ENGINE ASSEMBLY SHOP

INTRODUCTION:
In engine assembly shop, assembly of various components of engine is done in Crank case. Crank case, made of cast iron has bores, drills and space for mounting various components of engine such as bores for cylinder, cam shaft, IPD shaft, ideal gear, valves and space for crank shaft, lubrication oil pump, oil sump etc. These components are arranged in systematic order and in various sections. After engine assembly, engine is sent to ENGINE TESTING SHOP to test performance of engine. The various sections in assembly shop are:

1.CYLINDER HEAD PRE-ASSEMBLY:

Here, various accessories of cylinder head are assembled, which are necessary for proper functioning of cylinder head. For example, rocker arm bracket is joined to it to support rocker arms, rocker arm pin for joining of rocker arms and there are two locks provided for avoiding longitudinal motion of the two rocker arms and a return spring, which returns back rocker arm to its initial position. There are two valves, fuel inlet valve and exhaust valve. Fuel inlet valve permits the entry of fuel and exhaust valve provides exhaust for fuel.

2. CRANK SHAFT PRE-ASSEMBLY:

Here, ball wearing is attached to crankshaft, which further connects to fly wheel. A helical gear is also attached to one side of the crank shaft which provides movement to camshaft, I.P.D. shaft and lubrication oil pump through ideal gears.

3.PISTON PRE-ASSEMBLY:
In this section, assembly of piston and connecting rod is done and circular open cast iron rings also surround piston and this whole assembly is further connected to crankshaft in later section.

4.CRANK SHAFT ASSEMBLY:

In this section, crank shaft is assembled into space provided in crank case with the help of ball bearings and crank case is sent to next section for further assemblies.

5.LUBRICATING OIL & PUNCHING:

Now, sump, oil splash guard and oil suction pipe is assembled to it. The function of sump is to hold Engine oil and oil splash guard maintains the level of lubricating oil for the proper and sufficient supply of lubricating oil to the L.O.P.

6.GEAR FITTING:
Here, timing gears (cam shaft gear, IPD shaft gear, pump gear) and ideal gears are attached to crank case. All the timings gears are connected to crank shaft gear through ideal gears. The movement of timing gears regulates the functioning of engine like opening and closing of injection valves etc.

7.PISTON MOUNTING:
In this section, piston along with connecting rod is inserted into the cylinder bore and then connected to crank shaft. The lower hole of connecting rod is firmly attached in space provided in crank shaft.

8.LUBRICATING PUMP ASSEMBLY:

Here, oil splash guard is inserted into the sump and then connected to lubricating oil pump through oil suction pipe. Lubricating oil pump sucks lubricating oil from sump through suction pipe and distributes it to various galleries provided in the crank case for proper lubrication of various components. The function of oil splash guard is to provide proper suction of lubricating oil and to prevent scattering of oil. Lubrication oil gets collected in sump after lubrication through push rod gallery.

9.FRONT & REAR COVER ASSEMBLY:

Now, whole assembly of parts present in crank case is covered with front and rear covers. These covers are meant to provide proper insulation to parts assembled inside crank case. These covers are casted in foundry and then drilled, bored and finished in engine shop.

10.FLYWHEEL ASSEMBLY:
Here, flywheel is connected to crank shaft through ball bearings. Fly-wheel is arranged to take initial power from self stator through stator pinion which is impelled through solenoid switch by means of its electro-magnetic field and then it transmit that power to crank shaft from where it is transmitted to piston for compression of air. This compressed air is then used for fuel combustion.

11.CYLINDER HEAD MOUNTING:

Cylinder head is mounted on upper portion of cylinder. Cylinder head has rocker arms, rocker arm pins, brackets, return spring, inlet and exhaust valves etc. which are previously attached to cylinder head in the cylinder head pre-assembly and helps in proper functioning of engine.

12.WATER PUMP & M-FILTER ASSEMBLY:

Here, water pump and M-filter are assembled with engine. The function of water pump is to circulate water in engine to provide cooling of engine and filter helps in filtration of lubrication oil. A belt is mounted on water circulating pump, which rotates through crank shaft and provides circulation of water in engine.

13.ROCKER ARM ASSEMBLY:

In this section, rocker arms are assembled on valves. Function of rocker arms is to regulate opening and closing of inlet and exhaust valves. Rocker arms are connected to push rods, which are further attached with guide ways through valve tappets and helps in the motion of camshaft. Camshaft provides timed motion to rocker arms through push rods.

14.FUEL INJECTION PUMP AND ITS TIMING:

In this section, injection pump is installed sidewise on the crank case for the injection of fuel into the cylinder. Then it is given such a mechanism that whenever flywheel rotates, then at every 14 angular displacement, fuel injection pump

plunger which is connected near to fly-wheel works and fuel injection occurs in cylinder. MECHANISM OF FUEL INJECTION PUMP AND ACCELERATOR: A fuel injection pump works on the barrel plunger arrangement. At the top of F.I.P. there is an adaptor in which a pressure spring is fitted to control the movement of delivery rod. Below this there is a barrel with the plunger having cut section at the top. A small hole is also provided near top of barrel for the suction of fuel from the fuel main gallery. Plunger is further connected to the guide way through return spring, which in turn connected to the pump shaft. Pump shaft shifts the plunger upwards with the help of guide way for the injection of fuel. Along the axial motion of plunger there is also a rotational motion of plunger, which fixes the amount of fuel to be injected in the cylinder. This rotational motion is achieved by providing a rack and pinion arrangement connected to it, which is controlled by the accelerator rod, which in turn connected to accelerator paddle. If the cut section of plunger faces the barrel hole then there will be full suction of fuel and maximum acceleration is achieved and vice versa. The delivery rod protects the re-entrance of the injected fuel in the barrel. Extra pressure of fuel can be relieved with the help of pressure relief valve. An accelerator speed limit is

provided in the fuel injection pump for fixing the maximum limit of acceleration.

15.SELF STATOR & FUEL FILTERS ASSEMBLY:

Here, self stator and fuel filters are assembled in engine. Self stator is a device, which gives initial movement to flywheel. After giving rotation to fly-wheel, it comes to its initial position and crank shaft rotates of its own by virtue of pressure due to combustion of fuel by compressed air. Fuel filters (primary and secondary) are also assembled to engine whose function is to filter diesel, which is first fed to fuel main gallery and then fed to cylinders through injectors by means of barrel plunger arrangement.

16. RADIATOR ASSEMBLY:

Radiator is assembled with water pump through hosepipes. Radiator is a device having network of small fine tubes, which is meant for cooling of water by providing large surface area. It draws heat from the water circulating in the pipes and rejects it into the atmosphere in the form of radiation. The radiator comes into play when the temperature of cooling water exceeds above 80C. The cooling water from the cooling gallery enters in radiator through water outlet pipe. There is a heat sensitive device named as thermostat, provided between the water pump and the

radiator inlet. As the temperature of cooling water exceeds above 80C, thermostat valve opens and allows the hot water to flow into the radiator. Now the water is cooled as it passes through the pipes in the radiator and again enters in cooling gallery through water pump. For the air cooling fan is also provided with the crank case, which runs with the power of crank shaft. This cooling water remains circulating in the cooling gallery again and again until its temperature becomes 80C. At this stage, thermostat valves open and radiator comes into action. Also, there is a steam outlet pipe provided at the top of radiator, which is connected to blow off cock. The excess steam produced due to high atmospheric temperature is expelled through the exhaust pipe. The fresh water if necessary can be filled in radiator through cock.

17.AIR CLEANER:
Air cleaner is mounted on the bonnet of tractor for providing clean air to the engine. It comprises of three stages of purification. At the first stage, the atmospheric air is cleaned by means of filter. It removes particulate matter of large size. The air after passing through the first stage is bubbled out into the oil sump through a pipe connected to the filter at one end and dipped in oil at other end. The tiny dust particles sticks to the oil when air bubbles out through the oil. It can be regarded as the

second stage of the purification. Finally the air passes through membranes provided in the air pipe and it is called third stage of air purification. Now this air is used in the cylinder for compression.

18. AIR COMPRESSOR:

It is a device meant for providing compressed air which can be used for various purposes where compressed air is required like filling of tyres, removal of moisture, dust etc. from the engine. It is mounted near the F.I. pump and works with the help of injection pump drive shaft. It has a piston and cylinder arrangement in which piston compresses the air entering through the pipe connected to its inlet. This compressed air is then stored in the cylinder. As the air compressor has a optional use, thus it is provided with lever which connects or disconnects its functioning with I.P.D. shaft. This system consists of a lock, which is internally broached and helps in transmitting the motion of I.P.D. shaft to the connecting rod. The rotation of I.P.D. shaft rotates the dove ring, which in turn rotates the outer race of the ball bearing attached to it. The motion of outer race provides the free rotation of egg shaped disc, which in turn transmits the back and forth motion to the connecting rod attached to the piston.

19.ALTERNATOR:
It is device used to convert mechanical energy to electrical energy. In other words it is used to charge the battery of the tractor. It consists of rotor, which gets rotating motion from the crankshaft through fan belt. The rotation of rotor produces electricity which is used for running lights and charging battery.

**Now, engine assembly is completed and engine is sent to engine testing shop to detect any defects. If any, in engine.