28-08-2014, 03:47 PM
I am submitting my six months industrial training report which i have done from HMT ltd. Pinjore. During the time period of my training i have learnt many things and gained more practical knowledge.First of all they had given me a schedule regarding various shops like engine shop, heavy machine shop,light machine shop etc and after that given me project on study and documentation of stage wise assembly and testing procedure for engine of different tractor models.The result of training is that i got chance to see the processes in actual.
Study & Documentation of Stage Wise Assembly & Testing Procedures for Engines of Different Tractor models The engines of different models are assembled in the Engine Assembly shop. The different models of the engine are 2522, 3522, 4022, 4922, 5022, 6522, 7522. The engine of 2522 has two cylinders whereas the engine ranging from 3522 to 5022 has three cylinders and 6522 engine has four cylinders. There is a single assembly line dedicated for the entire assembly of the engines. The assembly is done manually. The air-guns and torque wrenches are used for fastening the bolts quickly and with adequate torque. The engines are mounted on the engine trolleys and are transported on the rail type line. There are pre-assembly compartments in the shop to assembly the different parts before the actual assembly to the engine. These are Piston pre-assembly, crankshaft pre-assembly, rocker-arm pre-assembly, flywheel pre-assembly, clutch pre-assembly connecting rod pre-assembly, cylinder head pre-assembly. The engines of HMT are also used in the DG-Sets, where they are named as 3502, 6502 etc. 1.2About HMT Engines:- The all HMT engines are four stroke engines. Deatailed Engine Assembly process:- 1. Cylinders liners are inserted into the cylinder block of crankcase. These are inserted using wrench. The half circle mark on the liner is generally pointed towards the injectection pump side. 2. IPD (Injection Pump Drive) shaft is inserted. 3. Crankcase is mounted on the trolley. 4. The crankshaft bearing liners are inserted. These are made up of gun metal. 5. Crankshaft is inserted supported on the bearing liners. 6. Bearing caps are mounted on the bearing seats and fastened by the stud and nuts. 7. Thrust bearing in two halves are inserted on side of the crankshaft. These prevents the side motion of the cranshaft. 8. Two thrust bearings are also put into the bearing caps and then they are fastened to the crankcase. 9. Bearing cap having idler gear for drive the lubrication pump, is fastened. 10. Main oil gallery plug at timing gear side. 11. Lubrication bolt fastened for lubrication of the idler timing gear and adjacently all other timing gears. 12. IPD shaft washer inserted. 13. Punching of the engine no. 14. Small plugs at main oil gallery at tappet side and water gallery side plugs are inserted. 15. Cam shaft is inserted carefully. 16. Timing gears are assembled. Three gears are inserted. One gear is for camshaft drive, second gear is for injection pump drive and third is idler gear to transfer motion from crankshaft gear to these gears. Detailed process of fitting timing gears is given later. 17. Piston assembly (with connecting rods) is inserted. The ring compressor is used to to tigth the piston rings and then the piston is forced into the cylinder liner. The ring compressor remains outside the liner. 18. The caps on the big end of the connecting rod are fastened with the help of nut and bolts. The torque of the nut is checked by the torque wrench. 19. Lubrication pump is fitted and fastened with two bolts. The inlet metal hose is conneted to the strainer to suck the oil from the sump and the outlet metal hose is connected to the hole in the crankcase which gives the way to filter. 20. The strainer is attached to the lucrication pump. Before it the sump cover is put below the pump and it covers the crankshaft. Then the sump cover is fastened to the crankcase with the help of six bolts and locking washers. 21. Dowel pins are inserted to guide the rear and front covers. 22. Rear cover is assembled with gasket. It is having a seal to prevent the leakage of lubrication oil at the flange. 23. Guiding bush are inserted on the top of crankcase to guide the cylinder head. 24. Front cover is assembled with gasket. It covers the timing gears anf prevent the leakage of lubrication oil. 25. Lower sump cover is mounted with gasket. The 16 bolts with locking washers are used for tightning the covers. 26. Flywheel is mounted on the flange of crankshaft. The dowel pin in the flange guides the flywheel. The flywheel is having angle marks on its periphery for timing purposes. 27. Clutch plate is inserted into the flywheel. 28. Then the clutch assembly is inserted into the flywheel with three legs is inserted into the three guiding cuts on the flywheel. Then the clutch is fastened using bolts. 29. The cylinder heads are mounted carefully using gaskets. The guiding bushes guide the cylinder heads. Each cylinder head is fastened using four bolts with proper torque. It is the part where maximum pressure is acted upon by the blow of gases. 30. Tappets are inserted into small cylinderical cavities from the space provided at the side of crankcase. The tappet touch with the cams on the camshaft so that up and down motion can be generated in the tappets which is further transferred to valves through push rod and rocker arms. 31. Water pump with gasket is assembled to the fornt side of the crankcase. Its position is above the front cover. There is two holes where pump is fitted. Through these holes water enter into the space around the cylinder liners in the crankcase. 32. Driving pulley on the crankshaft is fitted by a single bolt. It drives the water pump and alternator through V-belt. 33. Push rods are inserted through the provided holes. The push rod set upon the tappets. 34. Rocker arm assembly is mounted. Two bolts are used for each rocker arm assembly for fitting. One of the bolt has stud type head to mount the cylinder head cover. The push rodstouch with the rocker arms to provided them motion. The other end of the rocker arm touch the valve so that motion can be tranfered to them, provided by the push rods. Side covers are fitted to cover the side space provided for insertion of the tappets. 35. Exhaust manifold is attached to the exhaust gallery. 36. Cooling water manifold is atteched to the cooling water gallery which is on the same side of the exhaust gallery. 37. Cylinder head covers are mounted using single nut on the stud provided at the rocker arm bolt. 38. Bracket for the alternator mounting is attached. Alternator can swing in this bracket so that it can be tightened at the required position to make the V-belt streched and also when to loose the belt for change it. 39. Lubrication oil filter is mounted on side of the crankcase at provided space. It receives the oil from the oil pump and send to the main oil galley after filtering it. 40. Timing of the fuel injection is set. The detailed process is discussed later. 41. Fuel(diesel) filters of two stages are mounted on the side of crankcas 42. Alternator is hinged at the bracket and bolted in second bracket so that it can set at required position. This is because of V-belt tightning and loosing purpose. 43. Intake manifold is attached. The intake manifold is ligher in weight than exhaust manifold because exhaust manifold has to withstand burnt gases at high temperature and pressure. 44. Starting motor is attached on the flywheel side. It is used for starting the engine by rotating the flywheel at required rpm and get out of the mesh immediately when the engine starts. 45. EGR pipe is attached. It connects the exhaust manifold to the inlet manifold. The is resposible for some reduction in NOx pollutants. 46. The engine is now complete. It is then tranferred to the engine testing shop for test its power and other parameters. After assembly, engine is brought to engine testing section. In this section, practical checking of engine is done on engine. The water type dynamometer is used to put load on the engine. Engine is cooled by the giving water supply from outer source and then started it with external DC supply. During running the engine, the load is varied and various terms are checked such as lubricating oil pressure, load capacity, fuel consumption, torque, operating temperature, etc. Then proper operating of valves is checked. Water Type Dynamometer for testing engine Procedure for Engine Testing 1. Note starting time of engine and also bed no. which it is being tested. 2. Check oil level of engine and FIP. 3. Check clearance of valve tappets for inlet and exhaust. For inlet valve it is 0.3mm and for exhaust valve it is 0.4mm. It is given because on heating during engine operation push rods and other components expand. Exhaust valve expands more as it withstands more heat. 4. Check oil pressure at idle and rated rpm. 5. Check any unusual sound. 6. Check idle and fly up rpm. 7. Check leakage of water, fuel and oil at rated rpm. 8. Check load and torque at rated rpm, fuel timing in seconds for 100cc and recheck oil pressure. 9. Check outlet water temp. 10. Check leakage in front and rear oil seal. 11. Check visible blow hole in component, if any. 12. Pix OK sticker. 13. Check engine no. punched on engine. It is to be same as on sticker. The engine is kept running for 2 hours. For proper working, load capacity is checked by applying load on the shaft of engine through water. The lubricating oil pressure in the engine should be 3.8 to 4.2 Kg/ cm2. The temperature of the water should be 80-95 deg. C. The maximum RPM of the engine are kept 2200. Supplying a measured quantity of fuel, the fuel consumption is checked. For this test, 100 cc (cm3) fuel is supplied to the engine. The following formulae are used for calculate the SFC and engine Power.
Study & Documentation of Stage Wise Assembly & Testing Procedures for Engines of Different Tractor models The engines of different models are assembled in the Engine Assembly shop. The different models of the engine are 2522, 3522, 4022, 4922, 5022, 6522, 7522. The engine of 2522 has two cylinders whereas the engine ranging from 3522 to 5022 has three cylinders and 6522 engine has four cylinders. There is a single assembly line dedicated for the entire assembly of the engines. The assembly is done manually. The air-guns and torque wrenches are used for fastening the bolts quickly and with adequate torque. The engines are mounted on the engine trolleys and are transported on the rail type line. There are pre-assembly compartments in the shop to assembly the different parts before the actual assembly to the engine. These are Piston pre-assembly, crankshaft pre-assembly, rocker-arm pre-assembly, flywheel pre-assembly, clutch pre-assembly connecting rod pre-assembly, cylinder head pre-assembly. The engines of HMT are also used in the DG-Sets, where they are named as 3502, 6502 etc. 1.2About HMT Engines:- The all HMT engines are four stroke engines. Deatailed Engine Assembly process:- 1. Cylinders liners are inserted into the cylinder block of crankcase. These are inserted using wrench. The half circle mark on the liner is generally pointed towards the injectection pump side. 2. IPD (Injection Pump Drive) shaft is inserted. 3. Crankcase is mounted on the trolley. 4. The crankshaft bearing liners are inserted. These are made up of gun metal. 5. Crankshaft is inserted supported on the bearing liners. 6. Bearing caps are mounted on the bearing seats and fastened by the stud and nuts. 7. Thrust bearing in two halves are inserted on side of the crankshaft. These prevents the side motion of the cranshaft. 8. Two thrust bearings are also put into the bearing caps and then they are fastened to the crankcase. 9. Bearing cap having idler gear for drive the lubrication pump, is fastened. 10. Main oil gallery plug at timing gear side. 11. Lubrication bolt fastened for lubrication of the idler timing gear and adjacently all other timing gears. 12. IPD shaft washer inserted. 13. Punching of the engine no. 14. Small plugs at main oil gallery at tappet side and water gallery side plugs are inserted. 15. Cam shaft is inserted carefully. 16. Timing gears are assembled. Three gears are inserted. One gear is for camshaft drive, second gear is for injection pump drive and third is idler gear to transfer motion from crankshaft gear to these gears. Detailed process of fitting timing gears is given later. 17. Piston assembly (with connecting rods) is inserted. The ring compressor is used to to tigth the piston rings and then the piston is forced into the cylinder liner. The ring compressor remains outside the liner. 18. The caps on the big end of the connecting rod are fastened with the help of nut and bolts. The torque of the nut is checked by the torque wrench. 19. Lubrication pump is fitted and fastened with two bolts. The inlet metal hose is conneted to the strainer to suck the oil from the sump and the outlet metal hose is connected to the hole in the crankcase which gives the way to filter. 20. The strainer is attached to the lucrication pump. Before it the sump cover is put below the pump and it covers the crankshaft. Then the sump cover is fastened to the crankcase with the help of six bolts and locking washers. 21. Dowel pins are inserted to guide the rear and front covers. 22. Rear cover is assembled with gasket. It is having a seal to prevent the leakage of lubrication oil at the flange. 23. Guiding bush are inserted on the top of crankcase to guide the cylinder head. 24. Front cover is assembled with gasket. It covers the timing gears anf prevent the leakage of lubrication oil. 25. Lower sump cover is mounted with gasket. The 16 bolts with locking washers are used for tightning the covers. 26. Flywheel is mounted on the flange of crankshaft. The dowel pin in the flange guides the flywheel. The flywheel is having angle marks on its periphery for timing purposes. 27. Clutch plate is inserted into the flywheel. 28. Then the clutch assembly is inserted into the flywheel with three legs is inserted into the three guiding cuts on the flywheel. Then the clutch is fastened using bolts. 29. The cylinder heads are mounted carefully using gaskets. The guiding bushes guide the cylinder heads. Each cylinder head is fastened using four bolts with proper torque. It is the part where maximum pressure is acted upon by the blow of gases. 30. Tappets are inserted into small cylinderical cavities from the space provided at the side of crankcase. The tappet touch with the cams on the camshaft so that up and down motion can be generated in the tappets which is further transferred to valves through push rod and rocker arms. 31. Water pump with gasket is assembled to the fornt side of the crankcase. Its position is above the front cover. There is two holes where pump is fitted. Through these holes water enter into the space around the cylinder liners in the crankcase. 32. Driving pulley on the crankshaft is fitted by a single bolt. It drives the water pump and alternator through V-belt. 33. Push rods are inserted through the provided holes. The push rod set upon the tappets. 34. Rocker arm assembly is mounted. Two bolts are used for each rocker arm assembly for fitting. One of the bolt has stud type head to mount the cylinder head cover. The push rodstouch with the rocker arms to provided them motion. The other end of the rocker arm touch the valve so that motion can be tranfered to them, provided by the push rods. Side covers are fitted to cover the side space provided for insertion of the tappets. 35. Exhaust manifold is attached to the exhaust gallery. 36. Cooling water manifold is atteched to the cooling water gallery which is on the same side of the exhaust gallery. 37. Cylinder head covers are mounted using single nut on the stud provided at the rocker arm bolt. 38. Bracket for the alternator mounting is attached. Alternator can swing in this bracket so that it can be tightened at the required position to make the V-belt streched and also when to loose the belt for change it. 39. Lubrication oil filter is mounted on side of the crankcase at provided space. It receives the oil from the oil pump and send to the main oil galley after filtering it. 40. Timing of the fuel injection is set. The detailed process is discussed later. 41. Fuel(diesel) filters of two stages are mounted on the side of crankcas 42. Alternator is hinged at the bracket and bolted in second bracket so that it can set at required position. This is because of V-belt tightning and loosing purpose. 43. Intake manifold is attached. The intake manifold is ligher in weight than exhaust manifold because exhaust manifold has to withstand burnt gases at high temperature and pressure. 44. Starting motor is attached on the flywheel side. It is used for starting the engine by rotating the flywheel at required rpm and get out of the mesh immediately when the engine starts. 45. EGR pipe is attached. It connects the exhaust manifold to the inlet manifold. The is resposible for some reduction in NOx pollutants. 46. The engine is now complete. It is then tranferred to the engine testing shop for test its power and other parameters. After assembly, engine is brought to engine testing section. In this section, practical checking of engine is done on engine. The water type dynamometer is used to put load on the engine. Engine is cooled by the giving water supply from outer source and then started it with external DC supply. During running the engine, the load is varied and various terms are checked such as lubricating oil pressure, load capacity, fuel consumption, torque, operating temperature, etc. Then proper operating of valves is checked. Water Type Dynamometer for testing engine Procedure for Engine Testing 1. Note starting time of engine and also bed no. which it is being tested. 2. Check oil level of engine and FIP. 3. Check clearance of valve tappets for inlet and exhaust. For inlet valve it is 0.3mm and for exhaust valve it is 0.4mm. It is given because on heating during engine operation push rods and other components expand. Exhaust valve expands more as it withstands more heat. 4. Check oil pressure at idle and rated rpm. 5. Check any unusual sound. 6. Check idle and fly up rpm. 7. Check leakage of water, fuel and oil at rated rpm. 8. Check load and torque at rated rpm, fuel timing in seconds for 100cc and recheck oil pressure. 9. Check outlet water temp. 10. Check leakage in front and rear oil seal. 11. Check visible blow hole in component, if any. 12. Pix OK sticker. 13. Check engine no. punched on engine. It is to be same as on sticker. The engine is kept running for 2 hours. For proper working, load capacity is checked by applying load on the shaft of engine through water. The lubricating oil pressure in the engine should be 3.8 to 4.2 Kg/ cm2. The temperature of the water should be 80-95 deg. C. The maximum RPM of the engine are kept 2200. Supplying a measured quantity of fuel, the fuel consumption is checked. For this test, 100 cc (cm3) fuel is supplied to the engine. The following formulae are used for calculate the SFC and engine Power.