirements
on tractor design. Accordingly, models vary in such details as power generated, weight,
ground clearance, turning radius, and facilities for operating equipment. All models can,
however, be grouped under four general types: four-wheel, row-crop or high-wheel,
tricycle, and crawler.
Tractors are rated by their horsepower they deliver at the drawbar and at the belt. On
small models, the drawbar and belt horsepower may run as low as 10 (7.5 kW); on large
models the drawbar horsepower runs as high as 132 (98 kW), while belt horsepower
reaches about 144 (107 kW).
The major components are engine, clutch, and transmission. These components are
intimately related and designed to work in conjunction with each other to accomplish
specific work. Tractor engines are relatively low-speed; their maximum horsepower is
generated at crankshaft speeds in the neighborhood of 2000 rpm. These engines have
one, two, three, four, six, or eight cylinders and operate on gasoline, kerosene, liquid
petroleum gas, or diesel fuel. They are of the spark-ignition or diesel type, operating on
the four-stroke-cycle principle, and are cooled by water or air.
Power is transmitted to the rear wheels or to all four wheels. Drive to the front wheels is
mechanical or hydrostatic, its purpose being to increase drawbar pull at the will of the
operator. Transmissions have 3, 4, 5, 6, 8, 10, or 12 forward speeds and one or two
reverse gears. Clutch less hydraulic transmissions are also used, making it possible to
shift gears while in motion. Vehicle speeds are low, ranging from slightly more than 1
mi/h (1.6 km/s) to about 18 mi/h (28 km/h) in high gear.

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The basic design of an industrial tractor for hauling and for operating construction
equipment departs little from that of a farm tractor, and differences in design of models
fit the vehicle to its intended work. Because high ground clearance is not needed for
industrial work, the tractor is commonly built with a lower center of gravity and is
capable of traveling a few miles per hour faster than a farm tractor. If its use is confined
to hauling, it may not be equipped with hydraulic power. If it is to be used for operating
a scraper, backhoe, or front-end loader, its structure may be heavier and more rugged.
Process chart of tractor assembly line
Diff. Sub.
assy
Diff. Hsg.
Loading on
line
Trumpet
assy. Mtg.
Trumpet
Hsg. Assy.
Gear box
assy. Mtg.
Gear box
sub assy.
Rear cover
assy Mtg.
Rear cover
assy.
Oil
filling
Engine assy
& related
component
Engine
assy Mtg.Front axle
assy. Mtg.
Front axle &
related
components
Chasis
washing
Dry-up
zone
Primer
zone

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Tractor assembly shop
Tractor assembly shop is main shop of ITL. In this shop the different machined parts,
housing and other components which are 'finished or machined in other departments of
the industry and other component which are purchased from vendors are assembled here.
Then assembled components like differential housing, gearbox, rear cover, Trumpet
housing and other housing are send to main line for Tractor assembly. In main Tractor
assembly line tractors are send to paint shop through overhead endless chain rotating
conveyor. It is supported from ceiling and has a fixed path to travel which saves valuable
floor space. The arrangement is such that lifting mechanism (with help of hook) lowers
down for loading and unloading of tractors.
Following are main phase of assembly:
1) Differential housing assembly
2) Gearbox assembly
3) Rear cover assembly
4) Main line assembly phase
5) Paint phase
6) Assembly of accessories and inspection

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 DIFFERENTIAL HOUSING LINE
Differential is rear part of the tractor chassis. The main function of differential in tractor
to supply the power from gearbox to the wheels, it also helps to turn the tractor with the
wheels at different speed. It also helps to reduce the speed. The reduction of speed is
done in two stages.
First stage reduction in tail pinion and crown wheel meshing and second stage
reduction in bull gear meshing with left and rights B.P.shaft. It also consists of the
P.T.O. shaft (Power take off shaft), which is used to run the thrashers, pumps and
other accessory components with the help of pulley attached on it.

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PPrroocceessss cchhaarrtt ooff ddiiffffeerreennttiiaall aasssseemmbbllyy
Clean the casting &
punch the serial no. On
the casting
Load the casting on
the working trolley
Fit the drain plugs
with the washer &
tight it.
Fit the P.T.O.
shaft in the
casting
P.T.O. shaft sub
assy.
Wash the cage & B.P.
shaft sub assy. In
washing machine
Cage & B.P. shaft
sub assy.
Fitthe thrust bearing
cone on the left side
of casting
Insertthe leftB.P.shafton the left side of
casting& cage & insertthe right B.P. shaft
intothe cage fromthe rightside of casting
with little hammering
Cage & B.P. shaft assy.
Fit the seal carrier on
B.P. shaft with shim
(0.2-0.5mm) &tight it
temporary
Preloading(12kg) is
done to check the
No. Of shim &
bearing setting
Fit the T.P. carrier
with shim (0.2-
0.5mm) & tight it
temporary.
Apply yellow paint to
check backlash &
setting of teeth
If backlash is more than
0.3mm move shim from
right to left
If backlash is less than
0.2mm move shim Rt.
to Lt.
Tight the seal
carrier & T.P.
carrier tightly
Fit the trumpet
assy & bull gear in
Diff. Housing.
Trumpet sub. Assy.
Fit the link plate
& P.T.O. shaft
cover.
Fit the Brake
housing on the
spline of B.P. shaft.
Brake housing sub
assy.
Oil filter & P.T.O
shifter sub assy.
Fit the plain cover
withoil filter&P.T.O.
shifter sub assy.
Fit the sliding
& fixed P.T.O.
gear
Fit the
angle
Fit the
rocker link
Bkt.
Fitthe
Chain

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Following are the main parts of differential housing: -
 Crown wheel.
 Tail pinion.
 Cage assembly. (With sun, planet gears and cross)
 P.T.O. shaft.
 B.P. shaft left.
 B.P. Shaft right.
 Bull gears.
 Bevel gears.
 Bearings
 Bearing cones.
 Brakes housing assembly (with disc etc)
 Shims
 Gaskets
 Fasteners
Assembly of the crown wheel: -
First of all components are washed with oil to remove the dirt particles. Cage is having
two dowel holes, in these holes dowels are tightened for accurate fitting of crown, so that
all other holes of cage and crown come into same line. The crown wheel is pressed with
hydraulic press and then tightened by bolts with lock washer. Then right bevel gear is
placed on the cage seat. The four planet gears are put on cross with washer and then this
assembly put in the cage. Then the left bevel gear is placed on the planet gear. Operator
o checks the motion of gears and does the manual inspection. Cage left is placed on left
side of right cage assembly and then tightens by bolts and washers.

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 Tail pinion assembly: -
First of all in tail pinion assembly, the cone for taper roller bearing is pressed with
hydraulic press. The bearing is heated before the fitting. Then the tail pinion is inserted
inside bearing. Different sized shims are also placed before the tightening of rear cover
of cage. Whole assembly is tightening by nuts and bolts.
 Rear axle assembly: -
In rear axle assembly of tractor the bolts are tight fitted in holes of hub. Where the rear
tire is tighten with their bolts to whole assembly. For tight fitting the hydraulic press is
used and 120- kg /cm2 forces is apply. Two bearing either side of trumpet housing are
tighten at their respective place of cone. The rear axle is passed through these two
bearing with seal in trumpet. The cover is used to cover the open side of trumpet housing
(hub side). The inner side bearing is lubricated with oil and outer bearing is lubricated
with grease.
 Brake housing assembly: -
This tractor having heavy duty self-energizing, water sealed disc brakes. The brakes
operate with spherical roller and ventilation pipe, which gives better cooling. The
ventilated results in reduction of about 30% in pad temperature. Brake housing cover
contain two disc made of asbestos base non-metallic substance. The maximum
temperature resistance is about 300 0 C. Between these two discs a cast iron plate is
fixed which contain spherical steel rollers and held by spring. When ever brake is
applied the spherical roller move or lift from there place in the plate and try to expand
the plate. During expansion of cast iron plate the discs are strongly mounted on B.P. left
and B.P. right shaft to stop the axle. It also has actuators and link with rubber seal.
 P.TO. shaft assembly: -
Two bearings are tightly fit on P.T.O. shaft at there proper placed with help of circlip
lock, which are provided on both side of the bearing. First of all the P.T.O. shaft
assembly is passed through rear P.T.O. hole of differential housing, then two cones one
on B.P. left and other on B.P. right shafts are inserted tightly. The B.P. left and right
shaft assemblies are placed through the hole in cage housing of differential. The seal
carrier with different size of shims is tightened by bolts on both side of differential
housing (right and left side). Then pre - loading test is done with 10 Kgf to rotate the
cage assembly. If pre - load force is increase the efficiency of taper bearing is decrease
due to over friction between cages of bearing, and if pre - load force is decreased then

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the efficiency of taper bearing also decrease due to less contact with cover cage of
bearing. Then tail pinion assembly is inserted into respective holes with shims and tail
pinion teeth meshed with crown wheel teeth.
Following three testing is done on crown wheel and tail pinion: -
1.) Back lash testing.
2.) Percentage of- contact.
3.) Pattern test
1) Backlash testing: -
This test is performed with help of plunger dial gauge. Backlash of crown wheel is not
more than 20 to 30 micron. If it is deviated from this value then packing is change on
either side (left or right) of cage of bearing housing. But the numbers of shims are never
changed. If backlash is more then 30 micron then shims from right side is removed and
shifted in to left side. If it is less then 20 micron then vice versa.
2) Percentage of contact: -
Pattern test and percentage contact test is done with help of yellow paint which is applied
on teeth of crown wheel. The crown wheel is then rotated with hand and percentage
contact and pattern of tail pinion is impressed on the teeth of wheel. The percentage of
contact is 60% to 70% required. It can be increase or decrease by using the shims by
fastening it on tail pinion carrier. When increase in number of shims the pattern goes
increase and vice versa. Tail pinion pre – loading is 8 kgf. and crown wheel pre -
loading is 12 kgf. Crown wheel run out is 0.05 - 0.1 mm and backlash is 0.2 - 0.3 mm.
The bull gears are tighten to trumpet housing assembly with lock nut and the whole
assembly of trumpet housing is also tightened by nuts on studs and on outer side of
differential housing. The P .T .O. shaft head cover is tightening on P .T .0. Shaft to
protect the outer teeth. The sliding gear and P.T.O. shifter rod assembly is mounted on
differential housing. Two filters are placed inside of differential housing and then whole
assembly of differential housing is sent to the main line.
By assembling the different devices we can from the differential.Differential that we
assemble on the line are different in there sizes. It depends upon what model which we
assembling. Every model has their specification.

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The different views of the differential are: -
Top view full assembly of differential PTO fixed & sliding
 GEAR BOX ASSEMBLY
In ITL it is the main shop. In these tractors the sliding mesh type gearbox are used for
transmission the power at various speed from engine to differential. It is the main
assembly between the engine and differential housing. An improvement was achieved in
the form of constant mesh gear used in gearbox, which gives better results in higher
mechanical efficiencies and lower noise level due to the use of helical gears instead of
straight spiral gears. It gives the tractor a top speed of 3O km / hr and a minimum speed
of 2 km / hr. There are 8 forward and 2 reverse gears with a high and low selection:
Gear Max. Speed
I-Low 2.25 km/hr
I-High 8.86 km/hr
II-Low 4.24 km/hr
II-High 16.76 km/hr
III-Low 6.45 km/hr
III-High 25.40 km/hr
IV-Low 8.85 km/hr
IV-High 28.75 km/hr
Reverse-Low 2.81 km/hr
Reverse-High 11.08 km/hr

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Following are the main components of Gearbox: -
(a) Input shaft assembly.
(b) Output shaft assembly.
(c) Lay shaft assembly.
(d) Intermediate shaft assembly.
(e) Actuator shaft assembly.
(f) Gears.
(g) Gear box housing.
(h) Shifter rods.
(i) Shifter forks.
(j)Bearings.
(k) Fasteners, gaskets and spacers.
(l) Planet gear and carrier assembly with internal gear.
 Clutch actuator assembly: -
C.A. assembly contains clutch actuator guide on which the bearing is tight fitted and
locked with circlip. Inner bush is placed and held with C.A. guider springs.
 Lay shaft assembly: -
The lay shaft is hollow shaft with splines on outer surface. One end of the lay shaft is
threaded (in case of single clutch) and tightened from front side of gearbox with a
hexagonal nut. The whole assembly consists of gear Z-45 (i.e. constant mesh gear with
input shaft gear) spacer 15mm, gear Z-36, gear Z-30, spacer 30mm, gear Z-25, spacer
15mm and bearing with circlip. The whole assembly is washed. In case of dual clutch,
model the drive shaft is placed through the hollow lay shaft. The drive shaft consists of
splines on one end and a gear (Z-45) on the other end. The gear constantly meshed with
the gear on intermediate shaft. The main function of lay shaft is to rotate fixed gear on it
from where we can get different speeds with the help of sliding gear on drive shaft.

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 Input shaft assembly: -
Input shaft consists of spiral gear on one end and splines on the other end. Splined part
is attached to clutch and geared part (Z-19) is attached the constant mesh gear of lay
shaft i.e. Z-45. Input shaft is put into the gearbox with the bearing, which is locked by
circlip.
 Output shaft assembly: -
Output shaft assembly is solid shaft with splines on outer surface. The shaft is placed in
to gearbox with both ends supported by bearings and locked by circlip. The back part of
shaft is projected out side the gearbox to give drive from it. The assembly of shaft
consists of gears 24, 31 and 34 gears. The sliding gear 34 is used for first and reverse
gear, sliding gear 31 is used for second gear and sliding gear 24 for third and fourth gear.
These gears are provided with grooves on one side to attach gear shifter fork.
 Internal gear assembly: -
On internal gear two dowels are inserted at their proper place and faceplate with thrust
plate is placed over dowels. The purpose of the dowels is to locate holes on the plate
with respect to internal gear. The planet carrier contains three planet gears, which are
fixed to carrier with, help of pins inserted through them. The planet gear and carrier
assembly is placed inside the internal gear them thrust plate and outer plate is placed and
tightened by nuts.
 Assembly of Gear box: -
First of all the gearbox is placed over the trolley which is continuously moving with the
help of the chain system. The idler gear is placed with their idler gear shaft in gearbox its
respective place. Then lay shaft assembly is inserted into the respective holes and
tightened from front side by hexagonal nut. After this input shaft is placed from front
side of the gearbox housing. Its Z-19 is meshed with C.M. Z-45 of lay shaft. Then the
output shaft assembly is placed into the gearbox where its one side is inserted into the
input shaft hole. For dual clutch models the intermediate shaft, which is hollow, placed
over the input shaft and its Z-21 gear is meshed with Z-43 of connecting shaft, which
placed through the hollow lay shaft. The internal gear assembly is tightened on the
outside of gearbox with output shaft. The four selector rods are placed in the holes with
spring-loaded ball. The gear selector forks are insel1ed in to the groove of sliding gears
and then tightened to the gear shifter rods with help of the bolts. The forth selector rod is
meant for low and high-speed selection. This rod is connected to the drive shaft, which is
placed into the internal gear. Then Z.F. cover bracket is placed over the upper side of the
gearbox. Z.F. cover plate is consists have the steering assembly and high, low speed
shifter assembly. Then whole assembled gearbox is send to the main line assembly

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The different views of gearbox are: -
(lay shaft) (Shifter forks)
(Intermediate shaft) (Front view of normal Model gearbox)
(Rear view) (Clutch disengage)

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The basic diagram of gearbox with the attachment with the differential is
show below: -

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 RREEAARR CCOOVVEERR AASSSSEEMMBBLLYY
Rear cover assembly is used to cover the differential housing. It contains lift control
system, which is hydraulically operated. Driver seat is fitted on the upper side of rear
cover. The response valve housing (R. V.), control valve, cylinder and other components
assembly fitted inner and outer side of rear cover assembly.
The main components are fitted in rear cover assembly
(a) Control valve assembly.
(b) R. V. housing assembly.
(c) Hydraulic cylinder and piston assembly with lift arm.
(d) Operating sector assembly.
(e) Sensor tube assembly.
(t) Gaskets, bolts, nuts
(g) Other components.
 Ram cylinder assembly: -
It contain cylinder for single lever with piston inserted in side the cylinder. The relief
valve assembly is mounted at top front of cylinder. The connecting rod is placed in
piston rear side ands one side is locked with ram arm assembly. A rock arm, spacer and
seals
Are placed. At the end of rock arm assembly lift arm assembly is placed on the splinted
and then locked with bolts on both side.
 R.V housing assembly:-
It contain the response valve which having different valves and components are placed at
their respective place. It contains one response valve, check valve and release valve.
Two dome nuts are placed at their respective place. It is also connected with control
valve through pipe housing. The knob is placed at top of response valve to close or open
the response valve as per requirements.

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 Control sector assembly: -
It contains the draft crank assembly, which is placed through the hollow position crank
assembly. Both these assembly are connected to their lever. The position crank assembly
is connected to black mark lever and draft crank assembly is connected to red mark
lever. All assembly is fastened with bolts, nuts, washer and locknuts.
 Coupler assembly: -
In coupler assembly a draft rod having a flange and position rod contains spring on it.
Draft rod assembly is connected to the draft lever and position rod to position lever
through the control valve. This assembly is fitted inside rear cover. First of all rear cover
is mounted on the moving trolley and light with bolts. The control sector assembly is
placed at there respecting place with actuator shaft and compiler assembly. A sensor tube
with bush is placed at rear side of rear cover. Then a ram cylinder assembly is mounted
inside rear cover. Response valve housing is placed out side rear cover, which is
connected to control value through pipes. All other components assembly is a placed
their respective place control value container three value i.e. Back measure value (3-
6kgf) unloading value and scroll value. When oil from pump goes into R.V. housing
through pipes, which is further connected, to the check value through inner hole of R. V.
housing and Backpressure value of control values. The opening pressure checks value is
9-12kgf and opening pressure of backpressure value is 6kgf. During un-operated position
the oil is continuously through the backpressure value of control valve. During operating
of position arm the unloading valve close the gallery of oil to back pressure valve. Thus
the pressure in R. V. housing built up which open the check valve at 9-12kgf. As this
position the oil goes in the ram cylinder, which, further operate the lift arm. For
requirement of any position lift, the knob of response value of R. V. housing is rotate
which cut off the supply of oil and the position of ram arm is got. Sensor tube is work in
field working during plugging with harrow and when harrow deeply dug in soil, which
over load the tractor. But to avoid deep digging of harrow in soil the draft is set at
required position through sensor tube. The rocker arm attached to sensor tube and
harrow link, which push the sensor tube inside and automatically control value control
oil supply.

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The top view views of the rear cover assembly:-
The basic component that describe in the figure are:-
(1) Rock shaft (4) Spool arrangement
(2) Ram cylinder (5) Relief & pressure valve
(3) Coupler assembly (6) Rear cover housing
The views of the part of rear cover assembly: -

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 LINE ASSEMBLY PHASE
In line phase assembly all the components are assembled together. Firstly the differential
housing assembly is put on moving trolley, which is connected to the conveyor. Then the
gearbox assembly is joined with help of bolts to differential housing and then accessories
mounting are joined. Two lower links (L T. and RT.) are joining with link plate. The
anchor chain attached with angle plate (with attached to diff. rear side) and lower side
attached with lower link hook. The lift rod upper and right leveling rod assembly is
attached with end of rear cover. Two straight bars are attached with trumpet housing and
lower side link for supporting. Rocker link is attached with angle plate rocker bar. The
rocker attached to the sensor tube of rear cover assembly. Then engine assembly is
attached to gearbox assembly with nuts and bolts. At front side of engine assembly the
front axle beam assembly is fitted. In axle beam assembly pivot pin is placed at their
hole with thrust washer and the front axle bracket is attached with axle beam Assembly
with nuts and bolts. Two king pin stub axle assembly (L T. and RT.) are placed in front
axle beam assembled with their steering arm (L T. and RT.) tie rod end (L T. and RT.),
tie rod assembly, steering arm, hub, and wheel rim front (L.T. and RT.) and other
components. Whole brake assembly fitted on tractor and connected with brake housing
through mechanical links. Then clutch assembly is placed at their place. All other
mounting and accessory are fitted on tractor then it is sent to paint shop through
overhead conveyor. Firstly tractor is washed and then paint on it. Whole assembly is
heated in oven Then tyres, electrical panel, wiring system, meters, other components,
accessory and mounting are placed at their proper place and then it send to testing
department for testing. The way we can work on the tractor on the assembly line is
shown below: -

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 PAINT PHASE
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 &
delivers it to this level. Shlugs is applied at the corner or we can say at the circumference
of the gearbox where engine is attached with studs & bolts. Shlugs works as gaskets or
seals & avoid the oil leakage and
water mixing in the engine
. Then the engine and chassis system, mounted on the conveyor system enter the
paint shop area,
where it is washed, dried and painted. The engine and chassis assembly after the paint
shop reach here, and gets fitted with following parts:
 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.
 Bucket.
 Clutch plates
 Alternator.
 Self starter.
 Fuel pump
 .Then the whole assembly is mounted over the conveyor, which takes that piece
to different chambers of washing, drying, premiering, baking, painting & again
baking.

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 ASSEMBLY OF ACCESSORIES AND INSPECTION
After painting the conveyor takes the assembled piece to the Dismounting stage
where different parts & components like tyres, radiator, dashboard, sheet metal
parts, seating, steering wheel, etc 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 itself to be worthy to be sold and 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
dispatched after Pre– dispatch inspection (PDI).

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CONCULSION
My training was the great experience. I had the pleasure to do the work
with one of the most reputed manufacturer in their field INTERNATIONAL
TRACTOR LIMITED. I received experience in private sector. It was a good
learning time during my training, as I was fortunate to be placed in the
department related to manufacturing. I feel training has given me
exposure to undergo projects in manufacturing field as well as help me a
lot to understand the company work culture, working with terms and much
more. In the end I will like to thank all people who helped me throughout
my training to enhance my experience. I also pay my regards to my
lecturers for their guidance during my training.

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BIBLIOGRAPHY
 www.sonalika .com
 Search Engines (Google and Yahoo)
 Sonalika Library material.
 “ Production Management” books

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APPENDIX:
 MUV – Multity Utility Vehicles
 SUV – Sports Utility Vehicles
 SCM – Supply Chain Management
 Brand name – Sign or Symbol for unique identification
 Forecasteddemand –Future demand
 ICML – International cars & Motors Ltd.
 IATFL-International Auto Track Finance Ltd

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