Engine Assembly Shop

8/22/2019 Engine Assembly Shop

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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.


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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.


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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.


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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.


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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 fly-

wheel rotates, then at every 14 angular displacement, fuel injection pump


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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


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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


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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


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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.


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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.

Engine Assembly Shop

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