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TEST REPORT INDIAN COMBINE HARVESTER

SWARAJ-8100

BY

AGRICULTURAL MECHANIZATION RESEARCH INSTITUTE (AMRI), MULTAN GOVERNMENT OF THE PUNJAB, AGRICULTURE DEPARTMENT, LAHORE (June, 2014)

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TEST REPORT OF INDIAN COMBINE HARVESTER

SWARAJ-8100

Report Indian Combine/AMRI/2014

Test period 20-04-2014 to 10-05-2014

Name & Model of Combine INDIAN COMBINE HARVESTER

Harvester SWARAJ-8100

Manufactured by Punjab Tractors Ltd., India

Tested by Agricultural Mechanization Research Institute (AMRI), Multan, Government of the Punjab, Agriculture Department, Lahore

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CONTENTS

Sr. # Title Page #

1. Introduction 1

2. Brief Description

1

3. Specifications

3

4. Test Observations

8

5. Results and Discussion 8

6. Conclusion and Recommendations 12

7. Annexure I 14

8. Annexure II 15-16

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PERFORMANCE TEST CERTIFICATE

The performance evaluation data and results of INDIAN COMBINE

HARVESTER “SWARAJ-8100” presented in the report has been carried out

without any prejudice and favour to the manufacturer. The testing institution,

anyhow do not accept any responsibility whether expressed or implied to the

extent of combine harvester performance not commensurating with the data in

the test report, which may be due to variation in working environment and

operating conditions.

Sd/- Sd/-

Asstt. Agril. Engineer(T&T), Asstt. Agril. Engineer (D&D),

Agricultural Mechanization Agricultural Mechanization

Research Institute, Multan Research Institute, Multan

Sd/- Sd/-

Agricultural Engineer (T&T), Director,

Agricultural Mechanization Agricultural Mechanization

Research Institute, Multan Research Institute, Multan

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1. INTRODUCTION

Swaraj-8100 is indigenous Combine Harvester, manufactured by Punjab Tractors

Limited, India. It operates according to the longitudinal flow principle with proper

attachments for harvesting of wheat, paddy, sunflower, gram, mustard, soya bean

and safflower crop. The machine was gifted by Indian Chief Minister Punjab,

Parkash Singh Badal to the Chief Minister Punjab (Pakistan), Mian Muhammad

Shahbaz Sharif. The testing of the combine harvester was conducted by the AMRI

Engineers with the following objectives:

1. To assess combine harvester field performance, general condition, durability, repair and maintenance requirements under local agro climatic conditions.

2. To check the fuel consumption and hourly production of the combine harvester under different working conditions.

3. To obtain operator views regarding suitability of combine harvester.

2. BRIEF DESCRIPTION

The brief description of the machine is as under.

2.1 HARVESTER

It consists of the following:

a) Engine

b) Intermediate Drive Assembly

c) Gear Box, Clutch, Reduction and Brake Assembly

d) Front Wheels (Driven)

e) Rear Wheels (Steered)

f) Guide and Threshing Drum Assemblies

g) Feeder Conveyor Assembly

h) Cleaning System: Stepped Floor, Sieves Blower and Straw Walkers

i) Elevator Conveyor Assembly

j) Grain Bin

k) Discharging Unit

l) Hydraulic System

m) Electrical Equipment

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2.2 CUTTER BAR

It consists of the following:

a) Cutting Blade Assembly. 4.2 meters long (14ft) b) Reel Assembly. c) Conveyor Worm Assembly. d) Trailer Assembly.

2.3 INDICATORS

a) Engine speedometer: This meter directly indicates the speed of engine, and records hours run by the engine.

b) Threshing Drum Speedometer: This speedometer indicates the speed of Threshing Drum.

c) Oil Pressure Gauge: This gauge indicates the pressure of the lubricating oil of the engine.

d) Ampere Meter: It indicates charging/discharging of the batteries. e) Water Temperature Gauge: It indicates the water temperature

2.4 ELECTRICAL INDICATORS

a) Ignition switch b) Indicator switch c) Horn switch d) Dipper switch e) Switch for parking of combine on road side f) Switch for grain discharge light

2.5 CONTROLS

There are various controls provided on the operator’s platform so that the operator may have an easy approach for each control for the prompt functioning of the Combine Harvester. These are as under:-

a) Accelerator Control Lever b) Cutter Bar Height Control Lever c) High Low Lever d) Gear Selection Lever e) Hand Crank Lever f) Reel Speed Variation Lever g) Engine Stop Lever h) Clutch Levers i) Cutter Clutch Lever j) Thresher Clutch Lever k) Concave Adjustment Lever l) Hand Lever m) Grain Discharge Lever

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3. SPECIFICATIONS 3.1 ENGINE

Type ASHOK LEYLAND Bs III (Turbo charged)

Modle ALU-400 Direct Injection, four strokes, 6 cylinder, overhead valve Water cooled

Rated H.P 128 (B.S.)

Electrical equipment

Voltage 24 V

Storage batteries 12V / 120 Amp hr; 2 Nos.

3.2 SWEPT VOLUME Bore 107.18 mm (4.22”)

Stroke 120.65 mm (4.75”)

Compression ratio 16 : 1

Firing order 153624

F.I. Pump MICO (Plunger type)

3.3 CUTTING MECHANISM.

3.3.1 Cutter Bar

Width 4.2 m (14’)

No. of knives 58

Blade Speed 1.50 m/sec.

3.3.2 Cutter Bar Platform

Height adjustment Hydraulic control from Operator’s seat

Min. cutting height 60 mm

3.3.3 Reel

Diameter 1000 mm

Speed adjustment Variable through Mechanical variator

Speed range 15 – 48 rpm

Vertical height Adjustment Hydraulic controlled from Operators seat

Longitudinal position Adjustment

Mechanical

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3.4 THRESHING AND CLEANING MECHANISM

3.4.1 Threshing Drum:

Width 1274 mm

Diameter 600 mm

No. of rasp bars (Wheat) 8

No. of spikes (Paddy) 120 (8 x 15)

Speed adjustment Variable through Mechanical variator controlled from Operators seat.

Speed range (standard) 525 – 1125 rpm

3.4.2 Concave

No. of spikes (paddy) 31

First time 16

Second time 15

Bar Nos. 3 Big

Bar Channels 3 small

3.4.3 Straw Walkers:

No 5

Number of steps 5

Area 5.2 m

3.4.4 Cleaning Sieves.:

Upper sieve area 2.28 m

Lower sieve area 1.55 m

3.4.5 Blower:

No. of blades 6

Speed adjustment Variable

Speed range 350 – 1000 rpm

Direction adjustment Mechanically operated deflector

3.5 GROUND DRIVE

3.5.1 Clutch 13”Single Plate: Mechanical .

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3.5.2 Gear Box:

No. of gears

Forward 3

Reverse 1

Speed variation Infinitely adjustable in Each Gear through Hydraulic Control operated From Operator’s seat

3.6 Tyres.

Front (Driving) 18.4 – 15/30 12 PR

Rear (Steering) 7.50 – 16-12 PR

3.6.1 Road Speeds:

Forward:

1st gear 1.5-3.5 km/hr

2nd gear 2.3 – 8.5 km/hr

3rd geat 8.5 – 20 Km/hr

Reverse 3.5 Km/hr

3.7 STEERING AND BRAKES:

Wheel track Front 2400 mm

Wheel Base 3600 mm

Steering Hydraulically assisted Finger tip control

Brakes Disc brakes, mechanically Operated Wheels can be Braked independently or together

3.8 CAPACITIES;

Grain tank 2.0 m3

Fuel tank 245 liter

Hyd. Tank 15 liter

Engine sump 13.60 liter

Main gear box 18 liter

Reduction drives 1.5 liters each

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3.9 OVERALL DIMENSIONS:

3.9.1 Width.

Transport position 2950 mm

Working position 4600 mm

3.9.2 Length

Working position 8100 mm

Transport position with trailer

12500 mm

Transport position without trailer

7300 mm

3.9.3 Height:

Maximum 3950 mm

3.9.4 Ground clearance: Minimum 370 mm

4. TEST OBSERVATIONS:

The combine harvester Swaraj- 8100 was tested for 75 hours in different fields

and different wheat varieties in district Multan and Muzzafargarh. The test

observations are given in Annexure I &II.

5. RESULTS AND DISCUSSION

The Indian Combine harvester Swaraj- 8100 was tested in the field for the total of

75 working hours. Test observations recorded are discussed below:

5.1 Overall performance

The machine was operated in first gear at 1850 engine rpm. The operating

speed was 2 to 3 km/hr. The overall performance of the combine harvester

was found satisfactory at the testing sites as some minor defects were

observed during the testing.

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5.2 General Condition and Durability:

The general conditions of the machine at the testing period was found

satisfactory as some minor damages/abnormal wear of different components

was observed. Engine performance at low and high idle rpm was observed

to be satisfactory and no abnormal exhaust gases/color was observed. All

the control levers jammed together. The bushes, brackets, knives, lower

sieve were damaged during the testing.

5.3 Repair and Maintenance

a) The break lock of the combine harvester was jammed during the

operation in the field which was replaced

b) The belt of the main pulley was dislocated from its original position

which was adjusted.

c) The brackets of the bearing were broken during the operation in the

field.

d) The clutch lever was jammed during operation.

e) The rubber bushes of different brackets were damaged which were

replaced with new ones time to time.

f) The lower sieve was cracked and dislocated.

g) The nylon bushes of the reel were adjusted due to misalignment.

h) The grain tank auger conveyor was not properly functioning due to

which loss of grain was observed during unloading.

i) It was observed that once the machine started, all the system attached

automatically started which caused wear & tear, overloading and loss of

fuel. During traveling from one place to another place the whole system

of machine remained engaged to the main system. Despite of number

of efforts, the system could not be disengaged.

j) The cutter bar and knives of the machine were damaged during

operation which were replaced at AMRI workshop.

k) The speedometer of the threshing drum stopped working just after few

hours of operation.

5.4 Grain Losses

The following losses were observed during the testing of the combine

harvester.

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a) Grain breakage from the main outlet was from 1.1% ranging to 3.6 %.

b) Shattering of grain was observed in the laid down crop during

harvesting.

c) Unthreshed ears were observed from straw walker which was

recovered by increasing the speed of the threshing drum.

d) Falling down of the head of the cut crop was ignorable.

e) Grain losses were observed occasionally during the field operation

which was reduced by rechecking and adjusting the blower, threshing

drum and forward speed of the machine. It was also recorded that

initially the grain breakage percentage during harvesting was higher.

The machine was adjusted accordingly to minimize the grain breakage.

5.5 Fuel Consumption:

The fuel consumption was checked under variable working conditions in

different fields. It was observed 9.5 lit/hr on an average at 1850 rpm during

harvesting. The fuel consumption for marching was observed 7.5 lit/hr on

average during road marching. The machine was operated in first forward

gear.

5.6 Actual Hourly Rate of Work:

Actual hourly rate of work that is harvesting capacity of the machine was

calculated at twelve sites for different duration of tests. The average hourly

rate of work was found 0.95 ha/hr as the machine was operated in first gear

at 1850 rpm.

5.7 Operator Comments:

The operator of the machine and allied staff were interviewed regarding

their opinion about the overall performance of the combine harvester. In

general they offered satisfactory remarks about the machine performance in

special reference to the following.

Controllability

Control lever for different machine operations should be easy and

comfortable to operate.

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Foot Rest:

Foot rest should be provided for operator safety and comfort.

Silencer Noise:

The silencer noise level should be reduced.

Alarm system:

There is no indication system for the operator during breakage of

parts/choking of system.

5.8 Cost of Operation:

The cost of operation of Indian combine harvester Swaraj 8100 was

calculated on the basis of 10000 hours of operational life.

Capital Cost: (P), Rs. 2600000

Salvage Value (S) @ 10% of P, Rs. 260000 Total Life (L) in hours 2000 Annual Use in hours 200

Fixed cost (A)

Depreciation (P-S)/L, Rs/hr 1170

Interest I= {(P+S)/2 x interest rate/annual use}

@10%,Rs/hr 715

Insurance, Taxes & Shelter = {(P+S)/2 x insurance

rate/annual use} @2%,Rs/hr 143

Total fixed cost (A) = 1170+715+143 2028

Variable Cost (B) Repair & maintenance cost @ 25% of P/L, Rs/hr 325

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Fuel cost @ 9.5 Lit/hr and @ Rs.116/lit (avg.), Rs./hr 1102

Lubricants @ 2% of fuel cost, Rs/hr 22

Wages of Operational Staff, Rs/hr. 200

Total variable cost (B) = 325+1102+22.04+200 1649

Total Operational Cost Rs./hr (A+B) 3677

Harvesting Capacity, ha/hr 0.95

Cost of operation, Rs/ha. (3677 x 0.95) 3494

Cost of operation Rs./ac (3494/2.47) 1414

6. CONCLUSION AND RECOMMENDATIONS:

Overall performance of the Indian combine harvester Swaraj-8100 was found

satisfactory after testing of 75 hours. The following recommendations /

suggestions need to be considered for improvement of the operational capability

of the combine harvester.

a) The quality of the workmanship requires improvement.

b) The noise level causes fatigue to the operator which may be reduced.

c) The operation manual should be updated according to the machine.

d) The unloading grain auger should be hydraulically controlled.

e) The operator cabin must be air conditioned and seat should be made more

comfortable in order to operate the machine for longer time.

f) The grain tank capacity of the machine should be increased.

g) All the systems attached to the machine should be easily engage and

disengage.

h) Indication system or alarm may be provided near the operator seat during

any breakage or any other abnormality.

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ANNEXURE-I

FIELD TEST DATA SHEET

Test No.

Date of test

Duration of test

(Working hrs.)

Travel Speed Rate of Work

Fuel Consumption (Avg)

Pre

harv

es

t lo

ss

(kg

/ha

)

Po

sth

arv

es

t L

osse

s

(Kg

/ha

)

Cro

p t

hro

ug

hp

ut

(t/h

r)

Gra

in B

rea

ka

ge

in

Main

Ou

tle

t(%

)

Ge

ar

Use

d

Sp

ee

d (

km

ph

)

Are

a C

ov

ere

d (

ha/h

r)

Gra

in o

utp

ut

(kg

/hr)

Str

aw

(kg

/ha)

lit/hr lit/ha

1 25-04-2014 4 1st 2 to 3 0.97 3840 3667 9.0 9.27 8.8 122 3.84 2.5

2 26-04-2014 10 1st 2 to 3 0.97 3780 3610 10.0 10.3 8.9 120 3.78 3.6

3 27-04-2014 8 1st 2 to 3 1.1 3810 3604 9.7 8.81 9.3 118 3.81 2.1

4 28-04-2014 5 1st 2 to 3 0.93 3750 3487 9.8 10.53 9.4 117 3.75 1.5

5 29-04-2014 8 1st 2 to 3 0.93 4017 3840 10.0 10.75 9.5 125 4.02 1.7

6 2/5/2014 6 1st 2 to 3 0.97 4210 3950 9.0 9.27 9.1 115 4.21 1.2

7 3/5/2014 7 1st 2 to 3 0.9 4180 3900 9.5 10.6 10.1 112 4.15 1.3

8 6/5/2014 4 1st 2 to 3 0.86 4050 3720 8.7 10.11 10.4 117 4.05 1.4

9 7/5/2014 5 1st 2 to 3 0.86 4030 3770 8.8 10.2 10.6 126 4.03 1.4

10 8/5/2014 7 1st 2 to 3 0.97 3850 3680 10.0 10.3 10.9 126 3.85 1.7

11 9/5/2014 6 1st 2 to 3 0.93 3960 3720 9.5 10.2 10.5 118 3.96 1.1

12 10/5/2014 5 1st 2 to 3 0.93 3910 3705 10.0 10.75 10.8 120 3.91 1.1

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ANNEXURE-II

Performance test/practical field test under actual field condition

Particulars Practical field test

1 2 3 4 5 6 7 8 9 10

A- Test Conditions. (a) Conditions of crop (with reference to field to be harvested.

Rip

ened

Rip

ened

R

ipen

ed

Rip

ened

R

ipen

ed

Rip

ened

R

ipen

ed

Rip

ened

R

ipen

ed

Rip

ened

1- Crop and variety. Sehar Sehar Lasani Lasani Sehar Punjab11 Aas Aas Lasani Sehar

2- Whether susceptible to shattering at maturity Yes/No. No No No No No No No No No No

3- Date of sowing/planting Seed Rate. Kg/acre

15.11.13 60

18.11.13 50

20.11.13 60

15.11.13 60

21.11.13 50

18.11.13 55

16.11.13 60

24.11.13 70

29.11.13 75

26.11.13 60

4- Normal period of maturity days after sowing. 150 150 145 135 150 130 130 145 150 135

5- Plant height. Cm (average of 10 readings.) 70 68 70 72 73 70 69 67 70 70

6- Inclined angle of plant. (average of 10 readings) 6o 7o 10o 9o 7o 6o 9o 10o 10o 7o

7- Plant population per square meter. (average of observation taken randomly at 10 places)

215 220 210 217 200 220 190 195 205 210

8- Moisture content of grain. 10.2 10.4 11.2 11 10.6 10.4 10.8 10.9 11 11

9- Temperature. 38oC 38oC 39oC 40oC 42oC 41oC 37oC 39oC 40oC 42oC

10- Wind velocity (km/hr) 15 13 12 12 12 14 15 13 14 15

11- Cloud cover. mild nill nill nill mild nill nill nill nill mild

Contd…………..

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ANNEXURE-II

Particulars Practical field test

1 2 3 4 5 6 7 8 9 10

Data Sheet for Noise Measurement.

Sound level at driver's ear . 88db 88db 88db 88db 88db 88db 88db 88db 88db 88db

Detail of the Test Site. Field Field Field Field Field Field Field Field Field Field

Gear used 1st 1st 1st 1st 1st 1st 1st 1st 1st 1st

Travelling speed( Km/h) 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3

Labour requirement. 2 2 2 2 2 2 2 2 2 2

Number and man hours of persons employed during test:- 1) Operator.

4 10 8 5 8 6 7 4 5 7

2) Number of man hours used (Labour). 8 20 16 10 16 12 14 8 10 14

Ease of operation of machine (easy, manageable, difficult).

Ma

nag

eab

le

Ma

nag

eab

le

Ma

nag

eab

le

Ma

nag

eab

le

Ma

nag

eab

le

Ma

nag

eab

le

Ma

nag

eab

le

Ma

nag

eab

le

Ma

nag

eab

le

Ma

nag

eab

le

Ease of adjustment and precision of machine (good acceptable poor)

Acc

epta

ble

Acc

epta

ble

Acc

epta

ble

Acc

epta

ble

Acc

epta

ble

Acc

epta

ble

Acc

epta

ble

Acc

epta

ble

Acc

epta

ble

Acc

epta

ble

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DIRECTOR GENERAL AGRICULTURE (FIELD) PUNJAB & DIRECTOR AMRI VISITING THE TEST SITE

DIRECTOR GENERAL AGRICULTURE (FIELD) PUNJAB & DIRECTOR AMRI VISITING THE TEST SITE

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FIELD TEST TO DETERMINE GRAIN LOSS AND OTHER OBSERVATIONS

UNLOADING GRAIN FROM THE COMBINE HARVESTER

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GRAIN SAMPLE FROM THE GRAIN BIN SHOWING SOME BREAKAE DURING THE HARVESTING

GRAIN SAMPLE FROM THE GRAIN BIN SHOWING STRAW