INDUSTRIAL TRAININGAT
SWARAJ ENGINES LIMITED
Submitted byAmit Sharma2012UGMEL127M.E. (7th Semester)
Under the Guidance of :Mr. Amritpal SharmaEngine Assembly LineSwaraj Engines Ltd. Mohali
COMPANY ADDRESS :
MAHINDRA & MAHINDRA
SWARAJ ENGINES LIMITED
PHASE-9 , INDUSTRIAL AREA
S.A.S. NAGAR MOHALI
OBJECTIVES OF TRAINING
1. To study the various process which are done on various parts
of tractor engine
2. To study about Production Planning & Control.
3. To study the function of different departments with respect to
each other.
4. To study process flow charts.
5. To study about management.
6. To study about Human Resource Management and their
behavior about employees.
SWARAJ A GROWING ENTERPRISE
Hindi meaning of SWARAJ “ Freedom From Bondage ” and used
first by Bal Ganga Dhar Tilak during the time of freedom.
Punjab Tractors Limited (PTL) was the first tractor project in India,
moreover fully based upon Indian Technology.
SWARAJ is the brand name of SWARAJ GROUP.
It was established in 1965 by a team of dedicated Engineers &
Scientists working at Central Mechanical Engineering Institute at
Durgapur.
INTRODUCTION
POSITION OF SWARAJ PRODUCTS IN MARKET
The products of SWARAJ are not only restricted to Indian Market but they had entered in International Market.
SWARAJ tractors find an important place in developing countries like Ghana, Tanzania, Zambia, Kenya, Sudan, Uganda, Indonesia & Malaysia, etc.
They are also sending their Combines to South Korea having first A.C. Cabin Combine in India.
Long way back, they had also transported the machined rims to Japan, a project millions of dollar.
SWARAJ TRACTOR LIMITED Or PTL DIVISIONS
Swaraj Tractor Division (STD) Mohali Swaraj Combine Division (SCD) Chapparchiri Swaraj Foundry Division (SFD) Mazri Swaraj Automotive Limited Swaraj Engines Limited (SEL) Mohali Swaraj Mazda Limited (SML)
SWARAJ
TRACTOR DIVISION
SWARAJMAZDA
LIMITED
AUTOMOTIVE LIMITED
ENGINE LIMITED
FOUNDRY LIMITED
COMBINE DIVISION
SWARAJ ENGINES LIMITED
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.
SWARAJ ENGINES LIMITED
The Governor of Punjab Mr. S.S. Ray paid the foundation stone of the factory on 29th Dec. 1987.
It started production from 28th Dec. 1988.
The plant produces engines in the range of 20 H.P. to 50 H.P.
This plant had produced 18000 engines in the first year of its production. But now producing 270 engines averagely every day. There are 5,00,000 tractors working successfully in the fields which are having engines of SEL.
SHARE HOLDING PATTERN
SWARAJ ENGINES LIMITED
As on 30th September,2014
Shareholding1st Qtr2nd Qtr3rd Qtr4th Qtr5th Qtr6th Qtr
% of Shareholding
Mahindra & Mahindra Ltd (M&M)
33.22%
Kirloskar Industries Ltd. (KOEL)
17.39%
Mutual Funds 10.00%
Financial Institutions/Insurance CO’s/Banks
0.09%
FIIs 5.45%Public 33.84%
Various Engine Models
1. R-V2, Two cylinder ; 24 H.P.
2. R-V3, Three cylinder ; 39.5 H.P.
3. S15, Single cylinder ; 25 H.P.
4. RB-33, Three cylinder ; 54 H.P.
5. RB-30, Three cylinder ; 44 H.P.
6. RB-33 TC, Three cylinder ; 58 H.P.
VISION & MISSION
Vision :
Swaraj 2nd Largest
Brand in India with
Global Presence.
Mission :
3-2-3
In 3 years Double the
Revenue and Triple the
Profits
12
TYPES OF ENGINES MANUFACTURED IN SEL
The Plant manufactures Six types of Engines, which engines are
sent to the Swaraj Tractor Division, S.A.S. Nagar. One of these
is a Two Cylinder Engine exclusively Designed for R & D plant
of Swaraj. Out of rest one is two cylinder and Three cylinder
engines.
All engines are EURO-3 and SEL is planning for modifications
to be introduced, so that its engines may be EURO-4
compatible.
SPECIFICATION OF ENGINES
Model S-15 ; Swaraj S-15 ; Swaraj
H.P. 20-25 H.P. 24.5 H.P.Tractor 825 XM SWARAJ 722 SuperType 4-Stroke, Direct
Injection, Diesel Engine
4-Stroke, Direct Injection, Diesel Engine
No. of Cylinders 1 1Bore & Stroke 120136 mm 120126 mmDisplacement 1538 cc 1425 ccRated Engine Speed 1650 rev/min 1900 rev/min
RV-2, Two Cylinder EngineModel RV-2
KIRLOSKARRV-2 XM + 3A
H.P. 26.5 H.P. 25-30 H.P.Tractor SWARAJ 724 FE 724 XM
ORCHARDType 4-Stroke, Direct
Injection, Diesel Engine
4-Stroke, Direct Injection, Diesel Engine
No. of Cylinders 2 2Bore & Stroke 100 110mm 100 116 mmDisplacement 1728 cc 1824ccRated Engine Speed 2000 rev/min 1800 rev/min
RV-3, Three Cylinder Engine
Model RV-3 TR ; KIRLOSKAR
RV-3 XM + 3A
H.P. 39 H.P. 35-40 H.P.Tractor SWARAJ 735 FE 735 XMType 4-Stroke, Direct
Injection, Diesel Engine
4-Stroke, Direct Injection, Diesel Engine
No. of Cylinders 3 3Bore & Stroke 100 110mm 100 116 mmDisplacement 2592 cc 2734 ccRated Engine Speed 2000 rev/min 1800 rev/min
RV-30, Three Cylinder Engine
Model RV-30 TR ; KIRLOSKAR
RV-30 XM + 3A
H.P. 34 H.P. 30-35 H.P.Tractor SWARAJ 834 FE 834 XMType 4-Stroke, Direct
Injection, Diesel Engine
4-Stroke, Direct Injection, Diesel Engine
No. of Cylinders 3 3Bore & Stroke 110 100 mm 100 110 mmDisplacement 2474 cc 2592 ccRated Engine Speed 2000 rev/min 1800 rev/min
RB-30, Three Cylinder EngineModel RV-30 TR ;
KIRLOSKARRV-30 XM + 3A
H.P. 48 S.A.E. 40-50 H.P.Tractor SWARAJ 744 FE 744 XMType 4-Stroke, Direct
Injection, Diesel Engine
4-Stroke, Direct Injection, Diesel Engine
No. of Cylinders 3 3Bore & Stroke 110 110 mm 100 116 mmDisplacement 3136 cc 3307 ccRated Engine Speed 2000 rev/min 1800 rev/min
RB-33, Three Cylinder Engine
Model RV-33 TR ; KIRLOSKAR
RV-33 XM
H.P. 55 S.A.E. 50-55 H.P.Tractor SWARAJ 855 FE 855 XMType 4-Stroke, Direct
Injection, Diesel Engine
4-Stroke, Direct Injection, Diesel Engine
No. of Cylinders 3 3
Bore & Stroke 100 116 mm 110 122 mmDisplacement 3308 cc 3480 ccRated Engine Speed 2000 rev/min 1800 rev/min
SWARAJ TRACTOR ENGINE
WORK AT SWARAJ ENGINES LTD.
Various Departments at SEL include :
(1) Human Resource Department (H.R.D.) (2) Information Technology
(3) Accounts (4) Purchase
(5) Production Planning & Control (P.P.C.) (6) Industrial Engineering (I.E.)
(7) Machine Shop (8) Tool Room
(9) Tool Crib (10) Assembly Shop
(11) Engine Testing (12) Quality Engineering
(13) Standards Room (14) Store
(15) Maintenance
Define
Human Resource Department
1. Creating acceptable rules of practice to encourage highest degree of participation from its employees to contribute towards organizational goals.
2. It ensures maximum individual development, desirable working condition and desirable working relationship between employees and employers.
1. It ensures development of computing services in the organization to meet the future technological needs.
2. It is also responsible for the preventive maintenance of both hardware & software installed in the entire premises.
INFORMATION TECHNOLOGY
Accounts The main objective of accounts department is to determine, classify and
analyze the cost & income of the business enterprise.
It provides information for the following :
1. Cost control 2. Profitability3. Budgeting 4. Standard Costing5. Proper matching of cost with revenues6. Control of material and Supplies7. Wages and overhead costs8. Determining Expansion Policies
Purchase
1. Responsible for purchasing all types of materials in correct quality & quantity and at the most economical prices.
2. It has a unique position with a view that purchasing is one of the main function in the success of modern manufacturing concern.
3. The purchasing function act as a liaison agency, which operates between the factory and the outside vendors on all matters of procurement delivery of the articles in accordance with terms of purchase agreement.
1. The PPC cell at SEL is in charge of maintaining the inventory status, arranging receipt,
dispatch of components and follow up.
2. It also supervises transfer of components from the machine shop and stores to the
assembly shop and maintains the shop floor status of components.
PPC indicate two functions :
3. Production Planning is the function concerned with the planning, directing and
controlling of the methods to be used to make products and the way in which the
production facilities should be laid out in the space available for production.
4. Production Control is the function of management, which plans, directs, coordinate &
controls the material supply and processing activities of an enterprise. So that specified
products are produced by specific methods to meet and approved sales program.
Production Planning & Control (P.P.C.)
Industrial Engineering (I.E.)
1. Industrial Engineering is the back bone of the industry most important department in terms of production, Planning, designing, and optimization of methods governing the factory operations.
2. It is concerned with the design, improvement & installation of integrated system of people, materials, equipment & energy.
3. It draws upon specialized knowledge & skill in the mathematical , physical and social sciences together with principles & methods of engineering analysis and design to specify, predict and evaluate the results to be obtained from such system.
Machine Shop
Machine shop is responsible for the following functions :1. Machining of Crankcases, Cylinder Blocks, and Gear Casings of all engine
models.2. Machining & Assembly of Cylinder Heads.3. Machining & Assembly of Connecting Rods of AVL and SML models.4. Machining SML engine Crankcases & Cylinder Blocks.
Following machining operations are used :
5. Turning6. Drilling7. Boring8. Reaming9. Hole Milling10. Tapping11. Face Milling12. Chamfering13. Grooving14. Grinding15. Honing
1. Horizontal Milling Centers
2. Vertical Milling Centers
3. Surface Grinding Machine
4. Portable Grinding Machine
5. Radial Drilling Machine
6. Tapping Flexi-arms
7. Gang Milling Machine
8. Boring Machine
9. Honing Machine
10. Gun Drilling Machine
11. Washing Machine
12. Cylindrical Grinding Machine
Machines used in Machine Shop include :
Special Purpose Machines Used in M/C shop
The machine shop also houses 14 Advanced CNC Horizontal
Machining Centers comprising :
1. 7 Starrag Heckert HMC's for Crankcase machining
2. 3 Makino HMC's for Gear Case machining
3. 2 Makino HMC's for valve seat & valve guide generation
in cylinder head
4. Latest on the shop, 2 Makino HMC's for Cylinder Block
machining.
Machine Shop's Relation with other departments :
1. Industrial Engineering : Procurement of process sheets, time
study & tool planning.
2. Maintenance : Check for preventive & breakdown maintenance.
3. Tool Room : Requirements of jigs & fixtures, re-sharpening of
cutting tools, etc.
4. Assembly Shop : Reworking of rejected components and supply
of machined components.
5. Quality Engineering : Maintaining the Quality & Inspection of
components at each stage of production.
Tool Room
The tool room in SEL performs the following functions
:
Fabrication & Repair of Jigs & Fixtures
Manufacturing & Repair of Cutting Tools
Manufacturing of other small parts in- house.
Tool Re-sharpening
Development Work
Tool Crib
1. Tools go blunt and wear away with time after completing their life as tools for specific
machining operations.
2. Tool crib is responsible for replacement of these tools to ensure continuity of machining
on the shop floor.
3. It stocks and provides various types of tools including inserts, cutters, drills, boring bars,
reamers, taps, adaptors, other attachments, etc.
4. The tool crib in-charge issuing tool maintains the record of specification and number of
tools issued and notes the employee number and date of issue along with other details.
5. Various types of measuring instruments and gauges like vernier callipers, micrometers,
scales, vernier height gauge, bevel protector, spirit level etc. are also available along here
by auxiliary tools like spanners, hammers & hacksaw etc.
Various Cutting Tools in Tool Crib
Engine Assembly Shop
1. The objective of assembly shop is to combine individual components
into a useful product of higher value.
2. The assembly shop at SEL assembles RV-2, RV-3, RV-30, RB-30 & RB-
33 engines.
3. Assembly is done manually in which workers perform various
assembly operations by using dexterity, sense organs and intelligence
along with various tools and fixtures.
4. Different components are brought from the stores and the machine shop
to be assembled into engines on a common assembly line for all models.
Engine Testing
A completely assembled engine is tested and inspected at various
RPM's at full load, no load and over load in the Engine Testing area
to be finally marked as OK or Not OK.
Basic measurements undertaken to evaluate the performance of
the engine are :
BHP (Break Horse Power)
SFC (Specific Fuel Consumption)
Torque (Using Torque Indicator)
Speed (R.P.M.)
Engine Testing1. Air Consumption2. Lubricating Oil Consumption3. Smoke Density4. Water Inlet Temperature5. Water Outlet Temperature6. Engine Oil Temperature
Quality Department
Its Main Functions Are :
1. To separate defective components from non-defective ones.
2. Detecting Parts not meeting the specifications during processing
itself, so as to minimize any troubles that may arise at assembly time.
3. To make sure that final product meets the required specifications.
4. To detect sources of variations & troubles in finished product.
5. To build reputation of concern by reducing complaints from the
customer.
Quality at Receipt
1. Quality at receipt inspects all incoming materials to evaluate the vendor's quality and to reject those components which don't meet the specification.
2. Inspection of incoming components involves visual and dimensional check-up, and test of physical and chemical properties etc., using hardness tester, surface roughness tester and other gauges.
1. Quality of in-house processed components is either self-inspected or by quality inspectors for the purpose of avoiding flow of faulty materials into the production line.
2. It also houses the Coordinate Measuring Machine (CMM) for the purpose of checking dimensional accuracy of components.
QUALITY AT MACHINE SHOP
Quality at Engine Assembly Quality engineering examines the critical parameters
of engine like tightening of various nut & bolts, Studs, filling the proper clearance, etc. to ensure error free assembly.
Quality at Engine Testing Before finally dispatching the engine, It is tested for
B.H.P. ,S.F.C., Oil Pressure, Loose Nuts & Bolts, Leakages, Noise Level etc., to avoid any problems at customer's end.
Quality at Engine Assembly & Testing
Standard Room
1. Standard room, part of quality engineering department, contain various
measuring gauges and instruments like Calipers, Surface Plate, V-block,
Spirit Level, Combination Set, Engineers Square, Feeler Gauges, Slip
Gauges, Go-No Go Gauges, Dial Indicators, Vernier Height Gauges,
Barometer, Thermometer, Micrometer and Bevel Protectors.
2. The instruments and gauges in use are compared with standard gauges in
the standard room. In order to have an efficient use of working standards
and get accurate results, an agreed standard temperature of 20C is
maintained for the reference gauges.
CMM Room
Coordinate Measuring Machine is installed there for the
purpose of inspection of the coordinates of assembly
components like crankcase, cylinder head, etc. The machine
movements are in X, Y, & Z direction. And the 6 of freedom
of the component to be inspected can be done on that
machine.
Air bearings are used to move the arms of the machine.
Machine is fully automatic and attached with computer
assisted programs.
The gap between the surfaces in contact is 6 microns.
Pressurized air is used as a lubricant. Thus easy in operation.
A Sensor is also used to sense the coordinates and on stylus or
probe ruby metal ball is used to indent on the work piece.
Store
Store Management Ensures :
That the required materials are neither out of stock nor available in excess.
That there is proper storing of materials and proper method of keeping store records.
There is adequate procedure of the receipt and the issue of materials.
Receiving Store - All material from vendors is received and checked by Q.E. (receipt) and upon
clearance the goods are received, unpacked and their quantity and condition is checked.
Main Store - The material upon clearance by the quality reaches the main store. Here it is properly
stored in the bins or stocked. Upon receipt of material requisition from, the storekeeper issues the
material and records the quantities disbursed.
Rejection Store - The material, which is rejected by the Quality, is kept in rejection store to be send
back to the vendor.
Tool Store - The various types of tools used on the shop floor are kept here. Tools are issued on
material issue receipt and their return is recorded through material return slip. Proper record of tool
stock is kept and tool consumption is analyzed.
Various Stores in SEL
Maintenance Department
The Various Objectives of the Maintenance Department are :
1. To achieve minimum breakdown and to prevent loss in production time.
2. Overhauling of plant equipment & machinery.
3. To keep the plant in good working condition at the lowest possible cost.
4. To provide plant protection including fire protection.
5. To establish & maintain a suitable store of maintenance materials.
6. To maintain the various plant services.
7. Generation and distribution of power and other facilities.
Definition : TPM is a maintenance program concept and it resembles to Total Quality Management (TQM) in several aspects, such as•Total commitment to the program by upper level management is required.•Employees must be empowered to initiate corrective action.•It is a on-going process.
Goal of TPM :“Continuously improve all operational conditions, with in a production system ; by stimulating the daily awareness of all employees”.
TOTAL PRODUCTIVE MAINTENANCE (TPM)
TPM has Six Goals :1. Zero Breakdown2. Zero Defect3. Zero Losses4. Zero Accidents5. Zero Pollution6. Zero Health Hazard
TPM IMPLEMENTATION
JISHU HOZEN (JH )STEPSJH STEPS ACTIVITIESJH 0 Understanding Equipment & Thorough CleaningJH 1 Initial Cleaning & TaggingJH 2 Implementing CountermeasuresJH 3 Developing Tentative Standards for CLITA
JH 4 General Equipment Inspection (Equipment Competent Operator)
JH 5 Autonomous Inspection (Process Competent Operator)JH 6 StandardizationJH 7 Autonomous Management
Meaning Of 5S
Japanese Term English Equivalent
Meaning in Japanese Context
Seiri Sorting Throw away all rubbish and unrelated materials from the workplace
Seiton Systematic Arrangement
Set everything in proper place for quick retrieval and storage
Seiso Shining Clean the workplaceSeiketsu Standardization Standardize the way of
maintaining cleanlinessShitsuke Self-Discipline Practice ‘5 S‘ daily –
make it the way of life ; this also means ‘commitment’
Machining Lines at SEL
There are Five Machining Lines in Swaraj Engine Limited. These are as follows :1. Crankcase Machining Line2. Cylinder Block Machining Line3. Cylinder Head Machining Line (RB,RV)4. Connecting Rod Machining Line5. Gear Case Machining Line
CRANKCASE MACHINING LINE
Machine Name: Starrag Heckert
Model : WMW CWK 500 Features of Machine :1. High Flexibility2. Performance3. High Precision & Accuracy
Type : CNC (Computer Numerical Control)
Main Parts Of Machine Tool :1. Bed2. Pallet 3. Automatic Tool Changer (ATC)4. Spindle Head5. Tool Magazine6. Manual Pulse Generator7. Electric Cabinet and CNC unit8. Coolant Tank and Chip Conveyor
Advantages of Upgrading to CNC Machine Tools
1. CNC machine tools can be used
continuously 24hours a day, 365 days
a year and only need to be switched
off for occasional maintenance.
2. These are programmed to manufacture
same types of components multiple
times with the same accuracy and
precision each time, and each
component as an exact match.
3. Modern design software allow the
designer to simulate the manufacture
of his/her idea. There is no need to
make a prototype or a model. This
saves time and money.
Technical Specification
•Clamping surface: 500 mm 500 mm
•Maximum work piece weight : 800kg
•Maximum feed x/y/z : 38m/min
•Maximum numbers of tools slots: 240
CYLINDER HEAD
In an internal combustion
engine, the cylinder head sits
above the cylinders or top of the
cylinder block. It closes in the
top of the cylinder, forming the
combustion chamber. This joint
is sealed by a head gasket. The
head also provides space for the
passages that feed the air & fuel
to the cylinder, and that allow
the exhaust to escape. It is also
the place to mount the valves
and fuel injectors.
PARTS OF CYLINDER HEAD
A completely machined cylinder head after assembly on the Cylinder Head line comprises of following parts :
1. Inlet and Exhaust Valve Guides
2. Valve Seat
3. Inlet & Exhaust Valve
4. Oil Stem Seal and Valve Cap
5. Valve Spring
6. Collets & Spring Cap and Aluminium core plug
Valve GuidesInlet Exhaust
Valve Spring Valve
Seat
Spring Cap
CONNECTING ROD
In a reciprocating piston engine the
connecting rod connect the piston to the
small end side and crank shaft at the
Big end side . Together with the
crankshaft, They form a simple
mechanism that convert reciprocating
motion into rotary motion.
SMALL END : The small end is
connected with piston pin or gudgeon
pin which is currently most often press
fit There is bush provided inside the
small end side.
BIG END : The big end is connected
to the bearing journals on the
crankshaft.
Small EndBig End
ASSEMBLY LINE & ENGINE TESTING
Most of the products are formed from a large number of single parts produced at
different times by various production processes. All these may not be made at a
single place but are procured from different sources. The objective of assembly
shop is to combine individual components into a useful product of higher value.
The assembly shop at SEL assembles RV-2, RV-3, RV-30, RB-30 & RB-33 engines.
Assembly is done manually in which workers perform various assembly operations
by using dexterity, sense organs and intelligence along with various tools and
fixtures. different components are brought from the stores and the machine shop to
be assembled into engines on a common assembly line for all models.
Basic Engine Model
Key Components For Engine Assembly
(1) Crankcase (2) Crank Shaft
(3) Cam Shaft (4) Lubrication Pump
(5) Lubrication Filter (6) Gear Casing
(7) Cylinder Block (8) Cylinder Liner
(9) Piston Assembly (10) Connecting Rod
(11) Cylinder Head (12) Inlet & Exhaust
Manifold (13) Push Rods
(14) Rocker Arms (15) Water Pump
(16) Fuel Filter (17) Fuel Injection Pump
(18) Fuel Injector (19) Oil Sump
(20) Flywheel Assembly
Crankcase
The crankcase supports the individual main journals & bearings of crank shaft & also maintains the alignment of journal axis of rotation as they are subjected to rotary and reciprocating inertia forces.
The crankcase walls are flanged at the bottom to strengthen the casting & to attach the sump at bottom.
Core Plug
Upper Clamps
Un Machined Crankcase
The Crank Shaft converts the reciprocating
motion of piston in cylinder into rotary
motion of the flywheel or vice versa.
Power from the burnt gases in the
combustion chamber is delivered to the
crank shaft through piston and connecting
rod assembly.
The conversion of the motion is executed
by the use of offset in the crankshaft. The
stroke of piston is controlled by throws of
crank shaft . All Engine power is delivered
by crankshaft. And the material used for
crank shaft is alloy steel.
Crank Shaft
Cam Shaft
The cam shaft acts as a means of controlling
the opening & closing of both inlet and outlet
valves.
It also provides a drive to the ignition and
performs the function of distributing and
mechanizing fuel pump.
The Cam Shaft installed on one side of
crankcase is the second rotating shaft in the
crankcase after crank shaft. The gear mounted
on the Cam shaft is bigger in size and having
more teeth on its periphery in comparison to
crank shaft. The speed of the cam shaft is half
the speed of crank shaft.
Gear Casing
Gear Casing covers various gear assembly
in the diesel engine.
It is made of cast iron and its main function
is to provide housing for the gear assembly to
prevent any damage to the gears of cam shaft,
crank shaft, intermediate gear and lubrication
pump gear assembly etc.
Cylinder Block
Cylinder block is the
portion of the engine
between the cylinder head
and crankcase and is
supporting structure of the
entire engine. Large
diameter holes in the
casting form the cylinder
bore required to guide the
piston assembly.
Cylinder LinerThe Cylinder liner acts as
a medium between piston
assembly and casting.
It encloses the piston
assembly and protects it
against any damage.
It also increases the
cylinder bore life, due to its
high wearing against cast
iron.
Cylinder Liners
Piston Assembly
The piston converts the combustion pressure
to force on crank shaft. The piston is made
of aluminum alloy. Piston rings comprises of
compression rings located towards the top of
the piston and Oil control rings located
below the compression rings.
The function of the compression ring is to
seal the space between cylinder walls and
the piston preventing the escape of the
burning gases from the combustion chamber.
These rings help to obtain maximum power
by maintaining a seal with the cylinder wall
while keeping friction minimum as possible.
Compression Rings
Lubrication Rings
Head
Piston Pin Bore
Connecting Rod Assembly
The connecting rod joins the piston
to the crank shaft and transfers
reciprocating force to crank shaft
rotation. The small end of the
connecting rod reciprocates and
the big end of the connecting rod
follows the rotational pattern. For
this dynamic moment, connecting
rod should be as light as possible.
Bush
Piston Head & Connecting Rod Assembly
The piston head & connecting rod
assembly comprises of piston head
attached with the connecting rod small
end side. The piston head is connected to
the connecting rod by a pin called piston
pin or sometimes called as gudgeon pin.
On the bigger end of connecting rod it is
attached to the crankshaft.
Cylinder Head Assembly
Cylinder head is the casing bolted to the
top of the cylinder block. it houses the
inlet and exhaust valves and the
injection location holes. It forms the
upper face of the combustion chamber,
coolant passage, and lubricating passage.
The cylinder head is detachable for easy
access to the valves piston tops. The
valve arrangement of the engine controls
in and out movement of the charge and
exhaust gases. The valves are located in
the cylinder head. The valves disk heads
open or close the passage leading to the
cylinder during the movement of system.
Inlet Valve
Exhaust Valve
Valve Spring
Intake & Exhaust Manifold
The primary function of intake manifold is to carry the air to the intake port in the engine.
The exhaust manifold collects the high temperature spent gases from the cylinder exhaust port with the least possible back pressure while keeping the noise at a minimum level.
It is a strut which transmits the to and fro cam follower movement to
the pivoting rocker arm. Both ends of the push rod consist of semi
spherical ball and socket joint permitting the rod to tilt slightly and
revolve when the rocker arm oscillates about pivot.
PUSH ROD
Rocker Arm
Rocker Arms oscillate about its pivot and relay the push rod up and down to the stem of the valve. Therefore its arm acts as rocking beam. Rocker arms are manufactured with malleable cast iron.
Rocker Shaftwasher
s
Springs
Rocker Suppor
t
Rocker Arms
Rocker Arm Sub Assembly
Circlips
Water Pump
Usually centrifugal pump is
used for circulation of the
water in the cooling system.
Water enters the inlet pipe
from the bottom of the radiator
and is directed by passage to
the centre of impeller, where it
is caught by rotating vanes.
Due to centrifugal force water
is thrown out into the delivery
pipe and then to the water
jackets.
Thermostat Valve
A valve used in a cooling system to regulate the
engine temperature by automatically controlling the
amount of cooling water flowing from the water
jackets to the radiator core is called thermostat valve.
Whenever we start engine it is cool. It takes some
time to warm the engine parts so that they can work
efficiently. At that time we don't want that the cooling
water circulates through the water jackets. Because
we want that engine warms up as early as possible.
Therefore, a thermostat is installed in the cooling
system, initially to prevent the circulation of water
below a certain temperature through the radiator so
that the engine heats up quickly. When the required
temperature normally 70C is reached, the thermostat
allows the water to flow through the radiator. The
bellow type radiator is used in the cooling system.
Fuel Filter
The fuel filter screens out dust & rust particles from the fuel. They are of a bowl like design which collect water in the bottom (as water is denser than diesel) . The water can then be drained off by opening a valve in the bottom of the bowl and letting it runs out, until the bowl only contains only diesel. The fuel filter comprises of Primary filter and Secondary filter, in which primary filter removes dust particles first and then after final filtration is done by the secondary filter. Primary
Side Secondary Side
Fuel Injection Pump (FIP)
An injection pump is the device that pumps a
metered quantity of the fuel to the injectors or
nozzles under a very high pressure at correct instant
is called fuel injection pump. It rotates at half crank
shaft speed in a conventional four stroke engine. Its
timing is such that the fuel is injected very slightly
before top dead centre of the cylinder's
compression stroke.
The FIP is inline or rotary type pump driven by cam
shaft gear. The fuel supply is individual in each
cylinder according to the ignition timing or firing
order.
Feed Pump
Fuel Injector
The main functions of fuel injector is to develop
the pressure at which the injection begins, to
control the rate of injection for achieving the
required rate of increase in pressure and a
combustion process that is complete without
generating harmful emission, and to inject the
fuel into the combustion chamber.
A nozzle mounted in the combustion chamber to
supply the fuel to the engine cylinder in the form
of fine spray is called injector or fuel injector.
Sometimes also named as fuel atomizer.
Lubrication Pump
The purpose of lubrication pump is to circulate oil
under pressure to the oil gallery and drilled
passages to lubricate the various engine parts. The
various types of lubrication oil pumps are gear
type, rotor type, vane pump and plunger type
pump. Here we are using internal gear type oil
pump.
It consist of two spur gears of equal size enclosed
in a close fit housing. One is driving gear and
another is driven gear called idler gear. The oil
enters the pump from the suction port and it is
carried by the spaces between the gear teeth and the
pump body to the discharge port connected with oil
gallery. The pressure developed depends upon the
speed of the gears i.e. engine.
Driven Gear
Driver Gear Pump
Shaft
Gear Type Lubrication Pump
Oil Sump
The sump attached at the bottom of
the crankcase acts as storage for
engine lubricating oil. It collects the
oil draining from the side of the
crankcase walls and provides
centralized area for any contaminants
like water, liquid oil and worn metal
particles. It is provided with a drain
valve or plug at the bottom face.
Cast Iron Sump
Sheet Metal Sump
Drain Plug
Flywheel
The flywheel is a heavy and perfectly
balanced wheel usually bolted to a flange
on the rear end of the crank shaft which
stores energy to help the engine over idle
strokes of the piston. It keeps the fluctuation
of energy with in limit due to varying load
cycle. It provides the convenient mounting
point for clutch and starter rings. It stores
mechanical energy during the power stroke
and releases it during the other idle strokes
to keep the engine speed uniform. It is made
up of cast iron.
Flywheel
Starter Ring
ENGINE ASSEMBLY LINE & TESTINGENGINE ASSEMBLY LINE DIAGRAM
Crankcase
Crankshaft Fitment
Cam Shaft Fitment
Valve Timing Stage
Gear Casing Fitment
Piston Assembly
Bumping Shim Adjustment
Cylinder Block Fitment
Cylinder Head FitmentFIP
Fitment
Water Pump Fitment
Fuel Timing
Oil Sump Fitment
Engine Flywheel Assembly
Engine Testing
Engine Dispatch
Engine
Trolley
ENGINE TESTING The engine here is tested, inspected at various rpm’s and loads.Checking: * Full Load * No Load * Over Load * Unusual NoisePROCEDURE:1. Engine Testing Bed2. Clamping 3. Inlet and outlet connection joined4 .Inlet air supply.5. Exhaust for smoke and various dust
particles
6. Inlet of cold air.7. Outlet for hot water.8. Fuel oil supply.9. Pressure checking gauge
connection, of lubricating oil.10. Lubricating oil supply.11. Fuel oil overflow pipe.
1. B.H.P. (Brake Horse Power)
2. S.F.C. (Specific Fuel Consumption)
3. Air Consumption 4. Lubricating Oil
Consumption 5. Smoke Density
B.H.P. = I.H.P. - F.H.P
S.F.C. = 375750 / (Fuel time for 125 cc. B.H.P.)
Fuel Delivery:For 2 Cylinders : Fuel Delivery = 2500/ Fuel Time For 3 Cylinders : Fuel Delivery = 4500/ Fuel Time
Basic Measurements
PROJECTS UNDERTAKEN IN ASSEMBLY SHOP
1. Adjustment of Bumping Clearance, Significance of Bumping
Clearance and Procedure of bumping clearance setting in
Engine Assembly shop.
2. Adjustment of the Valve Clearance or Rocker Arm Clearance
of an Engine.
3. Adjustment of the Fuel Injection Pump Timing.
Adjustment, Significance & Procedure of Bumping Clearance
Engine Assembly Line Project 1
ByAmit Sharma
TraineeSwaraj Engines Limited
Mohali
Project GuidanceMr. Amritpal Sharma
Assembly ShopSwaraj Engines Limited
Mohali
Bumping Clearance :It is defined as the minimum distance
between or the gap between the cylinder
head (bottom face) and Top Dead Centre
(T.D.C.) of the piston.
For Setting of clearance two shims
(Spacers between liners and cylinder head
in order to lift the cylinder head to avoid
head noise. Otherwise if not inserted then
piston will hit to the cylinder head during
compression stroke. Size of shims are different.
Definition
CV Shim= Compression Volume ShimBumping Shim
Significance of Bumping Clearance1. If the clearance is not provided or given piston head of the engine during upward
movement from B.D.C. to T.D.C. will hit the engine cylinder head. Thus a jerk will be produced. To avoid this situation a clearance is provided between cylinder head and T.D.C.
2. The bumping clearance must be adjusted properly otherwise there is risk of damage and loss of engine efficiency.
3. If the bumping clearance is less then volumetric efficiency would increase but there is risk of the piston hitting the cylinder head, especially when the engine is unloaded during start and stopping.
4. If the bumping clearance is large then the extra clearance would result in a small volume of air being re-expanded every time causing increase in air temp, fall in efficiency and over-heating of engine. Generally, Bumping clearance depends upon manufacturer but as a thumb rule it should be between 0.5% to 1 % of bore of cylinder.
RV XM Engine With Digital GaugeBumping Chart (0.80 - 0.99)*
Digital Dial Bumping Shim Size CV Shim Size Bumping Clearance
0.40 ~ 0.20 0.6* 0 0.99 - 0.80
0.19 ~ 0.00 0.8 -0.6 0.99 - 0.80
-0.01 ~ -0.20 1 0.4 0.99 - 0.80
-0.21 ~ 0.30 1.2 -0.6 0.99 - 0.80
RB Engine With Digital Gauge Bumping Chart (0.80 - 1.00)
Digital Dial Bumping Shim Size CV Shim Size Bumping Clearance
-0.01 ~ -0.20 1 0.4 0.99 - 0.86
-0.21 ~ -0.34 1.2 -0.6* 0.99 - 0.86
-0.35 ~ -0.44 1.3 0.6* 0.99 - 0.86
-0.45 ~ 0.54 1.4 0.8 0.99 - 0.86
0.55 ~ -0.64 1..5 0.8* 0.99 - 0.86
Procedure Of setting Bumping Clearance1. Revolve the crank shaft pulley so that the
piston (1) and piston (3) comes at Top Dead Center (T.D.C.)
2. Now mount the bumping tools over the cylinder head by the clamps. Tight it with the help of torque wrench.
3. Take the bumping dial gauge and set zero of the gauge. Then adjust the piston head (1) & (2) by revolving the crank pulley.
4. Observe the deviation or reading from the dial gauge.
5. Now check the reading in the bumping chart as shown in Chart.
6. Select appropriate Bumping
shim & CV shim for the
engine according to the gauge
reading.
7. Apply some grease on the
cylinder head & liner with the
help of brush.
8. Now take the bumping shim &
CV shim and place it over the
cylinder head & liner area one
over the other. Place smaller
CV shim below the bumping
shim.
9. Now place the Cylinder Head
over the shims. And fit it
properly and tight its bolts
with torque wrench.
Grease
Cylinder Head
1. Before Shims are inserted on liners, oil grease is applied on shims in order to prevent rusting. Then these shims are placed on a inclined rod stand. In this arrangement shims get stick to each other. When they are inserted on liners then sometimes workers put more number of shims instead of one. This result in rejection of engine during testing.
2. The naming of positions of shims on the stand should be done properly.
Result : Bumping Clearance Setting is completed
Note :
Adjustment of Valve Clearance
Engine Assembly Line Project 2
ByAmit Sharma
TraineeSwaraj Engines Limited
Mohali
Project GuideMr. Amritpal SharmaEngine Assembly Shop
Swaraj Engines LimitedMohali
Definition :
Valve clearance is a space between the top of the valve stem and the rocker arm.
Its purpose is to allow for some mechanical expansion and lengthening of the valve step and pushrods as the engine warms up. This clearance is also called valve lash.
Tools Required : Feeler Gauge. Screw Driver, Ring Spanner etc.
Significance
If in sufficient valve clearance is set when the engine is cold then valves will not properly
close when the engine warms up. If too much clearance is provided (additional clearance)
then even after the engine warms up there will result in lost motion.
Lost motion mean that as the cam tries to open the valve the pushrod and rocker arm
moves to first take up the clearance before touching the valve to open the valve. The result
is late opening of the valve.
Excess valve clearance can be heard in an idling engine as series of ticking sounds that
sound disappear as the engine warms up. Over time mechanical wear causes an increase in
valve clearance with the symptomatic ticking sound in the engine (one more valves can
produce the sound). The first step is to remove the rocker cover and mechanically adjust
the clearance with an adjustment screw on the rocker arm.
Adjustment :
This is long and widely used method of adjusting valve clearance of an engine. The valve
arrangement was adjusted by adjusting a screw set in the end of the rocker that pressed on the end
of the pushrod.
This adjustment was made by rotating the engine until the cam was at its lowest point, giving the
widest gap, then adjusting the rocker until this gap was at the correct spacing, as measured with the
use of a feeler gauge.
Mis-adjusted tappets can give rise to an audible 'tappet rattle' from the rocker cover, if the valve
clearances are excessive.
Over-tight clearances may, even worse, lead to bent pushrods. The adjusting screw was locked by a
lock nut. If the screw became loose, the adjustment would also work loose. Such a simple matter as
a loose tappet locknut even led to an engine fire.
Procedure :
1. Remove the rocker cover of all the
three cylinders.
2. While adjusting the valve clearance the
engine should be at cold condition
3. Crank the engine with cranking tool by
rotating the crank pulley, So that the
piston (1) and Piston (3) is at Top Dead
Center (T.D.C.) compression stroke.
4. Now the cam will tends to down the
pushrods to down most position and
rocker arms will become free.
Procedure :1. Now loose the screw and nut with the help of
screw driver and ring spanner.
2. Insert the feeler gauge between the valve stem and rocker arm end.
3. Adjust the clearance to normal fit neither more tight.
4. The clearance should be 0.25 mm.
5. Now after doing it for 3rd cylinder.
6. Take it to the T.D.C. compression stroke and adjust the same clearance.
7. Tight the screw and nut of all rocker arms.
8. Now check the working of rocker arms by revolving the crank pulley.
Feeler Gauge
0.25 mm
Result :
The Valve clearance set is 0.25 mm.
And Valve clearance adjustment is completed.
Engine assembly Project 3
Adjustment of Fuel Injection Pump Timing
By Amit Sharma
TraineeSwaraj Engines Limited
Mohali
Project GuideMr. Amritpal SharmaEngine Assembly Shop
Swaraj Engines LimitedMohali
Definition of Fuel Injection Pump
•An Injection Pump is a device
that pumps an exact metered
amount of fuel, under high
pressure , at the right time to the
injector of a diesel engine.
•It is the heart of the diesel
engine.
The injection pump does the job
of both the throttle and the
ignition system in gasoline
engines.
Significance of Setting FIP Timing
Advantages of Proper Timing : Reduces engine smoke Improves Power Reduces engine injector noise and roughness Increases fuel economy. Symptoms of Improper Timing : Hard starting Rough running and Heavy smoke during start up Black smoke during acceleration Poor fuel economy Engine running hotter than normal
IDENTIFICATION FOR DIFFERENT MODELS OF FIPENGINE MODEL MODEL
NUMBERRV 2 XM +3A AVL 835RV 2 XM + 3A ORCHARD
835
RV 3 XM +3A AVL 834RV 3XM + 3A AVL (P.S)
834
RV 30 XM + 3A AVL 836RB 33 470RB 30 469RB 33 XM 797RB 30 XM 877
Standardisation Colour Coding of Marking Gauge
MODEL DEGREE (BTDC)
STOCK NO. COLOUR CODING
RVXM3A 12 J-780186 YELLOW
RV3XT(38HP) 12.5 J-780170 GREEN
RB54HP 11.5 J-785127 WHITE
RBXM/S15XM 14 J-785126 RED
RB TR+ 15 J-780178 BLACK
Procedure1. Take the FIP and Place it on the
side of crankcase.2. Now check the TDC or BTDC
mark on the pulley. and Bring the 1 & 3 cylinder piston to the top or in compression stroke.
3. Insert the studs and bolts inside the plate and tight it with the torque wrench.
4. Now Remove the plastic cover from the FIP shaft and Place FIP gear on the shaft and now take the hexagonal nut and slowly tight it with torque wrench.
5. Now lightly tight the 3 nuts mounted on the FIP gear supporting plate.
6. Bring the Drip tubes and remove the banjo bolts from the FIP and mount 2 drip tubes having closed end on the two outlet holes of FIP, where oil comes out through injectors pipes. and place one open ended drip tube on the 3rd hole of FIP.
7. Now tight these tubes with spanner and fill the FIP with diesel oil.
8. Now take the socket and revolve the FIP gear slowly until fuel comes out through the 3rd drip tube. and mesh the FIP gear with Cam shaft gear to match the timing.
9. Now tight the Hexagonal nut with torque wrench and attach injector pipes in place of drip tubes.
Method Used : Drip Tube Method
Drip Tube
FIP Gear
BTDC = Bottom Top Dead Centre before 15 TDC and Fuel Spray starts when piston moving upward from BDC to TDC during Compression stroke. TDC = Top Dead Centre
15
Result : FIP Timing is set
Crankshaft Anticlockwise Rotation
Thank You
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