Amit Sharma 2012UGMEL127 INDUSTRIAL TRAINING

INDUSTRIAL TRAININGAT

SWARAJ ENGINES LIMITED

Submitted byAmit Sharma2012UGMEL127M.E. (7th Semester)

Under the Guidance of :Mr. Amritpal SharmaEngine Assembly LineSwaraj Engines Ltd. Mohali

COMPANY ADDRESS :

MAHINDRA & MAHINDRA


PHASE-9 , INDUSTRIAL AREA

S.A.S. NAGAR MOHALI

OBJECTIVES OF TRAINING

1. To study the various process which are done on various parts

of tractor engine

2. To study about Production Planning & Control.

3. To study the function of different departments with respect to

each other.

4. To study process flow charts.

5. To study about management.

6. To study about Human Resource Management and their

behavior about employees.

SWARAJ A GROWING ENTERPRISE

Hindi meaning of SWARAJ “ Freedom From Bondage ” and used

first by Bal Ganga Dhar Tilak during the time of freedom.

Punjab Tractors Limited (PTL) was the first tractor project in India,

moreover fully based upon Indian Technology.

SWARAJ is the brand name of SWARAJ GROUP.

It was established in 1965 by a team of dedicated Engineers &

Scientists working at Central Mechanical Engineering Institute at

Durgapur.

INTRODUCTION

POSITION OF SWARAJ PRODUCTS IN MARKET

The products of SWARAJ are not only restricted to Indian Market but they had entered in International Market.

SWARAJ tractors find an important place in developing countries like Ghana, Tanzania, Zambia, Kenya, Sudan, Uganda, Indonesia & Malaysia, etc.

They are also sending their Combines to South Korea having first A.C. Cabin Combine in India.

Long way back, they had also transported the machined rims to Japan, a project millions of dollar.

SWARAJ TRACTOR LIMITED Or PTL DIVISIONS

Swaraj Tractor Division (STD) Mohali Swaraj Combine Division (SCD) Chapparchiri Swaraj Foundry Division (SFD) Mazri Swaraj Automotive Limited Swaraj Engines Limited (SEL) Mohali Swaraj Mazda Limited (SML)

SWARAJ

TRACTOR DIVISION

SWARAJMAZDA

LIMITED

AUTOMOTIVE LIMITED

ENGINE LIMITED

FOUNDRY LIMITED

COMBINE DIVISION


SWARAJ ENGINES LIMITED (SEL), Mohali was started in 1986 in

technical and financial collaboration with Kirloskar Oil Engines (KOEL)

for manufacture of diesel engines.

SEL is a joint venture between erstwhile Punjab Tractors Ltd. (PTL), which

has since been merged with Mahindra & Mahindra (M & M) and Kirloskar

Oil Engines (KOEL).

In recent years SEL has also been a super supplier of Hi-Tech Engine

components to Swaraj Mazda Limited (SML) and Swaraj Tractors Limited.


The Governor of Punjab Mr. S.S. Ray paid the foundation stone of the factory on 29th Dec. 1987.

It started production from 28th Dec. 1988.

The plant produces engines in the range of 20 H.P. to 50 H.P.

This plant had produced 18000 engines in the first year of its production. But now producing 270 engines averagely every day. There are 5,00,000 tractors working successfully in the fields which are having engines of SEL.

SHARE HOLDING PATTERN


As on 30th September,2014

Shareholding1st Qtr2nd Qtr3rd Qtr4th Qtr5th Qtr6th Qtr

% of Shareholding

Mahindra & Mahindra Ltd (M&M)

33.22%

Kirloskar Industries Ltd. (KOEL)

17.39%

Mutual Funds 10.00%

Financial Institutions/Insurance CO’s/Banks

0.09%

FIIs 5.45%Public 33.84%

Various Engine Models

1. R-V2, Two cylinder ; 24 H.P.

2. R-V3, Three cylinder ; 39.5 H.P.

3. S15, Single cylinder ; 25 H.P.

4. RB-33, Three cylinder ; 54 H.P.

5. RB-30, Three cylinder ; 44 H.P.

6. RB-33 TC, Three cylinder ; 58 H.P.

VISION & MISSION

Vision :

Swaraj 2nd Largest

Brand in India with

Global Presence.

Mission :

3-2-3

In 3 years Double the

Revenue and Triple the

Profits

12

TYPES OF ENGINES MANUFACTURED IN SEL

The Plant manufactures Six types of Engines, which engines are

sent to the Swaraj Tractor Division, S.A.S. Nagar. One of these

is a Two Cylinder Engine exclusively Designed for R & D plant

of Swaraj. Out of rest one is two cylinder and Three cylinder

engines.

All engines are EURO-3 and SEL is planning for modifications

to be introduced, so that its engines may be EURO-4

compatible.

SPECIFICATION OF ENGINES

Model S-15 ; Swaraj S-15 ; Swaraj

H.P. 20-25 H.P. 24.5 H.P.Tractor 825 XM SWARAJ 722 SuperType 4-Stroke, Direct

Injection, Diesel Engine

4-Stroke, Direct Injection, Diesel Engine

No. of Cylinders 1 1Bore & Stroke 120136 mm 120126 mmDisplacement 1538 cc 1425 ccRated Engine Speed 1650 rev/min 1900 rev/min

RV-2, Two Cylinder EngineModel RV-2

KIRLOSKARRV-2 XM + 3A

H.P. 26.5 H.P. 25-30 H.P.Tractor SWARAJ 724 FE 724 XM

ORCHARDType 4-Stroke, Direct



No. of Cylinders 2 2Bore & Stroke 100 110mm 100 116 mmDisplacement 1728 cc 1824ccRated Engine Speed 2000 rev/min 1800 rev/min

RV-3, Three Cylinder Engine

Model RV-3 TR ; KIRLOSKAR

RV-3 XM + 3A

H.P. 39 H.P. 35-40 H.P.Tractor SWARAJ 735 FE 735 XMType 4-Stroke, Direct



No. of Cylinders 3 3Bore & Stroke 100 110mm 100 116 mmDisplacement 2592 cc 2734 ccRated Engine Speed 2000 rev/min 1800 rev/min

RV-30, Three Cylinder Engine


RV-30 XM + 3A

H.P. 34 H.P. 30-35 H.P.Tractor SWARAJ 834 FE 834 XMType 4-Stroke, Direct



No. of Cylinders 3 3Bore & Stroke 110 100 mm 100 110 mmDisplacement 2474 cc 2592 ccRated Engine Speed 2000 rev/min 1800 rev/min

RB-30, Three Cylinder EngineModel RV-30 TR ;

KIRLOSKARRV-30 XM + 3A

H.P. 48 S.A.E. 40-50 H.P.Tractor SWARAJ 744 FE 744 XMType 4-Stroke, Direct



No. of Cylinders 3 3Bore & Stroke 110 110 mm 100 116 mmDisplacement 3136 cc 3307 ccRated Engine Speed 2000 rev/min 1800 rev/min

RB-33, Three Cylinder Engine


RV-33 XM

H.P. 55 S.A.E. 50-55 H.P.Tractor SWARAJ 855 FE 855 XMType 4-Stroke, Direct



No. of Cylinders 3 3

Bore & Stroke 100 116 mm 110 122 mmDisplacement 3308 cc 3480 ccRated Engine Speed 2000 rev/min 1800 rev/min

SWARAJ TRACTOR ENGINE

WORK AT SWARAJ ENGINES LTD.

Various Departments at SEL include :

(1) Human Resource Department (H.R.D.) (2) Information Technology

(3) Accounts (4) Purchase

(5) Production Planning & Control (P.P.C.) (6) Industrial Engineering (I.E.)

(7) Machine Shop (8) Tool Room

(9) Tool Crib (10) Assembly Shop

(11) Engine Testing (12) Quality Engineering

(13) Standards Room (14) Store

(15) Maintenance

Define

Human Resource Department

1. Creating acceptable rules of practice to encourage highest degree of participation from its employees to contribute towards organizational goals.

2. It ensures maximum individual development, desirable working condition and desirable working relationship between employees and employers.

1. It ensures development of computing services in the organization to meet the future technological needs.

2. It is also responsible for the preventive maintenance of both hardware & software installed in the entire premises.

INFORMATION TECHNOLOGY

Accounts The main objective of accounts department is to determine, classify and

analyze the cost & income of the business enterprise.

It provides information for the following :

1. Cost control 2. Profitability3. Budgeting 4. Standard Costing5. Proper matching of cost with revenues6. Control of material and Supplies7. Wages and overhead costs8. Determining Expansion Policies

Purchase

1. Responsible for purchasing all types of materials in correct quality & quantity and at the most economical prices.

2. It has a unique position with a view that purchasing is one of the main function in the success of modern manufacturing concern.

3. The purchasing function act as a liaison agency, which operates between the factory and the outside vendors on all matters of procurement delivery of the articles in accordance with terms of purchase agreement.

1. The PPC cell at SEL is in charge of maintaining the inventory status, arranging receipt,

dispatch of components and follow up.

2. It also supervises transfer of components from the machine shop and stores to the

assembly shop and maintains the shop floor status of components.

PPC indicate two functions :

3. Production Planning is the function concerned with the planning, directing and

controlling of the methods to be used to make products and the way in which the

production facilities should be laid out in the space available for production.

4. Production Control is the function of management, which plans, directs, coordinate &

controls the material supply and processing activities of an enterprise. So that specified

products are produced by specific methods to meet and approved sales program.

Production Planning & Control (P.P.C.)

Industrial Engineering (I.E.)

1. Industrial Engineering is the back bone of the industry most important department in terms of production, Planning, designing, and optimization of methods governing the factory operations.

2. It is concerned with the design, improvement & installation of integrated system of people, materials, equipment & energy.

3. It draws upon specialized knowledge & skill in the mathematical , physical and social sciences together with principles & methods of engineering analysis and design to specify, predict and evaluate the results to be obtained from such system.

Machine Shop

Machine shop is responsible for the following functions :1. Machining of Crankcases, Cylinder Blocks, and Gear Casings of all engine

models.2. Machining & Assembly of Cylinder Heads.3. Machining & Assembly of Connecting Rods of AVL and SML models.4. Machining SML engine Crankcases & Cylinder Blocks.

Following machining operations are used :

5. Turning6. Drilling7. Boring8. Reaming9. Hole Milling10. Tapping11. Face Milling12. Chamfering13. Grooving14. Grinding15. Honing

1. Horizontal Milling Centers

2. Vertical Milling Centers

3. Surface Grinding Machine

4. Portable Grinding Machine

5. Radial Drilling Machine

6. Tapping Flexi-arms

7. Gang Milling Machine

8. Boring Machine

9. Honing Machine

10. Gun Drilling Machine

11. Washing Machine

12. Cylindrical Grinding Machine

Machines used in Machine Shop include :

Special Purpose Machines Used in M/C shop

The machine shop also houses 14 Advanced CNC Horizontal

Machining Centers comprising :

1. 7 Starrag Heckert HMC's for Crankcase machining

2. 3 Makino HMC's for Gear Case machining

3. 2 Makino HMC's for valve seat & valve guide generation

in cylinder head

4. Latest on the shop, 2 Makino HMC's for Cylinder Block

machining.

Machine Shop's Relation with other departments :

1. Industrial Engineering : Procurement of process sheets, time

study & tool planning.

2. Maintenance : Check for preventive & breakdown maintenance.

3. Tool Room : Requirements of jigs & fixtures, re-sharpening of

cutting tools, etc.

4. Assembly Shop : Reworking of rejected components and supply

of machined components.

5. Quality Engineering : Maintaining the Quality & Inspection of

components at each stage of production.

Tool Room

The tool room in SEL performs the following functions

:

Fabrication & Repair of Jigs & Fixtures

Manufacturing & Repair of Cutting Tools

Manufacturing of other small parts in- house.

Tool Re-sharpening

Development Work

Tool Crib

1. Tools go blunt and wear away with time after completing their life as tools for specific

machining operations.

2. Tool crib is responsible for replacement of these tools to ensure continuity of machining

on the shop floor.

3. It stocks and provides various types of tools including inserts, cutters, drills, boring bars,

reamers, taps, adaptors, other attachments, etc.

4. The tool crib in-charge issuing tool maintains the record of specification and number of

tools issued and notes the employee number and date of issue along with other details.

5. Various types of measuring instruments and gauges like vernier callipers, micrometers,

scales, vernier height gauge, bevel protector, spirit level etc. are also available along here

by auxiliary tools like spanners, hammers & hacksaw etc.

Various Cutting Tools in Tool Crib

Engine Assembly Shop

1. The objective of assembly shop is to combine individual components

into a useful product of higher value.

2. The assembly shop at SEL assembles RV-2, RV-3, RV-30, RB-30 & RB-

33 engines.

3. Assembly is done manually in which workers perform various

assembly operations by using dexterity, sense organs and intelligence

along with various tools and fixtures.

4. Different components are brought from the stores and the machine shop

to be assembled into engines on a common assembly line for all models.

Engine Testing

A completely assembled engine is tested and inspected at various

RPM's at full load, no load and over load in the Engine Testing area

to be finally marked as OK or Not OK.

Basic measurements undertaken to evaluate the performance of

the engine are :

BHP (Break Horse Power)

SFC (Specific Fuel Consumption)

Torque (Using Torque Indicator)

Speed (R.P.M.)

Engine Testing1. Air Consumption2. Lubricating Oil Consumption3. Smoke Density4. Water Inlet Temperature5. Water Outlet Temperature6. Engine Oil Temperature

Quality Department

Its Main Functions Are :

1. To separate defective components from non-defective ones.

2. Detecting Parts not meeting the specifications during processing

itself, so as to minimize any troubles that may arise at assembly time.

3. To make sure that final product meets the required specifications.

4. To detect sources of variations & troubles in finished product.

5. To build reputation of concern by reducing complaints from the

customer.

Quality at Receipt

1. Quality at receipt inspects all incoming materials to evaluate the vendor's quality and to reject those components which don't meet the specification.

2. Inspection of incoming components involves visual and dimensional check-up, and test of physical and chemical properties etc., using hardness tester, surface roughness tester and other gauges.

1. Quality of in-house processed components is either self-inspected or by quality inspectors for the purpose of avoiding flow of faulty materials into the production line.

2. It also houses the Coordinate Measuring Machine (CMM) for the purpose of checking dimensional accuracy of components.

QUALITY AT MACHINE SHOP

Quality at Engine Assembly Quality engineering examines the critical parameters

of engine like tightening of various nut & bolts, Studs, filling the proper clearance, etc. to ensure error free assembly.

Quality at Engine Testing Before finally dispatching the engine, It is tested for

B.H.P. ,S.F.C., Oil Pressure, Loose Nuts & Bolts, Leakages, Noise Level etc., to avoid any problems at customer's end.

Quality at Engine Assembly & Testing

Standard Room

1. Standard room, part of quality engineering department, contain various

measuring gauges and instruments like Calipers, Surface Plate, V-block,

Spirit Level, Combination Set, Engineers Square, Feeler Gauges, Slip

Gauges, Go-No Go Gauges, Dial Indicators, Vernier Height Gauges,

Barometer, Thermometer, Micrometer and Bevel Protectors.

2. The instruments and gauges in use are compared with standard gauges in

the standard room. In order to have an efficient use of working standards

and get accurate results, an agreed standard temperature of 20C is

maintained for the reference gauges.

CMM Room

Coordinate Measuring Machine is installed there for the

purpose of inspection of the coordinates of assembly

components like crankcase, cylinder head, etc. The machine

movements are in X, Y, & Z direction. And the 6 of freedom

of the component to be inspected can be done on that

machine.

Air bearings are used to move the arms of the machine.

Machine is fully automatic and attached with computer

assisted programs.

The gap between the surfaces in contact is 6 microns.

Pressurized air is used as a lubricant. Thus easy in operation.

A Sensor is also used to sense the coordinates and on stylus or

probe ruby metal ball is used to indent on the work piece.

Store

Store Management Ensures :

That the required materials are neither out of stock nor available in excess.

That there is proper storing of materials and proper method of keeping store records.

There is adequate procedure of the receipt and the issue of materials.

Receiving Store - All material from vendors is received and checked by Q.E. (receipt) and upon

clearance the goods are received, unpacked and their quantity and condition is checked.

Main Store - The material upon clearance by the quality reaches the main store. Here it is properly

stored in the bins or stocked. Upon receipt of material requisition from, the storekeeper issues the

material and records the quantities disbursed.

Rejection Store - The material, which is rejected by the Quality, is kept in rejection store to be send

back to the vendor.

Tool Store - The various types of tools used on the shop floor are kept here. Tools are issued on

material issue receipt and their return is recorded through material return slip. Proper record of tool

stock is kept and tool consumption is analyzed.

Various Stores in SEL

Maintenance Department

The Various Objectives of the Maintenance Department are :

1. To achieve minimum breakdown and to prevent loss in production time.

2. Overhauling of plant equipment & machinery.

3. To keep the plant in good working condition at the lowest possible cost.

4. To provide plant protection including fire protection.

5. To establish & maintain a suitable store of maintenance materials.

6. To maintain the various plant services.

7. Generation and distribution of power and other facilities.

Definition : TPM is a maintenance program concept and it resembles to Total Quality Management (TQM) in several aspects, such as•Total commitment to the program by upper level management is required.•Employees must be empowered to initiate corrective action.•It is a on-going process.

Goal of TPM :“Continuously improve all operational conditions, with in a production system ; by stimulating the daily awareness of all employees”.

TOTAL PRODUCTIVE MAINTENANCE (TPM)

TPM has Six Goals :1. Zero Breakdown2. Zero Defect3. Zero Losses4. Zero Accidents5. Zero Pollution6. Zero Health Hazard

TPM IMPLEMENTATION

JISHU HOZEN (JH )STEPSJH STEPS ACTIVITIESJH 0 Understanding Equipment & Thorough CleaningJH 1 Initial Cleaning & TaggingJH 2 Implementing CountermeasuresJH 3 Developing Tentative Standards for CLITA

JH 4 General Equipment Inspection (Equipment Competent Operator)

JH 5 Autonomous Inspection (Process Competent Operator)JH 6 StandardizationJH 7 Autonomous Management

Meaning Of 5S

Japanese Term English Equivalent

Meaning in Japanese Context

Seiri Sorting Throw away all rubbish and unrelated materials from the workplace

Seiton Systematic Arrangement

Set everything in proper place for quick retrieval and storage

Seiso Shining Clean the workplaceSeiketsu Standardization Standardize the way of

maintaining cleanlinessShitsuke Self-Discipline Practice ‘5 S‘ daily –

make it the way of life ; this also means ‘commitment’

Machining Lines at SEL

There are Five Machining Lines in Swaraj Engine Limited. These are as follows :1. Crankcase Machining Line2. Cylinder Block Machining Line3. Cylinder Head Machining Line (RB,RV)4. Connecting Rod Machining Line5. Gear Case Machining Line

CRANKCASE MACHINING LINE

Machine Name: Starrag Heckert

Model : WMW CWK 500 Features of Machine :1. High Flexibility2. Performance3. High Precision & Accuracy

Type : CNC (Computer Numerical Control)

Main Parts Of Machine Tool :1. Bed2. Pallet 3. Automatic Tool Changer (ATC)4. Spindle Head5. Tool Magazine6. Manual Pulse Generator7. Electric Cabinet and CNC unit8. Coolant Tank and Chip Conveyor

Advantages of Upgrading to CNC Machine Tools

1. CNC machine tools can be used

continuously 24hours a day, 365 days

a year and only need to be switched

off for occasional maintenance.

2. These are programmed to manufacture

same types of components multiple

times with the same accuracy and

precision each time, and each

component as an exact match.

3. Modern design software allow the

designer to simulate the manufacture

of his/her idea. There is no need to

make a prototype or a model. This

saves time and money.

Technical Specification

•Clamping surface: 500 mm 500 mm

•Maximum work piece weight : 800kg

•Maximum feed x/y/z : 38m/min

•Maximum numbers of tools slots: 240

CYLINDER HEAD

In an internal combustion

engine, the cylinder head sits

above the cylinders or top of the

cylinder block. It closes in the

top of the cylinder, forming the

combustion chamber. This joint

is sealed by a head gasket. The

head also provides space for the

passages that feed the air & fuel

to the cylinder, and that allow

the exhaust to escape. It is also

the place to mount the valves

and fuel injectors.

PARTS OF CYLINDER HEAD

A completely machined cylinder head after assembly on the Cylinder Head line comprises of following parts :

1. Inlet and Exhaust Valve Guides

2. Valve Seat

3. Inlet & Exhaust Valve

4. Oil Stem Seal and Valve Cap

5. Valve Spring

6. Collets & Spring Cap and Aluminium core plug

Valve GuidesInlet Exhaust

Valve Spring Valve

Seat

Spring Cap

CONNECTING ROD

In a reciprocating piston engine the

connecting rod connect the piston to the

small end side and crank shaft at the

Big end side . Together with the

crankshaft, They form a simple

mechanism that convert reciprocating

motion into rotary motion.

SMALL END : The small end is

connected with piston pin or gudgeon

pin which is currently most often press

fit There is bush provided inside the

small end side.

BIG END : The big end is connected

to the bearing journals on the

crankshaft.

Small EndBig End

ASSEMBLY LINE & ENGINE TESTING

Most of the products are formed from a large number of single parts produced at

different times by various production processes. All these may not be made at a

single place but are procured from different sources. The objective of assembly

shop is to combine individual components into a useful product of higher value.

The assembly shop at SEL assembles RV-2, RV-3, RV-30, RB-30 & RB-33 engines.

Assembly is done manually in which workers perform various assembly operations

by using dexterity, sense organs and intelligence along with various tools and

fixtures. different components are brought from the stores and the machine shop to

be assembled into engines on a common assembly line for all models.

Basic Engine Model

Key Components For Engine Assembly

(1) Crankcase (2) Crank Shaft

(3) Cam Shaft (4) Lubrication Pump

(5) Lubrication Filter (6) Gear Casing

(7) Cylinder Block (8) Cylinder Liner

(9) Piston Assembly (10) Connecting Rod

(11) Cylinder Head (12) Inlet & Exhaust

Manifold (13) Push Rods

(14) Rocker Arms (15) Water Pump

(16) Fuel Filter (17) Fuel Injection Pump

(18) Fuel Injector (19) Oil Sump

(20) Flywheel Assembly

Crankcase

The crankcase supports the individual main journals & bearings of crank shaft & also maintains the alignment of journal axis of rotation as they are subjected to rotary and reciprocating inertia forces.

The crankcase walls are flanged at the bottom to strengthen the casting & to attach the sump at bottom.

Core Plug

Upper Clamps

Un Machined Crankcase

The Crank Shaft converts the reciprocating

motion of piston in cylinder into rotary

motion of the flywheel or vice versa.

Power from the burnt gases in the

combustion chamber is delivered to the

crank shaft through piston and connecting

rod assembly.

The conversion of the motion is executed

by the use of offset in the crankshaft. The

stroke of piston is controlled by throws of

crank shaft . All Engine power is delivered

by crankshaft. And the material used for

crank shaft is alloy steel.

Crank Shaft

Cam Shaft

The cam shaft acts as a means of controlling

the opening & closing of both inlet and outlet

valves.

It also provides a drive to the ignition and

performs the function of distributing and

mechanizing fuel pump.

The Cam Shaft installed on one side of

crankcase is the second rotating shaft in the

crankcase after crank shaft. The gear mounted

on the Cam shaft is bigger in size and having

more teeth on its periphery in comparison to

crank shaft. The speed of the cam shaft is half

the speed of crank shaft.

Gear Casing

Gear Casing covers various gear assembly

in the diesel engine.

It is made of cast iron and its main function

is to provide housing for the gear assembly to

prevent any damage to the gears of cam shaft,

crank shaft, intermediate gear and lubrication

pump gear assembly etc.

Cylinder Block

Cylinder block is the

portion of the engine

between the cylinder head

and crankcase and is

supporting structure of the

entire engine. Large

diameter holes in the

casting form the cylinder

bore required to guide the

piston assembly.

Cylinder LinerThe Cylinder liner acts as

a medium between piston

assembly and casting.

It encloses the piston

assembly and protects it

against any damage.

It also increases the

cylinder bore life, due to its

high wearing against cast

iron.

Cylinder Liners

Piston Assembly

The piston converts the combustion pressure

to force on crank shaft. The piston is made

of aluminum alloy. Piston rings comprises of

compression rings located towards the top of

the piston and Oil control rings located

below the compression rings.

The function of the compression ring is to

seal the space between cylinder walls and

the piston preventing the escape of the

burning gases from the combustion chamber.

These rings help to obtain maximum power

by maintaining a seal with the cylinder wall

while keeping friction minimum as possible.

Compression Rings

Lubrication Rings

Head

Piston Pin Bore

Connecting Rod Assembly

The connecting rod joins the piston

to the crank shaft and transfers

reciprocating force to crank shaft

rotation. The small end of the

connecting rod reciprocates and

the big end of the connecting rod

follows the rotational pattern. For

this dynamic moment, connecting

rod should be as light as possible.

Bush

Piston Head & Connecting Rod Assembly

The piston head & connecting rod

assembly comprises of piston head

attached with the connecting rod small

end side. The piston head is connected to

the connecting rod by a pin called piston

pin or sometimes called as gudgeon pin.

On the bigger end of connecting rod it is

attached to the crankshaft.

Cylinder Head Assembly

Cylinder head is the casing bolted to the

top of the cylinder block. it houses the

inlet and exhaust valves and the

injection location holes. It forms the

upper face of the combustion chamber,

coolant passage, and lubricating passage.

The cylinder head is detachable for easy

access to the valves piston tops. The

valve arrangement of the engine controls

in and out movement of the charge and

exhaust gases. The valves are located in

the cylinder head. The valves disk heads

open or close the passage leading to the

cylinder during the movement of system.

Inlet Valve

Exhaust Valve

Valve Spring

Intake & Exhaust Manifold

The primary function of intake manifold is to carry the air to the intake port in the engine.

The exhaust manifold collects the high temperature spent gases from the cylinder exhaust port with the least possible back pressure while keeping the noise at a minimum level.

It is a strut which transmits the to and fro cam follower movement to

the pivoting rocker arm. Both ends of the push rod consist of semi

spherical ball and socket joint permitting the rod to tilt slightly and

revolve when the rocker arm oscillates about pivot.

PUSH ROD

Rocker Arm

Rocker Arms oscillate about its pivot and relay the push rod up and down to the stem of the valve. Therefore its arm acts as rocking beam. Rocker arms are manufactured with malleable cast iron.

Rocker Shaftwasher

s

Springs

Rocker Suppor

t

Rocker Arms

Rocker Arm Sub Assembly

Circlips

Water Pump

Usually centrifugal pump is

used for circulation of the

water in the cooling system.

Water enters the inlet pipe

from the bottom of the radiator

and is directed by passage to

the centre of impeller, where it

is caught by rotating vanes.

Due to centrifugal force water

is thrown out into the delivery

pipe and then to the water

jackets.

Thermostat Valve

A valve used in a cooling system to regulate the

engine temperature by automatically controlling the

amount of cooling water flowing from the water

jackets to the radiator core is called thermostat valve.

Whenever we start engine it is cool. It takes some

time to warm the engine parts so that they can work

efficiently. At that time we don't want that the cooling

water circulates through the water jackets. Because

we want that engine warms up as early as possible.

Therefore, a thermostat is installed in the cooling

system, initially to prevent the circulation of water

below a certain temperature through the radiator so

that the engine heats up quickly. When the required

temperature normally 70C is reached, the thermostat

allows the water to flow through the radiator. The

bellow type radiator is used in the cooling system.

Fuel Filter

The fuel filter screens out dust & rust particles from the fuel. They are of a bowl like design which collect water in the bottom (as water is denser than diesel) . The water can then be drained off by opening a valve in the bottom of the bowl and letting it runs out, until the bowl only contains only diesel. The fuel filter comprises of Primary filter and Secondary filter, in which primary filter removes dust particles first and then after final filtration is done by the secondary filter. Primary

Side Secondary Side

Fuel Injection Pump (FIP)

An injection pump is the device that pumps a

metered quantity of the fuel to the injectors or

nozzles under a very high pressure at correct instant

is called fuel injection pump. It rotates at half crank

shaft speed in a conventional four stroke engine. Its

timing is such that the fuel is injected very slightly

before top dead centre of the cylinder's

compression stroke.

The FIP is inline or rotary type pump driven by cam

shaft gear. The fuel supply is individual in each

cylinder according to the ignition timing or firing

order.

Feed Pump

Fuel Injector

The main functions of fuel injector is to develop

the pressure at which the injection begins, to

control the rate of injection for achieving the

required rate of increase in pressure and a

combustion process that is complete without

generating harmful emission, and to inject the

fuel into the combustion chamber.

A nozzle mounted in the combustion chamber to

supply the fuel to the engine cylinder in the form

of fine spray is called injector or fuel injector.

Sometimes also named as fuel atomizer.

Lubrication Pump

The purpose of lubrication pump is to circulate oil

under pressure to the oil gallery and drilled

passages to lubricate the various engine parts. The

various types of lubrication oil pumps are gear

type, rotor type, vane pump and plunger type

pump. Here we are using internal gear type oil

pump.

It consist of two spur gears of equal size enclosed

in a close fit housing. One is driving gear and

another is driven gear called idler gear. The oil

enters the pump from the suction port and it is

carried by the spaces between the gear teeth and the

pump body to the discharge port connected with oil

gallery. The pressure developed depends upon the

speed of the gears i.e. engine.

Driven Gear

Driver Gear Pump

Shaft

Gear Type Lubrication Pump

Oil Sump

The sump attached at the bottom of

the crankcase acts as storage for

engine lubricating oil. It collects the

oil draining from the side of the

crankcase walls and provides

centralized area for any contaminants

like water, liquid oil and worn metal

particles. It is provided with a drain

valve or plug at the bottom face.

Cast Iron Sump

Sheet Metal Sump

Drain Plug

Flywheel

The flywheel is a heavy and perfectly

balanced wheel usually bolted to a flange

on the rear end of the crank shaft which

stores energy to help the engine over idle

strokes of the piston. It keeps the fluctuation

of energy with in limit due to varying load

cycle. It provides the convenient mounting

point for clutch and starter rings. It stores

mechanical energy during the power stroke

and releases it during the other idle strokes

to keep the engine speed uniform. It is made

up of cast iron.

Flywheel

Starter Ring

ENGINE ASSEMBLY LINE & TESTINGENGINE ASSEMBLY LINE DIAGRAM

Crankcase

Crankshaft Fitment

Cam Shaft Fitment

Valve Timing Stage

Gear Casing Fitment

Piston Assembly

Bumping Shim Adjustment

Cylinder Block Fitment

Cylinder Head FitmentFIP

Fitment

Water Pump Fitment

Fuel Timing

Oil Sump Fitment

Engine Flywheel Assembly

Engine Testing

Engine Dispatch

Engine

Trolley

ENGINE TESTING The engine here is tested, inspected at various rpm’s and loads.Checking: * Full Load * No Load * Over Load * Unusual NoisePROCEDURE:1. Engine Testing Bed2. Clamping 3. Inlet and outlet connection joined4 .Inlet air supply.5. Exhaust for smoke and various dust

particles

6. Inlet of cold air.7. Outlet for hot water.8. Fuel oil supply.9. Pressure checking gauge

connection, of lubricating oil.10. Lubricating oil supply.11. Fuel oil overflow pipe.

1. B.H.P. (Brake Horse Power)

2. S.F.C. (Specific Fuel Consumption)

3. Air Consumption 4. Lubricating Oil

Consumption 5. Smoke Density

B.H.P. = I.H.P. - F.H.P

S.F.C. = 375750 / (Fuel time for 125 cc. B.H.P.)

Fuel Delivery:For 2 Cylinders : Fuel Delivery = 2500/ Fuel Time For 3 Cylinders : Fuel Delivery = 4500/ Fuel Time

Basic Measurements

PROJECTS UNDERTAKEN IN ASSEMBLY SHOP

1. Adjustment of Bumping Clearance, Significance of Bumping

Clearance and Procedure of bumping clearance setting in

Engine Assembly shop.

2. Adjustment of the Valve Clearance or Rocker Arm Clearance

of an Engine.

3. Adjustment of the Fuel Injection Pump Timing.

Adjustment, Significance & Procedure of Bumping Clearance

Engine Assembly Line Project 1

ByAmit Sharma

TraineeSwaraj Engines Limited

Mohali

Project GuidanceMr. Amritpal Sharma

Assembly ShopSwaraj Engines Limited

Mohali

Bumping Clearance :It is defined as the minimum distance

between or the gap between the cylinder

head (bottom face) and Top Dead Centre

(T.D.C.) of the piston.

For Setting of clearance two shims

(Spacers between liners and cylinder head

in order to lift the cylinder head to avoid

head noise. Otherwise if not inserted then

piston will hit to the cylinder head during

compression stroke. Size of shims are different.

Definition

CV Shim= Compression Volume ShimBumping Shim

Significance of Bumping Clearance1. If the clearance is not provided or given piston head of the engine during upward

movement from B.D.C. to T.D.C. will hit the engine cylinder head. Thus a jerk will be produced. To avoid this situation a clearance is provided between cylinder head and T.D.C.

2. The bumping clearance must be adjusted properly otherwise there is risk of damage and loss of engine efficiency.

3. If the bumping clearance is less then volumetric efficiency would increase but there is risk of the piston hitting the cylinder head, especially when the engine is unloaded during start and stopping.

4. If the bumping clearance is large then the extra clearance would result in a small volume of air being re-expanded every time causing increase in air temp, fall in efficiency and over-heating of engine. Generally, Bumping clearance depends upon manufacturer but as a thumb rule it should be between 0.5% to 1 % of bore of cylinder.

RV XM Engine With Digital GaugeBumping Chart (0.80 - 0.99)*

Digital Dial Bumping Shim Size CV Shim Size Bumping Clearance

0.40 ~ 0.20 0.6* 0 0.99 - 0.80

0.19 ~ 0.00 0.8 -0.6 0.99 - 0.80

-0.01 ~ -0.20 1 0.4 0.99 - 0.80

-0.21 ~ 0.30 1.2 -0.6 0.99 - 0.80

RB Engine With Digital Gauge Bumping Chart (0.80 - 1.00)

Digital Dial Bumping Shim Size CV Shim Size Bumping Clearance

-0.01 ~ -0.20 1 0.4 0.99 - 0.86

-0.21 ~ -0.34 1.2 -0.6* 0.99 - 0.86

-0.35 ~ -0.44 1.3 0.6* 0.99 - 0.86

-0.45 ~ 0.54 1.4 0.8 0.99 - 0.86

0.55 ~ -0.64 1..5 0.8* 0.99 - 0.86

Procedure Of setting Bumping Clearance1. Revolve the crank shaft pulley so that the

piston (1) and piston (3) comes at Top Dead Center (T.D.C.)

2. Now mount the bumping tools over the cylinder head by the clamps. Tight it with the help of torque wrench.

3. Take the bumping dial gauge and set zero of the gauge. Then adjust the piston head (1) & (2) by revolving the crank pulley.

4. Observe the deviation or reading from the dial gauge.

5. Now check the reading in the bumping chart as shown in Chart.

6. Select appropriate Bumping

shim & CV shim for the

engine according to the gauge

reading.

7. Apply some grease on the

cylinder head & liner with the

help of brush.

8. Now take the bumping shim &

CV shim and place it over the

cylinder head & liner area one

over the other. Place smaller

CV shim below the bumping

shim.

9. Now place the Cylinder Head

over the shims. And fit it

properly and tight its bolts

with torque wrench.

Grease

Cylinder Head

1. Before Shims are inserted on liners, oil grease is applied on shims in order to prevent rusting. Then these shims are placed on a inclined rod stand. In this arrangement shims get stick to each other. When they are inserted on liners then sometimes workers put more number of shims instead of one. This result in rejection of engine during testing.

2. The naming of positions of shims on the stand should be done properly.

Result : Bumping Clearance Setting is completed

Note :

Adjustment of Valve Clearance

Engine Assembly Line Project 2

ByAmit Sharma


Mohali

Project GuideMr. Amritpal SharmaEngine Assembly Shop

Swaraj Engines LimitedMohali

Definition :

Valve clearance is a space between the top of the valve stem and the rocker arm.

Its purpose is to allow for some mechanical expansion and lengthening of the valve step and pushrods as the engine warms up. This clearance is also called valve lash.

Tools Required : Feeler Gauge. Screw Driver, Ring Spanner etc.

Significance

If in sufficient valve clearance is set when the engine is cold then valves will not properly

close when the engine warms up. If too much clearance is provided (additional clearance)

then even after the engine warms up there will result in lost motion.

Lost motion mean that as the cam tries to open the valve the pushrod and rocker arm

moves to first take up the clearance before touching the valve to open the valve. The result

is late opening of the valve.

Excess valve clearance can be heard in an idling engine as series of ticking sounds that

sound disappear as the engine warms up. Over time mechanical wear causes an increase in

valve clearance with the symptomatic ticking sound in the engine (one more valves can

produce the sound). The first step is to remove the rocker cover and mechanically adjust

the clearance with an adjustment screw on the rocker arm.

Adjustment :

This is long and widely used method of adjusting valve clearance of an engine. The valve

arrangement was adjusted by adjusting a screw set in the end of the rocker that pressed on the end

of the pushrod.

This adjustment was made by rotating the engine until the cam was at its lowest point, giving the

widest gap, then adjusting the rocker until this gap was at the correct spacing, as measured with the

use of a feeler gauge.

Mis-adjusted tappets can give rise to an audible 'tappet rattle' from the rocker cover, if the valve

clearances are excessive.

Over-tight clearances may, even worse, lead to bent pushrods. The adjusting screw was locked by a

lock nut. If the screw became loose, the adjustment would also work loose. Such a simple matter as

a loose tappet locknut even led to an engine fire.

Procedure :

1. Remove the rocker cover of all the

three cylinders.

2. While adjusting the valve clearance the

engine should be at cold condition

3. Crank the engine with cranking tool by

rotating the crank pulley, So that the

piston (1) and Piston (3) is at Top Dead

Center (T.D.C.) compression stroke.

4. Now the cam will tends to down the

pushrods to down most position and

rocker arms will become free.

Procedure :1. Now loose the screw and nut with the help of

screw driver and ring spanner.

2. Insert the feeler gauge between the valve stem and rocker arm end.

3. Adjust the clearance to normal fit neither more tight.

4. The clearance should be 0.25 mm.

5. Now after doing it for 3rd cylinder.

6. Take it to the T.D.C. compression stroke and adjust the same clearance.

7. Tight the screw and nut of all rocker arms.

8. Now check the working of rocker arms by revolving the crank pulley.

Feeler Gauge

0.25 mm

Result :

The Valve clearance set is 0.25 mm.

And Valve clearance adjustment is completed.

Engine assembly Project 3

Adjustment of Fuel Injection Pump Timing

By Amit Sharma


Mohali

Project GuideMr. Amritpal SharmaEngine Assembly Shop

Swaraj Engines LimitedMohali

Definition of Fuel Injection Pump

•An Injection Pump is a device

that pumps an exact metered

amount of fuel, under high

pressure , at the right time to the

injector of a diesel engine.

•It is the heart of the diesel

engine.

The injection pump does the job

of both the throttle and the

ignition system in gasoline

engines.

Significance of Setting FIP Timing

Advantages of Proper Timing : Reduces engine smoke Improves Power Reduces engine injector noise and roughness Increases fuel economy. Symptoms of Improper Timing : Hard starting Rough running and Heavy smoke during start up Black smoke during acceleration Poor fuel economy Engine running hotter than normal

IDENTIFICATION FOR DIFFERENT MODELS OF FIPENGINE MODEL MODEL

NUMBERRV 2 XM +3A AVL 835RV 2 XM + 3A ORCHARD

835

RV 3 XM +3A AVL 834RV 3XM + 3A AVL (P.S)

834

RV 30 XM + 3A AVL 836RB 33 470RB 30 469RB 33 XM 797RB 30 XM 877

Standardisation Colour Coding of Marking Gauge

MODEL DEGREE (BTDC)

STOCK NO. COLOUR CODING

RVXM3A 12 J-780186 YELLOW

RV3XT(38HP) 12.5 J-780170 GREEN

RB54HP 11.5 J-785127 WHITE

RBXM/S15XM 14 J-785126 RED

RB TR+ 15 J-780178 BLACK

Procedure1. Take the FIP and Place it on the

side of crankcase.2. Now check the TDC or BTDC

mark on the pulley. and Bring the 1 & 3 cylinder piston to the top or in compression stroke.

3. Insert the studs and bolts inside the plate and tight it with the torque wrench.

4. Now Remove the plastic cover from the FIP shaft and Place FIP gear on the shaft and now take the hexagonal nut and slowly tight it with torque wrench.

5. Now lightly tight the 3 nuts mounted on the FIP gear supporting plate.

6. Bring the Drip tubes and remove the banjo bolts from the FIP and mount 2 drip tubes having closed end on the two outlet holes of FIP, where oil comes out through injectors pipes. and place one open ended drip tube on the 3rd hole of FIP.

7. Now tight these tubes with spanner and fill the FIP with diesel oil.

8. Now take the socket and revolve the FIP gear slowly until fuel comes out through the 3rd drip tube. and mesh the FIP gear with Cam shaft gear to match the timing.

9. Now tight the Hexagonal nut with torque wrench and attach injector pipes in place of drip tubes.

Method Used : Drip Tube Method

Drip Tube

FIP Gear

BTDC = Bottom Top Dead Centre before 15 TDC and Fuel Spray starts when piston moving upward from BDC to TDC during Compression stroke. TDC = Top Dead Centre

15

Result : FIP Timing is set

Crankshaft Anticlockwise Rotation

Thank You

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Amit Sharma 2012UGMEL127 INDUSTRIAL TRAINING

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