Industrial Training Report Modify

8/11/2019 Industrial Training Report Modify

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2014

Submitted To

Captain

MiniTractors

Private

Limited

[Industrial Training Report]Prepared By: Students of Agricultural Engg.& Tech.

Junagadh Junagadh Agriculture University

Submitted by,

Vaghela AlpeshHirparaMaulikLimbasiyaMaulikChohan Gopal

Zapadiya Mahesh

Undhad Ashish


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Acknowledgement

We, the students of College of Agricultural Engineering & Tech. Junagadh

Agricultural University, do take this opportunity to express our intense feeling of

indebtedness to Captain Tractors Private Limited for providing us such an

important and a life time opportunity and very comfortable facility and

environment to get such an important and useful training during the month of

May, 2014. We also appreciate their behavior, humbleness and their attention

towards us during our training period in spite of their very busy schedule.

We also wish to record our heartfelt gratitude and regards to Mr. G. T.

Patel(Managing Director), Mr. M. T. Patel (Managing Director), Mr. Rajesh

G. Patel (Director) for providing us a chance to be with them and to gain

knowledge and practical training under their supervision.

We also wish to express our feeling of gratitude, humble regards and

sincere thank to Mr.Jagadish parmar for his simulative and invaluable

guidance, keen interest, inspiration, worthy suggestion, constructive criticism andalso sharing his valuable working experience with us throughout our training

programmer.

We cannot forget to express our regards and feelings to Miss.Martina

Desai and Mr.Mayur Sakhiya for their important and very valuable

information and sharing their thoughts and knowledge in terms of Business

Management, Marketing and Banking and Finance.


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HISTORY OF TRACTOR

(INTERNATIONAL)

WHAT IS A TRACTOR ?

A Tractoris a vehicle specifically designed to deliver a high tractive effort (or torque) at

slow speeds, for the purposes of hauling a trailer or machinery used in agriculture or

construction.

The word tractorwas taken from Latin, being the agent noun of trahere"to pull". The first

recorded use of the word meaning "an engine or vehicle for pulling wagons or ploughs"

occurred in 1901, displacing the earlier term traction engine(1859).

The first powered farm implements in the early 19th century were portable engines

steam engines on wheels that could be used to drive mechanical farm machinery by way

of a flexible belt.

Around 1850, the first traction engines were developed from these, and were widely

adopted for agricultural use. The first tractors were steam-powered plowing engines.

They were used in pairs, placed on either side of a field to haul a plow back and forthbetween them using a wire cable. Where soil conditions permitted (as in the United

States) steam tractors were used to direct-haul plows, but in the UK and elsewhere

plowing engines were used for cable-hauled plowing instead. Steam-powered agricultural

engines remained in use well into the 20th century until reliable internal combustion

engines had been developed.

In 1892, John Froehlich invented and built the first gasoline/petrol powered tractor in

Clayton County, Iowa, USA. After receiving a patent Froehlich started up the Waterloo

Gasoline Engine Company, investing all of his assets which by 1895, all would be lost and

his business resigned to become a failure.

After graduating from the University of Wisconsin, Charles W. Hart and Charles H. Parr

developed a two-cylinder gasoline engine and set up their business in Charles City, Iowa.

In 1903 the firm built fifteen "tractors". A term with Latin roots coined by Hart and Parr

and a combination of the words traction and power. The 14,000 pound #3 is the oldest


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surviving internal combustion engine tractor in the United States and is on display at the

Smithsonian National Museum of American History in Washington D.C. The two-cylinder

engine has a unique hit-and-miss firing cycle that produced 30 horsepower at the belt and18 at the drawbar.

In Britain, the first recorded tractor sale was the oil-burning Hornsby-Ackroyd Patent

Safety Oil Traction engine, in 1897. However, the first commercially successful design was

Dan Alboins three-wheel Ivel tractor of 1902. In 1908, the Sanderson Tractor and

Implement Co. of Bedford introduced a four-wheel design, and went on to become the

largest tractor manufacturer outside the U.S. at that time.

While unpopular at first, these gasoline-powered machines began to catch on in the 1910s

when they became smaller and more affordable. Henry Ford introduced the Fordson, the

first mass-produced tractor in 1917. They were built in the U.S., Ireland, England and

Russia and by 1923; Fordson had 77% of the U.S. market. The Fordson dispensed with a

frame, using the strength of the engine block to hold the machine together. By the 1920s,

tractors with a gasoline-powered internal combustion engine had become the norm.


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TYPES OF TRACTOR

ROW-CROP TRACTORS:

A row-crop tractor is a tractor tailored specifically to the growing of row crops (crops

grown in rows, as in truck farming), and most especially to cultivating. The big tractors

tended to be very big and heavy, so they were not well suited to getting into a field of

already-planted row crops to do weed control. Row-crop tractorslight, affordable, and

reliablecorrected this flaw.

ORCHARD TRACTORS:

Tractors tailored to use in fruit orchards typically have features suited to passing undertree branches with impunity.

GARDEN TRACTORS:

Garden Tractors (also called Mini Tractors) are small, light and simple tractors designed

for use in domestic gardens. Garden Tractors are usually designed primarily for cutting

grass, being fitted with horizontal rotary cutting decks. As well as dedicated manufacturers,

many makers of agricultural tractors have made (or continue to make) ranges of garden

tractors, such as Case, Massey-Ferguson, International Harvester and John Deere.

ENGINEERING TRACTORS:

The durability and engine power of tractors made them very suitable for engineering

tasks. Tractors can be fitted with engineering tools such as dozer blade, bucket, hoe, ripper,

and so on. The most common attachments for the front of a tractor are dozer blade or a

bucket. When attached with engineering tools the tractor is called an engineering vehicle.

A bulldozer is a track-type tractor attached with blade in the front and a rope-winch

behind. Bulldozers are very powerful tractors and have excellent ground-hold, as their main

tasks are to push or drag things.


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TRACTOR HISTORY IN INDIA

1945 to 1960

War surplus tractors and bulldozers were imported for land reclamation and cultivation

in mid 1940's. In 1947 central and state tractor organizations were set up to develop and

promote the supply and use of tractors in agriculture and up to 1960, the demand was met

entirely through imports. There were 8,500 tractors in use in 1951, 20,000 in 1955 and

37,000 by 1960.

1961 to 1970

Local production began in 1961 with five manufacturers producing a total of 880 unitsper year. By 1965 this had increased to over 5000 units per year and the total in use had

risen to over 52,000. By 1970 annual production had exceeded 20,000 units with over

146,000 units working in the country.

1971 to 1980

Six new manufacturers were established during this period although three companies

(Kirloskar Tractors, Harsha Tractors and Pattie Tractors) did not survive. HMT, a large public

sector unit, began manufacturing Agricultural Tractors in 1972. Escorts Ltd. began local

manufacture of Ford tractors in 1971 in collaboration with Ford, UK.

1981 to 1990

Annual production exceeded 75,000 units by 1985 and reached 140,000 in 1990 when

the total in use was about 1.2 million. Then India - a net importer up to the mid-seventies -

became an exporter in the 1980s mainly to countries in Africa.

1991 to 1997

Since 1992, it has not been necessary to obtain an industrial license for tractor

manufacture in India. India now emerged as one of the world leaders in wheeled tractorproduction.


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1997 to 1999

In 1998 Bajaj Tempo, already well established in the motor industry, began tractor

production in Pune. In April of the same year New Holland Tractor (India) Ltd launchedproduction of 70 hp tractors with matching equipment. Larsen and Toubro have established

a joint venture with John Deere, USA for the manufacture of 35-65 hp tractors. Mahindra

and Mahindra are also developing 60-200 hp range.

1999 to Present

Facing market saturation in the traditional markets of the North West (Punjab, Haryana,

and Western Uttar Pradesh) tractors sales began a slow and slight decline. By 2002 sales

went below 200,000. Manufacturers scrambled to push into eastern and southern India

markets in an attempt to reverse the decline, and began exploring the potential for

overseas markets. By 2004 a slight uptick in sales once again due to stronger and national

and to some extent international markets. But by 2006 sales once again were down to

216,000 and now in 2007-08 have slid further to just over 200,000.


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CURRENT MANUFACTURERS OF

TRACTOR IN INDIA

Angad Tractors, SAS Motors Limited:

SAS Motors Limited, the manufacturer of AngadTractors, is a public limited company

incorporated in April 2003. Its flagship product is Angad 240 D tractor. The company is

engaged in sourcing, assembling, manufacturing, and marketing of Angad brand tractors

and farm machineries. SAS Motors also provides a range of agricultural equipments.

Angad Tractors (SAS Motors Limited) main mission is to make low cost tractors, power

tillers, and other farm machineries designed on appropriate technology platform available

to the Indian farmers. Currently, SAS Motors Limited manufactures tractors ranging from15-35 hp.

Balwan Tractors, Force Motors Ltd:

Formerly known as Bajaj Tempo Ltd. until 2005, Force Motors Ltd., makers of India's

ubiquitous 3-wheeler Tempos since 1957 in a collaboration with Vidal & Sohn Tempo

Werke, Germany. In 1999 began production of Ox and Ox 45 Brand Tractors both which

incorporated transmission technology from the German manufacturer ZF. Additional line

Balwan was introduced in 2004 and between the lines Force Motors offers a line of two-

wheel and four-wheel tractors in a horsepower range from 10 to 50 HP. In India BALWAN

600 launched shortly. It has a 60 HP engine. Balwan Tractors are one of the good tractors in

India for agricultural purposes. They have a Benz engine.

Captain Tractors Pvt. Ltd:

Founded in May 1994 and located in Rajkot, India, Captain Tractors manufactures mini-

tractors under the Captain brand.

Crossword Agro Industries:

Located in Rajkot, India, Crossword manufactures small tractors under the Nissan,Atmak and Captain brand names.


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Eicher:

In 1949, Eicher Good Earth was set up in India with technical collaboration with Geber.

Eicher a of Germany, imported and sold about 1500 tractors in India. On April 24, 1959Eicher came out with the first locally assembled tractor from its Faridabad factory and in a

period from 1965 to 1974 became the first fully manufactured (100% indigenization) tractor

in India.

Escorts (Escort, Powertrac and Farmtrac):

Escorts Ltd began local manufacture of Ford tractors in 1971 in collaboration with Ford.

Escort manufactures produces tractors in the 27-75 HP range and has already sold over 6

lakh tractors. Its tractors are marketed under three brand names, Escort, Powertrac and

Farmtrac.

HMT Tractors:

HMT is a large public sector unit and began manufacturing Agricultural Tractors in 1972

under the HMT brand name with technology acquired from Zetor of the Czech Republic. It

manufactures its tractors in Pinjore, Panchkula in a large factory that also manufactures

machine-tools, and Hyderabad It has a capacity of 20,000 tractors per annum.

Mahindra Gujarat Tractor Limited (MGTL):

The company was originally incorporated in the state of Gujarat in 1963 with technicalcollaboration with Motokov-Praha of Czechoslovakia as Gujarat Tractor Corporate Ltd. It

was taken over by Mahindra & Mahindra Limited. The company is engaged in

manufacturing of tractors in a range of 30-60 hp which are marketed under Shaktimaan

brand.

John Deere:

In 2000, John Deere set up production in a joint venture with Larsen & Toubro Ltd in

Sanaswadi, The factory currently produces tractors in of 35, 38, 40, 42,45, 50, 55, 65, 75 and

89 HP capacities for domestic markets and for export to the USA, Mexico, Turkey, North andSouth Africa, and South East Asia. Pune factory started to produce new 55 to 75 Hp 5003

series tractors for European market in 2008.


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Indo Farm:

Indofarm Founded in Baddi, Himachal Pradesh, India in 1999, and Indo Farms builds

tractors in the 33 to 90 hp ranges. Company is also manufacturing 9 to 18 ton cranes and 15to 50 kV silent gen sets. Ursus Poland is its technical partners. Indo farm tractors are

becoming famous in Indian tractor customers because of their better working performance,

quality and reasonable prices. Company is exporting their products to many developed

countries like: New Zealand, UK, Poland, Germany etc. tractor manufacturing is fully

computerized and marketing team is very dedicated and experienced.

Mahindra & Mahindra :

M&M's Farm Equipment Sector origins lie in a joint venture in 1963 between the

Company, International Harvester Inc., and Voltas Limited, and were named InternationalTractor Company of India (ITCI). In 1977, ITCI merged with M&M and became its Tractor

Division. After M&M's organizational restructuring in 1994, this division was called the Farm

Equipment Sector. The Farm Equipment Sector has also ventured into manufacturing of

Industrial Engines. M&M Industrial engines are used for various applications like generator

sets, industrial, construction, marine, compressors, etc. These engines are manufactured at

the Company's engine assembly plants at Kandivli and Nagpur. M&M has two main tractor

manufacturing plants located at Mumbai and Nagpur in Maharashtra.

Apart from these two main manufacturing units, the Farm Equipment Sector has

satellite plants located at Rudrapur in Uttaranchal and Jaipur in Rajasthan. The Farm

Equipment Sector as reported by the Company has a dealer network of over 450 dealers.

This dealer network is managed by 28 area offices, situated in all the major cities and

covering all the principal states and M&M tractors has sold more than 13,00,000 tractors

since its inception.

M&M's Farm Equipment Sector is perhaps the largest exporter of Indian tractors to the

USA and the west. The plant in China reportedly has a production capacity of 12,000

tractors annually.

In March 2007, M&M bought a controlling 43% stake in the Mohali-based tractor firm

Punjab Tractors (Swaraj) that will reportedly increase M&M's share in the domestic farm

equipment market from just over 30% to 40%. The 43% stake includes 29% owned by

private equity firm Actis Capital and 14.2% by the Delhi-based Burman family. In July 2007,

Mahindra upped its stake to 64.6%.

MARS Farm Equipments Ltd :

Originally established in 1976, the MARS Group is engaged in manufacturing/marketing

of dump trucks, loaders, foggers, and agricultural tractors and attachments. Based in

Lucknow, U.P., it began manufacturing two mini-tractor models under the Marshal name in

2005, Captain DI 2600 of 25 HP and Trishul MT DI 625 10 HP.


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New Holland :

New Holland Ag's entry into India was facilitated by FIAT's acquisition of Ford-New

Holland in 1991. By 1998 New Holland Ag. (India) completed the construction of a newplant in Noida, near New Delhi, with a capacity of 5000 tractors in the 35 - 75 hp range.

Sonalika (International Tractors Ltd.) :

International Tractors Limited was incorporated on October 17, 1995 and began

manufacturing tractors designed by Central Mechanical Engineering Research Institute

(CMERI). Its engines were initially designed on the successful HMT brand of engines, and

gear-box as per PTL design.

TAFE :

Tractors and Farm Equipment Limited (TAFE) was established in 1961 to manufacture

and market Massey Ferguson tractors and related farm equipment in India. AGCO, the

owner of Massey Ferguson, now owns 24% of TAFE. Tractors are built and sold in India

under both the TAFE and Massey Ferguson brands, and exported under both brands as well.

In 2005, TAFE bought the Eicher Motors tractor and engine division.

Standard :

Standard Combine began building tractors in Barnala, Punjab, India. In Standard

Tractors, tractors are being manufactured in the range of 35, 45, 50, 60, and 75 HP withrespective model names: Standard 335, Standard 345, Standard 450, Standard 460, and

Standard 475. Engines for all these tractor models, except the last one, are manufactured

within the plant as Standard Engines, in specific names SE 335, SE 345, SE 450 and SE

460, respectively. All the above-mentioned models of Standard Engines have shown

compliance to the TREM-III emission norms, as have been verified by the ARAI. However,

two new variants of tractor of 35 hp (Standard 335-I) and 45 hp (Standard 345-I), equipped

with famous Perkins engines (assembled within the Standard Tractors plant), and two

completely new models of tractor of 30 hp (Standard 330) and 40 hp (Standard 340) are on

the verge to be launched. Besides these, three 3-wheelers (two passenger-carriers and one

cargo), one 4-wheeler (cargo), a crane, an electric 3-wheeled mini-car, and two 2-wheelers(scooters) are either in the process of development or on the verge of launch from the

Standard Tractor Division.


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PREVIOUS INDIAN TRACTOR

COMPANIES Tractor companies that did no t survive and were not acquired by o ther

com panies are:

Auto Tractors Ltd., Pratapgarh :

Had manufacturing plant at Pratapgarh (U.P.) and were making tractors with Leyland

engines.

Asian Tractors Ltd :

Began building tractors in 1989 from their own designs.

Haryana Tractors Ltd :

As a part of Pratap Steel Rolling Mills Ltd., Haryana began building tractors from their

own designs in 1983.

Ford Tractors :

Ford (formerly Ford Tractor Division) began producing Ford Tractors in India in 1972with a tie up with Escorts. In 1986 Ford acquired New Holland and tractor operations was

transferred to Ford-New Holland and made into an independent corporation. In 1991, Fiat

began an arranged purchase of Ford-New Holland that was completed in 1993, ending Ford

Motor Company's long history of tractor production. The deal required that New

Holland/FIAT stop using the Ford name. New Holland India Pvt began production of tractors

in India in 1998.

Harsha Tractors :

In 1975, Harsha Tractors Ltd began manufacturing tractors in conjunction with

Motoimport of Russia. Tractor production never amounted to much, and has since ceased.

Kirloskar Tractors :

Founded in cooperation with Deutz-Fahr of Germany in 1974. It has since ceased to

manufacture tractors. However, the company continues to manufacture engines under

license from Deutz.


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CTPL Product Details

and specifications

Mini Tractors1. 2wd segment (Captain Mini Tractor 120 DI 2WD )

2. 4wd segment (Captain Mini Tractor 200 DI 4WD )

Technical Specifications

DimensionsLength: 2286 mm

Width: 1168 mm / 1016 mm

Height: 1955 mm with exhaust pipe

Wheel Base: 1550 mm

Ground Clearance: 260 mm

Track Width:965 mm / 812 mm (Driving Wheels)

Track Width: 902 mm (Steering Wheel)

Weight Of TractorWith Oil & Diesel Without Standard Ballast: 845 Kg.

Engine SpecificationsMake: FIELDMARSHAL (Hatz Design)

Model: FH-785

Type: four stroke, direct injection

Horse Power: 9.5 hp

Bore/Stroke: 85/110 mm

No. of Cylinders: One

Capacity: 625 cc

Engine rated speed: 2600 rpm

Cooling System: Air-cooled

Air Cleaner: Oil bath air cleaner with pre cleaner Length: 30.3"Fuel Equipment: 0.5 lit. fuel oil filter with plunger type fuel pump (Mico)

Hydraulic SystemTo operate three point linkage & upload trailer material.Drive - from engine through `V` belt.Output of hydraulic pump: 17.5 liters min.Transport lock provided
http://www.tradeindia.com/fp767477/Captain-Mini-Tractor-DI-2600-4WD.htmlhttp://www.tradeindia.com/fp767477/Captain-Mini-Tractor-DI-2600-4WD.htmlhttp://www.tradeindia.com/fp767477/Captain-Mini-Tractor-DI-2600-4WD.htmlhttp://www.tradeindia.com/fp767477/Captain-Mini-Tractor-DI-2600-4WD.html


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TransmissionClutch:Dry, friction plateGear Box:Four forward, one reverseFoot brakes:Internal expanding shoe type mechanical brakes.

Parking Brakes:Pawl & Atchet type locking arrangement.Steering:Mechanical worm and peg typeMinimum Turning:With brakes: 2.85 metersRadius:Without brakes: 3.85 meters.

TrailerPay Load: 1.5 TonneTrailer Size: 8 ft. X 5 ft. X 1 ft. (40 cu. Ft.)Tyre:6.00 X 16 (8 Ply Ratting)

TyresFront:5.20 x 14 (8 ply rating)

Rear: 8.00 x 18 (4 ply rating)

Road Speed (kmph)

Gears Low Gears High Gears

1 2.30 04.71

2 3.86 07.93

3 6.21 12.75

4 9.15 18.78

Reverse 1.72 03.53

Rear PTO Shaft Speed Range

Gears RPM

1 326

2 550

3 882

4 1300

Oil Capacity(in liters)Diesel Oil tank:21.00 lit.Engine Oil sump:01.08 lit.

Main Gear Box:01.60 lit.Reduction Gear Box:00.50 lit.Differential:01.20 lit.Sterling Box:00.50 lit.Air Cleaner:00.15 lit.Hydraulic Tank:14.00 lit.


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Multiple Attachments and Implements1. Automatic Seed Drill

2.

Leveler3. Cultivator4. Sprayer Pump5. M.B. Plough6. Trailer7. Reaper8. Thresher9. Rotary Tiller10.Loader11.Centrifugal Pump12.Reversible Plow13.Generator14.Horticulture Sprayer

15.Automatic Seed Cum Fertilizer Drill16.Puddling17.Mud Pump18.Furrow Attachment19.Chiesel Plough20.Grapes Sprayer21.Tanker22.Fertilizer Attachment23.Self Propelled Reaper
http://captaintractors.com/autoseedreal.htmhttp://captaintractors.com/leveler.htmhttp://captaintractors.com/cultivator.htmhttp://captaintractors.com/sprayerpump.htmhttp://captaintractors.com/mbplough.htmhttp://captaintractors.com/trailer.htmhttp://captaintractors.com/reaper.htmhttp://captaintractors.com/thresher.htmhttp://captaintractors.com/rotary_tiller.htmhttp://captaintractors.com/loader.htmhttp://captaintractors.com/loader.htmhttp://captaintractors.com/centrifugal_pump.htmhttp://captaintractors.com/centrifugal_pump.htmhttp://captaintractors.com/reversible_plow.htmhttp://captaintractors.com/reversible_plow.htmhttp://captaintractors.com/generator.htmhttp://captaintractors.com/generator.htmhttp://captaintractors.com/horticulture_sprayer.htmhttp://captaintractors.com/horticulture_sprayer.htmhttp://captaintractors.com/automseedsumfrtlzrs.htmhttp://captaintractors.com/automseedsumfrtlzrs.htmhttp://captaintractors.com/puddling.htmhttp://captaintractors.com/puddling.htmhttp://captaintractors.com/mudpump.htmhttp://captaintractors.com/mudpump.htmhttp://captaintractors.com/furrow_attachment.htmhttp://captaintractors.com/furrow_attachment.htmhttp://captaintractors.com/chiesel_plough.htmhttp://captaintractors.com/chiesel_plough.htmhttp://captaintractors.com/grapes_sprayer.htmhttp://captaintractors.com/grapes_sprayer.htmhttp://captaintractors.com/tanker.htmhttp://captaintractors.com/tanker.htmhttp://captaintractors.com/fertilizer_attachment.htmhttp://captaintractors.com/fertilizer_attachment.htmhttp://captaintractors.com/selfpropelledreaper.htmhttp://captaintractors.com/selfpropelledreaper.htmhttp://captaintractors.com/selfpropelledreaper.htmhttp://captaintractors.com/fertilizer_attachment.htmhttp://captaintractors.com/tanker.htmhttp://captaintractors.com/grapes_sprayer.htmhttp://captaintractors.com/chiesel_plough.htmhttp://captaintractors.com/furrow_attachment.htmhttp://captaintractors.com/mudpump.htmhttp://captaintractors.com/puddling.htmhttp://captaintractors.com/automseedsumfrtlzrs.htmhttp://captaintractors.com/horticulture_sprayer.htmhttp://captaintractors.com/generator.htmhttp://captaintractors.com/reversible_plow.htmhttp://captaintractors.com/centrifugal_pump.htmhttp://captaintractors.com/loader.htmhttp://captaintractors.com/rotary_tiller.htmhttp://captaintractors.com/thresher.htmhttp://captaintractors.com/reaper.htmhttp://captaintractors.com/trailer.htmhttp://captaintractors.com/mbplough.htmhttp://captaintractors.com/sprayerpump.htmhttp://captaintractors.com/cultivator.htmhttp://captaintractors.com/leveler.htmhttp://captaintractors.com/autoseedreal.htm


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1. Automatic Seed Drill

Length:30.3"Width:19"Height:37.4"Weight: 110 Kg. with cultivatorDiesel Cons.: 0.75 Ltr./Hour (Approx)Area Covered: 1.25 to 1.50 Acre/Hour(Approx)Seed: For Sowing Sesamum to Garlic SeedsHopper: Single

2. Leveler

Length:48.4"Width:21"Height:14.7" + 19.5 (Hitch Point)

Weight: 36 Kg.Diesel Cons.: 1Ltr./Hour (Approx)Area Covered:4 ft. width & 0.5 to 0.75Acre/hr. (Approx)
http://captaintractors.com/autoseedreal.htmhttp://captaintractors.com/autoseedreal.htm


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3. Cultivator

Length: 48" + 30"Width: 15.5Height: 16.7" + 19.5"

Weight: 114 KgTine: 5 Nos.Diesel Cons.: 1 Ltr./Hour (Approx)Depth in the soil: 4" to 6"Width in the soil: 48"Area Covered: 1 Acre/Hour (Approx)

4. Sprayer Pump

Length:38"Width:30.7"Height:51.5"Weight: 150Kg. (Approx)Nozzle: 13 Nos. (Adjustable Height &Distance between nozzle)Diesel Cons.: 0.75 Ltr./Hour (Approx)Area Covered: 2 to 3 Acre/Hour(Apporx)Tank Capacity:200 Ltrs.

5. M.B. Plough

Length:28.7"Width:20"Height:21.6" + 15.7" (Hitch point)Weight:61 Kg. Farrow: TwoDiesel Cons.:1 to 1.25 Ltr/Hour

Depth in the soil:6" to 8"Width in the soil:24"Area Covered:0.5 Acre/Hour (Approx)
http://captaintractors.com/cultivator.htmhttp://captaintractors.com/sprayerpump.htmhttp://captaintractors.com/mbplough.htmhttp://captaintractors.com/mbplough.htmhttp://captaintractors.com/sprayerpump.htmhttp://captaintractors.com/cultivator.htm


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6. Trailer

Length:96"Width:60"

Height:12Volume:40 Cu. ft.Weight:36Kg.Diesel Cons.:1 Ltr./Hour (Approx)Road Speed:18 Km/HourPay Load:1.5 ton with Hyd. Tippingsystem

7.

Reaper

Length:60"Width:54"Height:20.4"Weight:170 Kg.Diesel Cons.:1 Ltr/HourArea Covered:1 Acre/Hour (Approx)Enables Reaping work of 4 feet widthWheat, Rice & Soyabean

8. Thresher

Thresher Dia:2 feet Drum for multi

purpose crops

Diesel Cons.:1 to 1.25 Ltr/Hour
http://captaintractors.com/trailer.htmhttp://captaintractors.com/reaper.htmhttp://captaintractors.com/thresher.htmhttp://captaintractors.com/thresher.htmhttp://captaintractors.com/reaper.htmhttp://captaintractors.com/trailer.htm


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9. Rotary Tiller

Length :36"Width :18"Height :18" (Hitch point)Weight :175 Kg. (Approx)

Diesel Cons. :1 to 1.25 Ltr/Hour(Approx)Area Covered :0.5 Acre/Hour(Approx)Technical Details:1.L type Blade 16 nos 24" workingwidth2.J type Blade 16 nos. 30" workingwidth

10.

Loader

Length:36"Width:18"Lifting Height:7.5 feetBucket Cap.:600 Kg. (12 Cu. Ft.)Diesel Cons.:1 Ltr./Hour (Approx)Capacity:5 to 7 min. for small trailer10 to 15 min. for Big trailer

11. Centrifugal Pump

Pump Size:2.5 x 2.5 & 3" x 2.5"

Discharge:9 to 49 Lps.

Head range:21 to 29 mtrs.

High Head:3000 to 10000 feet.
http://captaintractors.com/rotary_tiller.htmhttp://captaintractors.com/loader.htmhttp://captaintractors.com/centrifugal_pump.htmhttp://captaintractors.com/centrifugal_pump.htmhttp://captaintractors.com/loader.htmhttp://captaintractors.com/rotary_tiller.htm


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12. Reversible Plow

Length:49.6Width:36"Height:16.5" + 15.7 (Hitch point)

Weight:3000 to 10000 feet.Farrow:TwoDiesel Cons.:1 to 1.25 Ltr./Hour(Approx)Depth in the soil:8" to 10"Width in the soil:24"Area Covered:0.5 Acre/Hour (Approx)

13. Generator

KVA:7.5 KVA - Three/Single phase

Diesel Cons.:1Ltr./Hour (Approx)

Capacity:5 Hp motor

14. Horticulture Sprayer

30 to 40 feet height covered with H.T.P.pump enables spray for Apple, Mango &Chiku

Diesel Cons.:0.75Ltr./Hour (Approx)

Capacity:2 Gun will be used at a timeTank : 200 ltr.
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15. Automatic Seed Cum Fertilizer Drill

Length:30.3"Width:19"Height:37.4"

Weight:110 Kg. with CultivatorDiesel Cons.:0.75 Ltr./Hour (Approx)Area Covered:1.25 to 1.50Acre/Hour (Approx)Seed:For sowing sesamum to garlicseedsHopper:Single

16.

Puddling

Enables Puddling work. Tractor withRotary Tiller, Puddler, Cultivator & HalfCage wheel.

Diesel Cons.:1 to 1.25 Ltr./Hour(Approx)

Area Covered:0.5 Acre/Hour

(Approx)

17. Mud Pump

Size:80 mm x 80 mm (Suction &Delivery)Head Range:6 to 20 mtr.Out Put:20 to 3.4 Lps.

Features:Can handles Solids waste upto 15.5 mmApplication :Tiles & Marble factories,Chemical, Diesel, Petrol Refinery,Swimming Pools, Construction sites andNagar Palika Services
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18. Furrow Attachment

Length:21.4"

Width:15.5"

Height:19.2" + 15.7" (Hitch point)

Weight:39 Kg.

Application:To make water flow smallchannels in the field.

19. Chiesel PloughLength:48" + 30" (Attachment)

Width:15.5"

Height:16.7" + 19.5" (Hitch point)

Weight:80 Kg.

Tine:3 Nos.

Diesel Cons.:1 Ltr./Hour (Approx)

Depth in the soil:6"Area Covered:1 Acre/Hour (Approx)

20. Grapes Sprayer

Length:78"Width:48"Height:54"Tyre Size:600.16

Tank Cap.:550 Ltrs.Diesel Cons.:1 Ltr./Hour (Approx)Area Covered:0.75 Acre/Hour(Approx)Nozzle:6 Nos. (Adjustable)Pump:H.T.P. Pump
http://captaintractors.com/furrow_attachment.htmhttp://captaintractors.com/chiesel_plough.htmhttp://captaintractors.com/grapes_sprayer.htmhttp://captaintractors.com/grapes_sprayer.htmhttp://captaintractors.com/chiesel_plough.htmhttp://captaintractors.com/furrow_attachment.htm


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21. Tanker

Length:96"

Width:42"

Weight:450 Kg.

Tank Capacity:2000 Ltr

22.

Fertilizer AttachmentLength:63"

Width:11.2"

Height:25.6"

Weight:42 Kg.

Diesel cons.:1 Ltr/Hour (Approx)

Area Covered:Fertilizer Can be

applied in 3 row

23. Self Propelled Reaper

Length:94.5"Width:45.3"Height:43.3"

Weight:180 Kg.Engine:Greaves/HondaFuel Cons.:1.25 Ltr/Hour (Approx)Speed:3 Km./HourArea Covered:0.5 Acre/Hour (Approx).Enables Reaping Work of 3 feet widthWheat, Rice & Soyabean
http://captaintractors.com/tanker.htmhttp://captaintractors.com/fertilizer_attachment.htmhttp://captaintractors.com/selfpropelledreaper.htmhttp://captaintractors.com/selfpropelledreaper.htmhttp://captaintractors.com/fertilizer_attachment.htmhttp://captaintractors.com/tanker.htm


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ENGINE

An engine or motor is a machine designed to convert energy into useful mechanical

motion.Devices converting heat energy into motion are referred to as engines, which come in

many types. A common type is aheat enginesuch as aninternal combustion enginewhich typically

burns a fuel with air and uses the hot gases for generating power. External combustion engines

such assteam enginesuse heat to generate motion via a separate working fluid

The internal combustion engine is an engine in which thecombustionof afuel(generally,

fossil fuel) occurs with an oxidizer (usually air) in a combustion chamber. In an internal

combustion engine the expansion of the high temperature and high pressure gases, which are

produced by the combustion, directly applies force to components of the engine, such as the

pistons or turbine blades or a nozzle, and by moving it over a distance, generates useful

mechanical energy.

An external combustion engine (EC engine) is a heat enginewhere an internal working

fluidis heated by combustion of an external source, through the engine wall or aheat exchanger.

The fluidthen, by expanding and acting on the mechanismof the engine produces motion and

usable work.

Cut- section of engine-
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Engine Configurations

Internal combustion engines can be classified by theirconfiguration.

a) Two-stroke cycle

b) Four-stroke cycle (or Otto cycle)

As their name implies, four-stroke internal combustion engines have four basic steps thatrepeat with every two revolutions of the engine:

1. Intake stroke: The first stroke of the IC engine is also known as the suction stroke

because the piston moves to the maximum volume position (downward direction in the

cylinder). The inlet valve opens as a result of piston movement, and the vaporized fuel

mixture enters the combustion chamber. The inlet valve closes at the end of this stroke.

2. Compression stroke: In this stroke, both valves are closed and the piston starts its

movement to the minimum volume position (upward direction in the cylinder) and

compress the fuel mixture. During the compression process, pressure, temperature and

the density of the fuel mixture increases.3. Power stroke: When the piston reaches the minimum volume position, the spark plug

ignites the fuel mixture and burns. The fuel produces power that is transmitted to the

crank shaft mechanism.

4. Exhaust stroke: In the end of the power stroke, the exhaust valve opens. During this

stroke, the piston starts its movement in the minimum volume position. The open

exhaust valve allows the exhaust gases to escape the cylinder. At the end of this stroke,

the exhaust valve closes, the inlet valve opens, and the sequence repeats in the next

cycle. Four stroke engines require two revolutions.

Diesel cycle

Fig:P-v Diagram for the Ideal Diesel cycle. The cycle follows the numbers 1-4 in clockwise

direction.
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Most truck and automotive diesel engines use a cycle reminiscent of a four-stroke cycle,

but with a compression heating ignition system, rather than needing a separate ignition system.

This variation is called the diesel cycle. In the diesel cycle,diesel fuel is injected directly into the

cylinder so that combustion occurs at constant pressure, as the piston moves.

Otto cycle:Otto cycle is the typical cycle for most of the cars internal combustion engines, that

work using gasoline as a fuel. Otto cycle is exactly the same one that was described for the four-

stroke engine. It consists of the same four major steps: Intake, compression, ignition and

exhaust.

PV diagram for Otto cycle On the PV-diagram, 1-2: Intake: suction stroke 2-3: Isentropic

Compression stroke 3-4: Heat addition stroke 4-5: Exhaust stroke (Isentropic expansion) 5-2:

Heat rejection The distance between points 1-2 is the stroke of the engine.

Parts of a Four-Stroke Engine-

Cylinder Head

Also referred to as the top end, the cylinder head houses the pistons, valves, rocker

arms and camshafts.
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Valves

A pair of valves, used for controlling fuel intake and exhaust, are controlled by a set of

fingers on the camshaft called lobes. As the intake valve opens, a mixture of fuel and air from

the carburetor is pulled into the cylinder. The exhaust valve expels the spent air/fuel mixture

after combustion..

Camshaft

Usually chain or gear-driven, the camshaft spins, using its lobes to actuate the rocker

arms. These open the intake and exhaust valves at preset intervals.

The Piston

The piston travels up and down within the cylinder and compresses the air/fuel mixture

to be ignited by a spark plug. The combustive force propels the piston downward. The piston isattached to a connecting rod by a wrist pin.

Piston Parts-

1. Head Or Crown

2. Piston Rings

3. Skirt

4. Piston Pin

Crankshaft

The crankshaft is made up of a left and right flywheel connected to the piston's

connecting rod by a crank pin, which rotates to create the piston's up-and-down motion. The

cam chain sprocket is mounted on the crankshaft, which controls the chain that drives the

camshaft.


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Fig:engine components

GOVERNOR of an engine-

A governor, or speed limiter, is a device used to measure and regulate the speed of a

machine,such as anengine.A classic example is thecentrifugal governor,also known as theWatt

or fly-ball governor, which uses weights mounted on spring-loaded arms to determine how fast

a shaft is spinning, and then usesproportional controlto regulate the shaft speed.

Fig:Centrifugal "flyball" governor
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Types of governor-1) Centrifugal governor

2) Pneumatic governor

3) Hydraulic governor

1)Centrifugal governor

A centrifugal governor is a specific type ofgovernorthat controls thespeedof anengine

by regulating the amount of fuel(orworking fluid)admitted, so as to maintain a near constant

speed whatever theloador fuel supply conditions. It uses the principle ofproportional control.

Diesel engine speedis controlled solely by the amount of fuel injected into the engine by

the injectors. Because a diesel engineis not self-speed-limiting, it requires not only a means of

changing engine speed (throttle control) but also a means of maintaining the desired speed.

The governor provides the engine with the feedback mechanism to change speed as needed

and to maintain a speed once reached. A governor is essentially a speed-sensitive device,designed to maintain a constant engine speed regardless of load variation. Since all governors

used on diesel engines control engine speed through the regulation of the quantity of fuel

delivered to the cylinders, these governors may be classified as speed-

2)Pneumatic governor-

Pneumatic governor that is responsive to the air flow (vacuum) in the intake manifold of

an engine. A diaphragm within the governor housing is connected to the fuel control linkage

that changes its setting with increases or decreases in the vacuum.
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3)Hydraulic governor-

Although hydraulic governors have more moving parts and are generally more

expensive than mechanical governors, they are used in many applications because they are

more sensitive, have greater power to move the fuel control mechanism of the engine, and canbe timed for identical speed for all loads. In hydraulic governors, the power which moves the

engine throttle does NOT come from the speed-measuring device, but instead comes from a

hydraulic power piston, or servomotor. This is a piston that is acted upon by fluid pressure,

generally oil under the pressure of a pump. By using appropriate piston size and oil pressure,

the power of the governor at its output shaft (work capacity) can be made sufficient to operate

the fuel-changing mechanism of the largest engines. The speed-measuring device, through its

speeder rod, is attached to a small cylindrical valve, called apilot valve. The pilot valve slides up

and down in a bushing, which contains ports that control the oil, flow to and from the

servomotor. The force needed to slide the pilot valve is very little; a small ball head is able tocontrol a large amount of power at the servomotor. The basic principle of a hydraulic governor

(fig. 5-7) is very simple. When the governor is operating at control speed or state of balance,

the pilot valve closes the port and there is no oil flow.


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ENGINE TROUBLESHOOTING CHECKLIST

AIR INTAKE SYSTEM CHECKS

Air cleaner element holed or not sealing correctly.

Incorrect size air cleaner element for type of housing.

Cracked or distorted air cleaner element housing.

Restriction gauge adapter broken.

Inlet or induction system from air cleaner to engine damaged.

Leak in vacuum piping.

Leak in air feed to compressor.

Inlet manifold gasket leaking or cracked. Injector seat leaking (petrol engines).

Damaged or missing breather.

Damaged or missing dip-stick seal.

Faulty or missing oil filler cap.

Faulty or missing crankcase ventilation.

Oil storage or top-up containers and funnels dirty.

COOLING SYSTEM CHECKS

Faulty thermostats, radiator shutters or shutterstats.

Radiator fins or cores blocked or clogged.

Defective water pump.

Coolant level low.

Radiator pressure relief cap defective.

Fan belts loose.

Faulty thermostatic fan.

Engine overloaded (lugging).

Cooling fins clogged or defective (air cooled engines).

Engine caked with dirt.

Defective water hoses.

Pressurize system and check for leaks.

Check sampling technique, was sample taken cold?

Oil cooler passages blocked or restricted.

Air entrained in cooling system.


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Insufficient coolant capacity.

Incorrect air/fuel ratio or timing (gas and petrol engines).

Incorrect coolant mixture.

Incompatible coolant mixture.

FUEL DILUTION CHECKS

Sampling technique (sample pump washed out with fuel or solvent).

Leaking fuel inlet and return pipes, pump seals and unions.

Faulty lift/transfer pump.

Worn or faulty injectors (e.g. incorrect spray pattern or break out pressure).

Extended idling periods.

Faulty internal injector seals or O-rings.

Fuel leaks - pressure test system.

Incorrect thermostat fitted.

Extended periods under low engine load.

Pump calibration or timing incorrect.

Restricted fuel return lines.

Contaminated fuel.

Faulty engine protection system.

Low operating temperature.

BOTTOM END WEAR CHECKS Check filter for abnormal wear particles.

Abnormal noise on start up.

Check for low oil level.

Check oil pressure profile.

Check for faulty oil pump, oil pick up and pressure relief valve.

Overheating.

Coarse dirt entry.

Check for cause of fuel dilution.

Incorrect oil grade used.

TOP END WEAR CHECKS

High blow-by and crankcase pressure.

Low compression.

Lack of power.


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Dirt entry in air intake system.

Abnormal noise.

Piston torching caused by defective injector spray patternand timing.

INCOMPLETE COMBUSTION (SLUDGE) CHECKS Restricted air intake system.

Restricted exhaust system (damaged exhaust pipe or silencer).

Fuel system malfunction (timing and faulty injectors).

Faulty turbocharger operation or pressures.

Check for low compression and excessive blow-by.

Extended oil and filter change periods.

Excessive exhaust back pressure (exhaust brake malfunction).

Low engine operating temperature.

After-cooler or inter-cooler malfunction.

Dirty oil or filter by-pass valve defective.

Extended idling periods.

Faulty altitude compensationdevice.

Dirty or contaminated/adulterated fuel.

Faulty thermostats or radiator shutters (incorrect operating temperature).

Faulty or incorrect engine brake operation.

Incorrect thermostat fitted.

WATER OR INTERNAL COOLANT LEAK CHECKS

Pressure test cooling system to locate leak.

Pressure test with sump removed to locate leak.

Release pressure with sump removed to locate leak.

Blown cylinder head gasket.

Defective cylinder head seals.

Leaking sleeve seals.

Leaking oil cooler.

Cylinderliner cracked or holed.

Injector cooling seals leaking.

Engine breather blocked, missing or damaged.

Low engine operating temperature.

Extended idling periods


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LUBRICATION SYSTEM

I.C. engine is made of many moving parts. Due to continuous movement

of two metallic surfaces over each other, there is wearing of moving parts,

generation of heat and loss of power in the engine. Lubrication of moving parts is

essential to prevent all these harmful effects.Lubrication produces the following effect-

1) Reduces frictional effect

2) Cooling effect

3) Sealing effect

4) Cleaning effect

Types of Lubricants

Lubricants can be classified by their originanimal (e.g. oil, goose grease), vegetable

(e.g., soybean oil, linseed oil), or mineral (e.g., petroleum, molybdenum sulfide). From ancient

times until the late 19th cent. lubricants were obtained from vegetable oils or animal fats and

oils. Today most are derived from mineral oils, such as petroleum and shale oil, which can be

distilled and condensed without decomposition. Synthetic lubricants, such as silicones, are of

great value in applications involving extreme temperatures. In certain types of high-speed

machinery films of gas under pressure have been successfully used as lubricants.

The lubricating system of an engine is an arrangement of mechanism and devices which

maintains supply of lubricating oil to rubbing surfaces of an engine at correct pressure and

temperature.

The parts which require lubrication are

Cylinder walls and piston

Piston pin

Crankshaft and connecting rod bearing

Camshaft bearings

Valve operating mechanisms Cooling fan

Water pump

Ignition mechanism


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Types of Lubrication Systems-

1. Splash system

2. Forced feed system

3. Combination of splash and forced feed

In captain tractor splash system is used. So it is given as-

1. Splash Lubrication System

In the splash lubricating system, oil is splashed up from the oil pan or oil trays in the

lower part of the crankcase. The oil is thrown upward as droplets or fine mist and provides

adequate lubrication to valve mechanisms, piston pins, cylinder walls, and piston rings.

In the engine, dippers on the connecting-rod bearing caps enter the oil pan with each

crankshaft revolution to produce the oil splash. A passage is drilled in each connecting rod from

the dipper to the bearing to ensure lubrication. This system is usually used in single cylinder

engines with closed crankcase.

Fig:splash unit


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2. Forced feed lubrication system-

In this system, the oil is pumped directly to the crankshaft, connecting rod, piston pin,

timing gears and camshaft of the engine through suitable paths of oil. Usually the oil first enters

the main gallery, which may be a pipe or a channel in the crankcase casting. From this pipe, it

goes to each of the main bearings through holes. From main bearings, it goes to big endbearings of connecting rod through drilled holes in the crankshaft. From there, it goes to

lubricate the walls, pistons and rings.

Fig:forced feed system

OIL FILTER-

An oil filter removes all the dirty elements of the oil in an effective way. It is a type of

strainer using cloth, paper, felt, wire screen or similar elements. An oil filter is afilter designed

to remove contaminants from engine oil, transmission oil, lubricating oil, or hydraulic oil.Oil

filters are used in many different types ofhydraulic machinery.A chief use of the oil filter is in

internal-combustion engines in on- and off-roadmotor vehicles,lightaircraft,and variousnaval

vessels. Other vehicle hydraulic systems, such as those in automatic transmissions andpowersteering,are often equipped with an oil filter.

Wearing of parts, oil consumption and operating cost of an engine can be considerably

reduced by proper maintenance of oil filters. These are of two types-

a) Full-flow filter

b) By-pass filter
http://en.wikipedia.org/wiki/Filtrationhttp://en.wikipedia.org/wiki/Engine_oilhttp://en.wikipedia.org/wiki/Automatic_transmission_fluidhttp://en.wikipedia.org/wiki/Lubricant#Mineral_oilhttp://en.wikipedia.org/wiki/Hydraulic_fluidhttp://en.wikipedia.org/wiki/Hydraulic_machineryhttp://en.wikipedia.org/wiki/Internal-combustion_enginehttp://en.wikipedia.org/wiki/Automobilehttp://en.wikipedia.org/wiki/Aircrafthttp://en.wikipedia.org/wiki/Navalhttp://en.wikipedia.org/wiki/Automatic_transmissionhttp://en.wikipedia.org/wiki/Power_steeringhttp://en.wikipedia.org/wiki/Power_steeringhttp://en.wikipedia.org/wiki/Power_steeringhttp://en.wikipedia.org/wiki/Power_steeringhttp://en.wikipedia.org/wiki/Power_steeringhttp://en.wikipedia.org/wiki/Automatic_transmissionhttp://en.wikipedia.org/wiki/Navalhttp://en.wikipedia.org/wiki/Aircrafthttp://en.wikipedia.org/wiki/Automobilehttp://en.wikipedia.org/wiki/Internal-combustion_enginehttp://en.wikipedia.org/wiki/Hydraulic_machineryhttp://en.wikipedia.org/wiki/Hydraulic_fluidhttp://en.wikipedia.org/wiki/Lubricant#Mineral_oilhttp://en.wikipedia.org/wiki/Automatic_transmission_fluidhttp://en.wikipedia.org/wiki/Engine_oilhttp://en.wikipedia.org/wiki/Filtration


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a)Full-flow filter-

In this filter, the entire quantity of oil is forced to circulate through it before it enters the

engine. A spring loaded valve is usually fitted in the filter as a protection device against oil

starvation in case of filter getting clogged. Filter element consists of felt, cloth, paper, and

plastic.

Fig:full-flow filter

b)By-pass filter-

In this type of filter, the supply lines are from the pump and are connected to permit only a

part of the oil through the filter, the balance oil reaches directly to the engine parts.

Mechanical filter-

Mechanical designs employ an element made of bulk material (such as cotton waste) or

pleatedFilter paper to entrap and sequester suspended contaminants. As material builds up on

(or in) the filtration medium, oil flow is progressively restricted. This requires periodic

replacement of the filter element (or the entire filter, if the element is not separately

replaceable).
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TROUBLES IN LUBRICATION SYSTEM

Excessive oil consumption- when there is excessive oil consumption, the reasons are-

i. More oil goes to combustion chamber and gets burnt

ii. Some leakage occurs in some part of the line.iii. Loss of oil in form of vapour through ventilating system.

Oil can enter the combustion chamber through rings and cylinder walls, worn piston rings

and worn bearings.

Low oil pressure-it results due to-

i. weak relief valve spring

ii. worn oil pump

iii. cracked oil line

iv. obstruction in the oil lines

v. very thin oilvi. worn-out bearings

Care should be taken to remove these defects as far as possible to increase the oil pressure

in the lubricating system.

Excessive oil pressure- it may result due to

i. stuck relief valve

ii. strong valve spring

iii. clogged oil line

iv. very heavy oil

These defects should be removed to reduce the excessive oil pressure in the lubricating

system. Sometimes defective oil pressure indicator shows high oil pressure.

LUBRICATING SYSTEM MAINTENANCE

There are certain lubricating system service jobs that are more or less done

automatically when an engine is repaired. For example, the oil pan is removed and cleaned

during such engine overhaul jobs as replacing bearing or rings. When the crankshaft is

removed, it is usual procedure to clean out the oil passages in the crankshaft. Also, the oil

passages in the cylinder block should be cleaned out as part of the overhaul. As a Construction

Mechanic, you will be required to maintain the lubrication system. This maintenance normally

consists of changing the oil and filter(s). Occasionally you will be required to perform such

maintenance tasks as replacing lines and fittings, servicing or replacing the oil pump and relief

valve, and flushing the system. Oil and Filter Change It is extremely important that the oil and

filter(s) of the engine are serviced regularly.


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Fuel system

Properties of fuel

Fuel is a substance consumed by the engine to produce energy. The common fuel for

internal combustion enginesare:

Petrol

Power kerosene

High speed diesel oil

Light diesel oil

Quality of fuel

The quality of fuel mainly depends upon the following properties: Volatility of fuel

Calorific value of fuel

Ignition quality of fuel

Volatility:

Volatility of fuel has considerable effect on the performance of the engine by affecting

the following:

a) Ease of starting the engine

b) Degree of crankcase oil dilutionc) Formation of vapour lock in the fuel system

d) Accelerating characteristics of the engine

e) Distribution of fuel in multicylinder engine

Calorific value:

The heat liberated by combustion of a fuel is known as calorific valueor heat valueof

the fuel. It is expressed In kcal/kg of the fuel. The heat value of a fuel is an important measure

of its worth, since this is the heat which enables the engine to do work.

Ignition quality:

Ignition quality refers to ease of burning the oil in the combustion chamber. Octane

numberand cetane numberare the mesasures of ignition quality of the fuel.


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Detonation (Knocking):

Detonation or engine knocking refers to violent noises, heard in an engine, giving a

pinging sound during the process of combustion. It occurs during the process of combustion of

the mixture within the cylinder after the ignition has taken place. It is an undesirable

combustion and results in sudden rise in pressure, a loss of power and overheating of the

engine. It is caused by -

Improper combustion chamber

High compression pressure

Early ignition timing

Improper fuel

Inadequate cooling arrangement

Preignition

Burning of air-fuel mixture in the combustion chamber before the piston has reached

the top dead centre is called preignition. It occurs when the charge is fired too far ahead of the

top dead centre of the piston due to excessive spark advance or excessive heat in the cylinder.

Fuel Test

A few important tests are recommended to determine the suitability of fuels for an I.C.

engine. The following are the important tests.

1. Gravity test:

The gravity of a fuel or oil may be expressed as specific gravity or as API gravity, a scale

devised by American Petroleum Institute. The specific gravity of a liquid is the ratio of its weightto the weight of an equal, volume of water at 60'1

01 the relationship of the API gravity scale to

specific gravity is expressed by the formula:

A.P.I. degrees = 141.5 131.5

Specific gravity of oil at 60'T

The instrument used for testing the specific gravity of oil is known as hydrometer. The

lighter fuel of lower specific gravity has higher API gravity expressed in degrees. Pure water has

got API gravity as 10.

2. Distillation test:It is a measure of volatility of a fuel. In this test, measured amount of oil is boiled in a flask,

starting from a low temperature and gradually increasing it. The amount of condensed vapour

corresponding to each temperature is collected and noted separately. This process goes on

operating till the evaporation ceases.


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3. Vapour pressure test:

A special instrument known as Reid vapour pressure test is commonly used to measure the

vapour pressure of a fuel. The pressure is read on the Bourdon gauge at 100F temperature.

Vapour pressure is a measure of starting ability as well is vapour lock tendencies of the fuel.

4. Sulphur test:

Sulphur test is done for the following purposes:(a) To find out presence of corrosive sulphur compounds in the fuel oil.

(b) To find out quantity of free and combined sulphur present in the fuel oil.

The corrosive sulphur is indicated by immersing a polished strip of copper in the fuel for 3

hours at 122F. A comparison is made with this strip and a freshly polished copper. If' corrosive

sulphur is present, the colour would be discoloured. For finding the total quantity of sulphur,

sample of fuel is burnt in test bombs or wick lamps and sulphur is measured.

5. Carbon residue:

Carbon residue is an indication of the carbon forming properties of the oil under certain

engine conditions. It is a means of measuring the amount of carbon residue left on evaporating

in oil under specified conditions.

6. Colour test:

Colour test also indicates certain physical properties of oil to some extent but it is not a very

reliable test.


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7. Gum test:

Gum test is a measure of the presence of gum in the oil. The test consists of evaporating

samples of fuel in special apparatus. The residue is weighed in milligrams per 100cc of fuel. The

evaporation takes place in a copper dish and is continued for a longer period of time, indicating

gum-forming properties that may develop upon storage, exposure to air and light.

8. Flash test:

The flash point of oil is the temperature at which inflammable vapours are given off. The oil

sample is heated and the temperature at which distinct flash is obtained when flame is passed

over the container is called flash point. The results are important for safety and fire protection

measures.

Qualities of diesel fuel

The diesel fuel is of two types:1. High speed diesel oil (HSD)

2. Light diesel oil (LDO)

High speed diesel oil is used for high speed diesel engines. It is lighter than LDO. Light diesel

oil is the main source of fuel for slow speed engines.

I. Diesel fuel should be free from acid or any foreign matter, dirt and moisture.

II. It must be able to lubricate the fuel pumps and fuel injection nozzles, light fuels lack

sufficient lubricating qualities.III. Diesel fuels are rated according to the cetane number, which is the indication of ignition

quality of the fuel. The higher the cetane number, the better the ignition quality of the

fuel.

Fuel combustion

The process of fuel combustion converts the chemical energy of the fuel into heat energy.

Fuel combustion of I.C. engine takes place in two ways:

1) A mixture of air and fuel is compressed and ignited by a spark. This is called spark

ignition engine or carburetor type engine.

2) Air alone is compressed and fuel is injected near the end of the

Compression stroke. Fuel is ignited by the heat of compression.

This is called diesel engine or compression ignition engine.

For getting maximum power from the carburetor engine, it is essential:


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1) To maintain proper proportion of fuel and air.

2) To ignite the mixture at the proper time.

Best result is obtained when carburetor is so adjusted that alit- fuel ratio is about 15:1. Such

mixture is called chemically correct mixture. This relation is explained in the following example.

Example 5.1. Find air-fuel ratio for complete combustion of fuel in a carburetor engine,wane petrol which approximates to hexane C6H14.

Solution. Air contains 23% oxygen by weight.

Petrol when mixed with oxygen forms carbon dioxide (CO2) and water.

C6H14+ 02 CO2 + H2O ...(1)

After balancing the above equation, it is obtained as:

2(C6H12) + 19(O2) = 12(CO2) + 14(H20)

or (2 x 86) + (19 x 32) = (12 x 44) + (14 x 18) or 780 = 780

Oxygen per kg of fuel = 608/172=3.54kg

Correct air supply per kg of fuel = 3.54 x 100/23

= 15.36 kg,

Correct air-fuel ratio = 15.37:1

Fuel Supply System In Spark Ignition EngineThe fuel supply system of spark ignition engine consists of

1. Fuel tank 2. Sediment bowl

3. Fuel lifts pump 4. Carburetor and5. Fuel pipes.

In some spark ignition engine, the fuel tank is placed above the level of the carburetor. The

fuel flows from the fuel tank to the carburetor under the action of gravity. There are one or two

filters between the fuel tank and the carburetor. A transparent sediment bowl is also provided

to hold the dust and dirt of the fuel. If the tank is below the level of the carburetor, a lift pump

is provided in between the tank and the carburetor for forcing fuel from the tank to the

carburetor of the engine, The fuel comes from the fuel tank to the sediment bowl and then to

the lift pump. From there the fuel goes to the carburetor through suitable pipe. From the

carburetor, the fuel goes to the engine cylinder through the inlet manifold of the engine.


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Fuel system of spark ignition engine

METHOD OF SUPPLYING FUEL TO TILE JET OF THE CARBURETOR

If the fuel tank above the carbutor, the fuel flows by gravity force to a float chamber which

maintains constant head at the jet of the carburetor. If the tank is below the carburetor, thereare three methods of supplying fuel to the jet of the carburetor:

(a) Suction method

(b) Overflow method

(c) Float valve method


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(a) Suction method:

In this method, there is a check valve, provided in the fuel tank. The check valve is connected to

the needle valve through a pipe. It is mainly used on single cylinder engine operating at

constant load or speed. Any change in engine load or speed, requires adjustment of the needle

valve. The fuel is drawn from the tank through a tube and the amount of fuel is controlled by a

needle valve.

(b) Overflow method:

A pump sup-plies fuel to a chamber equipped with an overflow pipe. It is used on

stationary single cylinder engine.

Carburetor with feed pump to fuel reservoir


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A fuel pump is used to maintain regular supply of fuel oil. Excess fuel is sent back to the fuel

tank by a return pipe.

Diaphragm type fuel pump

(c) Float valve method:

A diaphragm pump is used to lift the fuel from the tank to the float chamber. This

method is common on multicylinder engines. The amount of fuel is controlled by a float

operated needle valve in the pressure line.

CARBURETOR

The process of preparing an air-fuel mixture away from the cylinders of an engine is called

carburetion and the device in which this process takes place is called carburetor

Principle of carburetor

The basic principle of all carburetor design is that when air flows over the end of a narrow

tube or jet containing liquid, some liquid is drawn into the air stream. The quantity of liquid

drawn into they air stream increases as the speed of air flow over the jet rises and also the

quantity is greater if the jet is made larger.In practice, the fuel level in the jet is maintained by a float chamber. The fuel levels in the

jet and in the float chamber are always the same. As the fuel is consumed, the level in the float

chamber goes down. The float in the float chamber also goes down and the needle valve comes

off its seat allowing more fuel into the chamber from the fuel tank. When the fuel level rises to

its correct level, the float presses the needle valve back to its seat and cuts off the fuel flow.


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The velocity of the air flowing over the jet is increased by a constriction. in the induction pipe

known as Venturi.

A throttle butterfly valve provides an adjustable obstruction in the induction pipe. It is

used to control the flow of air-fuel mixture to the engine. As the butterfly valve is turned into

the accelerate position, the air flow over the jet increases and more fuel is drawn out into the

air stream, keeping the mixture strength constant.A second butterfly valve called Choke is used to provide a richer mixture for the engine to

start in cold condition. The choke controls the volume of air entering into the venturi. A second

jet is fitted near the throttle butterfly which is used when the engine is idling.Fuel is delivered to the float chamber through fuel pipe either by gravity or by a pump.

The float chamber is connected with the mixing chamber (venturi) via fuel nozzle equipped with

fuel jet.

Float and needle valve maintain a constant fuel level in the float chamber. As the float

chamber is filled with fuel, the float rises by virtue of its buoyancy; this actuates the needle

valve to close the inlet passage when the desired level of fuel is reached. When the fuel levelgoes down, the float also goes down; allowing more fuel to enter the float chamber and same

sequence is maintained.

Function of Carburetor

The main functions of the carburetor are:

I. To mix the air and fuel thoroughly

2.To atomise the fuel

3.To regulate the air-fuel ratio at different speeds and loads and

4.4. To supply correct amount of mixture at different speeds and loads.

COMPONENTS OF CARBURETORA carburetor consists of the following components:

I. Venturi tube. It is provided to produce low pressure in the throat of the carburetor.

The suction force causes the fuel to rise in the jet. The fuel is discharged at a rate

proportional to the air velocity, available at that point.

II. Float chamber. Float chamber is a reservoir to maintain a constant level of fuel in

the carburetor. Fuel comes from the tank to the float chamber. There is a hollowfloat provided with a needle. With the level of the fuel going down, the float with

the needle also goes down allowing the fuel to come into the float chamber from

the fuel tank. As the fuel level goes up, the needle closes the passage and the fuel

does not come in the float chamber. Thus a constant level in float chamber is always

maintained.


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III. Throttle. It is a butterfly valve between the mixing chamber of the carburetor and

the inlet manifold of the engine to regulate the quantity of charge. It may be

operated by a hand lever, a foot lever or a governor.

IV. Choke. It is a device for restricting the air supply, in the carburetor. With restriction

of air supply, the mixture becomes richer which helps in starting the engine easily. Itis a type of butterfly valved in the air passage of the carburetor unit.

V. Main jet. It is a small opening of exact size through which fuel passes from the float

chamber to the throat of the carburetor in form of spray. The jet may be of fixed

type or adjustable type. Small stationary single or multicylinder engines are usually

equipped with fixed type of jet, whereas large size tractor engines are equipped with

adjustable type of jet.

VI. Idling jet. It is a special type of jet which supplies fuel at idling speed or low speed of

the engine. It usually consists of a passage which goes to the air stream at the end of

the butterfly. The opening is on the manifold side of the butterfly. When the

butterfly valve is closed, the sucking force in the manifold pulls the necessary idling

fuel from the idling jet.

VII. Compensating jet. Whet main jet supplies richer mixture at higher speed the

compensating jet supplies leaner mixture at that speed. This helps the mixture to

maintain correct proportion of air-fuel at different loads and speeds. There is an

accelerating well through which the jet gets the fuel.

VIII. Economizer. It is a device for regulating the fuel supply in the main jet. The

difference of air pressure at the air intake and above the throttle, affects the

movement of the piston.

METHOD OF MOUNTING CARBURETOR ON ENGINE

On the basis of ways of mounting the carburetor on the engine body, carburetor may be

divided into two classes:

1.Downdraft carburetor.

It is mounted above the intake manifold of the engine, so that the air enters the upper

part of the carburetor and the mixture flows downward into the manifold. Downdraftcarburetors are used mostly on automobiles, trucks and stationary engines,

2. Updraft carburetor.

It is mounted below or beside the engine block and the mixture flows upward into the

engine.


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Fuel pump for carburetor engine

It is also called gasoline pump. It is a diaphragm type pump. It consists of (1) body, (2) cover

and (3) lead. The pump body accommodates pivoted rocker arm with its return spring and has a

priming lever. Flexible diaphragm is made of varnished or rubberized cloth. Plates connect the

diaphragm to spindle whose lower end is linked with inner end of the rocker arm,. Under the

diaphragm there is a pressure spring. The pump is driven from an eccentric or a special fuel

pump lobe on the engine camshaft. As the camshaft rotates, the eccentric pushes against the

outer end of the rocker arm forcing the arm to pivot on its pin. Operation of diaphragm creates

a vacuum in the chamber above the diaphragm which, opens inlet valve and makes petrol flow

from the fuel tank through the fuel line and filter.

Precautions in handling carburetors

1) The carburetor should be serviced by wiping it clean, checking the mounting, eliminating

fuel leaks, draining the sludge from the float chamber and washing the filter.

2) Carburetor components should always be washed in clean gasoline. Care should be

taken not to damage the gasket, while opening or closing the carburetor.

3) Jets should always be blown with compressed air only Never use wire or any other

metallic object to clean the jets and passage.

4) Check the carburetor and do setting of the jet at regular interval for satisfactory

performance of the engine.

FUEL SYSTEM OF DIESEL ENGINE

Fuel system of diesel engine consists of the following components Fuel tank

1. Fuel lift pump or feed pump

2. Fuel filter

3. Fuel injection pump

5. High pressure pipe

6. Over flow valve

7. Fuel Injector (Injection nozzles)


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Fuel is drawn from the fuel tank by the Feed pump (Fig. 5.8] and forced to the Injection

pump through Fuel filter. The Injection pump supplies high pressure filet to injection nozzlesthrough delivery valves and high pressure pipes. Fuel is injected into the Combustion chamber

through Injection nozzles. The fuel that leaks out from the injection nozzles passes out through

leakage pipe and returns to the.Fuel tank through the over flow pipe.

Overflow valve installed at the top of the filter, keeps the feed pressure under specified

limit. If the feed pressure exceeds the specified limit, the overflow valve opens and then the

excessive fuel returns to fuel tank through overflow pipe.

General lay out of fuel supply in diesel engine


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1. Fuel Tank

It is a storage tank of suitable size and shape, usually made of mild steel sheet. Atmospheric

pressure is maintained in the tank with the help of a pin hole on the cap. Usually a wire gauge

strainer is provided under the cap to prevent foreign particles. Usually a drain plug is provided

at the bottom for flow of fuel.

2. Fuel Lift Pump (Feed pump or Transfer pump)

Fuel lift pump may be

(i) Plunger type,

(ii) Diaphragm

Plunger TypeIt may be single acting or double acting pump usually mounted on the side of the

Injection pump housing. It is driven by injection pump camshaft.

It transfers fuel from the fuel tank to the inlet gallery of the Injection pump through

fuel filter, the fuel pressure at the feed pump must be in the range of 1.5 to 2.5 kg/cm2, It

delivers adequate amount of fuel to the injection pump. The pump consists ofi) Body, (ii) piston, (iii) inlet valve, (iv) Pressure valve

The valves are tightly pressed against their seats by springs. The piston is free to slide in the

bore.

The fuel contained in the space below the piston is forced to flow through filter to the

injection pump. At the same time, downward movement of the piston creates a depression in

the space above the piston, which causes the fuel to be drawn in the transfer pump from the


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fuel tank through inlet valve and filter. When starting the engine and venting any possible air,

the priming pump provides manual pump operation also.

Diaphragm type FeedPump

It consists of:I. Main body 2. Diaphragm

3. Spring 4. Rocker arm

5. Inlet and outlet valve 6. Sediment bowl

Suction is created in the main chamber of the pump by pulling down the diaphragm. The

fuel is sucked through the inlet valve. During this period, outlet check valve remains closed.

When there is no pressure of the cam on the rocker arm of the pump, it returns its original

position due to the tension of the return spring.

Upper movement of the diaphragm creates a pushing effect on the fuel, which has entered

the chamber during its downward movement, under the pressure of the fuel, outlet valve

opens and the fuel is pumped through outlet chamber. Thus the fuel flows from the tank to

Fuel Injection pump.

Preliminary filter (Sediment bowl assembly)This filter is mostly fitted on the fuel lift pump. It prevents dust and foreign materials from

reaching inside the fuel line. It usually consists of a glass cap with gasket. Heavy dust particles

settle at the bottom and clean fuel flows ahead.

Fuel filterMostly two stage filters are used in diesel engines:

1. Primary 2. Secondary

1. Primary filter removes coarse material, water and dust.

2. Secondary filter removes fine dust particles.

Filters are made of different materials like:

(a )Metal element

(b)Felt and cloth element

(c ) Paper disc

(d)Metal element consists of porous metal filter elements.

(e ) Felt & cloth element is a cloth of special weaving, which facilitates easy filtration.


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(f ) Paper disc type filtering element is enclosed in a metal case, which can be replaced

easily after being clogged.

FUEL INJECTION PUMP

It is a high pressure pump, which supplies fuel to the injectors according to the firing orderof the engine. It is used to create pressure

Varying from 120 kg/cm2to 300 kg/cm

2. It supplies metered quantity of fuel to each cylinder at

appropriate time.

Fuel Injection pump is usually of two types:

1. Multi element pump

2. Distributor (Rotary) type pump


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1) Multi element pump.

Each fuel pump unit consists of the following components:

(a) Plunger and barrel (b)Camshaft

(c) Delivery valve (d)Fuel control valve

Plunger and Barrel

Each pump element consists of

1. Plunger

2. Barrel

The plunger has helical groove. The rotation of the plunger changes the position of its

helical groove with respect to the barrel port. The fuel enters the barrel through these ports.

Control rod of the pump governs the movement of plunger. This control rod is connected to the

governor by a linkage. Locking screw controls the length of stroke of the plunger. Calibration is

necessary in such cases.

Working of plungerWhen the plunger is at BDC, the barrel is occupied by the fuel which has entered through

the barrel ports either under the force of gravity or from a fuel pump. As the plunger rises, the

fuel is pushed back through the barrel ports until they are closed by the top of the plunger

position. The effective stroke of the plunger begins at this point. Further upward movement

forces the fuel through the delivery valve, causing it to lift up from its seat. The fuel then enters

the pipe, connecting the pump to injector. A corresponding amount of fuel leaves it at the other

end and enters the cylinder through the injector.

This action continues until the plunger reaches a position when the lower edge of the

control helix uncovers the barrel ports allowing the fuel to pass out via the vertical slot in the

plunger.


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By rotating the plunger, the effective stroke can be shortened or lengthened depending

upon which part of the helix is in line with the barrel port, through which the fuel escapes at

the end of stroke. Thus the quantity of fuel, injected into the cylinder can be varied.

Camshaft

The camshaft of a fuel pump is timed with the crankshaft and operates the figake4and

exhaust valves. It also operates the plunger at the correct sequence according to the firing

order of the the engine.

The fuel from tank passes through filters and flows to Fuel injection pump and fr

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