ENGINE SHOP

INTRODUCTION:
In this shop, assembly of engine, gearbox and Main transmission housing is done. After this, washing, drying and painting of whole assembly is done. Tyres, bonnet, fuel tank, steering wheel, panel, mudguard, seats and lights are also connected to above assembly in later sections. Then, tractor is dispatched from shop. It also comprises of assembly of various components of gearbox and main transmission housing. The various sections of engine shop are:

1.M.T. HOUSING SUB-ASSEMBLY:

In this section, various components of main transmission housing are assembled. These components comprises of Bevel pinion, crown wheel, differential cage and differential shaft, HPL shaft, HPL pinion, HPL pump with filter. Bevel pinion is attached to crown wheel. Spiral bevel pinion is arranged to take power from gearbox through supline shaft and transmit it to crown wheel. Teeth present on bevel pinion gear coincide with teeth of crown wheel and power transmission occurs. The crown wheel is in turn connected with right differential cage. There are two cages i.e. left cage and right cage.

Inside these cages, there are two sun gears and four planet gears. These gears together constitutes differential which helps in power distribution on curves. The cage gets rotating movement through planet pins, on which planet gears are mounted. When the tractor is in straight motion, then crown wheel supplies the power to right cage and through planet pins, this power is transmitted to planet gears. From planet gears, power is transmitted to sun gears on both sides in the cages and through these sun gears; power is transmitted to differential shaft. The differential shaft transmits this motion to gearwheel through pinion. Gear wheel supplies that motion to wheel shaft and in turn to tyres through tyre hubs. Wheel shaft finally rotates both wheels with same speed due to power transmitted from sun gears. On left turn, the rotation of left sun gear becomes slower and right sun gear rotates faster due to the axial rotation of planet gears and vice versa for right turn. This mechanism helps in efficient turning of wheels.

In 6522 tractors, Differential lock is also present. It locks rear wheels i.e. differential becomes constant. Differential lock is mounted on differential shaft and has splines cut on it. Its other portion, having broaches opposite to broaches of differential shaft is mounted on crown wheel, which has internal broaches cut on it. Its movement is regulated using a lever, which when

moved combines two portions of lock i.e. broaches of lock with broaches of portion with crown wheel. Now, direct transmission of power occurs from crown wheel to lock and in turn to differential shaft, which transmits it to sun gear and then to planet gear, and in end to another sun gear. Hence, left and right movement of differential is restricted and whole power is used to push the tractor forward. This lock is particularly useful, when tractor is drowned in mud.

2.GEAR BOX (SLIDING TYPE) SUB-ASSEMBLY:

In this section, various components of gearbox are assembled together. These components comprises of hollow clutch shaft, main clutch shaft, lay shaft, spline shaft, reduction shaft, bevel pinion shaft, speed gears transmission gears, binder gear, constant mesh gear, high and low speed gears. The description of working and connections of these components is given below: A. Hollow clutch shaft: It is mounted on main clutch shaft and is connected to engine by hollow shaft clutch plate. It is used to drive first P.T.O. shaft through binder gear. This P.T.O. passes through lay shaft and reduction shaft. One end of hollow clutch shaft is connected to clutch plate and other end is in contact with binder gear through pinion. Though, power used to drive P.T.O. is obtained from hollow clutch shaft but functioning of P.T.O.

shaft is regulated by binder gear. There is a lever above gearbox housing, which connects binder gear with hollow clutch shaft. Now, teeth cut on P.T.O. matches with splines of binder gear and hence, P.T.O. runs with rpm of engine or hollow clutch shaft. This power is then further used in various purposes. The position of binder gear is adjusted with fork connected to lever. a. Main clutch shaft: It is inserted in hollow clutch shaft and is also connected to engine through main clutch plate and in turn to fly wheel. It extends up to supline shaft and gives rotating motion to lay shaft through constant mesh gear. It always remains in constant position, hence named so. b. Lay shaft: It is present below spline shaft and is having speed gears mounted on it. It takes power from main clutch shaft through constant mesh gear. The gears present on it have keys, which helps in permanent fixing of speed gears i.e. they remain in constant position on lay shaft. The speed gears then transmit power to transmission gears present on spline shaft. First P.T.O. shaft is also inserted between lay shaft. c. Spline shaft: It is mounted in front of main clutch shaft above lay shaft region. There are pin roller bearings present between spline shaft and main clutch shaft, which help in transmission of power from main clutch shaft to spline shaft only in case of fourth forward transmission gear. 4-5 power

transmission gears with one reverse gear are mounted on this shaft having sliding motion, which receive power from lay shaft through speed gears. The power from these gears is then transmitted to bevel pinion through high or low speed gears. Generally, there are three sliding gears, one gear for 1st forward and reverse gear, second for 2nd and 3rd forward gear and third for 4th forward gear. These gears also work in two conditions, i.e. high speed and low speed. High speed is used when lesser power is required for tractor and high speed is desired e.g. on roads. Similarly, low speed is used when high power is required for tractor and operator requires low speed e.g. in fields. The transmission of these gears is regulated using a lever, which has a fork and dove ring attached to it. High-speed gear is fixed on spline shaft and low speed gear is mounted on bevel pinion shaft with free motion. In high speed condition, half portion of broaches on dove ring meshes with the teeth of high speed gear and half of the broaches of dove ring meshes with step dove gear which in turn meshes with the bevel pinion shaft. In this way, bevel pinion fixed on the bevel pinion shaft transmits motion to crown wheel.In case of low speed, half of broaches of dove meshes with the teeth of low speed gear and half the broaches of dove ring meshes with step dove gear and in turn to bevel pinion shaft. The transmission to low gear is provided through gears on reduction shaft.

d. REDUCTION SHAFT: It is connected to lay shaft and have P.T.O.

shaft passing through it. It takes power from spline shaft and a gear on it provides transmission to low speed gear. It may also be connected to HPL (Hydraulic pump lift) shaft through lever.

e. HYDRAULIC PUMP LIFT SHAFT: This shaft is inserted between

P.T.O. I and P.T.O. II.i.e. Its one end is temporarily connected to P.T.O. I and other to P.T.O. II permanently. There are four conditions for driving P.T.O. and HPL. These conditions are achieved manually with help of a lever. The description of these conditions is given below: 1. In first condition, Broaches of HPL shaft matches with teeth cut end of reduction shaft, which rotates PTO II but pump does not works as teeth cut on pump shaft does not make any contact with teeth of gear used to drive the pump. It should be noted that power transmission to HPL shaft occurs through gearbox i.e. HPL shaft rotates with rpm of gear box. 2. Second position is neutral position in which HPL shaft does not work. Therefore, PTO II as well as pump will not work and neutral stage is achieved. In this stage, broaches of HPL shaft does not make any contact with spline cut on reduction shaft or on PTO I. 3.In third condition, direct transmission of power occurs from PTO I to HPL shaft and teeth of HPL shaft combine with teeth of pump driving gear. Now,

both HPL and PTO II works. This lift can be used in various purposes. Here, power transmission occurs with engine i.e. HPL shaft rotates with rpm of engine. 4.When lever is pushed in 4th position, then HPL shaft moves forward and only PTO II moves under action of HPL shaft. In this condition, power transmission occurs directly through engine. In this case the PTO II get transmission through PTO I.

3.MECHANICAL BRAKE ASSEMBLY:

In this section, mechanical brakes are assembled with differential shaft. There are two brake bushes, one of which is connected to the brake cover and other one is connected rigidly to outside face of MT housing. There are two discs connected to differential shaft through supline, one of which is near to the brake cover and other one is connected near to the MT housing. There is a two-plate mechanism between the two discs. Plates have springs, ball bearings, and forks arranged in it. Ball bearing is initially fixed in its position and fork is connected with brake paddle, which in turn pulls spring. When brake paddle is pressed, then it pulls wire and hence springs are also pulled. Consequently, plates change their position and due to this, ball bearing dislocates from its position and comes in between two plates. Now,

both these plates expand and insert a pressure on discs, which make a rigid contact with brake bushes. As a result, motion of differential shaft get stopped and which results in stopping of wheels

4.GEAR SHIFTING ASEEMBLY:

In this section, gear box cover, gear shifting rod and forks are assembled with gear box. Cover provides insulation to components installed in gear box and forks and gear shifting rod helps to change gears.

5.PORTAL/DX MOUNTING:
Here, portal and direct axle is mounted with MT housing. Portal consists of bull gear, which provides motion to wheels. The teeth of bull gear matches with teeth of differential shaft pinion gear fixed on differential shaft, which transmits power to it. The bull gear having internal broaches in it get matched with the supline of wheel shaft, which in turn supplies, the motion to tyres.

6.LIFT MOUNTING:
In this section, hydraulic lift is mounted on MT housing. Its working is regulated using hydraulic pump having HPL shaft.

HPL shaft takes power from engine through PTO I or through reduction shaft. The HPL gear gets motion from HPL shaft and pumps oil to the lift through pipe so that it can work with oil pressure.

7.ENGINE MOUNTING:
Here, engine is mounted with MT housing and gearbox assembly. Main clutch shaft is connected to main clutch plate while hollow clutch shaft is connected to hollow clutch plate. Both these shafts pass through pressure plate, whose function is to provide pressure for proper functioning of clutch plates. These clutch plates help to break connection of gear box with engine when clutch pedal is pressed. The motion is provided to pressure plate through flywheel fixed to it. Flywheel is fixed with the crank shaft from where it get motion.

8.WASHING ZONE:
In this zone, washing of whole assembly is done to remove oil, dust etc. from it. The assembly is then dried by means of air blowers to remove moisture from it.

9.PAINTING ZONE:
In this zone, painting is done to protect the tractor from corrosion etc.

10.CHASIS BAKING OVEN:

In chasis baking oven, tractor is baked for 20 minutes and at 60-70 C so as to dry paint.