Report on Summer Industrial Training

At

Escorts Agri Machinery

Faridabad

Submitted by:
Anshu Girdhar
ME-14/012
Mechanical Department

Satyug Darshan Technical Campus

Bhupani-Lalpur Road, Faridabad-121002
1
Anshu Girdhar – Training Report
 Table of Contents:
S.No. Subject Page No.

1. Table of Contents 1
2. Certificate 2
3. Acknowledgement 3
4. Introduction 4
5. History 4-8
6. Mission 8
7. Board of Directors 9
8. Business 10-11
9. Tractors 12-13
10. Tractor Assembly 14-32
11. Engine Testing 33-37
12. Backend 38-40
13. Differential Assembly 41-44
14. Rear Assembly 44-45
15. Gear Box Assembly 45-46
16. Paint Shop 47
17. Rear & Front Wheel Fitting 48
18. Accessories 49
19. Final Testing 50-51
20. Conclusion 52

2
Anshu Girdhar – Training Report
 Acknowledgement
I would like to thank to all those with whom I worked and
whose thoughts and insights helped me in increasing my
knowledge and understanding of working in organization. I
would like to pay my sincere gratitude to Mr. Rajesh Goel,
Mr.Ram Mohan & all employees, who helped me during the
course of my training by providing their valuable suggestions,
ideas, and guidance which proved beneficial for completion of
my training. Besides I would also thank to all the supervisors,
Foreman and workers who helped me to understand the depth
of my training, what they want out of the project. These people
made me comfortable to understand the functioning of each
machine & assembly of tractor parts, differential and gear box.
These peoples never made me feel as a trainee in the
department rather provide an atmosphere like a family and feel
proud being the part of their industry. Lastly but not least I
thank one and all who helped me directly or indirectly in
completion of my report. I have been really opportunistic to be
a part of the Escort Group during my summer training, which
is one of the leading tractor company in today’s scenario.

I am once again, thankful to members of ESCORTS Group

for their co-operation.

ANSHIU GIRDHAR

3
Anshu Girdhar – Training Report
 Introduction
The Escorts Group is an Indian engineering company that
operates in the sectors of agri-machinery, construction and
material handling equipment, railway equipment and auto
components. Headquartered in Faridabad, Haryana, the
company was launched in 1944 and has marketing operations
in more than 40 countries. Escorts Group’s management team
includes Rajan Nanda as the Chairman and Nikhil Nanda as
the Managing Director.

HISTORY :
Escorts Group was founded in 1944 by two brothers, Hari
Nanda and Yudi Nanda, in the name of Escorts Agents Ltd. in
Lahore. They started business career in Jammu at fairly early
age with family enterprise "Nanda Bus Service" which
pioneered organised transport system in North India and the
master-mind behind 'ESCORTS' industrial business. H.P
Nanda was also the former director of RBI BANK and IDBI.
ESCORTS of which he was both director and President.
Escorts Limited was incepted in 1960 after the company set up
its manufacturing base at Faridabad start manufacturing X Ray
machine with collaboration of Westinghouse & Heating
Elements with Elpro.
Since inception, Escorts Group has been associated with
engineering companies such as Minneapolis Moline, Massey
Ferguson, Goetze, Mahle, URSUS, CEKOP, Ford Motor
Company, J.C. Bamford Excavators, Yamaha, Claas, Carraro,
First Pacific Company, Hughes Communications, Jeumont
Schneider, Dynapac, etc.

1944 - Launch of Escorts (Agents) Ltd.

4
Anshu Girdhar – Training Report
1948 - Pioneered farm mechanization in the country by
launching Escorts Agricultural Machines Limited, with a
franchise from the U.S. based Minneapolis Moline, for
marketing tractors, implements, engines & other farm
equipment. Launch of Escorts (Agriculture and Machines) Ltd.

1949 - Franchise of Massey Ferguson tractors for northern

India.

1951 - Escorts established India's first private Institute of Farm

Mechanisation at Delhi.

1953 - Escorts (Agents) Ltd. and Escorts (Agriculture and

Machines) Ltd. merged to form Escorts Agents Pvt. Ltd.

1954 - 1st industrial venture of Escorts to manufacture piston

rings in collaboration with Goetze of Germany, in an era when
joint ventures of Indian firms with foreign companies were
virtually unheard of.

1958 - Started importing Massey Ferguson tractors from

Yugoslavia for marketing the same in India.

1959 - Collaboration with Mahle of Germany to manufacture

pistons. Soon, Escorts became the largest producer of piston
assemblies in India.

1960 - Set up of Escorts Limited

1961 - Setting up of manufacturing base at Faridabad for

manufacture of tractors in collaboration with URSUS of Poland
and 50% indigenous components. Launch of Escort brand of

5
Anshu Girdhar – Training Report
tractors. Collaboration with CEKOP of Poland for
manufacture of motorcycles and scooters. Escorts moves into
high gear by nurturing the two wheeler culture. The first
Rajdoot motorcycle rolls off the assembly line.

1969 - Escorts Tractors Limited was born. A technical and

financial joint venture with the global giant Ford Motor
Company, USA, to manufacture Ford tractors in India. The
years ahead saw Escorts grow as the largest tractor
manufacturer in India.
 Escorts Institute of Farm Mechanisation (EIFM)
established at Bangalore.
 Escorts Employees Ancillaries Ltd. (EEAL), a unique
venture in industrial democracy comes into being.
1971 - 1st February, the first tractor FORD 3000 rolled out of
the factory.
 Escorts diversifies and starts manufacturing construction
equipment.
1974 - Crossing national boundaries, Escorts exports for the
first time. After winning a global tender, 400 tractors were
exported to Afghanistan, which was perhaps the world's largest
ever airlift of tractors.

1977 - Escorts enters the world of self-developed technology by

setting up its first independent R&D Center. Escorts Scientific
Research Centre marked its beginning at Faridabad by
developing its own Engines for E-27 and E-37.
1978 - Escorts founder Mr. HP Nanda awarded the "Great
Cross of Merit" - the highest civilian honour conferred by the
Federal Republic of Germany.

6
Anshu Girdhar – Training Report
1979 - Collaboration with JCB Excavators Ltd., UK for
manufacture of excavators.

1980 - Foray into healthcare, Escorts Hospital and Research

Center set up in Faridabad.

1990-91 - First Public Issue in February 1991, over-subscribed

four times. Shares listed on Delhi and Bombay Stock
Exchanges.

1991 - Escorts Chairman HP Nanda receives the Chevalier de

la Legion d'Honneur medal from France for his contribution
towards improving Indo-French economic relations and
strengthening trade ties.

1993 - FORD 3620 tractor launched.

1996 - Disengagement of joint venture collaboration with New

Holland and launch of FARMTRAC Tractor.

1997 - Joint Venture with Carraro of Italy for manufacturing

and marketing of transmission and axles. Joint Venture with
First Pacific Company of Hong Kong - Escotel Mobile
Communications.

1998 - POWERTRAC series of tractors launched. MoU was

signed with Long Manufacturing Company, USA for setting up
a Joint Venture in USA.

1999 - MoU for Joint Venture with a Polish Company POL-

MOT was signed for assembly, manufacturing and marketing
of Farm Machinery.

7
Anshu Girdhar – Training Report
2004 - Divested Escotel Mobile Telecommunications to Idea
Cellular
TS16949 certification for Agri Machinery Group

2005 – Divested Escorts Heart Institute and Research Centre

(EHIRC) to Fortis Healthcare
2006 - Divested in Carraro India Ltd.

2008 - ECEL launches Fully Hydraulic Crawler Cranes

2009 - ECEL commissions state-of-art manufacturing plant for

pick-n-carry cranes and vibratory compactors

Mission :
By 2020, Escorts will be among the top 3 Engineering
Companies in India. We shall achieve this goal by being the
preferred solution provider to the needs of our customers, by
practicing respectful and ethical business practices, by being the
employer of choice within the engineering industry, and by
providing superior returns to our investors.

Knowledge Management Centre

Set up in 1976, the Escorts Knowledge Management Centre
(KMC) is spread over 100,000 sq.m. area in Faridabad. This
centre designs the entire tractor – engine, transmission plus
hydraulic systems and vehicle design consisting of sheet metal,
controls and accessories.
The KMC has facilities such as engine laboratory featuring
computerized test beds with online control, data acquisition
and analysis, advanced vehicle testing laboratory, noise
vibration and harshness lab, metrology lab, and materials
engineering lab.
8
Anshu Girdhar – Training Report
Logo :

Businesses
Escorts Agri
Machinery
Escorts Agri Machinery was launched in 1960. The company
manufactures tractors under the brand names of Farmtrac,
Powertrac and Steeltrac.[4] It has four manufacturing plants in
Faridabad and one subsidiary unit in Poland in the name of
Farmtrac Europe.

Escorts Construction Equipment

Escorts Construction Equipment manufactures and markets
construction and material handling equipment like pick and
carry cranes, backhoe loader, vibratory rollers and forklifts.
The manufacturing and assembly facility is located in Faridabad
Escorts Railway Products
Escorts Railway Products manufactures and supplies critical
railway components such as air brake system, EP brake system,
9
Anshu Girdhar – Training Report
draft gears and couplers, composition brake blocks, dampers
and rubber components to Indian Railways.
Escorts Auto Products
Escorts Auto Products manufactures auto suspension products
such as shock absorbers, struts and telescopic front forks for
the automotive industry. The company collaborated with
Fichtel & Sachs, Germany to introduce the concept of shock
absorbers manufacturing in India in 1966. The manufacturing
unit is located in Faridabad.

10
Anshu Girdhar – Training Report
 Board of Directors

Name Position

Mr. Rajan Nanda Chairman

Mr. Nikhil Nanda Joint Managing Director

Mr. Rohtash Mal ED & CEO (AMG)

Mr. Kanwal Kishore Vij ED & CEO (ECE)

Mr. Vikram Singhal ED & Business

Head

Mr. G.B Mathur EVP- Law & Company

Secretary

Mr. O.K Balraj EVP & GROUP CFO

Mr. Ishan Mehta EVP- HR & ER

11
Anshu Girdhar – Training Report
 Tractors
At Escorts Agri Machinery, the catalyst for the next wave of
farm mechanization has brought about two large customer
centric initiatives to the fore at Escorts – New Products and
variants that are aligned with changing and emerging
applications & end usages and the shift of Escorts from being a
standalone tractor manufacturer to being a complete 'Farm
Solution' provider.

The Escorts Jai Kisan Series recognizes the new market order
for varied needs of the Indian farmer, changing tractor uses for
specialized applications and usage of modern and heavy-duty
implements & attachments, thereby offering wider options for
agricultural, infrastructure as well as specialized applications for
land development activities.

The Jai Kisan Series comes in five new categories –

ValueMaxx, LoadMaxx, AgMaxx, InfraMaxx and SuperMaxx.
While the VALUEMAXX is the variant for basic agricultural
purposes, the LOADMAXX and AGMAXX variants
specialize in haulage-based applications and specialized Agri-
applications. The SUPERMAXX series is ideal for all types of
agriculture and non-farming purposes besides offering add-on
applications for dual needs whereas, the INFRAMXX variant
would specialize in infrastructure-based applications. The 'Jai
Kisan Series is currently available in the FARMTRAC line of
Escorts tractors.

12
Anshu Girdhar – Training Report
Farmtrac

• Tractors that are designed with help from a leading

European engineering company.
• The new Farmtrac Executive series tractors comes with new
style, improved operator ergonomics, and a host of world-class
features.

Powertrac
The new Diesel-Saver Plus series enhances power of the
current engines by about 10%, and at the same time reduces
their fuel consumption by 10%.

13
Anshu Girdhar – Training Report
 Tractor Assembly

Engine Sub Assembly

Gear Front
Real Engine Axle
Differential Box
Axle Assembly
Assembly Assembly

Gear Box Sub

Assembly Paint

Rearhood Front Real Wheel

Radiator
Fitment Wheel Fitment

Accessories Hydraulic
Test

14
Anshu Girdhar – Training Report
 Engine Assembly

Cylinder Block

A cylinder block is
an integrated structure comprising the cylinder(s) of
a reciprocating engine and often some or all of their associated
surrounding structures (coolant passages, intake and exhaust
passages and ports, and crankcase).

Caps Front Support Stud

15
Anshu Girdhar – Training Report
 Tapids

Bearings function
to:
• Reduce friction.
• Support moving
parts under load
• Serve as
replaceable wear
surfaces
Bearings
A crankshaft is a mechanical
part able to perform a
conversion
between reciprocating
motion and rotational motion.
Most reciprocating internal
combustion engines end up
turning a shaft. This means
that the linear motion of a
piston must be converted into
rotation. This is typically
achieved by a crankshaft.
Crank Shaft

16
Anshu Girdhar – Training Report
 Fuel Injection Pump(FIP)
Fuel system

Fuel Injection
Larger gasoline engines used in automobiles have mostly
moved to fuel injection systems (see Gasoline Direct
Injection). Diesel engines have always used fuel injection
system because the timing of the injection initiates and controls
the combustion.
Autogas engines use either fuel injection systems or open- or
closed-loop carburetors.
Fuel Pump
Diesel engines use an all-mechanical precision pump system
that delivers a timed injection direct into the combustion
chamber, hence requiring a high delivery pressure to overcome
the pressure of the combustion chamber. Petrol fuel injection
delivers into the inlet tract at atmospheric pressure (or below)
and timing is not involved, these pumps are normally driven
electrically. Gas turbine and rocket engines use electrical
systems.

17
Anshu Girdhar – Training Report
 Thrust Washers

18
Anshu Girdhar – Training Report
 Camshaft
with
cam gear

A camshaft is a shaft to which a cam is fastened or of which a

cam forms an integral part.
In internal combustion engines with pistons, the camshaft is
used to operate poppet valves. It then consists of a cylindrical
rod running the length of the cylinder bank with a number of
oblong lobes protruding from it, one for each valve. The cam
lobes force the valves open by pressing on the valve, or on
some intermediate mechanism as they rotate.
The relationship between the rotation of the camshaft and the
rotation of the crankshaft is of critical importance. Since the
valves control the flow of the air/fuel mixture intake and
exhaust gases, they must be opened and closed at the
appropriate time during the stroke of the piston. For this
reason, the camshaft is connected to the crankshaft either

19
Anshu Girdhar – Training Report
directly, via a gear mechanism, or indirectly via a belt or chain
called a timing belt or timing chain.

Cylinder Liner

 a bore in which an engine piston moves back and forth

 replaceable
 the material of the liner must withstand extreme heat and
pressure developed within the combustion space at the
top of the cylinder, and at the same time must permit the
piston and its sealing rings to move with a minimum of
friction

20
Anshu Girdhar – Training Report
 Piston

Piston
A piston is a component of reciprocating engines. It is located
in a cylinder and is made gas-tight by piston rings. Its purpose is
to transfer force from expanding gas in the cylinder to
the crankshaft via a piston rod and/or connecting rod. In two-
stroke engines the piston also acts as a valve by covering and
uncovering ports in the cylinder wall.

 one of the major moving parts

 crown
 must be designed to withstand extreme heat and
combustion pressure
 made of cast iron or aluminium (to reduce weight)

21
Anshu Girdhar – Training Report
 Oil Pump

Valves
All four-stroke internal combustion engines employ valves to
control the admittance of fuel and air into the combustion
chamber. Two-stroke engines use ports in the cylinder bore,
covered and uncovered by the piston, though there have been
variations such as exhaust valves.
Piston engine valves
In piston engines, the valves are grouped into 'inlet valves'
which admit the entrance of fuel and air and 'outlet valves'
which allow the exhaust gases to escape. Each valve opens once
per cycle and the ones that are subject to extreme accelerations

22
Anshu Girdhar – Training Report
are held closed by springs that are typically opened by rods
running on a camshaft rotating with the engines' crankshaft.

Control valves
Continuous combustion engines—as well as piston engines—
usually have valves that open and close to admit the fuel and/or
air at the startup and shutdown. Some valves feather to adjust
the flow to control power or engine speed as well.

Exhaust system

Internal combustion engines have to effectively manage the

exhaust of the cooled combustion gas from the engine. The
exhaust system frequently contains devices to control both
chemical and noise pollution. In addition, for cyclic
combustion engines the exhaust system is frequently tuned to
improve emptying of the combustion chamber. The majority of
exhausts also have systems to prevent heat from reaching places
which would encounter damage from it such as heat-sensitive
components, often referred to as Exhaust Heat Management.

Cooling system

Combustion generates a great deal of heat, and some of this

transfers to the walls of the engine. Failure will occur if the
body of the engine is allowed to reach too high a temperature;
either the engine will physically fail, or any lubricants used will
degrade to the point that they no longer protect the engine.
The lubricants must be clean as dirty lubricants may lead to
over formation of sludge in the engines.

23
Anshu Girdhar – Training Report
Cooling systems usually employ air (air-cooled) or liquid
(usually water) cooling, while some very hot engines using
radiative cooling (especially some rocket engines). Some high-
altitude rocket engines use ablative cooling, where the walls
gradually erode in a controlled fashion. Rockets in particular
can use regenerative cooling, which uses the fuel to cool the
solid parts of the engine.

Flywheel
The flywheel is a disk or wheel attached to the crank, forming
an inertial mass that stores rotational energy. In engines with
only a single cylinder the flywheel is essential to carry energy
over from the power stroke into a subsequent compression
stroke. Flywheels are present in most reciprocating engines to
smooth out the power delivery over each rotation of the crank
and in most automotive engines also mount a gear ring for a
starter. The rotational inertia of the flywheel also allows a much
slower minimum unloaded speed and also improves the
smoothness at idle. The flywheel may also perform a part of
the balancing of the system and so by itself be out of balance,
although most engines will use a neutral balance for the
flywheel, enabling it to be balanced in a separate operation.
24
Anshu Girdhar – Training Report
The flywheel is also used as a mounting for the clutch or a
torque converter in most automotive applications.

Starter Motor

25
Anshu Girdhar – Training Report
All internal combustion engines require some form of system
to get them into operation. Most piston engines use a starter
motor powered by the same battery as runs the rest of the
electric systems. Compressed air can be supplied from another
engine, a unit on the ground or by the aircraft's APU. Large
stationary and marine engines may be started by the timed
injection of compressed air into the cylinders — or occasionally
with cartridges. Jump starting refers to assistance from another
battery (typically when the fitted battery is discharged),
while bump starting refers to an alternative method of starting
by the application of some external force, e.g. rolling down a
hill.
Heat shielding systems
These systems often work in combination with engine cooling
and exhaust systems. Heat shielding is necessary to prevent
engine heat from damaging heat-sensitive components. The
majority of older cars use simple steel heat shielding to
reduce thermal radiation and convection. It is now most
common for modern cars are to use aluminium heat shielding
which has a lower density, can be easily formed and does not
corrode in the same way as steel. Higher performance vehicles
are beginning to use ceramic heat shielding as this can
withstand far higher temperatures as well as further reductions
in heat transfer.

26
Anshu Girdhar – Training Report
 Lubrication systems

Internal combustions engines require lubrication in operation

that moving parts slide smoothly over each other. Insufficient
lubrication subjects the parts of the engine to metal-to-metal
contact, friction, heat build-up, rapid wear often culminating in
parts becoming friction welded together e.g. pistons in their
cylinders. Big end bearings seizing up will sometimes lead to
a connecting rod breaking and poking out through the
crankcase.

Several different types of lubrication systems are used. Simple

two-stroke engines are lubricated by oil mixed into the fuel or
injected into the induction stream as a spray. Early slow-speed
stationary and marine engines were lubricated by gravity from
small chambers similar to those used on steam engines at the
time — with an engine tender refilling these as needed. As
engines were adapted for automotive and aircraft use, the need

27
Anshu Girdhar – Training Report
for a high power-to-weight ratio led to increased speeds, higher
temperatures, and greater pressure on bearings which in turn
required pressure-lubrication for crank bearings
and connecting-rod journals. This was provided either by a
direct lubrication from a pump, or indirectly by a jet of oil
directed at pickup cups on the connecting rod ends which had
the advantage of providing higher pressures as the engine speed
increased.

Control systems
Most engines require one or more systems to start and shut
down the engine and to control parameters such as the power,
speed, torque, pollution, combustion temperature, and
efficiency and to stabilise the engine from modes of operation
that may induce self-damage such as pre-ignition. Such systems
may be referred to as engine control units.
Many control systems today are digital, and are frequently
termed FADEC (Full Authority Digital Electronic Control)
systems.

28
Anshu Girdhar – Training Report
 Timing Gear Housing
The gear train with a two to one reduction through which the
crankshaft drives the camshaft and thus controls valve timing in
a four-stroke cycle internal-combustion engine.
It involves :
 Cam Gear
 Timing Gear
 Crank Gear
 Edler Gear

29
Anshu Girdhar – Training Report
 TG Cover

g
Cylinder Head

The cylinder head (often informally abbreviated to just head)

sits above the cylinders on top of the cylinder block. It closes in
the top of the cylinder, forming the combustion chamber.

30
Anshu Girdhar – Training Report
This joint is sealed by a head gasket. In most engines, the head
also provides space for the passages that feed air and fuel to the
cylinder, and that allow the exhaust to escape.

Rocker arm
A rocker arm (in the context of an internal combustion
engine of automotive, marine, motorcycle and reciprocating
aviation types) is an oscillating lever that conveys radial
movement from the cam lobe into linear movement at
the poppet valve to open it. One end is raised and lowered by a
rotating lobe of the camshaft (either directly or via
a tappet (lifter) and pushrod) while the other end acts on
the valve stem. When the camshaft lobe raises the outside of
the arm, the inside presses down on the valve stem, opening
the valve. When the outside of the arm is permitted to return
due to the camshafts rotation, the inside rises, allowing the
valve spring to close the valve.

31
Anshu Girdhar – Training Report
 Rocker Head or Rapid Head

Water Pump
A coolant pump is a type of pump used to recirculate a
coolant, generally a liquid, that is used to transfer heat away
from an engine or other device that generates heat as a by
product of producing energy.

Assembled Engine
32
Anshu Girdhar – Training Report
 Testing of Engine

With a growing demand for transportation IC engines have

gained lot of importance in automobile industry. It is therefore
necessary to produce efficient and economical engines. While
developing an IC engine it is required to take in consideration
all the parameters affecting the engines design and
performance. There are enormous parameters so it becomes
difficult to account them while designing an engine. So it
becomes necessary to conduct tests on the engine and
determine the measures to be taken to improve the engines
performance.

33
Anshu Girdhar – Training Report
 Performance parameters
1. Power and Mechanical
Efficiency
2. Fuel Air Ratio
3. Volumetric Efficiency
4. Specific Output
5. Specific Fuel Consumption
6. Thermal Efficiency and
Heat Balance
7. Exhaust Smoke and
Emissions
8. Effective Pressure and
Torque

Power and mechanical efficiency

An IC engine is used to produce mechanical power
by combustion of fuel. Power is referred to as the rate at which
work is done. Power is expressed as the product of force and
linear velocity or product of torque and angular velocity. In
order to measure power one needs to measure torque or force
and speed. The force or torque is measured by
Dynamometer and speed by Tachometer. The power
developed by an engine and measured at the output shaft is
called the brake power (bp) and is given by,

𝟐𝒏𝝅𝑻 where:
𝒃𝒑 =
𝟔𝟎
T is the torque, in Newton meter (N.m),
n is the rotational speed, in minutes,
bp is the brake power, in watt.

34
Anshu Girdhar – Training Report
Indicated Power
It is the power developed in the cylinder and thus, forms the
basis of
evaluation of combustion efficiency or the heat release in the
cylinder.

Thermal efficiency and heat balance

It is the ratio of output to that of energy input in the form of
fuel. It gives the efficiency with which the chemical energy of
fuel is converted into mechanical work. It shows that all
chemical energy of fuel is not converted into heat energy.

35
Anshu Girdhar – Training Report
Thermal efficiency and total energy input- The methodology
for calculating thermal efficiency of a unit is described in this
section to help to determine whether the unit qualifies to
exemption or not. It also includes total energy input which also
helps in determining thermal efficiency.
The thermal efficiency standard for a unit are decided
by CAIR model trading rules, the CAIR FIP, CAMR, the
CAMR Hg model trading rule, and the proposed CAMR
Federal Plan, EPA. However, the thermal efficiency standard
applicable to all fuels combusted by a unit are decided by
the United States Environmental Protection Agency (EPA),
while the application of the standard to natural gas and oil are
made by FERC.

Exhaust smoke and other emission

Exhaust emission test

Smoke and other emission are undesirable for public
environment. Due to global warming and emphasis on air
pollution all possible things are tried to keep them low. Smoke
also indicates incomplete combustion of fuel.

36
Anshu Girdhar – Training Report
Practical solutions for reducing air pollution:
 There have been very few solutions made available that are
both cost-effective and efficient regardless of health
complicated issues.
 Gives protection of firemen, children and other public
workers who are exposed to harmful gases.
 No loss mileage or horsepower in engine.
 Does not use engine resources to operate.
 Installation and compatible of all diesel engines are easy,
which quickly solves the root of the problem.
 Prolonged filter and maintenance are easy, which
automatically triggers diesel emission filtration.
 Shielding yourself by providing legal safe workplace.
 Effective on high octane low sulphur diesel fuel or ordinary
fuel.
 Reduction in 99% diesel emission.

37
Anshu Girdhar – Training Report
 Volumetric efficiency

It is the ratio of the actual volume of the charge drawn in

during the suction stroke to the swept volume of the piston.
The amount of air taken inside the cylinder is dependent on
the volumetric efficiency of an engine and hence puts a limit on
the amount of fuel which can be efficiently burned and the
power output. The value of volumetric efficiency of a normal
engine lies between 70 and 80 %, but for engines with forced
induction it may be more than 100 %. Naturally aspirated
engines can have volumetric efficiencies of more than 100% by
using properly designed induction piping, utilizing resonance in
the induction pipe (by selecting the induction pipe length
according to the rotation speed at which maximum VE is
desired) as well as the inertia of the air mass in the induction
piping. Using inertia effects requires high air speeds in the
induction system, which is normally accompanied by high flow
losses. By careful design and streamlining of the inlet port and
valves, much of the losses can be reduced to an acceptable
level. Resonance and inertia effects are normally only used in
high speed sports engines, for example as found in many
modern motorcycles.

Thermostat

38
Anshu Girdhar – Training Report
A thermostat is a component which senses the temperature of
a system so that the system's temperature is maintained near a
desired set point. The thermostat does this by switching heating
or cooling devices on or off, or regulating the flow of a heat
transfer fluid as needed, to maintain the correct temperature.

Clutch :

39
Anshu Girdhar – Training Report
A clutch is a mechanical device that engages and disengages the
power transmission, especially from driving shaft to driven
shaft.
Clutches are used whenever the transmission of power or
motion must be controlled either in amount or over time (e.g.,
electric screwdrivers limit how much torque is transmitted
through use of a clutch; clutches control whether automobiles
transmit engine power to the wheels).
In the simplest application, clutches connect and disconnect
two rotating shafts (drive shafts or line shafts). In these devices,
one shaft is typically attached to an engine or other power unit
(the driving member) while the other shaft (the driven member)
provides output power for work. While typically the motions
involved are rotary, linear clutches are also possible.
In a torque-controlled drill, for instance, one shaft is driven by
a motor and the other drives a drill chuck. The clutch connects
the two shafts so they may be locked together and spin at the
same speed (engaged), locked together but spinning at different
speeds (slipping), or unlocked and spinning at different speeds
(disengaged).

Differential Assembly

40
Anshu Girdhar – Training Report
 Differential Housing

A differential is a gear train with three shafts that has the

property that the angular velocity of one shaft is the average of
the angular velocities of the others, or a fixed multiple of that
average.

The differential assembly in a rear-wheel drive vehicle has

three functions. The first, and most obvious, is to redirect the
power flow to drive the rear wheels. The power flow must
make a 90° turn between the drive shaft assembly and the rear
wheels. This is accomplished in the differential assembly by the
drive pinion and ring gears.

The second function of the differential assembly is to multiply

engine power, reducing speed at the output in the process. If
there were no gear reduction (1:1 gear ratio), the vehicle would
accelerate very slowly. In some cases, the engine would be
unable to move the vehicle.

41
Anshu Girdhar – Training Report
At the very least, gas mileage would be harmed, since the
engine would not reach its most efficient rpm range. For this
reason, the ring and drive pinion assembly, by design, provides
a reduced speed at its output. The reduction is between 2:1
and about 5:1, depending on the engine size, vehicle weight,
and intended use of the vehicle.

The third function of the differential assembly is to allow the

vehicle to make turns. If the assembly did not make allowances
for the different speeds of the rear wheels during turns, one tire
would lose traction with the ground as the vehicle turned
corners. The differential assembly allows the vehicle to make
smooth turns.

The differential assembly consists of numerous parts, including

the differential drive gears (ring and drive pinion gears), pinion
bearings, differential case, spider and side gears, and side
bearings.

42
Anshu Girdhar – Training Report
 It is a system comprising a
splined output shaft on a tractor or
truck, designed so that a PTO
shaft, a kind of drive shaft, can be
easily connected and
disconnected, and a
corresponding input shaft on the
application end. The power take-
off allows implements to draw
energy from the engine.

PTO Shaft

PTO Shifter

43
Anshu Girdhar – Training Report
A differential couples the input shaft (or prop shaft) to
the pinion, which in turn runs on the crown wheel of the
differential. This also works as reduction gearing to give the
ratio. On rear wheel drive vehicles the differential may connect
to half-shafts inside an axle casing or drive shafts that connect to
the rear driving wheels. Front wheel drive vehicles tend to have
the pinion on the end of the main-shaft of the gearbox and the
differential is enclosed in the same casing as the gearbox. They
have individual drive-shafts to each wheel. Older 4x4 vehicles
and tractors usually have a solid front axle, the modern way can
be a separate differential and drive shaft arrangement for the
front.

Rear assembly

Real assembly line is starting of assembly shop. Before the

various differential parts such as bp shaft, differential cage etc.
are assembled, the various sub-assembly of parts listed above
are performed in the sub units. In the first unit, both the bp
shafts are fitted with various components such as circular clips,
bearings etc. to be able to be assembled to the differential
44
Anshu Girdhar – Training Report
Cage. This constitutes the assembly of cross bar, planetary gear,
planetary gear cover, and crown wheel etc.
The Axles are assembled in a different sub
assembly shop. First rear axle wash and dry
and then fixed wheel side bearing and there
on the whole unit along with
the bull gears is assembled to the differenti
al Cage. Dc assemble after these
assemblies.

Gear Box Assembly

The gear box assembly is the third stage of the assembly unit in
which the gear box is assembled. Firstly, the gearbox cage is
collected from the conveyor roller and successively parts such
as the counter shafts, clutch shafts, main shaft along with the

45
Anshu Girdhar – Training Report
ball bearings are assembled to the unit. There is separate sub
unit assembling the planetary cage and gears, which is then
attached to the gear box output shaft.
First gear on main shaft with 38 teeth and reverse gear with 38
teeth, second gear with 35 and and third with 28 teeth. This is
the constant mesh type transmission.

After Assembly of the transmission there is leakage testing is

perform. In this test first gear box is full of oil and then sealed.
After that the pressure is increase up to10 bar. Then the by the
motor power the clutch shaft is revolve at 2700 rpm. This test
check meshing of gears. After that whole unit is assembled to
the main line and make a complete one unit.

46
Anshu Girdhar – Training Report
 Paint Shop

Paint shop is completely automatic. In the paint shop first there

is degreasing ,water rinsing and demineralized water rinsing.
After that air blowing is done. Paint Baking Oven removes the
moisture from water-based coatings and adhesives. After that
un smasking and touch up and painted the body.
Procedure as follows:
1. Degreasing
2. Water Rinsing
3. D M Water Rinsing
4. Air Blowing
5. Moisture Drying Oven
6. Primer Painting
7. Finish Booth

47
Anshu Girdhar – Training Report
 Rear and Front wheel fitting

After painting there is fitting of rear wheel with tyre size

of 12.4×28 and front wheel fitment with the tyre size of 6×16.
After fitting the wheels there is following fitment.

48
Anshu Girdhar – Training Report
 Accessories

 Fan and Motor

 Rear hood
 Radiator and coolant
 Steering wheel
 Mirror
 Air filter
 Front light
 Seat
 Silencer

49
Anshu Girdhar – Training Report
 Final Testing

50
Anshu Girdhar – Training Report
Final testing of tractor is lift testing and the test of track. At
there a hydraulic force of 1050 kg applied and testing is done.

51
Anshu Girdhar – Training Report
 Conclusion

Summer training in Escorts Ltd. really helped me to familiarize

myself to the practical knowledge of industrial production
and processes. The whole training period was very
interesting, instructive and challenging. Through this training I
was able to gain new insights and more comprehensive
understanding about the real industry working condition and
practice. I got the idea of working of automatic CNC machines,
Testing techniques of Diesel engine, tractors and Assembly
plant. All of this valuable experience and knowledge that I have
gained were not only acquired through the direct involvement
in task given but also through other aspect of the training such
as work observation, interaction with operators, supervisor and
other peoples involved in the process. In assembly plant i saw
how tractor are assembled. I get knowledge about different-
different sub assemblies of tractor assembly plant. Differential
sub assembly, transmission sub assembly, transmission testing,
paint of body and different sub stations. It was a good idea and
good chance to expose to the work environment that we will
have to face and practice after we graduate.

As a result of the training now I am more confident to enter the

employment world and build my future career.

52
Anshu Girdhar – Training Report