3. OBJECTIVESOFTRAINING
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.
4. SWARAJAGROWING 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.
5. POSITION OFSWARAJ 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.
7. SWARAJ ENGINES LIMITED
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.
8. 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.
10. 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.
11. 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 OFENGINES 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.
12
13. 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 Super
Type 4-Stroke, Direct
Injection, Diesel
Engine
4-Stroke, Direct
Injection, Diesel
Engine
No. of Cylinders 1 1
Bore & Stroke 120136 mm 120126 mm
Displacement 1538 cc 1425 cc
Rated Engine Speed 1650 rev/min 1900 rev/min
14. RV-2, Two Cylinder Engine
Model RV-2
KIRLOSKAR
RV-2 XM + 3A
H.P. 26.5 H.P. 25-30 H.P.
Tractor SWARAJ 724 FE 724 XM
ORCHARD
Type 4-Stroke, Direct
Injection, Diesel
Engine
4-Stroke, Direct
Injection, Diesel
Engine
No. of Cylinders 2 2
Bore & Stroke 100 110mm 100 116 mm
Displacement 1728 cc 1824cc
Rated Engine Speed 2000 rev/min 1800 rev/min
15. 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 XM
Type 4-Stroke, Direct
Injection, Diesel
Engine
4-Stroke, Direct
Injection, Diesel
Engine
No. of Cylinders 3 3
Bore & Stroke 100 110mm 100 116 mm
Displacement 2592 cc 2734 cc
Rated Engine Speed 2000 rev/min 1800 rev/min
16. RV-30, Three Cylinder Engine
Model RV-30 TR ;
KIRLOSKAR
RV-30 XM + 3A
H.P. 34 H.P. 30-35 H.P.
Tractor SWARAJ 834 FE 834 XM
Type 4-Stroke, Direct
Injection, Diesel
Engine
4-Stroke, Direct
Injection, Diesel
Engine
No. of Cylinders 3 3
Bore & Stroke 110 100 mm 100 110 mm
Displacement 2474 cc 2592 cc
Rated Engine Speed 2000 rev/min 1800 rev/min
17. RB-30, Three Cylinder Engine
Model RV-30 TR ;
KIRLOSKAR
RV-30 XM + 3A
H.P. 48 S.A.E. 40-50 H.P.
Tractor SWARAJ 744 FE 744 XM
Type 4-Stroke, Direct
Injection, Diesel
Engine
4-Stroke, Direct
Injection, Diesel
Engine
No. of Cylinders 3 3
Bore & Stroke 110 110 mm 100 116 mm
Displacement 3136 cc 3307 cc
Rated Engine Speed 2000 rev/min 1800 rev/min
18. RB-33, Three Cylinder Engine
Model RV-33 TR ;
KIRLOSKAR
RV-33 XM
H.P. 55 S.A.E. 50-55 H.P.
Tractor SWARAJ 855 FE 855 XM
Type 4-Stroke, Direct
Injection, Diesel
Engine
4-Stroke, Direct
Injection, Diesel
Engine
No. of Cylinders 3 3
Bore & Stroke 100 116 mm 110 122 mm
Displacement 3308 cc 3480 cc
Rated Engine Speed 2000 rev/min 1800 rev/min
20. 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
22. 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.
23. 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. Profitability
3. Budgeting
4. Standard Costing
5. Proper matching of cost with revenues
6. Control of material and Supplies
7. Wages and overhead costs
8. Determining Expansion Policies
24. 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.
25. 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 :
1. 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.
2. 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.)
26. 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.
27. 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 :
1. Turning
2. Drilling
3. Boring
4. Reaming
5. Hole Milling
6. Tapping
7. Face Milling
8. Chamfering
9. Grooving
10. Grinding
11. Honing
29. 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.
30. 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.
31. 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
32. 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.
34. EngineAssembly 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.
35. 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.)
36. Engine Testing
1. Air Consumption
2. Lubricating Oil Consumption
3. Smoke Density
4. Water InletTemperature
5. Water OutletTemperature
6. Engine OilTemperature
37. 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.
38. 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.
39. 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
40. 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.
41. 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.
42. 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.
43. 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
44. MaintenanceDepartment
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.
45. 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”.
TOTALPRODUCTIVE MAINTENANCE (TPM)
46. TPM has Six Goals :
1. Zero Breakdown
2. Zero Defect
3. Zero Losses
4. Zero Accidents
5. Zero Pollution
6. Zero Health Hazard
TPM IMPLEMENTATION
48. 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 workplace
Seiketsu Standardization Standardize the way of
maintaining cleanliness
Shitsuke Self-Discipline Practice ‘5 S‘ daily – make it
the way of life ; this also
means ‘commitment’
49. Machining Lines at SEL
There are Five Machining Lines in Swaraj Engine Limited.
These are as follows :
1. Crankcase Machining Line
2. Cylinder Block Machining Line
3. Cylinder Head Machining Line (RB,RV)
4. Connecting Rod Machining Line
5. Gear Case Machining Line
51. MainPartsOfMachineTool:
1. Bed
2. Pallet
3. Automatic Tool Changer (ATC)
4. Spindle Head
5. Tool Magazine
6. Manual Pulse Generator
7. Electric Cabinet and CNC unit
8. Coolant Tank and Chip Conveyor
52. 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.
54. 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.
55. 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
SpringCap
56. 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 End
Big End
57. ASSEMBLYLINE & 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.
60. 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.
Upper Clamps
Un Machined
Crankcase
61. 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
62. 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.
63. 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.
64. 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.
65. CylinderLiner
The 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
66. PistonAssembly
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
67. Connecting RodAssembly
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
68. Piston Head & Connecting RodAssembly
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.
69. Cylinder HeadAssembly
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.
InletValve Exhaust
Valve
Valve Spring
70. 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.
71. RockerArm
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
Shaft
washers
Springs
Rocker
Support
Rocker Arms
Rocker Arm Sub Assembly
Circlips
72. 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.
73. 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.
74. 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
75. Fuel InjectionPump(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
76. 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.
77. LubricationPump
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
GearType Lubrication Pump
78. OilSump
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
79. 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
81. ENGINE TESTING
The engine here is tested, inspected
at various rpm’s and loads.
Checking:
* Full Load
* No Load
* Over Load
* Unusual Noise
PROCEDURE:
1. Engine Testing Bed
2. Clamping
3. Inlet and outlet connection joined
4 .Inlet air supply.
5. Exhaust for smoke and various dust
particles
82. 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.
83. 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
84. PROJECTS UNDERTAKEN INASSEMBLYSHOP
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.
85. Adjustment, Significance & Procedure of
Bumping Clearance
Engine Assembly Line Project 1
By
Amit Sharma
Trainee
Swaraj Engines Limited
Mohali
Project Guidance
Mr. Amritpal Sharma
Assembly Shop
Swaraj Engines Limited
Mohali
86. BumpingClearance:
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= CompressionVolume ShimBumping Shim
87. Significance of Bumping Clearance
1. 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.
89. Procedure Of setting Bumping Clearance
1. 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.
90. 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
91. 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 :
92. AdjustmentofValveClearance
Engine Assembly Line Project 2
By
Amit Sharma
Trainee
Swaraj Engines Limited
Mohali
Project Guide
Mr. Amritpal Sharma
Engine Assembly Shop
Swaraj Engines Limited
Mohali
93. 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.
94. 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.
95. 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.
96. 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.
97. 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
99. Engine assembly Project 3
Adjustment of Fuel Injection Pump Timing
By
Amit Sharma
Trainee
Swaraj Engines Limited
Mohali
Project Guide
Mr. Amritpal Sharma
Engine Assembly Shop
Swaraj Engines Limited
Mohali
100. 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.
101. Significance of Setting FIPTiming
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
103. 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
104. Procedure
1. 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.
105. 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 : DripTube Method
DripTube
FIP Gear
106. 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
