SONALIKA

MODIFICATIONS AND FITMENT OF HVAC CABIN IN SOLIS

NARROW TRACK 75

REPORT
SUBMITTED IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR
Six Month Industrial Training

at

INTERNATIONAL TRACTOR LIMITED, HOSHIARPUR

(from 01 June, 2016 to 6 September, 2016)

SUBMITTED BY

SAMEER JOSHI
Mechanical Engineering
131101
1311680

Mechanical Engineering Department

GURU NANAK DEV ENGINEERING COLLEGE
LUDHIANA, INDIA

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INTERNATIONAL TRACTOR LTD

1.1 SONALIKA GROUP INTRODUCTION

Sonalika Group is contributing to green revolution in India Since 1969. Initially it started with
Farm Equipments and Machinery. Brand name of the group products is "SONALIKA". Market
share in Farm Equipments is 80 % in India. Group turnover is 220 Million USD (INR 1000
Crores). Sonalika Group is one of the top five tractor manufacturers in India. Apart from
tractors its product line includes multi utility vehicles, three wheelers, engines , Hydraulic
Systems , Casting , Forging , Brake System , Automotive components manufacturing and
various farm equipments and implements. Sonalika group since the inception has tried to
understand customers need to be able to facilitate them with its value for money products. The
company has a state of art manufacturing facilities, spread in acres, located in the pollution free
suburbs of Punjab and Himachal Pradesh.

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THE COMPANYS BACKGROUND

Sonalika is also an environmentally responsible corporate citizen and has developed in-house,
the vehicle engines that confirm to Bharat II Norms. It is now in the process of developing the
Bharat III engines for its advanced products. No wonder Sonalika products have created a niche
for themselves not only in India but also in foreign markets including France, Zimbabwe and
many of the South - Asian Countries.
Sonalika Group started its journey of success during 1976 when foundation of small-scale unit
to fabricate and assemble Wheat Harvesting Machines (Thrashers) was laid. With the passage
of time this small initiative was taken by Mittal brothers in 1976 turned into a great success due
to the undulated efforts of its promoters and thousands of employees who worked unaltered
throughout. The great success provided further motivation ultimately resulting in setting up a
new plant in the name of International Tractors Limited for the production of tractors, the
demand and requirement of which was steadily growing at that time. The plant which set up at
Chak- Gujran (Hoshiarpur) is now spread over an area of 65 acres (approx.) Now Sonalika
group consists of 2 companies: International Tractors limited and INTERNATIONAL CARS
AND MOTORS LTD (ICML) where company is manufacturing MULTI UTILITY VEHICAL
(MUV) by the brand name of RHINO .

MISSION
International Tractors Ltd. offer quality product with distinctive features at reasonable price.
The company ensure better than the best after sale service for the satisfaction of the customer.
The firm is ranked as best in terms of its quality and production front. Company is exporting its
tractors to different Asian as well as African countries.

MEMORANDUM OF UNDERSTANDINGS
The Indian tractor market is dominated by low price, no frills, rugged, versatile and low to
medium powered tractors. Tractors have an integral part of farm mechanization and have a
crucial role to play in increasing productivity. In India 90% of the tractors are financed by bank
credits at concession rates. Availability of credit therefore, is the most crucial factor impacting
tractor demand.

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ITL has signed MoUs with various banks all over the country for tractor retail finance, which is
giving a special impetus to company. It has resulted in easy availability of loans to farmers
coupled with quick disposal of cases. The payment rotations have also become faster from the
dealers to the company, which helps cost cutting.

WORK CULTURE

The I.T.L. seeks to create a culture where each employee, vendor, and dealer feels himself
responsible and integral part of the enterprises. The work culture at I.T.L is open &
participative. Learning is encouraged in the company. Every member respects 5F formulas
1. Fast 2. Focused
3. Fair 4. Friendly.
5. Fun

This governs its approach to business and relationships within the organization. It has designed
its management structure in response to the needs of quick decision-making and operational
flexibility even through hierarchies and designation does exit. It is a highly informal
organization where communication moves in all direction, decision-making is quick and to a
large extent delegated

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1.2 OBJECTIVES OF COMPANY

The main objective of the company is to bring the latest technology of high quality and cost
advantage to its consumers. By having a strong r & d with help of its technological partner
Renault agriculture, the fully computerization manufacturing facility ensures a non-stop supply
of quality tractors.
Apart from the general objective every departments have their own objectives. Which are in
tune with the main objective of the company? In that sense the main objective of personnel
department is maximum utilization and development of the human resources available keeping
all the aspect of human being in view.
The personnel department of ITL, ensures the welfare of the employees at the maximum level,
and keeps morale of the company at high.

CORPORATE MISSION OF THE COMPANY

1. To achieve international standards of excellence in all aspects of agriculture and diversified
business with focus on customer delight through value of products and services and cost
reduction.
2. To maximize creation of wealthy value and satisfaction for the shareholders.

3. To attain leadership in developing, adopting and assimilating state of the art technology for
competitive advantage.

4. To provide technology and services through sustained research and development.

5. To faster a culture of participation and innovation for employees growth and conditions.
6. To cultivate high standards of business ethics and total quality management for a strong
corporate identity and brand quality.
7. To help enrich the quality of life of the community and preserve ecological balance and
heritage through a strong environment conscience.

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At present the company has a strong nationwide network of 528 dealers. The distribution in the
various states is

Andhra Pradesh 26
Assam 04
Bangladesh 01
Bihar 37
Gujarat 31
Haryana 37
Himachal Pradesh 04
Jammu & Kashmir 01
Karnataka 18
Kerala 01
Madhya Pradesh 68
Maharashtra 35
Mizoram 01
Nepal 09
Orissa 10
Punjab 48
Rajasthan 53
Tamil Nadu 25

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1. 3 VARIOUS MODELS OF TRACTORS

Fig. 1.1 SONALIKA DI 35 Fig. 1.2 SOLIS 75

Fig. 1.3 SONALIKA DI-750 Fig. 1.4 SONALIKA GT 26

Fig. 1.5 SONALIKA 45-RX Fig. 1.6 SOLIS 60

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1.4 DEPARTMENTS OF ITL AND THEIR H.O.Ds

DEPARTMENT IN-CHARGE

R&D - MR. ANISH DHEER

MATERIALS - MR. S. C. KHANNA

Q. C. - MR. N. C. KOHLI

PURCHASE - MR. PARVEEN SARDANA

STORE - MR. DALBIR S. BISHT

FINANCE - MR. RAJNEESH JAIN

EDP/SAP - MR. RAJNISH BEDI

PRODUCTION - MR. ASHOK KAPOOR

PAINT SHOP - MR. S.C.SHAMRA

ASSEMBLY - MR. SATWINDER SANGHA

HMS - MR. PARAMHANS SINGH

LMS - MR. ANIL VERMA

H.T. SHOP - MR.BIKRAM PATHANIA

REWORK - MR. SURINDER BHARDWAJ

ENGINE DIVISION - MR. K. C. MADA

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CHAPTER 2

TRAINING DEPARTMENT AT SONALIKA

THE BASIC DEPARTMENTS IN MOST OF THE INDUSTRIES ARE

R&D (Research and Development)

Assembly
Quality and Inspection
Engine shop
ME (Manufacturing Engineering) Department
Sales department
Marketing Department
Export Department

BRIEF STUDY OF DIFFERENT DEPARTMENTS

2.1 PRODUCTION

ITL has fully integrated and state of the art assembly facilitation for producing world class
tractors. Several productivity improvements in assembly line over the years have made it
possible to manufacture nearly 37000 tractors per Year. Automation of assembly line not only
increased production capacity, but also provided a quantum jump to the quality of assembled
tractors. ITL assembly line producing tractors in broad range from 20HP to 120HP with
effective planning of resources.

2.2 QUALITY, ASSEMBLY & TESTING

Hydraulic Test Rig Up to 1600Kg Lifting Capacity

Millipore Testing Equipment. Torque calibrator

Hydraulic presses

A unique 3-Stage oil filtration system having modern facility of centrifuge filtration

Batch type Special purpose machines (SPM) at various locations for washing of heavy
castings, components & subassemblies

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Pipe flushing machine for proper cleaning of hoses & pipes
Induction Heaters for controlled heating of bearings

STANDARD TESTING PROCEDURES FOR FINAL PRODUCT

Roller Testing
Field Testing
Road Testing

QUALITY ASSURANCE

THE ENTIRE EVOLUTION OF QUALITY IS CLASSIFIED INTO 4 PHASES

Inspection Phase

Quality Control Phase

Quality Assurance Phase

Total Quality Management Phase

EQUIPMENTS USED FOR QUALITY ASSURANCE

Profile Projector used for inspection of Critical Parameters e.g. Thread, Gear profiles etc.

3D Co-ordinate Measuring Machine(CMM)

Software Used For Measurement(CMM)-(Geometrical 3D measuring software) In this

software, we can calculate & store co-ordinate of component as per drawing specification as
well as Geometrical tolerances (Flatness, Concentricity, Parallelism & Positioning) with
Graphical Presentation. With help of Geopak Win generate a program of each component &
run in CNC mode, safe a time, generate presentable report as per requirement. Scanning is the
option in GEOPAK WIN, with that you record contours and surfaces, realize nominal actual
comparisons with contours, calculate geometrical elements at the contour after scanning &
import contours from external systems, respectively export them to systems (Auto cad, Ideas
for modeling purpose).

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2.3 Manufacturing Engineering (ME) Department

The R&D designs the parts and sends them to the vendor to develop the parts as per R&D
design. R&D sends the design details to the ME department. Here starts the role of the ME
department. ME makes assembly procedure by managing line processes and new design.

Vendor Department (VD) gives the parts to protoshop to assemble parts in presence of ME
representative to validate the sample & procedure as per assembly line point of view. ME
department has the authority to approve & reject these parts.

All the approvals are to be made in the protoshop. ME gives the GO ahead for production line.
ME, Production & plant quality validates jointly on the production line for new models or
samples. After all the fitments found OK on production line, GO ahead for regularization of
new model or sample is given jointly.

Other major functions of ME department include

Time Study
Line balancing
Tool design
Improvement of regular design

Therefore, ME department basically acts as the intermediate or the bridge between R&D
department and the production line.

MANUFACTRING
UNIT

GEAR HEAT
HEAVY LIGHT MACHINE
TREATMENT PRESS SHOP
MACHINE SHOP SHOP
SHOP

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2.3.1 Heavy Machine Shop:-

Fig. 2.1 Technicians Operating VMCs.

All the major components of Tractors are machined in HMS. These are

Crank Case.
Differential housing.
Gear Box Housing.
Clutch Housing.
Trumpet Housing.

This infrastructure is equipped with the advanced CNC Machining Centres, Special Purpose
and General Purpose Machines. All the components are thoroughly checked and inspected for
its Geometrical accuracy on the imported 3D Coordinate Measuring Machine.

2.3.2 Light Machine Shop: - It is a shop where manufacturing of sophisticated Control Valves
for high pressure (200 Bar) Tractor applications is done with Hardened (60HRC) Bush and
Spools for prolonged service life. This infrastructure have capabilities to Design, Develop and
Manufacture complete Hydraulic Assemblies for Tractor applications of Lift Capacity up to
3000 Kgs. and Flow rates up to 45 LPM.

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Fig. 2.2 Technician tightening bolts with Pneumatic Gun.

Components Manufactures in Light Machine Shop:-

Control Valve.
Composite Valve.
Feathering Valve.
Relief Valve.
Release Valve.
Hardened Alloy Steel Bush & Spool Assemblies.

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2.3.3 Gear Heat Treatement Shop:-

Fig. 2.3 Heat Treating of Spur Gear.

Having World Class manufacturing facilities to deliver best quality of transmission gears,
shafts & assemblies for automobile and tractor applications. The Facility delivers all types of
gears & shafts like Main Shafts, Lay shafts, Input Shafts, Synchromesh Gears, Gears with Dog
Teeth, Shifter Sleeves, Synchro Hubs & Cones.

2.3.4 Press Shop:-Stamping facility is equipped with Ultra-modern presses from

internationally renowned suppliers. This facility delivers all type of sheet metal components i.e.
Skin Panels, Inner panels, Floor Panels, Pillars, Reinforcements, Cross Members, Oil Pans,
Fuel tanks etc.

Fig. 2.4 Stamping Operation on 1200T Hydraulic Press.

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List of Various Presses used in the Press Shop:-

Presses:- QTY.

Hyd. Press 1200T with bolster size of 4x2.5 Mtrs. 1 Nos.

Hyd. Press 1200T with bolster size of 4x2.5 Mtrs. 1 Nos.

Mech. Press 630T with bolster size of 2.6x2 Mtrs. 1 Nos.

Mech. Press 400T with bolster size of 3.5x2 Mtrs. 2 Nos.

Mech. Press 400T with bolster size of 3.25x1 .8 Mtrs. 1 Nos.

Mech. Press 250T 1 Nos.

Mech. Press 100T 3 Nos.

Mech. Press 75T 5 Nos.

Mech. Press 20T 3 Nos.

Mech. Press 10T 1 Nos.

The Press shop also includes two Rapido 5 Axis Laser Cutting machine from M/S Prima (Italy)
with a travel of 3.5 X 1.7 x 0.8 Mtrs. and can cut thickness up to 5 mm. These are used to cut
sheet metal of specified sizes , end products being used for further processing i:e for Pressing.
There were also two Injection Moulding Machines used for making Wet air cleaner unit or
other plastic accessories.

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2.4 ASSEMBLY

2.4.1 Engine Assembly Line:-

Fig. 2.4 3-Cyilnder Diesel Engine Assembly.

The State of Art assembly line for Engines is one of the best lines fitted with high quality
automated slat conveyor system having various safeties and DC Multi Nut Runner systems on
the different stages which ensures consistent production. The diesel engines assembled here are
from 28 HP to 90 HP. The Main Engine Assembly facility Includes:-

The conveyor is fitted with 28 fixtures for mounting of all engine models with facility for
360 degree rotation for various assembly operations.
All Stages are equipped with DC Multi Nut Runners for optimized and consistent
production.
The Complete Shop is Air Pressurized to ensure dust free environment for the quality
production.

2.4.2 Tractor Assembly Line:-

Sonalika Group possesses two state of art assembly lines in India and two abroad. In India
assembly lines are situated at Punjab and Himachal Pradesh.

International Tractors Ltd. has tractor assembly line equipped with capacity of 80,000 tractors
and engines per year. The plant has in house facilities for producing transmission hydraulic
components and engines. To further enhance the quality of Tractors, Gears, Shafts and other
important components are manufacturers in house and are tested on high end testing facilities.
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Highlights of Assembly Facilitations:-

Automated conveyors.
Toe-in conveyors.
Slat conveyor.
Overhead conveyor.

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2.5 ENGINE TESTING

Engine testing is done for checking the performance of newly assembled engine to found out
any assemble fault, their H.P., leakage and other faults. Engine testing shop of the I.T.L. is
equipped with latest digital control equipments. The engine testing is done with help of turbine
(water) or hydro dynamometer. The hydro dynamometer are four in number so that four engine
is tested at a time. The shop is equipped with heavy-duty oil filter, which is used to clean the oil
from dust or other large particle. The shop has bush pump tester which is used to test the pump
if there are any fault. The engine power is measured on the bases of S.A.E. ratings. The society
of automobile engineers U.S.A has specified the method of measuring the power output of the
engine for standardized purpose. The engine is run without generator, air cleaner, cooling fan
etc. However standard circulating pump, fuel pump is fitted to the engine. The horsepower of
the engine is measured with dynamometer and measured values are then corrected for the
standard pressure, ampere and humidity condition prescribed.

2.5.1 PROCEDURE OF TESTING: -

Before starting the engine the lubricating oil is filled into the engine and then engine is
mounted on the fixture. The flywheel is directly attached to turbine through connecting shaft
and engine is started. The engine is made to run for three hours to check the engines leakage
and if there is any leakage then that fault is found out and again put into the testing and if again
there is any fault then that engine is rejected. After minute running the tappet clearance is
checked. Tappet clearance is to be kept .25.005. The clearance is necessary otherwise the
thermal expansion of valve will alter the opening of closing of valve angles. After that engine is
run at 2400 r p.m. m. for 2.30 hours and then the engine is run at various r.p.m. and loads to
calculate the power, b.h.p. and s.f.c. . If the engine is seen to emitting too much smoke than
smoke level is also checked.

2.5.2 POWER OUTPUT: -

The engine shop is having latest technology and all the information is available digitally. The
load can be increased or decreased r.p.m. or s.f.c. can be changed from within the electronic
cabin. Power test is done. on 2200 r.p.m. (Maximum r.p.m. of engine is 2400) where torque is

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rated and is indicated on digital meter. The alteration in r.p.m. is made by varying the load and
fuel supply is kept constant. The power is calculated as follows

POWER = (R.P.MTORQUE)/(7023.746) H.P.

If the power calculated from above formula comes lower than prescribed limit than usually fuel
timing is altered. The fuel timing is altered with the help of F.I. pump. Usually the engine is
tested on 18 Celsius advancement By revolving the pump away from engine the timing is
reduced and by revolving F.I.P. toward the engine the time is advanced. The advancement
usually lower down the power, so timing is reduced unto possible limit to increased the power.

S.F.C.: -

It is one of the most important parameter for engine comparing. It is defined as the ratio of
amount of kg of fuel used per hour by the engine to power produced by the engine.

S.F.C. = (297000) / (POWERTIME) Gm/B.H.P/Hr.

Constant = fuel gravity volume of oil (100 cc) time

0.825 100 3600 = 297000

2.5.3 TORQUE BACKUP TEST: -

It is capacity of engine for maximum load that after the engine r.p.m. Will decreased to zero.

TORQUE (backup) = {T (max) T (rated)} / {T (rated)} 100

T (rated) is displayed by meter on 2200 50 r.p.m. and

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T (max) is displayed by meter at 1500 + 100 r.p.m. T (max) is found by loss of r.p.m and
increased of torque. The engine is loaded till torque is max and after which the loaded cause
drop in torque.

2.5.4 PROCEDURE OF ENGINE TESTING

After complete assembly of engine ,Engine comes to testing shop for testing. In engine testing
firstly engine put on the testing bed and then flywheel of engine attach with the dynmo , fuel
supply , water supply and air cleaner. Now engine is ready for testing. Testing is done to test
the engine for various problems like oil leakage , RPM checking , torque , fuel consumption.

RUNNING TIME OF RPM LOAD%

ENGINE
(minutes)
5 700 NIL
10 1000 25
15 1500 50
10 1800 75

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2.6 ENGINE ASSEMBLY PROCEDURE

The assembly of engine is done in 14 stages that is described as below:

STAGE: 1
Washing of crankcase:-
i) Block is placed in a washing machine.
ii) Different nozzles are there in that washing machine.
iii) Water + chemical is sprayed for 15-20 min. Chemical used is COROSEAL -33. It is a
corrosion inhibitor, manufactured by Pratap Tex-chemPvt. Ltd. Pune
iv) Temp. range of washing machine is 45-60 degree C.
v) 2 Heaters are used to heat the water + chemical mixture.

STAGE:-2
1. Cleaning of crankcase--- After washing the crankcase is sent to second stage with the
help of roller belt. And then crank case is cleaned with the help of air pressure followed
by the rubbing of brush into the holes provided for the different components.

2. Tightening of plugsplugs are fitted on the crankcase.These plugs are provided to

stop the oil leakage from crankcase through the holes.

3. Loading of crankcase and air blowingCrankcase is loaded to the place of working,i:e

it is brought to the conveyer belt and fixed on the fixture with the help ofbolts.So that
further steps to be done.

4. Cylinder liner fitment: -Fitment of cylinder liner into the crankcase bymandreling and
hammering.The liners available in I.T.L.. are of three grades i.e. A, B & C grades. The
A grade liner has dimension of +12 microns, B grade has dimension of +24
microns and Cgrade has dimension of +36 microns. The cylinder lining has 2 seats
one is for oil and other is for water. The grade sign of liner should be kept toward
camshaft.

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5. Fitment of tappetsTappet is also known as cam follower. It is attached to the rocker
arm with the help of push rod, which opens the inlet and outlet valve.

STAGE:-3

Crankshaft Fitting: -Firstly Crank caps are opened with help of opener. Then on the first crank
cap BIG gear is fitted with help of mandreling and pressing .Bush type liner are inserted into
the bearing holes. The linear is provided with recess to store a minimum amount of oil, which
wets the crankshaft during starting of engine. The bearing cup is opened and crankshaft
assembly is placed into it. The bearing cup is tightened again with 10-12-kgm torques and
crankshaft is checked, that it is revolving easily.

STAGE: -4
Cam shaft fitting:-

The camshaft is inserted into the camshaft hole with be-baring and bolt ends are locked by
circlip. The crankshaft is forged from alloy steel or cast from hardened cast iron and is case
hardened. The tap-pet used on cams is of spherical base and are slightly wear pattern preve-
nting edge loading which is major cause of failure. The one end of camshaft is provided with
gear, which is linked with idler gear Z-50. for exact-ct timing the camshaft gear mark is
matched with mark on ideal gear. Another gear is attached with idler gear, which serve the
purpose of driving the fuel injection pump.

Timing gear fitting: -

The idler gear shaft is pushed into the crankcase and roller type bearing with lock is inserted
into the shaft. The idler timing gear is then pressed into the bearing. The timing gear is punched
at two places and punched sign has to be matched with the punched mark on crankshaft.

STAGE:-5

Piston Assembly fitting: -

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The piston assembly is fitted into the linear and big end is tightened to the crankshaft with 8-10
kgm torque. The pistons are also grade as A, B, C has same that Agrade line is fitted with A-
grade piston assembly. the grade mark should be towards camshaft. The piston ring cuts should
be so adjusted that there should not be in same line.

STAGE: -6
Lubricating oil pump mounting: -
The lubrication oil pumps connected to crank shaft gear by an idler gear of 2-3 degree. The
crankshaft gear and pump gear are of 22 teeths each. The pump is provided with a relief valve
that opens at 4 kgf forces. In case there is over loading or some thing injected in main oil
gallery then pressure is released from this valve.

STAGE:-7
Rear cover and Front cover fitment: - The rear cover and front covers are cleaned properly with
air and then fitted to engine with seals in between. Main function of front cover is to cover the
timing gears and to prevent the oil leakage from crank case. Rear cover is fitted to cover the
rear side of crank shaft and to stop the oil leakage from crank case.

STAGE:- 8
Pulley mountingPulley is mounted onto the crankshaft with the help of mandrel.
Function of this pulley is to drive the alternator, water pump and fan.

Cylinder head mounting: - The cylinder head assembly is placed on the piston and studs
are passed through its. If the height of piston at T.D.C. from the surface is more than
0.1mm than the gaskets of given thickness are used. If it is 0.1mmto 0.5mm than 1.2mm
thick gasket is used If it is 0.5mm to 0.8mm than 1.5mm thick gasket is used. cylinder
head nuts are tightened by 21 kgm forces.

STAGE: -9

Flywheel mounting: - The flywheel is mounted the crankshaft and bolts are tightened with 8-9
kgm force. The F.I. pump is connected to the F.I.P. gear through theF.I.P. drive shaft. The
F.I.P. drive shaft is special desig-ned to advance the timing of injection. The both ends of F.I.P.
drive shaft is provided with spline on one side a key is provide which is locked to timing gear
and recess on other side is pushed into the the F.I.pump slots. The angle between the key and
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recess is of 18 degree. Thus the fuel injection is advanced by 18 degree. F.I.pump slots. The angle
between the key and recess is of 18 degree. Thus the fuel injection is advanced by 18 degree.
Oil pan fitment and disk plug fitmentOil pan covers the bottom end of crankcase and
preserve the lubricant oil .It also acts as a container for impurities and unwanted material.

STAGE: -10
Fitment of push rod and Rocker Arm
It attaches rocker arm and tappet . Its main function is that when cam shaft lift the tappet and
tappet lifts the push rod. After that push rod pushes the rocker arm from the back and the valve
is open. The rocker arms with spherical followers are inserted into galleries and connected to
the rockers arm. To compensate for thermal expansion the gap between inlet rocker arm and
valve is adjusted to 0.3mm. The gap between exhaust valve and exhaust rocker arm is 0.4mm.

STAGE: -11
Water body fitment: - The water body is mounted with thermostat control valve. The valves
open at 70 Celsius. Thus engine is kept at correct temperature. The pulley is mounted on
crankshaft. Water return line exhaust flange and inlet manifold mounting.

STAGE: -12
Fitment of valve cover and alternatorFitment of valve is present just to cover the rocker
arm. Fitment of alternator is done to convert mechanical energy into electrical energy and that
electrical is used to charge the battery.

STAGE: -13
Fuel injection pump mounting and set fuel injection pump.
The gear of F.I.P. is first of all meshed with the F.I.P. drive shaft (with recess) and is loosely
tightened. To set the timing of gear first of all pointer is tighten on the crankcase and flywheel
is rotated which is mashed for (6, 18, 20 & 24) angles. The pointer is set at 18 degree of
flywheel and then the pump is rotated clockwise till the oil from first nozzles stop out flowing.
At this position a cut mark is made on both the pump and crankcase for future settings. The
pump is tightened properly and pipes are tightened over nozzles and injectors.

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Fitment of oil filterFitment of oil filter done to filter the oil which is circulated to
crankcase.It takes oil from lubricate pump and then move this oil to the oil gallery.

STAGE: -14
Fitment of Fuel filter and Self Starter - After removing the engine from conveyer belt to
roller belt. Before removing the engine from conveyer belt the base plate, filters and other
accessories are properly tightened. The main function of fuel filter is tofilter the fuel.Fuel
coming from fuel tank goes to primary filter, then it moves to fuel filter. Then its filtered and
moves to main line of FIP.

2.7 RESEARCH AND DEVELOPMENT CENTRE

Sonalika is equipped with Research & Development Centre which has on board more than 300
specialist engineers and most updated technology to provide customized solutions to our
customers. It manufactures products which have been thoroughly designed and tested by the
R&D personnel.

The main thrust of the R&D function is to accelerate innovation and maximize the value of
each product designed to provide economic benefit to customers at large. The highly skilled
and experienced man power develop products ranging from 20-110HP catering to both
domestic and international markets. The products undergo through multiple check points for
quality assurance before they go for production. They have been recognized both nationally and
internationally.

Situated at Hoshiarpur, Punjab, Sonalika ITLs R&D department has an in-house testing
facility for all the parts to ensure 100% quality. Equipped with the most updated technology it
provides solutions by creating a real time situation to understand the problem. And, then taking
into account other factors like the terrain and geography in which it is used, the product is
redesigned to suit the customers specific needs. Further, the R&D department works in
coordination with the production department to ensure smooth transition of technology from
design department to assembly line production.

Sonalika ITLs strength lies in manufacturing products which are a result of the efficient
designing and testing by its state of art R&D center. It has 3 sub departments which function in
full co-ordination to achieve the best possible standards.
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R&D Centre

Design Prototype Testing

2.7.1 Design Facilities:-

Ideas Nx & CATIA Software

Product Design Package + Surfacing Set
Power Mill 3-Axis CAM software
Ideas to UG Software
Metaphase
Auto CAD
CAE Software for Analysis of Design.
Team Center module being used in management techniques

2.7.2 Prototype Facilities:-

The designs thus produced are actually manufactured in the Proto Shop which is
equipped with the Following:-
Horizontal Machining Centre HMC-500m
Vertical Machining Centre VMC-600m

2.6.3 Testing Facilities:-

Transmission Test beds

Testing Rigs
MGR Test Track.
DAQ( Data Acquisition).
Field Testing

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2.6.4 OTHER FACILITIES

Inspection and Metallurgical Facilities with Well-equipped standard room having

computerized Lead & Profile Testers, Surface Roughness Testers, Contour Testers

and Gear Roll Testers etc.

Metallurgical laboratory equipped with the LECO Glow Discharge Spectrometer,

LECO Micro hardness Tester, Microscopes with the Image Analyzer, Universal Testing

Machines, Vickers, Rockwell, Brinell& Super facial Hardness Testers.

Mechanical and Chemical composition tester.

Universal Tensile Tester.

Destructive / Non Destructive Testing for welding joints.

3-D Co-ordinate Measuring Machine.

Leakage testing Machine.

Oil pump test rig.

Oil contamination testing.

Test cells with hydraulic dynamometers for 100% Engine Testing.

Emission test cell for conducting emission measurement Installed by AVL, imported

from AVL Austria.

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CHAPTER 3
RESEARCH AND DEVELOPMENT CENTER
Under the assistance of Testing Head Mr. Dina Haran we were told to work under Mr. Parmod
Singh, Manager of DAQ lab.

He gave us exposure to the DAQ lab (Data Acquisition), to basically what actually is done
under this lab, which broadly divides it into 2 sets that is Loading and vibration testing. It
consists:-

1. Electro Dynamic Shaker.

2. Fatigue Rig (Endurance testing under Static & Cyclic Loading).

3. Accelerometers (Single axis & Tri axis).

4. Strain gauges.

3.1 INTRODUCTION TO DAQ

Data acquisition is the process of sampling signals that measure real world physical conditions
and converting the resulting samples into digital numeric values that can be manipulated by a
computer. Data acquisition systems, abbreviated by the acronyms DAS or DAQ, typically
convert analog waveforms into digital values for processing. The components of data
acquisition systems include:

Sensors, to convert physical parameters to electrical signals.

Signal conditioning circuitry, to convert sensor signals into a form that can be converted
to digital values.
Analog-to-digital converters, to convert conditioned sensor signals to digital values.

There are also open-source software packages providing all the necessary tools to acquire data
from different hardware equipment. These tools come from the scientific community where
complex experiment requires fast, flexible and adaptable software. Those packages are usually
custom fit but more general DAQ package like the Maximum Integrated Data Acquisition
System can be easily tailored and is used in several physics experiments worldwide or with the
help of instruments likeIMCs and LMSs
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Before conducting these test some reference value or we can say field value is required which
is provided by FLDAs (field load data analysis) road simulation or by CAE analysis. In DAQ
lab we are familiar with IMC and LMS for collecting data with accelerometers, different type
of sensors, Instruments and Strain gauges.

3.2 IMC:-

Fig. 3.1 IMC

The IMC CRONOScompact is the single most comprehensive data acquisition system for
electromechanical testing on the market today. Integrating measurement, control and simulation
into one housing provides you with ther eliability of absolute synchronization, and the
convenience and ease of use of having all of your tools in one place.

Whether you are measuring highly dynamic vibrations beyond the audio range, using multiple
PID control loops for test stand automation, or monitoring process signals and fieldbus data
throughout an entire test cell, IMC CRONOScompact is there for you. From high voltage to
current fed, and strain gauges to thermocouples, the integrated signal conditioning of IMC
CRONOScompact also ensures every sensor you need is compatible. At a glance:-

Portable and rack-mounted enclosure options.

Modular reconfigurable hardware adaptable to changing testing requirements.
Supports virtually any physical sensor.
Sophisticated and intuitive triggering system.
Versatile storage options including onboard removable flash media.
Networkable with other IMC systems for synchronous acquisition of thousands of
channels.
Onboard real-time data analysis and reduction.
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Standalone, remote or interactive operation.
Configuration and operation software included.

3.3 LMS:-

Fig. 3.2 LMS

Fig. 3.3 Vibrational Data

recording with LMS

The LMS SCADAS suite of data acquisition systems delivers the data quality and format that
you require for all types of noise, vibration and durability measurements in the laboratory or in
the field. Depending on your needs, you can use a LMS SCADAS system as an autonomous
recorder or as a frontend connected to a personal computer. Seamless integration with LMS
Test. Lab and LMS Test. Xpress software helps you accelerate measurement setups and
delivers correctly formatted results. LMS SCADAS provides you with best-in-class data
acquisition for reliable results and optimal testing productivity.

LMS SCADAS data acquisition systems cover a broad range of engineering applications for all
kinds of manufacturing industries and help you develop better products in a shorter timeframe.
Some of them are listed as under:-

Added Flexibility with Lab Mobility.

On-demand Channel and Signal Conditioning.
Simplified Test Setups.
Top Performing Growth Investment.
Superior Data Quality for Effective Testing.
Optimized Investment and Reliability.

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The Quality Leader in Data Acquisition Systems.
After conducting all these tests or simulations or on the basis of customer complaints and field
failures or according to new design improvements, parts are tested on testing machines or by
gauging. Objective of gauging is to study dynamic stress analysis of tractor or component with
implement for different agricultural operations.

3.4 ACCELEROMETERS:-

Piezoelectric accelerometers offer tremendous versatility for shock and vibration

measurements. These rugged sensors can withstand adverse environmental conditions. A wide
variety of configurations are available to support multiple application requirements. Specialty
units are also available through mechanical or electrical design modifications or additional
qualification testing.

There are two broad categories for piezoelectric accelerometers those that contain built-in
signal conditioning electronics (ICP type, voltage mode) and those that do not (Charge
Mode). Generally, ICP accelerometers are preferred, due to ease of use, easier data system
calibration setup, and lower system cost. ICP accelerometers typically come in one of two
sensitivities: 10 mV/g (+/- 500 g) or 100 mV/g (+/- 50 g) ranges. Charge Output accelerometers
are typically used in high temperature environments, which would otherwise destroy the
electrical components in an ICP type accelerometer.

3.4.1 Single Axis Accelerometers:- Motion of a rigid body can be characterized within six
degrees of freedom. Providing mechanical excitation to simulate this motion as may be
encountered in the real world can entail a variety of test machines. There are various
pound/force vibration shakers for structural testing. Regardless of the apparatus, the goal is
always to ensure that the product under test can adequately perform, and reliably survive, in the
environment in which it will be deployed, or to which it will be exposed during transport.
PCB accelerometers provide the measurement signals needed to control the vibratory input
and to analyse the products reaction to such testing. Did the test achieve the acceleration
amplitudes and frequencies desired? Did the product react in a consistent manner? Did any
components or mounting techniques become altered? These are just a few of the questions that
can be verified by analysing the signals generated by PCB accelerometers.

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Fig. 3.4 Uni-Accelerometer pasted on Foot Rest of a Tractor.

3.4.2 Triaxial Accelerometers:- It offer simultaneous measurements in three orthogonal

directions permitting the entire vibration being experienced by a structure to be analysed. Each
unit incorporates three separate sensing elements that are oriented at right angles with respect to
each other. Each direction (axis) is considered an individual channel by the data system. Multi-
pin electrical connectors, individual cable leads, or multiple coaxial connectors provide the
signal outputs for the x, y, and z-axis acceleration.
The use of Triaxial accelerometers has gained popularity since the desire for in-depth structural
vibration analysis has increased and multi-channel data acquisition costs have declined. These
devices are vital tools for structural analysis testing requirements. Manufacturers perform this
analysis during product development, engineering studies, troubleshooting, and product use
validation.

Fig. 3.5 Tri-Accelerometers (with bakelite base) on Left

&Right side Brake Pedal
Fig. 3.6 Tri-Accelerometer
( with bakelite base) on
Silencer.

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3.5 Electro Dynamic Shaker:-

3.5.1 Introduction to ED Shaker:- Vibration

testing is done to introduce a forcing function
into a structure, usually with the use of a
vibration test shaker or vibration testing
machine. These induced vibrations, vibration
tests, or shaker tests are used in the laboratory
or production floor for a variety of things,
including qualifying products during design,
meeting standards, regulatory qualifications
(e.g. MIL-STD 810, etc.), and fatigue testing,
screening products, and evaluating
performance.
Most often electro dynamic and servo
hydraulic shakers are used, depending on
Fig. 3.11 Electro Dynamic Shaker with Silencer
the frequency range and displacement mounted in Z Direction.
required. Data Physics, incorporating a
long history of Ling Electronics
technology, produces industry standard electro dynamic vibration and shaker equipment for
vibration tests, vibration testing and shaker testing. Data Physics is a turnkey supplier of
vibration test systems from electro dynamic shakers to intuitive and advanced vibration
controllers.
Electrodynamic (ED) shakers are well suited for most vibration tests and offer several
advantages over alternative approaches. Compared to hydraulic shakers, ED shakers are
capable of much higher frequencies. These high frequencies can be very important in
testing electronics and electronic assemblies. ED shakers are also capable of reproducing a
wide range of shock and SRS pulses in addition to general vibration testing. Lastly, ED
shaker have very linear behaviour, so controlling the vibration test may be easier or
possible when not otherwise possible.
Data Physics vibration test equipment provides a full range of shock and vibration testing
that includes force generation, control, and measurement. Many advanced features are
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incorporated in both the hardware and software to provide state-of-the-art solutions for
shock and vibration testing.

Fig. 3.12 Uni &Tri accelerometers Caliberation using ED Shaker.

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 System Characteristics:- SONALIKA

Armature Diameter 360 mm.

Sine Force (peak) 3000 kgf (6600 lbf, 30 kN).

Random Force (rms) 3000 kgf (6600 lbf, 30 kN).

Shock Force (rms) 6000 kgf (13200 lbf, 60 kN)

Acceleration (sine) 85 g.

Velocity (sine peak) 1.8 m/sec.

Displacement (pk-pk) 51 mm (2 in).

Axial Resonance (5%) 2600 Hz.

Useful Frequency Range DC to 2800 Hz..

Mains Input Over & Under Voltage, Over Current, Loss of

Input Phase, Over Temperature Amplifier & Shaker, Field

Protection Interlocks
Fail, Cooling, User Safety Interlock if specifically required

by the customer.

System complies and marks to the international safety

Safety Compliance
requirements w.r.t. CE and CSA.

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3.6 Fatigue Rig:-

It is a Hydraulic Static and Cyclic Loading machine manufactured by MTS company, used to

check the endurance of various loading parts for example axles, universal joints, Brackets etc.

hydraulic actuators and piston apply load in one direction as in static loading and in 2 directions

as in cyclic loading to find the maximum load in kgf it can withstand without breaking .whole

system is Software control.

Suitable fixtures are made to hold the testing components rigidly on the Bed (Bed having T-

slots cut all along the length). Various Sensors are mounted on the piston to check Fluid

Pressure, axial displacement like LVDT &RVDT, plus Servo motor valves to control and

maintain flow.

Fig. 3.17 Front Axle Bracket(FAB) testing under Cyclic loading on Actuator1.

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Fig. 3.18 Differential Sun &Planet gear testing under Static Loading on Actuator2.

Fig. 3.19 Fixture to hold the Front axle tightely on bed while under testing.

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CHAPTER 4
PROJECTS

MODIFICATIONS AND FITMENT OF HVAC CABIN IN SOLIS

NARROW TRACK 75.

4.1 PROBLEM FORMULATION

SONALIKA, being one of the pioneer in tractor industry today, There is an urge to produce new
variants and models to remain as a strong contender in the market. As the industries are
exaggerating every minute, we come across some eye-popping inventions every now and then.
Furthermore, SONALIKA have various joint ventures and projects with worlds some great tractor
companies such as with TURKEY and JAPAN etcetera.

One such modification was required in SOLIS NARROW TRACK 75 which being one of its
kind did not have AC cabin till date. Moreover, it was a part of SONALIKAS joint venture
with TURKEY to develop a new variant.

Besides this, INDIA who houses agriculture as a major ingredient in its GDP needs renovation.
Farmers who plough their lands for almost 6-8 hours a day have their faces covered with dust and
sweat. With the addition of HVAC (Heating, Ventilation, Air condition) in tractors, farmers can
work in their fields for more than 15 hours per day as compared to the earlier used to. With extreme
weather conditions of high temperature in summers and minus degree temperature in winter these
tractors are assent to the farmers, thus ensuring the cabin is climate controlled for all season
comforts.

4.2 MAJOR MODIFICATIONS

1. CABIN

HVAC tractors comes along with an embedded glass chamber such that even incursion of air
cant take place. These are designed by keeping in mind the comfort level required nowadays
and the harsh and severe temperature to which farmers come across in their field work.

2. ROPS (ROLL OVER PROTECTION STRUCTURE)

It was removed as there was no need of having ROPS in AC Cabin.

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3. HANDLES

These were re- positioned according to the Cabins placement.

5. FLOOR REST SIZE.

Basically, tractors have 450 mm X 300 mm floor rest size .But this was reduced by 50mm in
length.

6. CUSHIONING.

Cushioning is an integral part of a HVAC tractors. Thus, proper selection of material For
cushioning is very vital as it can lead to infiltration of outside air into the cabin and hinder its
performance.

7. LEVERS

In case of HVAC tractors, levers such as gear shift levers, hand brake levers, parking brake
lever etcetera are considerably smaller in size and are compact in design to aid the cabin.so, and
these were altered too.

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4.3 CABIN

PARTS OF CABIN

REAR LIGHTS 2
FRONT LIGHTS 2
FRONT GLASS 1
SIDE GLASS 2
REAR GLASS 1
GAS SPRINGS 6
LOCK HANDLES 3
FRONT GLASS WIPERS 2
SUN WISER 1
SPEAKERS 1
CABIN OVER HEAD LIGHTS 1
AIR OUTLET DUCT 2
AIR TEMPERATURE SELECTOR 1
DRIVER SEAT 1
SEAT BELT. 1
HOOK 2
FLOOR MATS 2

Fig 6.1 Verim AC cabin

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4.4 SPECIFICATIONS OF CABIN PARTS

SERIAL NUMBER : 1008546AA

REAR GLASS : FR GLASS (HS TEMPERED)

FRONT GLASS : FR GLASS (HS TEMPERED)

SIDE GLASS : FR GLASS (STARGLASS)

SIDE VIEW MIRROR : E9 024077

GAS SPRINGS : MAUSER

Lock handles : CD

Front glass wiper : DOGA

SUN WISER : ITI INDUSTRIALE (MANUFACTURER)

GAS SPRINGS : SAM O MATIC (TURKISH MANUFACTURER)

CABIN STRUCTURE AND MOUNTING

TYPE : VRMO5

EC APPROVAL : C11;2009/752009/75307700

MANUFACTURER : VERIM KABIN VE TARIM MAK SAM(TURKEY).

SERIAL NO : 2015-1322

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TYPE OF TRACTORS FOR WHICH CABIN IS INTENDED
SOLIS 60N

SOLIS 75N

SOLIS 90N

4.5 ASSEMBLY PROCEDURE

Initially ,the tractor was lifted from its position with the help of overhauling cranes having
motors of HP. Tires were dismantled and cranes and were used to kept the tractor in balance.

THE VARIOUS PROCESSES THEN FOLLOWED WERE

STEERING WHEEL & DRIVER

SEAT REMOVAL
FLOOR REST AND ROPS CUT
OFF
FENDERS REMOVED

INSTALLATION OF CABIN

CUSHIONING

Fig 4.2 Flowchart of Assembly Procedure.

1. STEERING WHEEL & DRIVER SEAT REMOVAL

Firstly, the drivers seat and steering wheels were removed. The reasons they being removed
were

a) Smaller and compact utilities are used in case of HVAC tractors.

b) They can pose as a hindrance to the foremen working.

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2. FLOOR REST AND ROPS CUT OFF

Normally, the tractors which are available in the market are bigger in size but these HVAC are
compact yet more efficient.

Floor rest size in particularly in case of basic tractors are of 450mm X 300mm in dimensions
and there is no need of ROPS in HVAC tractors.

However, the floor base was cut off of length 50mm intently to make floor base size as per the
requirements specified.

All the process of cutting took place in MOCKUP department and after cutting it was allowed
to cool down for 3 4 hours. Moreover, some other parts were removed too such as Bush
Holders.

Fig 4.3 Floor Base

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EQUIPMENTS USED FOR CUTTING

Gas Welding : Oxygen Acetylene Welding

Grinder

SPECIFICATIONS OF NUTS & BOLTS

(4) M10 Nuts & Bolts were used for FLOOR REST 3 M10 Nuts & Bolts were used for SIDE
FLOOR

(3)M10 Nuts & Bolts were used for CENTRAL FLOOR

4. DRILLING

One of the main process involved in this whole mechanism was drilling holes for the proper
placement of the cabin in its pre designed locations which were made using drilling machine.

SPECIFICATIONS OF DRILLING PROCESS

PARTS HOLES DRILLED

FLOOR REST 4

DASHBOARD 5

FRONT LIGHTS 4

REAR LIGHTS 4

SHEET COVER 15

MOUNTING COVER 12

FENDERS 8

5. CABIN INSTALLATION
After all the drilling process, cabin was lifted using overhauling cranes and was moved charily with
utmost care so that it fits the calculated positions and desired holes. After being placed on the
tractor, it was checked by the cabin whether it meets the requirements or not .and then the
fitting process begins.
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NUTS AND BOLTS USED FOR FITTMENT PROCESS

M6 Nuts & Bolts were used for FRONT LIGHTS

4 M6 Nuts & Bolts were used for REAR LIGHTS.
15 M4 Nuts & Bolts were used for SHEET COVER.
6 M2 Nuts & Bolts were used for DASHBOARD.
12 M8 Nuts & Bolts were used for MOUNTING COVER.

6. ELECTRIC CIRCUITS
After all the necessary work, all the various electric circuit were brought back to life by
connecting them to their respective equipments.

PARTS WHICH WERE ELECTRICALLY COUPLED

REAR LIGHTS
FRONT LIGHTS
SPEAKERS
DC OUTPUT
AIR TEMPERATURE SELECTOR
AIR OUTLET DUCT
FRONT INDICATOR LIGHTS
CABIN OVERHEAD LIGHTS.

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TROUBLESHOOTING DURING ENGINE ASSEMBLY

OIL LEAKAGE FROM OIL PAN

REASON:

1 Oil leakage from oil pan drain plug.

2 Oil pan socket welded area damage.

ANALYSISOil leakage from oil pan drain plug due to damage of threads due to excess
torquing and due to more torque socket area also damage. And this causes oil leakage from
specified area. Oil pan is provided with drain plug to drain the lubricant oil from engine .Due to
thread damaging of drain plug, oil leakes from engine through the oil pan drain plug .Oil pan or
sump forms the bottom half of the crankcase. It is attached to the crankcase through set screws
and with a gasket to make the joint leak proof.

Suggestion-

1. If the screw is tightened up to appropriate torque of 3.5kgf; it will result in complete mating
of screw and hence no leakage will occur.

2. Avoiding cross tightening of the screw will also decrease the leakage because zero cross
tightening will result in complete mating of screw leaving no passage for leakage.

Sound in Engines

Causes:-

1. Timing gear not manufactured under tolerance

2. Valve tappet touching

3. Connecting rod loose

Remedies

1. Change the full set of timing gears

2. Tighten the connecting rod.

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Suggestions

Full set of timing gears leads to loss of three gears with increase input costs. When the timing
gears are manufactured it must be checked whether these are getting properly aligned or not.

Timing Out

Causes:-

1. Timing gears interchange

2. Make of timing gears not properly matched

Remedies

1. Interchange the timing gear which has been wrongly placed.

2. Match the marking numbers on the timing gears and put them in proper order.

Suggestion

When gears are checked for alignment, numbers should be punched on them in such a way that
a set of gears has same set and these must be transported to engine assembly in a proper
packing with number written on the packing to avoid mixing of the gears.

SUGGESTIONS

1. These lubrication holes should be cleaned properly.

2. Earlier pneumatic guns had tolerance of +-40 which causes excess tightening of caps but
now new guns have been installed which has tolerance limit of +-10; which results in
approximate desired torque.

BLACK EXAUST

REASONS

1. Incorrect fuel pump timing

2. Incorrect valve timing.

3. Poor compression.

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4. Incorrect type fuel.

5. Exhaust pipe restriction.

6. Incorrect tapped adjustment.

SUGGESTIONS

1. Rocker arm clearance to exhaust is .40 mm and intake has .30mm. but due to large clearance
of pneumatic guns this limit increases results in improper tightening results in opened valve
most of time. This causes the problem of black exhaust.

2. Crank case has inlet and outlet water holes, these holes are closed due to not proper cleaning.
By cleaning these intake and exhaust holes with care we can overcome the problem of black
exhaust.

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