VOCATIONAL

TRAINING REPORT

MAHINDRA YUVRAJ 215

PANCHNATH AUTO PVT.LTD.
Shapar, Rajkot- Gujarat.

Guided by: Prepared by:

Mr. Harshil Vadaliya Vudari Tharun,
Mechanical Engineering,
SVNIT, Surat.

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 ACKNOWLEDGMENT
The subjects we learn can be seen implementing in an industry and training at such earlier
stage gives a wider perspective to change the thought process and the way we analyze things.

I would like to thank Mr. Jigar Maru who gave me this wonderful opportunity, to get
industrial exposure at the crucial stages and extend his help even in the further in-plant training.

I would also like to extend my gratitude to Mr. Harshil Vadaliya who helped me in learning
the various activities under the hood and provide a constant help in revisiting my fundamentals.

I would like to thank Mr. Birju Bhadania who constantly assisted me during this training
period and define a proper work hierarchy.

I would even like to thank all the employees here who helped me understand the
procedure involved and patiently take their time in explanations and facilitate me for successful
completion of training.

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 ABSTRACT
In the current competitive market, every industry wants to give the right product to the
customer with right quality at right time. To perform this function industry need to be well
balanced, smooth production flow and achieve it by managing all the resources available and
allocate them as per their requirement and their capability. Industrial training gives an idea of how
the system works, production of required material, problems raised during production and
rectification methods. The study showed the various industrial engineering techniques applied,
standard operation procedures implemented in the assembly line.

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 INDEX

PREFACE PAGE NO

Acknowledgement………………………………………………………………………………………………………..

Abstract………………………………………………………………………………………………………………………..

1. Company profile……………………………………………………………………………………………………….. 1

2. History…………………………………………………………………………………………………………………….. 2

3. Introduction……………………………………………………………………………………………………………. 3

4. Cleaning machine I & II……………………………………………………………………………………………. 4

5. Engine assembly line

5.1 Crank case loading……………………………………………………………………………………… 7

5.2 Cam follower assembly & mounting…………………………………………………………… 8

5.3 Flywheel fitment…………………………………………………………………………………………. 9

5.4 Piston hose, piston & oil sump mounting……………………………………………………… 9

5.5 Timing gear & backlash check……………………………………………………………………… 11

5.6 Cylinder head assembly………………………………………………………………………………… 12

5.7 Intake & exhaust mounting,

fuel filter mounting…………………………………………………………..………………………… 13

5.8 PTO mounting…………………………………………………………………………………………… 14

5.9 Alternator mounting……………………………………………………………………………………… 14

6. Engine testing……………………………………………………………………………………………………………… 15

7. Transmission

7.1 Spline shaft sub assembly mounting…………………………………………………………… 15

7.2 Reverse idler gear assembly………………………………………………………………………… 16

7.3 Rail and fork assembly………………………………………………………………………………… 16

7.4 Lay shaft assembly …………………………………………………………………………………….. 17

7.5 Backlash………………………………………………………………………………………………………… 18

7.6 RAC sub assembly mounting…………………………………………………………………………. 19

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 7.7 Brake assembly mounting……………………………………………………………………………… 19

7.8 PTO shaft sub assembly mounting…………………………………………………………… 20

8. Transmission leakage testing………………………………………………………………………………………. 21

9. VTU assembly

9.1 VTU body……………………………………………………………………………………………………… 22

9.2 Control valve………………………………………………………………………………………………… 23

9.3 VTU testing and setting………………………………………………………………………………… 23

10. Pre paint assembly

10.1 Engine & transmission docking………………………………………………………………… 24

10.2 Front axle sub assembly & fitment…………………………………………………………… 25

10.3 Drop arm & tie rod fitment………………………………………………………………………. 26

10.4 Brake pedal setting & hand brake ratchet mounting…………………………………… 26

10.5 LH,RH floor panel fitment…………………………………………………………………………… 27

10.6 Fuel pipe,

Hand and foot accelerator………………………………………………………………………… 28

10.7 Fuel tank assembly& governor control linkage………………………………………… 28

10.8 Draw bar, check chain bracket & lever link fitment…………………………………… 28

10.9 Three point linkage fitment………………………………………………………………………… 29

11. Paint shop-I

11.1Washing & masking…………………………………………………………………………………… 29

11.2Painting & baking……………………………………………………………………………………… 30

12. Paint shop-II

12.1 Degreasing tank………………………………………………………………………………………… 31

12.2 Water rinse-I……………………………………………………………………………………………… 31

12.3 Water rinse-II……………………………………………………………………………………………… 31

12.4 Surface actuation………………………………………………………………………………………… 32

12.5 Phosphating tank……………………………………………………………………………………… 32

12.6 Water rinse-III…………………………………………………………………………………………… 32

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 12.7 Water rinse-IV……………………………………………………………………………………… 33

12.8 Water dry off oven…………………………………………………………………………………… 33

12.9 Primer coating………………………………………………………………………………………… 33

12.10 Red colour coating………………………………………………………………………………… 34

13. Post paint assembly

13.1 Demasking, greasing………………………………………………………………………………… 35

13.2 Oil filling, Driver seat, fender SA & interconnector fitment……………………… 35

13.3 Battery, fuel cut off valve, fuse box mounting…………………………………………… 36

13.4 Installation of wheels & exhaust silencer…………………………………………………… 36

13.5 Air cleaner, dome, precleaner fitment………………………………………………………… 37

13.6 Other mountings…………………………………………………………………………………………. 37

13.7 Removing air lock………………………………………………………………………………………… 38

14. IQS area………………………………………………………………………………………………………………………38

15. Testing area

15.1 Roller testing……………………………………………………………………………………………… 39

15.2 Toe in setting……………………………………………………………………………………………… 40

15.3 PTO testing………………………………………………………………………………………………... 41

16. Pre dispatch inspection……………………………………………………………………………………………… 42

17. Rework area……………………………………………………………………………………………………………… 43

18. Ready for dispatch…………………………………………………………………………………………………… 43

19. Conclusion………………………………………………………………………………………………………………… 44

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1.COMPANY PROFILE

 We have project in Panchanath Auto Pvt. Ltd. This is collaborated with Mahindra and
Mahindra Ltd. They assemble tractors under the name Mahindra Yuvraj 215. 2 stands for
mini tractor segment and 15 stands for 15 HP.
 Mahindra is the only Indian company among the top tractor brands in the world. It is today
a full range player with a presence in almost every segment of the automobile industry,
from two wheelers to CV’s, UV’s and SUV’s and sedans. Mahindra recently acquired a
majority stake in REVA Electric Car Co Ltd.(now called as Mahindra REVA), strengthening its
position in the electric vehicles domain.
 The PAL brand is backed by Field Marshal, leaders in the manufacturing of diesel engines in
the country. Field marshal is an ISO 9001:2000 company reputed for manufacturing the
latest technology, light weighing, fuel efficient and compact diesel engines.
 Within four decades of its inception, the company has spread its wings by introducing a
large range of products spanning from diesel engines to mini tractors, from fertilizers to
engine oils. PAL being the latest venture of Field Marshal. The leadership team is comprised
of the corporate executive committee and other business group heads. Their expertise and
knowledge in each of their respective field have helped elevate them to a position of
leadership with many responsibilities.
 The plant in which the training was conducted is of Mahindra small tractors.
o Marketing facilities
o Land area : 8 acres
o Building area : 50,000 Sq.ft.

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2. HISTORY OF MAHINDRA GROUP

 The US $6 billion Mahindra group is among the top 10 industrial houses in India.
Mahindra & Mahindra is the only Indian company among the top 3 tractor manufacturers
in the world.
 Mahindra‘s farm equipment sector has recently achieved the Japan quality medal, the only
tractor company worldwide to be bestowed this honor. It also holds the distinction of being
the only tractor company worldwide to win the Deming prize.
 Mahindra is the market leader in multi utility vehicles in India. It made a milestone entry
into the passenger car segment with Logan.
 The group has a leading presence in key sectors of the Indian economy, including the
financial services, trade and logistics, automotive components, information technology and
infrastructure development.
 With over 62 years of manufacturing experience, the Mahindra group has built a strong
base technology, engineering, marketing and distribution which are key to its evolution as a
customer centric organization, the group employs over 50,000 people and has several
state-of-art facilities in India and overseas.
 The Mahindra group has ambitious goal aspirations and has a presence in 5 continents.
Mahindra products are today available in every continent except Antarctica. Mahindra &
Mahindra has one tractor manufacturing plant at China, three assembly plants in the
United States and one at Brisbane, Australia.
 It has made strategic acquisitions across the globe including Stokes Forgings(UK). Jeco
Holding AG (Germany) and Schoneweiss & Co GmbH (Germany). Its global subsidiaries
include Mahindra Europe Srl. based in Italy, Mahindra USA Inc. and Mahindra South Africa.
 Mahindra group has ranked in its top 200 list of the world’s most reputable Companies and
in the top 10 list of the most reputable Indian companies. Mahindra has recently been
honored with the Bombay Chamber Good Corporate Citizen Award for 2006-2007.

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3.INTRODUCTION

As we know that Mahindra Yuvraj 215 is manufactured here in the plant, let’s have a glance
at the tractor.

The Yuvraj 215’s low cost of ownership and best-in-class fuel efficiency is bringing
mechanization opportunities to farmers with small landholdings across India and revolutionizing
earnings capabilities.

Mahindra designed the Yuvraj 215 for small farm operations. With one cylinder and 15 HP, the
Yuvraj 215 is compact and easy to operate. It is built for long life and low maintenance,
durability and dependability. It offers the first water-cooled single cylinder engine in the 15 HP
segment, and its side shift gear is easy and convinient to use.

The Yuvraj 215 achieves a top speed of 25 kmph, the highest in its class. It can haul up to 1.5
tons. It’s ideal for farmers ready to upgrade from bullocks or power tillers, or for farmers who
need an additional machine for specific applications like inter-culture, power generation, or
water pumping. Farmers who cultivate vegetables, tend orchards, or raise cash crops can all
benefit from the Yuvraj 215’s strong value proposition of affordability, power, and performance.

A tractor is made up of various components. There are innumerable parts in a tractor and
each part is essential for the proper functioning of a tractor. All the parts are categorized
into four major sections. They are

 Engine
 Transmission
 Hydraulics
 Chassis & sheet metal
 Electrical

Each section has sub groups comprising of various sub assemblies. So initially the sub
assembly is done and then the sub assemblies are sent to the main assembly line for
assembly onto their respective body.

Before any sub assembly, cleaning of all individual parts is necessary. It is done in the
cleaning machine.

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4.CLEANING MACHINE-I

 The raw materials which are imported are to be cleaned first as they contain grease, oil and
other foreign particles.
 Transcase, PTO axle, RAC returner, PTO returner, Lay shaft returner, Bull case are cleaned in
this cleaning machine.
 The parameters involved in this cleaning machine are
 Water bath level -2000liters
 Water temperature -50-70ᶱC
 Solvent pressure -5-6kg/cm2
 Bath intensity -3-5%
 Bath chemical -Syn clean 21
 Machine time is 4 minutes.
 Compound is loaded on cleaning tray using lifting tackle.

 Component is placed inside the machine.

 Component is dried using pressurized air after the cleaning is done.
 Then the components are placed on the assembly dispatch tray.

CLEANING MACHINE-II

 It is smaller compared to cleaning machine-I.

 Small components are cleaned in this machine.
 VTU body, cylinder head, cylinder block, counter balance, crank case, connecting rod,
intake & exhaust manifolds, hydraulic pump mounting bracket, bearing flange mounting
are the components cleaned in this machine.
 The working operation is similar to that of cleaning machine-I

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In tightening the nuts, generally 2 types of pneumatic tools are used.

 Shut off tool- In this tool torque is continuously provided. After attainment of requisite
torque, air by passes the pneumatic gun.
 Impact tool- In this tool torque is provided due to hammering effect.

After cleaning is done all the parts are arranged nearby to their sub assembly line. As the
complete tractor assembly starts with the engine assembly, we will discuss it first.

5. ENGINE ASSEMBLY LINE

Here are few exploded views of engine assemblies.

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5.1 Crank case loading and bracket mounting

 Initially crank case is loaded onto line and Lubricating Oil Pump (LOP) gear sub assembly is
mounted onto the crankcase.

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 Bearing mounting ring is mounted on the crankcase upon which the flywheel is mounted
later.

 During this stage sub assembly of counter balance, cam follower, flywheel and crank shaft
is done

 Then bracket mounting on the crank case is done and is moved in for next process on the
assembly line of engine.

5.2 Cam follower sub assembly & mounting

 A governor assembly is employed to the crank shaft. LOP gear is mounted.

 A counter balance is added.
 A key is inserted onto the crankshaft. The other half of the key sits in the pinion gear.
 The cam gear is in meshing with the pinion gear.

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  3 cam followers are present. One for fuel, one for inlet valve, one for exhaust valve.
 4 Mounting rods are inserted to hold the cylinder head assembly

5.3 Fly wheel bush filment

 The engine is rolled in the opposite side to attach the flywheel.

 Silicone gel(acts as a gum) is added on the outer rig and on the fly wheel.
 The mounting flanges are bolted. Manual inspection of bolts is done and marked yellow.
 Dowel pin is inserted on the crank shaft.
 Flywheel is mounted taking the dowel pin as reference and the flywheel is locked using 6
allen nuts and later the dowel pin is removed.
 Starter motor is made to mesh with the flywheel.
 Oil filter bracket is inserted.

5.4 Piston & Oil sump mounting

 Rings on mounting rods are placed to raise the elevation of cylinder head and maintain
same level with cylinder head and piston crown.
 Cylinder block is inserted.

GOETZE piston & piston liners are used. It is the manufacturing company for pistons and piston
liners.

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IN PISTON Circlip is inserted. It is used to lock the gudgeon pin.

IN CONNECTING ROD -Brass bearing is inserted on both the surfaces of bigger end of the rod.

-It wears first before the connecting rod surface.

Piston comprises of three rings.

1st-Compression ring

2nd-Scraper ring

3rd- Oil ring

Each ring is separated by 120 degrees clockwise starting from the upward arrow on the piston.

 Cylinder block is placed over the mounting rods and piston is fixed inside the cylinder
block.
 The big end of the connecting rod is tightened up from the bottom direction.
 Strainer is attached from the bottom to filter the oil from foreign particles.
 Flange sealant is applied over oil sump and bolted beneath the engine.

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5.5 Timing gear train & back lash check

 Cam shaft, driving gear and LOP gear are located in their respective positions.
 The three gears are made to mesh with each other and after inspection dummy front cover
is mounted.

Inspection: Fuel timing & fuel cut off checking

 Fuel injection pump (FIP) is inserted near the cam shaft bearing.
 Fuel is allowed to pass through the FIP and fuel cut-off is adjusted at 14ᶱ bTDC using
time setting guage. For this adjustment, at the FIP SHIM’s are used. One SHIM for 1ᶱ
deviation.

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5.6 Cylinder head assembly

 Expansion plug is inserted at the bottom of the cylinder head. It serves as a blowoff valve
when there is some malfunction in the exhaust gas outflow.
 Exhaust and inlet valve spools are inserted, the diameter of inlet valve is greater than that
of exhaust valve.
 Rocker arms are fixed in the cylinder head and springs are also placed on the inlet and
exhaust valve rods.
 In order to remove the extra air outside, Air breather is added on top of the cylinder head.
 Diesel spill pipe is also attached to allow excess oil to overflow.

Push rod tube, Rocker arm cover, High pressure pipe are also added in the same stage.

 A smaller size dowel pins are added onto the mounting rods.
 Gasket for cylinder head is put on in between the case to the cylinder head. It is helpful in
preventing the leakage of air during compression stroke.
 High pressure pipe is inserted between fuel injector and fuel injector pump.
 Push rods connect cams to the rocker assembly for opening and closing of the valves.
 Rocker arm is tightened with push rods below them and rocker arm cover is placed in
position.

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5.7 Intake & exhaust mounting, fuel filter mounting

 Intake and exhaust manifolds are mounted.

 Diesel filter is mounted on L-bracket on the flywheel body. It accommodates fuel pump.
 Banjo bolt is inserted into FIP. It has a cavity inside through which fuel is injected into FIP.
 Water pump is mounted on the opposite side of the flywheel. It supplies water to the
water jacket surrounding the engine and other essential parts. It is connected to the main
inlet of the water jacket through a hose.

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5.8 PTO mounting

 PTO pulley is added. It is mounted on the crank shaft.

 Oil filter is added opposite to the FIP. It purifies oil before entering the sump.
 Low idle bolt is added to governor. It acts as a lever mechanism for throttling purpose.

5.9 Alternator mounting

 Alternator/dynamo is attached on a mounting, top of the crank case.

 Timing belt is added and runs over alternator, water pump and PTO pulley. Belt is tightened
by displacing the alternator over a movable bracket and after required tension in the belt,
the alternator is tightened.
 Hydraulic pump mounting bracket holder is added.

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6. Engine testing:

 2.5 lit of engine oil is filled though the oil cap at the top.
 Air cleaner is mounted above inlet manifold.
 As per the following table, the engine testing is done.

So as the engine testing is done, the engines are kept aside in a row. After the engine cools down,
they are taken out of the engine testing area and clutch plate is mounted.

7. TRANSMISSION

7.1 Spline shaft sub assembly mounting

 Transcase is kept on the assembly line

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 Spline shaft is inserted first and locked using Circlip.

 SHIM is inserted on the body upon which pinion shaft is mounted.

 NRB and cluster gear are mounted on the spline shaft and locked with a lock plate.

7.2 Reverse idler gear assembly

 Reverse idler gear is mounted.

7.3 Rail and fork assembly

 Rail and fork are assembled on the transcase which helps in shifting the gears.

 Forks are placed in between gears.

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7.4 Lay shaft assembly

 Lay shaft is mounted in the next stage. Gears on the lay shaft are removed, lay shaft is
inserted from the front and the removed gears are added again from top of the transcase.
 Loctite is applied on the body to avoid oil leakage.
 Spline shaft is covered with a returner (spline shaft cover).
 Ball bearing is added on the other side of the layshaft and locked with a Circlip.
 Oil seal is added onto the ball bearing.
 From the sides ring gear(differential),bull case(bull pinion shaft) are mounted.

 Gear rods are inserted into position by connecting them with forks through a over head
shaft.
 The order of gear arrangement are first, second, third, high, low, reverse.

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7.5 BACKLASH

 When both the bull pinion shafts are rotated in the opposite direction, there exists some
play in between both the shafts. This is backlash. This error is rectified by
adjusting(tightening/loosening) the stud gear and the play is minimized.
 The SHIM film inserted depending on the adjustment required. The general
implementations are 900µm on right hand side of bull case and 1200 µm on left hand side
of bull case.
 The backlash deflections accepted are different for different directions

Right hand gear – 0.2 µm to 1.3 µm

Left hand gear – 0.2 µm to 1.3 µm

Pinion gear – 0.2 µm

 To shift the gears, gear rod assembly is mounted and the shafts are locked in position.
 Oil seal is added to the bull case at the outer side of the transcase near the bull case end.
 Stud gear is removed from the bull case, oil seal is inserted over the stud gear and re
tightened into the bull case.
 Dye shaft is connected to the lay shaft.

 Silicone gel is applied on the face of Clutch housing, bolted to transcase and is worn over
the dye shaft.
 Gear box is covered with a plate and tightened with bolts.

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7.6 RAC sub assembly mounting
 Sealant is applied to the body to avoid leakage.
 Remove RAC locknut, lock plate, bull gear and their SHIM’s from RAC assembly.
 Fitment of RAC sub assembly on transcase from out, lock it with the bull gear from inside
 Insert bull gear lock nut and lock plate.
 Bend the lock plate into the lock nut using a blunt chisel.
 Place all the bolts and tighten them using appropriate torque.
 Carry the similar operation for other side of the transcase and fix the RAC sub assembly.

7.7 Brake assembly mounting

 Insert brake liners on bull pinion shaft.

 Apply sealant on the housing of the brake mounting.
 Attach the brake housing over the brake liner and bolt them up, tighten the bolts.
 Install air pipe on the brake assembly using a Banjo bolt and lock it with a brass nut.

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 7.8 PTO shaft mounting

 PTO shaft is directly coupled with the lay shaft. It has a direct attachment from the gearbox,
without transferring the power to the spline shaft, power is directly transmitted through lay
shaft.
 2 dowel pins are used to insert the PTO mounting properly
 It is bolted and then properly tightened.
 A seal is positioned into the outer side of the PTO shaft

PTO shaft sub assembly:

 PTO housing in which PTO gear and PTO shaft are mounted.
 PTO gear is mounted on PTO housing using a pressure bearing on the other side, the
bearing is mounted and locked with a Circlip.
 In the above hole, drive shaft is mounted. Returner is mounted, locked with nuts on the
side opposite to PTO gear.

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8. Transmission leakage testing

Initially air leakage test is done.

 Lock the suction filter mounting hole with a plug.

 Locate the air leakage testing plate on hydraulic mounting face.
 Connect the air pump to the leak testing plate.

Specifications of the leakage test

 Leakage testing pressure - 100mbar

 Initial air filling time – 90 sec.
 Stabilizing time – 3 sec
 Testing time – 1 sec
 Allowable leakage value – 50cc/min

If leakage is observed above the prescribed value, red light is signaled on the testing machine.

Then comes the oil testing

 The whole gear box is filled with oil.(15-16 liters of servo 13T oil)
 Motor is connected to the dye shaft and the motor is operated.
 Possible chances of leakage are noted, even during the application of brakes.
 Bolt on top of the transcase determines the amount of oil inside.

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9. VTU assembly

VTU- Vary touch unit

9.1 VTU body

 Rocker arm is mounted on rock shaft, rock shaft is mounted on VTU body.
 Cam PC is added. It is used to bring back the spool valve into position.
 Rock shaft bush is added. Washer is added on one side and oil seal on both sides are added
in order to prevent oil leakage. They are fixed properly by using a dolly and hammer.
 Lift arm is inserted on both the sides and locked with a Circlip.
 Quadrant is inserted in position and tightened with 40N-m torque.
 Crank toppling is locked with draft sensing element.
 PC roller, PC link, DC link are mounted on the quadrant shaft. These three are
interconnected.
 DC bush is locked with DC outer.
 DC cable is attached to DC lever & Circlip is placed over it.
 DC outer link is cabled with crank toppling.

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9.2 Control Valve

It comprises of spool valve, pressure valve, relief valve.

 When Isolation valve is closed, piston entry of oil is not permitted. It goes to relief valve and
then goes out. From this maximum pressure of relief valve is measured.
 When spool valve is pressed inside, the oil flows into the piston continuously. In order to
avoid this, DC cable which is attached with the PC roller, pulls back the spool valve and oil
entry to the piston is stopped.
 The control valve when mounted, the piston assembly houses rocker arm.

9.3 VTU testing and setting

 The level of lift arm is set to zero degrees with reference to the horizontal axis.
 The maximum value of pressure is noted when the non returning valve opens. It is also
called as the relief valve pressure. It is generally about 1786 Psi to 2276 Psi.
 PC- position control is set. It is generally used to fix a position of the lift arm. The max value
of PC is 71 to 73 degrees.
 DC- draft control is set. It is generally used to avoid blows or sudden jerks. DC is set just 2 to
3 degrees in excess to the PC.
 During testing maximum capable load and maximum allowable angular lift is set.

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10. PRE PAINT ASSEMBLY

10.1 Engine & transmission docking

 Trolley is placed on line.

 Transmission & engine are docked onto trolley.

 Dye shaft of the transmission side, crankshaft from the engine are matched and crankshaft
is inserted into the dye shaft. Cross shaft is inserted on the clutch plate housing and all of
them are bolted tightly initially using 2 bolts.

 The remaining bolts are added and tightened.

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 2 way threaded nut is inserted into the transcase on which battery stand is initially placed.
Then with help of nuts Battery stand and gear box shifter are mounted.

 High pressure pipe line is connected from the control valve of VTU to the hydraulic pump to
send in pressurized oil into the VTU for functioning of the lift arm.
 Gear box control rod is connected to the cross shaft.

 Battery cable is bolted along with a nut on the battery stand.

 PTO shaft is covered.

10.2 Front axle sub assembly and fitment

 Front axle is mounted on a base support.

 Tie rod is mounted on front axle & locked with a capston nut.
 Radiator bracket is mounted on top of the front axle.

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10.3 Drop arm & tie rod fitment

 Drop arm is fitted to the gear box on the left side.

 Front axle is mounted infront of the engine.
 Tie rod is fixed between drop arm and front axle.

10.4 Brake pedal setting & hand brake ratchet mounting

 Dowel pin is inserted on transcase for mounting the hand brake.

 Brake shaft is placed beneath the transcase.

 On the same shaft on the left side, clutch pedal is mounted. It is linked to the clutch plate.

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10.5 LH,RH foot panel fitment

 LH foot pedal is mounted above the brake shaft behind the clutch pedal.

 On the right hand side, both RH and LH brakes are mounted on the brake shaft.
 For the functioning of LH brake, a key is inserted onto the brake shaft and LH brake pedal is
mounted. When the LH brake is pressed, as it is locked with the key, the shaft rotates and
activates the LH brake shoes.

 RH foot rest is mounted.

 RH brake pedal is directly mounted onto the brake shaft and is connected to the RH brake.
 Both the brakes are attached with a return spring which facilitates the returning of the
brake pedal to its original position.
 Heights of the brakes are locked and adjusted.

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10.6 Fuel pipe, hand & foot accelerator

 A governor linkage is added from the lever of the engine near FIP to the cross shaft.

 Handle accelerator mounted on the gear box shifter is also tightened.

10.7 Fuel tank assembly & governor control linkage

 Diesel tank is fitted.

 Using Banjo bolts, fuel pipe from diesel tank to the fuel filter is fitted. Fuel flows into the
fuel filter through the Banjo bolts from the fuel tank.

10.8 Draw bar, check chain bracket & lever link fitment

 Interconnecting tube is used on which seat is mounted.

 Top link is added to give support to 3 point linkage.
 Draw bar is added to the side of transcase and check chain bracket is attached. The
appropriate length is set and chain bracket is locked firmly.

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 10.9 Three point linkage fitment

 Four linkages are mounted; two from sides attached to the lift arms and two from the
bottom attached to the drop arm individually are mounted. Two linkages from top are fixed
to the bottom linkages using nuts and chain are also attached to the bottom linkages.

11.PAINT SHOP-I

In paint shop washing of whole assembly, application of paint and baking (heating) are the
operations involved.

11.1 Washing & masking

 For the first 5 minutes the assembly is washed using a chemical compound.
 Later, to remove the chemical, the assembly is washed with soft water for 3-5 minutes. The
temperature of water is around 55-60ᶱC
 In the next stage to remove the water present on the assembly, pressurized air is blown
over, which removes all the water present. The pressure of air is around 4-5 bar.

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 Right after washing, masking is done to protect all the grease nipples from entry of paint. Then
it is sent into the paint shop.

11.2 Painting and baking

In the paint shop, paint is sprayed all over the body. The specifications in the paint shop are

 Grey paint is used to paint the body.

 Air pressure is 45-55Psi.
 Paint pressure is 3-4 bar.
 The flow rate of paint is 200-300 cc/min.

After the painting of body is done, it is sent to the baking oven where the paint is properly attached
to the surface of the body.

The temperature inside the baking oven is 155±5ᶱC and the maximum limit is 180±5ᶱC.

The total cycle time here is 30 min. it is divided into 3 parts where each cycle comprises of 10 min.

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12. Paint shop-II

There is another paint shop outside of the assembly line building. It is used to paint all the
individual parts i.e. fenders, dome, and other plates. The operations followed are

12.1 Degreasing tank

 Raw metal which has come in shipment is dipping into the degreasing tank.
 As the raw material contains grease and other foreign particles, in the degreasing tank it is
washed with chemical water to remove all the contaminants.
 This is carried out for 4 minutes.

12.2 Water rinse-I

 After degreasing of the raw material is done, to remove the chemicals, the metal is dipped
in soft water for 1 minute.
 For circulation of water air is continuously bubbled from the bottom.

12.3 Water rinse-II

 To remove the trace of chemicals and other contaminants, raw material is again dipped in
another soft water bath for 1 minute.

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12.4 Surface actuation

 To increase the phospatizing ability of raw material, the metal is surface activated.
 For this the metal is dipped in water containing Nifan Zn Zs chemical.
 The cycle time is 1 minute.

12.5 Phosphating tank

 A coating of phosphate is added onto the raw material which helps in better adhering of
the paint.
 The cycle time is 4 minutes.

12.6 Water rinse-III

 To remove the sludge, excess phosphate adhered, the coated metal is dipped in soft water
for a minute.

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12.7 Water rinse-IV

 Similar operation is carried out here. Remaining contaminants are also removed.

12.8 Water dry off oven

 After all the cleaning is done, in order to remove the water from the coated metal, it is
heated in oven.
 The temperature of oven is around 120ᶱC.
 The cycle time is 10 minutes.

12.9 Primer coating

After these series of processes, the coated metal is sent for primary coating.

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 The coated metal is hanged to the conveyer rails which run all over the paint shop.
 Initially a primer coating of white grey colour is coated in the paint booth.
 The primer coated metal is then transported to the oven for heating and proper adhesion
of primer.
 The temperature of oven is around 150-155ᶱC.
 The primer coated metal comes out of the oven after 40 minutes.

12.10 Red colour coating

 The same line is made to move again into the paint booth where red coating is applied this
time.
 Inside the paint booth to avoid dispersal of paint all over the booth, a blower is present
behind the booth which sucks air. Water runs on the wall behind. It adsorbs the paint mist
present in the booth and settles down with the flowing water.
 The waste paint is collected and removed from the paint booth.
 After application of paint is done through air brush, the parts are transported to the oven.

 The total cycle time for the paint booth is 4 hours in which 35 items are painted. This time
includes oven baking also. Here this paint shop runs on 5-S technique.

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13. POST PAINT ASSEMBLY

13.1 Demasking, greasing

 Grease mask is removed and grease is pumped in.

 After paint is dried, wiring is done.
 Installation of gear knob.
 Diesel sensor is inserted into the diesel tank.
 Driver seat and radium danger sticker are mounted.
 A 7 pole socket is mounted which can be used as an external aid.
 This stage is called as natural cooling-1

13.2 Oil filling, driver seat, fender SA & interconnector fitment

 16 liters of Servo 19 oil is poured into the gear box.

 A stud is mounted beside the battery case for mounting of battery.
 Fender RH and LH are mounted.
 This stage is natural cooling-2

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13.3 Battery, fuel cut off valve, fuse box mounting

 A lead acid battery of 12V, 65 amp is mounted on the battery stand by using the stud as a
support.
 Fuel cut off valve, fuse box are mounted in this stage.

13.4 Installation of wheels & exhaust silencer

 Nuts of wheels are pressed and locked into position.

 Exhaust silencer is installed.
 Front and rear wheels are installed.

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13.5 Air cleaner, dome, precleaner fitment

 Air cleaner is fitted to the inlet manifold.

 500 ml of oil is added to air cleaner.
 Scuttle, mirror is mounted on the body over the diesel tank.
 Dashboard dome is mounted and the internal wirings are connected.
 Middler is added.
 Pre cleaner is added over the main cleaner.

13.6 Other mountings

 4 liters diesel is added for testing of tractor and for small distance travel inside the plant.
 Steering, radiator and radiator fan are mounted.
 Radiator inlet and outlet are fixed with water supply hoses.
 500 ml of coolant and 2-2.5 ltr of water are added in the radiator.
 Hood is mounted on the engine.
 Stickering on the hood is done and beading around the hood is placed.

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 13.7 Removing air lock

 As diesel is filled lately, air might be trapped inside piping system. In order to remove the
air, the Banjo bolt at the FIP is loosened up and air is pumped into the diesel tank by which
air entrapped comes out. Banjo bolt is again retightened.
 Tractor is rolled out

14. IQS AREA

 Some under parts are not painted or paint might not be reached till the bottom. Those
areas are manually painted using spray can.

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  Inspection of lights, paint is done and then sent to the testing arena.

15. Testing area

In the testing area

All the below operations are done then the product is available ready for dispatch (RFD).

15.1 Roller testing

 Put the tractor on the roller tester.

 Lower the hydraulic jack by the help of air pressure valve.

 Run the tractor on tester, operate on each gear i.e. 3 high gears, 3 low gears and 3 reverse
gears.

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 Easy engagement of gears, noise from transmission, noise from engine, brake performance
and hydraulic PC,DC check is also verified in this stage.
 In case of hydraulic check, 500Kg is the weight which has to be lifted during inspection.

 All the above are identified. If everything is OK then tractor is sent to PDI.

15.2 Toe in setting

 Toe in setting is done during PDI

 Keep front tyres in straight ahead position.
 Loosen both clamps of tie rods.
 Take toe in gauge and put infront of front tyre.

 Fix a probe of toe in gauge to one of the wheel and adjust the tie rod such that the centre
of other front wheel also falls on the centre of the second probe.

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 Follow the same procedure on the back side of the front tyre.
 After both the front and rear sides are fixed, tighten the nut on the tie rod without
disturbing the adjusted nut.
 Tighten the screw on the tie rod which connects the steering wheel also.

15.3 PTO testing

 Before starting of PTO ensure that water connection is started to the dynamometer.
 Match the tractor’s PTO shaft to the dynamo meter’s coupling.
 Ensure that the coupling & PTO shaft are properly locked.

 Start the tractor and run it in low idle condition.

 Observe the PTO performance measures on the screen of dynamo meter
@1000 RPM of the engine the PTO has 1.28KW power, 45.1Nm torque and 261 RPM
@2500 RPM of engine(high idle) PTO readings are 4.53KW, 65.3Nm,660 RPM.
 The acceptable range of PTO rpm is from 592-610 RPM.
 So to check this, the load on the brake dynamo meter is increased. This reduces the RPM
on the PTO and even the engine RPM.

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  When RPM on PTO is brought to 596 RPM then the values of PTO observed were 7.63KW
power, 123.4Nm torque. The engine RPM drops to 2250 which is the rated RPM of engine.

 Correction factor at 41ᶱC is 1.05

So correct power = correction factor*rated power
at PTO =1.05*7.63
=8.01KW

16. PRE DISPATCH INSPECTION (PDI)

 Check the tractor serial number and that number should match with the number on RH
fender.
 Check working of horn, head lamp, parking lamp, plough lamp, cluster light and notify if
malfunction is observed.

 Measure the oil levels in the gear box, air cleaner, and transmission by using a dipstick.
 Check the coolant level in the radiator and the water level.
 Check for any leakages at fuel systems, hydraulic systems, transmission joints, oil drain
plugs, engine joints, cooling system.

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  Check for the governor lever and air pressure in both the tyres.
 Seal the transmission box from both sides. One from top where oil is poured and another
from where oil is drained.
 Send the tractor for quality assurance. After that tractor is ready for dispatch(RFD)

17. Rework area

 If any problem is observed in the tractor during PDI or roller test or road test, the tractor is
brought back to the rework area.
 Here the problem is identified and repair at the requisite position is done by technicians
and again sent for PDI.

18. Ready for dispatch

 The tractor is thoroughly checked by the technicians of Mahindra. If any problem persists,
the same is informed to the PDI section and sent for reworking.

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Conclusion
The techniques used in the plant as based on the standard operating procedures of the
individual assembly or sub assembly. Constant supervision by the line supervisors helps in
maintaining the overall performance quality excellent for efficient performance of the company.

This is a great opportunity where a treasure of practical knowledge is obtained from the
industry. I am really thankful to each and every individual for their complete support in completing
the training successfully.

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