SIX WEEKS INDUSTRIAL TRAINING AT

SONALIKA INTERNATIONAL TRACTORS LIMITED

Internship report

Submitted in Fulfilment of the Required for Award of the Degree Of

DIPLOMA
IN
MECHANICAL ENGINEERING

Submitted by

ASHUTOSH MISHRA
(130985321104)

Submitted to

Er. KAILASH GUPTA

Dean of The College & Professor of Mechanical Department

SWAMI PARMANAND POLYTECHNIC COLLEGE

Under

THE PUNJAB STATE BOARD OF TECHNICAL EDUCATION AND

INDUSTRIAL TRAINING
CEMBER 2015
 ACKNOWLEDGEMENT

No work of significance can be claimed as a result of an individual effort and nothing can be achieved
without an optimal combination of inspiration and perception. For the inspiration part of work, we
own deepest gratitude to those individuals without the help and guidance of whom the successful
completion of this training could not have been possible. The energy of many has contributed in so
small measures in the completion of this training. We take this as an opportunity to express us deep
gratitude to all those who helped us in the completion of this training. It is with immense pleasure and
satisfaction that we present our first attempt in practical experience in the form of the training work.
There are many people who helped me in successful completion of our training. I would like to take
this opportunity to thank one and all. I express my sincere thanks to engineers of ITL for giving
necessary advices, guidance and all facilities to make life easier. I choose this moment to
acknowledgment his contribution gradually.

It is my radiant sentiment to place on record my best regards, deepest sense of gratitude to Mr.
MANOJ KUMAR trainer for their careful and precious guidance which was extremely valuable for
my study both theoretically and practically.

I perceive this opportunity as a big milestone in my carrier development. I will strive to use gained
skills and knowledge in the best possible way, and I will continue to work on their improvement, in
order to attain desired career objectives.

ASHUTOSH MISHRA

130985321104

5the semester / mechanical engineering

i
 ABSTRACT

Industrial Training is a most important part of study curriculum in engineering education field. I am a
student of Diploma in Mechanical Engineering at Swami Parmanand Polytechnic College, Mohali,
Punjab had undergone industrial training for six months in Sonalika International Tractors Limited.

So for the industrial training I have preferred Tractors Industries because of its Bright Future.
INTERNATIONAL TRACTORS LTD. Hoshiarpur is one of the best firm, which has got ISO
(International Standard Organization) 9001 certificate in just two years of its establishment. Now
Company has joint venture with Yanmar, Japan. The profits and growth of company is amazingly
superb. In just three of establishment the company is ranked in top positions. The Research &
Development centre of firm is completely modern with latest technology. The Work force of company is
highly skilled at the top levels as well as at the floor level. At the same time the fresh graduate brings
in the fresh ideas.

The following report does not discuss the details of these experiences and discuss mostly about the
training and how it was completed. It is much more fulfilling experience than any report will be able to
express. I feel pride to get an opportunity to have my practical training at INTERNATIONAL
TRACTORS LIMITED HOSHIARPUR I thank everyone who has contributed to make this experience
truly complete and stimulating.

The Training provides:

 Aims at making one aware of industrial environment which means that one gets to know the
limitation, constraint and freedom under which the engineer works.

 Exposure to Industrial Environment. Marketing and Management Technique.

 An opportunity to undertake training work relating to real technical problem.

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 TABLE OF CONTENTS

CERTIFICATE
ACKNOWLEDGMENT i
ABSTRACT ii
LIST OF CONTENT iii-iv
LIST OF FIGURES v-vi
LIST OF TABLE vii
CHAPTER – 1 INTRODUCTION TO THE COMPANY 1-14
1.1 Introduction 1
1.2 Company Profile 2
1.3 Vision & Mission Statement 3
1.4 Core Values 3
1.5 Logo Rationale 4
1.6 Sonalika Group 5
1.7 Engine Model & Specification 11
CHAPTER – 2 15-19
2.1 Highlights of Sonalika 15
2.2 International Market 17
2.3 Certificate 18
CHAPTER – 3 INTRODUCTION TO ENGINE 20-24
3.1 Engine 20
3.2 Engine Assembly 21
3.3 Process Layout 23
3.4 Stage of Engine Assembly 24
CHAPTER -4 MACHINE AND EQUIPMENT 25-39
4.1 Auto Lap machine 25
4.2 Equipment 26

iii
4.3 Main Assembly 27
Stage 1 – 14 27-39
CHAPTER – 5 ENGINE TESTING 40-42

CHAPTER – 6 ENGINE REWORK 43-45

6.1 Introduction 43
6.2 Cause of Rework on Engine 43
CHAPTER – 7 PROJECT WORK 46-54
7.1 Introduction 46
7.2 Comparison of SI & CI Engine 47
7.3 Classification of Engine 48
7.4 Valves 49
7.5 Chare Stratification 51
7.6 Environmental Concern 53
CONCLUSION 55
REFERENCES 56

iv
 LIST OF FIGURE
Fig No 1 Sonalika Group Unit 5
Fig No 2 Rhino Rx 7
Fig No 3 Harvester 10
Fig No 4 DI-90 12
Fig No 5 About the firm 16
Fig No 6 Certificate ISO 9001:2000 18
Fig No 7 Certificate ISO 14001:1996 19
Fig No 8 fully assembled engines 20
Fig No 9 assembly area 22
Fig No 10 auto lap machine 25
Fig No 11 torque wrench 26
Fig No 12 pneumatic bolt tighter 26
Fig No 13 fuel injection system 28
Fig No 14 crank shaft 29
Fig No 15 gear train 30
Fig No 16 cam shaft 31
Fig No 17 piston connecting rod 32
Fig No 18 connecting rod 33
Fig No 19 cylinder head 34
Fig No 20 flywheel 35
Fig No 21 rocker arms 36
Fig No 22 intake manifold 37
Fig No 23 exhaust flange 37
Fig No 24 alternator 37
Fig No 25 oil filters 38
Fig No 26 stator motor 39
Fig No 27 testing machine 40
Fig No 28 rotary engine 48
Fig No 29 reciprocating engine 48
v
Fig No 30 v type engine 49
Fig No 31 valves 49
Fig No 32 valve assembly parts 50
Fig No 33 valves 51
Fig No 34 charges stratification 52

LIST OF TABLE

Table 1 DI-90 Engine Specifications 14

Table 2 International Market 17

vi
Table 3 process layout 23
Table 4 stages of engine assembly 24
Table 5 comparison of SI and CI engine 47

vii
 CHAPTER 1 - INTRODUCTION TO SONALIKA

1.1 INTRODUCTION
SONALIKA INTERNATIONAL Established in 1969, Sonalika group since from the very
beginning has tried to understand customer need to be facilitating them with its value for
money, hard earned. Sonalika has a state of art manufacturing facilities, spread in acres,
located at hoshiarpur and tax free zone at AMB in Himachal Pradesh.

Sonalika is the one of the top 3 tractor manufacturing companies in India, other products
include off, Multi utility vehicles, engines and various farm equipment’s. Today the group
stands tall with an approximate turnover of 3200 Crore INR. An average growth of 30%
makes it one of the fastest growing corporate in India. It is also one of the few debt free
companies.

Group has strength of about 2000 employee technocrats History reveals that innovation is the
key to continued progress and when applied to technology that touches human life, it can
unfold a whole new economic phenomenon that has the power to change the world.

The industry has gradually transformed itself into a world-class player involved in building
state of the-art products, solutions and technologies. As an industry, they are very conscious
of responsibility to society Sonalika Foundation intends to become a catalyst, encouraging
our members to do more, capturing best practices for quality and harnessing a greater range
of resources, from the industry and beyond to make a major impact on the development
Tractor and car plants work in 2 to 3 shifts depending upon volume of work for maximum
production. They have ventured in to automobile sector also with the launching of Rhino.
1.2 COMPANY PROFILE

1
Sonalika group since the inception has tried to understand customer need to be facilitating
them with its value for money products. The Company has a state of art manufacturing
facilities, spread in acres, located in the free shrubs of Punjab and Himachal Pradesh.

Sonalika is the one of the top 3 tractor manufacturing companies in India, other products
include off, Multi utility vehicles, engines and various farm equipment’s. Today the group
stands tall with an approximate turnover of 1200Crore INR. An average growth of 30%
makes it one of the fastest growing corporate in India. It is also one of the few debt free
companies. Group has strength of about 3000 employees. The company works on the
maxims of low production cost and clean and safe environment.

History reveals that innovation is the key to continued progress and when applied to
technology that touches human life, it can unfold awhile new economic phenomenon that has
the power to change the world. With unique initiatives like the Thought Leadership Forum,
Leadership Forum, we have been able to create unique platform for learning through success
stories of industry leaders No, Doubt that the Sonalika products has created a niche for
themselves not in India but also in foreign market. As at our production any defect even at
micro level is been taken care of and justified. The technology ibr painting and machinery we
use is high quality paint shop with a grade services and methods The industry has gradually
transformed itself into a world class player involved in building state of art products,
solutions and technologies. Sonalika Foundations intends to become a catalyst encouraging
our members to do more, capturing best practices and assisting their reproduction and
harnessing a greater range of resources, from the industry and beyond, to make a major
impact on development of society. It has been our visions to cater the agriculture and auto
industry with qualify abrasive products through untiring dedication and leadership. As we
step in to our fifth decade of existence, we continue to lead the development of industry
driven standards and initiative for the tractor industry in India.
1.3 VISION & MISSION STATEMENT

VISION STATEMENT: -

 The dream Training of Sonalika group is to cater the agricultural and auto industry
with quality abrasive products through untiring dedication and leadership.
 To Become the world's leading tractor manufacturing company and a major player in
automotive products and services.

2
  To provide value for money to the customers by producing High Quality Innovative
Products at competitive price.

MISSSION STATEMENT: -

we pay personal attention to customers so that, we can build products they need, and not
merely sell the products we build.

1.4 CORE VALUES

 To accomplish our mission, the ownership, staff, and management go to great lengths
to treat each customer like a member of the family and provide them with the best
choice of products and highest quality of service in the industry.
 Innovative in field and business
 Fast adaptability to change
 Provide enjoyable working environment to employees
 Offer service with a smile to customers
1.5 LOGO ROTIONALE

Red symbolizes the strength, power, determination, and desire of company.

Yellow surrounding the Sonalika produces a warming effect, arouses cheerfulness, stimulates
mental activity. and generates the same.
Greenleaf in the center symbolizes growth, harmony, freshness, and fertility.

3
 Black underlining the logo associates with power, elegance, and formality.
Orange surroundings the complete log represents enthusiasm, fascination, happiness,
creativity, encouragement, and stimulation.

All this permutation of persona represents the Sonalika group as an asset in the industry
Company is manned by cream of the industry's best of technocrat and senile staff. They are
proud of reputation as service & solution provider and innovator in agro industries. In a time
marked by rapidly changing technology, they have developed best of the R & D team and
have also developed the excellent quality control system to deliver high quality results in the
industry. Their actions are guided by their core values of integrity, quality, commitment, and
innovation. They are committed to living their values doing so, building a business as great as
their products. Throughout their history, company has earned a reputation for high quality and
integrity, and this has been an asset of incalculable value. They strive to live up to
expectations, not just because it is for good business, but also because it is the right thing to
do. Their core values are never to be compromise for immediate success.
1.6 SONALIKA GROUP –

Sonalika group is one of the top automobile and agriculture machinery manufacturer in India.
Apart from tractors its product line includes multi utility vehicles, three wheelers, engines and
various farm equipment’s and implements. Established in 1969, Sonalika group since the
inception has tried to understand customer need to be facilitating them with its value for
money products. The Company has a state of art manufacturing facilities, spread in acres,
located in the free shrubs of Punjab and Himachal Pradesh. Sonalika is the one of the top 3
tractor manufacturing companies in India, other products include old Multi utility vehicles,
engines and various farm equipment’s. Today the group stands tall with an approximate tumor
of 5000 Crore INR. An average growth of 30% makes it one of the fastest growing
corporation India. It is also one of the few debt free companies. Group has strength of about
2000 employee technocrats. The company works on the maxims of low production cost and
clean and safe environment' Such efforts have fetched the company the accreditation like ISO
9001 and ISO 14001.

SONALIKA GROUP UNITS

Sonalika group divided into four companies’. Sonalika group units is as follow

4
 :

Fig 1 Sonalika Group Unit

1.6.1 INTERNATIONAL TRACTORS LIMITED

International Tractors Limited was incorporate on October 17, 1995 for the manufacture of
Tractors and has since then built a distinct position for itself in the Tractor industry. ITL is
manufacturing various Tractors of Sonalika brand between 30 H.P to 90 H.P, and CERES
brand between 70 hp to 90hp. The tractors manufactured by company have secured a
reputation of performance, quality and reliability in the market because of their maximum
pulling power, minimum fuel consumption and low emission. All this makes ITL one of the
top five tractor selling companies in India. These tractors are also exported to various
countries including South Africa, Australia, Zimbabwe, Sri Lanka, Nepal, France, Canada,
Bangladesh etc.

The company is marketing efforts are promoted by the network of 600 Dealers, and 400 sub
dealers and 50 Stockiest supervised by various regional sales offices. Such a networking has
enabled the company to grow like a well-knit family whose roots lie in its customers, who
have been providing constant feedback and support to allow the company to turn their dreams
into products.

It is a matter of Pride and Honor for us that our Manufacturing Process, Quality Control
Systems and Research & Development facilities are ISO - 9001 :2000 Certified by the Joint
Accreditation System of Australia and New Zealand. We are the First Tractor manufacturing,
company in the country to be accredited with ISO - 14001. Its bears testimony to the fact that

5
company is having world- class R.&D facilities, maintaining controls and systems of
International Standards and Environment noffns. We are also the first tractor manufactures in
the country producing 50 & 60 HP Tractors fitted with diesel engines manufactured in-
House , meeting Bharat II norms of Smoke & Mass Emission. These engines have been tested
and certified by ARAI, Pune. United States Environmental Norms Agency, Washington DC
has also certified our engines. These Certifications enabled SONALIKA Tractors to enter into
World market. All the models of Tractors and Combines Harvesters manufactured by us are
tested & approved by Central Farm Machinery and Tractors Training & Testing Institute,
Budni (MP) India, (the government of India Institute authorized for issuing test reports).
1.6.2 INTERNATIONAL CARS AND MOTOR LIMITED

From tractor to utility vehicle 'All for one' human nature says it all. Utility, comfort, luxury
and more…!!

Today with the changing times, the needs and expectations of the customer are changing. He
is technically well aware and economically conscious. He is not only concerned about his
own safety but also about the safety of the environment. He wants a multi utility product i.e.
product with power and Punch. Therefore, we, at Interactional Cars & Motors Limited
developed a team that is constantly working with the dreams that vehicles inspire. Our team
is exploring human ideas and desires by developing the ecstatic driving experience with
intelligent technology- simple, safe and green.

6
 Fig 2 Rhino Rx
The blast in the waiting Rhino

There’ something special waiting and it's Just for YOU.

The hole new RHINO. There's nothing more robust! There's nothing sportier!
There's nothing more elegant!

Stylish and roomy, just meant to cater to the requirements of YOUR Family. The
Team ICML is the lead of technocrats and design engineers working in the
inspiring state of art environment. Every member of the team has vast
experience in his or her respective field, which has enabled them to develop
various prototypes in the short duration of time. Some of these have taken the
final shape and are ready for launch.

The Company will commence its commercial manufacturing operations at its

ultra-modern plant equipped with state-of-art facilities, which is under

7
construction at Amb, Himachal Pradesh, very soon. At rove is a model of
harmoniously composed, simple, modern and environmental friendly plant. The
objective is not only to attain top quality products, but also to meet today's
requirements for productivity, safety, and environmental protection throughout
the entire process of modern automobile creation - from the conceptual stage to
final assembly. To add robust testing facilities have been created for various
kinds of quality tests and finally the road tests.

The plant's location is also an advantage in itself. This is because of the income
tax holiday for the industrial set-ups in the state of Himachal Pradesh.
Government also offers exemption on the excise duty on sales of vehicles from
here. The cumulative effect of the above provides for srjssrantial saving on the
cost of the vehicle, which will add on the buying power of the customers.

1.6.3 INTERNATIONAL AUTOTRAC FINANCE LIMITED

International Autotrac Finance Limited is a non-banking finance company approved by

RBI.IAFL provide finance to customers of International cars & motors limited in rural &
semi urban areas across India through customer friendly schemes. Its parent company
Sonalika Group ranks among the largest tractor & farm equipment manufacturer in India.

Business Plans of IAFL

First Phase: In the first phase, the area of operations will be in the state of Punjab, Haryana,
Jammu, H. P (Done). Second Phase: In the second phase, the area of operations will be
extended to other parts of Northern India. Third Phase: In the third phase, the area of
operations will be extended to whole India.

1.6.4. SONALIKA AGRO INDUSTRIES CORPORATION

Sonalika Agro was established in 1971 to support the Indian farmers with mechanization
technology to facilitate persistence of green revolution. Sonalika Agro Industries Corporation
the groups maiden venture is one of the foremost Farm equipment’s and implements
manufacturing companies in India with 80% share in threshers alone. Its product line includes

8
Combine Harvesters, Tractor/Self Driven straw reapers, Potato Planters, Maize seller
±cumDehuskers, seed ±Cum- Fertilizers Drills, various kinds of threshers, etc.; Sonalika
Agro is a pioneer in manufacturing tractors mounted combine harvester, which is not popular
in India, but also in various others countries across the globe. Today, the company is
supporting the farmers with world class farming equipment to ease the process of making the
Green Revolution II, a dream come true. In the light of the company's mission, highly
qualified and experienced staff is working as a family in the manufacturing facility at
Hoshiarpur (Pb).
1.6.5 SONALIKA AGRICULTURE DEPARTMENT

Sonalika Agro was established in l97l to support the Indian farmers with mechanization
technology to facilitate persistence of green revolution. Today, the company is supporting the
farmers with world class farming equipment to ease the process of making the Green
Revolution II, a dream come true.

In the light of the company's mission, highly qualified and experienced staff is working as a
family in the manufacturing facility at Hoshiarpur (Pb). This plant is equipped with advanced
technology to develop, manufacture and test the modern products for the modem farmer. The
company has a wide range of farm equipment’s and implements to facilitate the farmers in all
kinds of farming activities. It has a large dealer network spread all over country and have
approximately 80% share in Indian market of farm machinery. Its products are also exported
to Asian & African countries through various export promotion counsels.

9
 Fig. 3: - Harvester
1.7 ENGINE MODEL & SPECIFICATION

Sonalika International Tractors limited has manufactured these models of tractors-

1. DI- 730
2. DI-730 II
3. DI-730 III
4. DI- 734
5. DI- 35
6. DI- 35 II
7. DI- 740
8. DI- 740 III
9. DI- 745 III
10. DI- 750 II
11. DI- 750 III
12. DI- 55
13. DI- 60
14. DI- 60 III (Turbo)
15. DI- 75
16. DI- 90

10
 17. DI- 30 Baghwan
1.7.1 DI-90

Fig 4: - DI-90

ENGINE SPECIFICATION

Model 4105 DC

HP category 90 HP Range

Type Turbo Charged With Oil Cooler 4 Stroke Diesel, Direct Injection

No. of cylinders 4

Bore & Stroke (mm) 105/118 mm

Displacement 4087CC

Compression ratio 18.5:l

Rated engine Speed 22OO RPM

Air Cleaner Dry Air Cleaner With Clogging Sensor

11
Cooling system Forced Water Circulation

Fuel injection pump Mico Bosch

CLUTCH Specification

Type Dual clutch

TRANSMISSION 8 forward, 2 reverse speeds with high and low selector levers.

GEAR SPEEDS Km per hour with rear tyre size 12.4.28

1-L 3.22

2-L 4.43

3-L 7.00

4-L 9.49

1-H 12.92

2-H 17.76

3-H 28.05

4-H 38.05

R-L 4.12

R-H 16.52

P.T.O.

Type 06 Spline

RPM 540 RPM Standard

BRAKES Heavy Duty, Self-Energizing Water Sealed Disc Brakes with parking
Brake For Additional Safety

HYDRAULIC 2 Lever, Automatic Position And Draft With Mix Control

a) Position control To hold lower links at any desired height.

b) Automatic Draft control To Maintain uniform draft

c) Mix Control For simultaneous use of position and draft controls for optimum
field output

12
Hydraulic pump Double Gear pump (12+9.5 CC) Delivering 26.4 Lpm for Hyd.
Lift & 20.9 LPM for steering at rated engine speed
LINKAGE 3 point linkage category Il suitable for category Il type pins

LIFTING CAPACITY l600kg At ENDS Of LOWER LINKS

ELECTRICAL 12 Volt, 88 AH Battery, Starter Motor Alternator, Hour meter Ammeter

INSTRUMENTS Electrical Temp Gauge, Oil pressure Gauge &Fuel

Gauge
TYRES PNEUMATIC

Front Tyre 9-16

Rear Tyre 18.4-30

WHEEL BASE 2000 mm

DIMENSIONS

Overall length 3715 mm

Overall Width 1950 mm

Overall Height 2350mm

Min. Ground Clearance 400 mm

Weight of tractor 3640 KG

Table 1: - DI-90 Engine specifications

CHAPTER 2

2.1 HIGHLIGHTS OF SONALIKA

2010
• Sonalika Tractors are now Euro-III A Norms Complaint.
• Started Export of Tractors to Argentina & Serbia.

13
 • Executed the export order to Cameroon worth 40 Million US$.

2009
• GranDIaunch of technical advanced world track series of Tractors.
• Developed in-house unique DIESEL SAVER LINIT for SONALIKA TRACTORS.
• Became only company in India to produce 90 H.P Tractors. 2008

• Launch of RX Series of Tractors. Aesthetically appealing designs and shape accepted

across the world.
• Export of Tractors Started to USA.

2007
• Joint Venture between International Tractors Limited and Magma Shrachi Finance.

2006

 Successfully Developed Four Wheel Front Axles and Transmission of Tractor for
Yanmar.
2005

• Achieved Turnover of USD 235 Million

• Joint Venture with Yanmar for manufacturing of Tractors in India 2001

• Started in house manufacturing of engine for tractor application.

2000

 Entered into Joint Venture with Renault France and Class Germany, which helped the
group to upgrade its technology and systems.
ABOUT THE FIRM

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 Industry Automobile

Founded 1969

Founder Lakshman Das Wide

Headquarters India

Area Served World Wide

Products Tractors, Multi-utility vehicles,

Engines, Farm Machinery
Attachments, Diesel gensets, auto
components and pick & carry cranes

Number of Employees 7000

Website http://www.sonalika.co m

Fig NO: - 5

2.2 INTERNATIONAL MARKET

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The credit of Somalia’s success goes to its sheer dedication that enabled it to traverse beyond
national boundaries and carve a niche for itself. Today Sonalika Group is known for its world
class quality products not only in India but across the globe. Today, Sonalika products are
making their presence felt in more than 62 countries. The global recognition of Somalia’s
growth has been highlighted by strategic investment into the group by leading international
Brands like Yanmar of Japan. Not just this, the group also has its own Research &
Development wing rvith world-class facilities adhering to the highest quality standards.

Sonalika tractors have presence in the following countries:

• Algeria  Croatia  Kuwait  Peru  Syria

 Angola  DR Conga  Kenya  Nigeria  Tanzania

 Argentina  Dubai  Lesotho  Qatar  Togo

 Armenia  Ecuador  Libya  Russia  Tunisha

 Australia  Egypt  Madagascar  Saudi Arabia  Turkey

 Bangladesh  Ethiopia  Malawi  Senegal  Uganda

 Benin  Gambia  Malaysia  Serbia  Uruguay

 Brazil  Ghana  Mali  Seychelles  USA

 Burkina  Guatemala  Mauritius  Sierra Leona  Venezuela
Faso
 Burundi  Guyana  Morocco  Slovenia  Yemen

 Cameroon  Honduras  Mozambique  South-Africa  Zambia

 Canada  Iran  Namibia  Sri lanka  Zimbabwe

 Chile  Iraq  Nepal  Sudan

 Colombia  Ivory Coast  Nicaragua  Suriname

• Costa Rica  Jordan  Niger  Swaziland

Table No- 2

2.3 CERTIFICATIONS

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1). ISO 9001:2000
international Tractors Limited with Sonalika brand of Tractors has been certified as ISO 9001
ISSUED BY International Standard Organizational is for use when conformance to specifies
requirements is to be assured by supplier during several stages which may include design,
development, production, installation and servicing.

Sonalika has arranged collaboration with French Renaults for technical know-how and
marketing. With the help of this collaboration SONALIKA will Develop its own D1-740
tractor engine which will help it to reduce its cost.
This Certification can be earned by those organizations only who can establish and
sernonstrate strict compliance of quality systems prescribed under ISO 9001 as highest level
of certification under which the organizations possess capabilities in the area of design and
development and in manufacturing and marketing functions. It is indeed a great honor for the
international Tractors Limited to have achieved this distinction that too within short span of
its inception. It is the 2ND such company in India, which has received this certification.
This scope of registration covers design, development, production and installation. The
Registration is a quality mark. Sonalika has also been certifies as ISO 1400i which is another
golden feather in Company's Cap and another stamp of quality.

Fig 6: -CERTIFICATIONS ISO 9001: 2000

2). ISO 14001: 1996 ENVIRONMENT MANAGEMENT SYSTEM

Sonalika has also been certifies as lSO 14001 which is another golden feather in Company's
Cap and another stamp of quality.

17
We are the First Tractor Manufacturing company in the country to be accredited with ISO -
14001. It bears testimony to the fact that company is having world-class R&D facilities
maintaining controls and systems of International

Fig 7: - CERTIFICATIONS. ISO 14001: 1996

CHAPTER NO 3 INTRODUCTION TO ENGINE

3.1 ENGINE
Engine is a mechanical device which creates its own energy to run, from fuel. It converts
chemical energy into mechanical energy. Engine can also have called as heart of an
automobile It consists of various mechanisms for its own power generation such as cooling
circuits, current generating circuits and fuel pumping circuits etc. Four stroke diesel engine is
used in Sonalika Tractors.

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 Fig: -8 Fully Assembled Engine
“Serial no of every engine is punched on its crank case, it contains many information
about engine”: -

31007FLI13F12I477

3: - Cylinders

100: - Bore size

FLI: - Model family code

13: - year (2011) (23 for 2012)

F: -Month (June)

121477-serial no of crank case

3.2 : ENGINE ASSEMBLY

Engines are used for different purposes. The engine used in INTERNATIONAL TRACTORS
LTD. is of the made by SIMPSON, which are exported also. The production of shop is about
150 engines per day and can be increased if required. The shop is having latest testing
equipment. In testing shop, engine is checked for efficiency, specific fuel consumption,
power, torque, leakage, f.p.m. and other faults like below from crankcase. The finally tested
are sent to the assembly.
The State of Art assembly line for Engines is one of the best lines fitted with high quality
automated slat conveyor system having various safeties and DC Multi Nut Runner systems on

19
the different stages which ensures consistent production. The diesel engines assembled here
are from 28 Hp to 110 Hp. The Main Engine Assembly Facility Includes: -
The conveyor is fitted with 28 fixtures for mounting of all engine models with facility for
360degree rotation for various assembly operations.
All Stages are equipped with DC Multi Nut Runners for optimized and consistent production.
The Complete Shop is Air Pressurized to ensure dust free environment for the quality
production.
Other Facilities Includes: -
• Leakage testing Machine

• Washing Machine

• Oil pump test rig.

• Test cells with hydraulic dynamometers for 100% Engine Testing.

The crankcase from H.M.S. is first of all cleared with water. The washing machine is rotary

type which revolve the crankcase along with it and water nozzles from all direction clear any

rust and chips. The washed cylinder is then dried in the same procedure in which instead of

water nozzles, hot air is blown. The washed and dried crankcase is than loaded on to the

trolley. The trolley is special made on bearing which can rotate the engine at any angle and

engine can be fixed at any place.

20
 Fig no: - 9 assembly area

This is the most vital department of the industry as complete engines are assembled here. It

provides a clean, tidy, dust free environment under controlled temperature conditions to the

workers working on the assembly line. The assembly line is basically a belt conveyor with a

series of mounting stations built upon it to mount the crankcase or engine block and carry on

the assembly operations. The mounting is of such a type so the crankcase mounted on it can

be swiveled to convenient angular positions while working on it. The crankcase mounted at

one end of the conveyor eventually passes through each of the stages where workers keep on

adding the components one by one and finally a completely assembled engine is obtained at

the end of the assembly line. The components to be fitted are provided to the workers on the

stands and shelves behind them.

3.3 PROCESS LAYOUT

21
 ENGINE ENGINE ENGINE
ASSEMBLY TESTING REWORK

TRACTOR ENGINE
ASSEMBLY TESTING

Table No. 3 PROCESS LAYOUT

22
3.4 STAGES OF ENGINE ASSEMBLY: -

1. Air Cleaning 2

2. Fuel Injection Pump Fitment

3
3. Crankshaft timing gear fitment
4. Cam shaft fitment 4

5. Fitment of Connecting rod and piston assembly 1

5
6. Oil pump fitment
7. Front and rear cover fitment
6
8. Fitment of head Assembly
9. Fitment of flywheel and oil pan
7
10. Fitment of push rod, tappets and rocker arm assembly
11. Fitment of inlet manifold, water pump and side cover 8
12. Fitment of valve cover and alternator
9
13. Fitment of injector, oil filter
14. Fitment of fuel filter and self-starter 10

11

14
13 12

Washing
of engine
block

Table No. 4 ENGINE ASSEMBLY PROCESS LAYOUT

Chapter-4:
MACHINES AND EQUIPMENTS

4.1 AUTO LAP MACHINE

This machine is used to grind the valve surface

Mfd. By: Abhijat Equipment’s Pvt. Ltd. Maharashtra, INDIA.

23
 I. First of all, solution (Silicon Carbide) is applied. Solution is also known as Valve
Grinding Compound.
II. Then valves are placed on cylinder head.
III. Then cylinder head placed under the grinding equipment. IV. Then auto
srryitchIs on, grinding is done & machine gets automatically switch.

Fig: - 10 Auto Lap Machine

4.2 EOUIPMENTS:

i) Torque Wrench: - This is used to tight the bolts with equal torque.

24
 Fig: -11 Torque wrench

ii) Pneumatic Bolt Tighter: -This uses air pressure to tighten the bolts.

Fig: -12 Pneumatic bolt Tighter

4.3 MAIN ASSEMBLY:

Engine is the main part of every machine. In case of tractor, a diesel engine is used because it
provides large horse power economically, because of high compression ratio. The efficiency

25
is further increased with the use of "TURBO CHARGERS". In Sonalika I.T.L. the engine is
assembled in various stages. These stages are discussed ahead.

STAGE 1

WASHING
4.3.A Engine Block is placed in a washing machine.
4.3.B Different nozzles are there in that washing machine.
4.3.C water + chemical is sprayed for 15-20 min. Chemical used is COROSEAL -
33. It is a corrosion inhibitor, manufactured by Pratap Tex- chem Pvt. Ltd.
pune.
4.3.D Temp. range of washing machine is 45-60 degree.
4.3.E 2 Heaters are used to heat the water + chemical mixture.
4.3.F Drying is done with the help of a pressurized air.
4.3.G Crankcase is transferred from washing area to next stage with the help of roller
conveyors.

INSTRUCTIONS
4.3.H Hold the crank case firmly in the machine.
4.3.I Chemical used for washing is "chemetallrai".
4.3.J Clean the holes with the hand brush. 4.3.K
Water pressure used for washing is "40 bar".

Crank case
The basic framework of the engine is formed by the cylinder block. It houses the liners,
which serves as bearings and guides for the piston reciprocating in them. Around the
cylinders, there are passages for circulation of coolant. Cylinder block also carried lubrication
oil to various components through drilled passages called oil galleries. Function support for
the main journals and bearing of the crankshaft. Material is used for crankcase is cast iron.

STAGE 2

1. Fuel Injection Pump Fitment.

2. Inspection of crank case.

26
 3. Fitment of liners.

INSTRUCTIONS:

4.3.L Check the cleanliness of all holes and galleries.

4.3.M Check the training ion of the cylinder liner on the top case of the crank case. 4.3.N
Proper fitment of cylinder sealing.

Fig: -13 Fuel injection system

FUEL INJECTION PUMP:

It can also be called mini-engine, because of its working. The function of the FIP is supply
the diesel to the combustion chamber with proper quantity according to the load variation.
There are two types for FIP is used in Sonalika:
a) Reciprocating type
b) Rotary type

27
 STAGE 3

1. Fitment of Crank shaft.

2. Fitment of all gears:
 Crank shaft gear or timing gear, 
Down iDIe gear.

INSTRUCTIONS:
4.3.O Proper use of lubricating oil in all journals of cam shaft and check the free rotation.
4.3.P correctly match the timing marks and check the back-lash between all the gears
{0.05mm- 0.35mm).
4.3.Q Timing is done by placing one dot of the gear teeth in between the two dots
of the other gear teeth.

CRANKSHAFT
A crankshaft-related to Crank is a mechanical part able to perform a conversion Between
reciprocating motion and rotational-motion. In a reciprocating-engine, it translates
reciprocating motion of the piston into rotational motion. The material used for it is H.C.S
Or chromium steel.
It is typically connected to a flywheel to reduce the pulsation characteristic of the Four
Stroke Cycle, and sometimes a torsional or vibrational damper at the opposite end, to
reduce the torsional vibrations often caused along the length of the crankshaft by the
cylinders farthest from the output end acting on the torsional elasticity of the metal.

Fig: -14 Crank Shaft

28
TIMING GEARS

The gear train with a two to one reduction through which the crankshaft drives the
camshaft and thus controls valve timing in a four stroke cycle IC engine and also controls
the lubrication pump gear, hydraulic pump gear. All timing gears are made up of Mild
steel.

Fig: -15 Gear train

STAGE 4

1. Fitment of cam shaft.

INSTRUCTIONS
4.3.R proper use of lubricating oil in all joumals of cam shaft and check the free rotation

CAM SHAFT
The camshaft is inserted into the camshaft hole with bearing and bolt ends are locked by
clip. The crankshaft is made up of high carbon steel. There is side camshaft, the lobe is
29
connecting with tappets which further operates the rocker arms with the help of push rods
and is responsible for the opening and closing valves. The crankshaft must turn 2 times to
turn the camshaft once.

Fig: -16 Cam Shaft

STAGE 5

4.3.S Fitment of Piston

4.3.T Fitment of Connecting Rod

INSTRUCTIONS

4.3.U Crank pin should be without any dent.

4.3.V Proper use of lubricating oil on crank pin.
4.3.W Torqueing of connecting rod and cap with 8'50Kg'm. 4.3.X Fitment of three
rings namely pressure, normal and oil ring to avoid leakage.

PISTON ASSEMBLY FITTING: -

The piston assembly fitted to the linear and big end is tightened to the crankshaft with 8-
10 kg-m torque, the piston ring cuts should be so adjusted that there should not be in
same line.

30
PISTON
A piston is a component of reciprocating engines, reciprocating pumps, gas compressors
and pneumatic cylinders, among other similar mechanisms. In an engine' its purpose is to
transfer force from expanding gas in the cylinder to the crankshaft via a connecting rod.
The diesel enters inside the cylinder from the ejector and the piston moves upwards and
the compression stroke take place, produces spark and the mixture of diesel and air is set
on fire and it produces an energy that pushes the piston downwards.
Pistons are made of aluminum alloy. The piston is slightly smaller than the cylinder,
which allows the piston to slide up and down. There is a clearance or gap between piston
and cylinder. The gap must be closed hence pistons rings are used, to prohibited the air
fuel mixture or oil enters to the combustion chamber.

There are two types of piston rings: -

a) Compression ring
b) Oil ring

Fig: -17 Piston connecting rod

31
CONNECTING ROD
In a reciprocating piston engine, the connecting rod connects the piston to the crankshaft.
Together with the crank, they form a simple mechanism that converts linear motion into
rotary motion. Connecting rod is made of forged steel.

Fig: -18 Connecting Rod

STAGE 6

1. Fitment of lubricating oil pump.

INSTRUCTIONS

• Mounting of hexagonal bolt with the help of

am 10*130  Torqueing of mounting bolt at 4Kg.m.
• Checking backlash (minimum 0.5mm).  All
parts should be Tully tightened.

STAGE 7

1. Fitment of rear cover

2. Fitment of front cover and pulley

INSTRUCTIONS
• Proper fitment of gasket and cross tightening of mounting bolts.
• Proper pressing of oil seal.
• Uniform fitment of oil seal.

32
 STAGE 8

1. Fitment of head assembly.

INSTRUCTIONS

• Checking of mounting bolts.

• Proper fitment of gaskets.
• Cross tightening of mounting bolts and torqueing at2l Kg.m.

CYLINDER HEAD
It is attached to the top of the cylinder block, by means of studs fixed to the block. The
gaskets are used to provide a tight leak proof joint at the interface of the head and the
block. The cylinder head forms a combustion chamber above each cylinder. It also
contains valve guides, valve seats, cooling water jackets and threaded holes for spark
plug or injector. Heads are cast from cast iron or aluminum alloy.

Fig: -19 Cylinder Head

33
 STAGE 9

1. Fitment of flywheel.
2. Fitment of oil Pan.

INSTRUCTIONS

• Cross tightening of mounting bolts at 8.9Kg.m.

• Proper use of gasket sealant

FLYWHEEL
A flywheel is a rotating mechanical device used to store rotational energy and acts as a
temporary reservoir of the energy, which stores energy when the energy supply is more
than required for an operation and releases the stored energy when the supply power does
not fulfill the needs. Flywheel is provided at the end of the crankshaft. Cast iron is used
for it.

Fig: -20 Flywheel

STAGE 10

1. Fitment of push rod, tappet and rocker arm assembly.

2. Setting of rocker into their holes.

34
ROCKER ARMS
A rocker arm is an oscillating lever that changes radial movement from the cam lobe into
linear movement. As the arm is acted on by a camshaft lobe, it pushes open either an
intake or exhaust valve. This allows fuel and air to be drawn into the combustion chamber
during the intake stroke or exhaust gases to be expelled during the exhaust stroke. Many
modern rocker arms are made from forged steel.

Fig: -21 Rocker Arms

STAGE 11

1. Fitment of inlet manifold.

2. Fitment of water return line.
3. Fitment of exhaust manifold & EGR pipe.
4. Fitment of water pump and side cover.

INLET MAINFOLD

In automotive engineering, an inlet manifold or intake manifold is the part of an engine

that supplies the air to the cylinders. The word manifold comes from the old English word
manifold and refers to the multiplying of one (pipe) into many.

35
EXHAUST MANIFOLD

In contrast, an exhaust manifold collects the exhaust burnt gases from multiple cylinders into
a smaller number of pipes and takes those gasses outside the engine. Even distribution is
important to optimize the efficiency and performance of the engine.

Fig: -22 Intake Manifold Fig: -23 Exhaust Flange

STAGE 12

1. Fitment of valve cover.

2. Fitment of alternator.

ALTERNATOR

An alternator is an electrical generator that converts mechanical energy to electrical

energy in the form of alternating current. It usually mounts on the side of engine. The
engine crankshaft pulley drives the alternator through a belt at 2-3 times crankshaft speed.
For reasons of cost and simplicity, most alternators use a rotating magnetic field with a
stationary armature.
In principle, the relationship between the rotor and stator makes emf.

36
 Fig: - 24 Alternator
STAGE 13

1. Fitment of injector.
2. Fitment of oil filter.

INSTRUCTIONS

• Setting of timing of fuel injection.

• Proper fitment of gasket and centering guide.

OIL FILTER

An oil filter is a filter designed to remove contaminants from engine oil, transmission oil,
lubricating oil, or hydraulic oil. Oil filters are used in many different types of hydraulic
machinery. A chief use of the oil filter is in internal-combustion engines in on and off
road motor vehicles, light aircraft, and various naval vessels. Other vehicle hydraulic
systems, such as those in automatic transmissions and power steering, are often equipped
with an oil filter. Gas turbine engines, such as those on jet aircraft, also require the use of
oil filters. Aside from these uses, oil production, transport, and recycling facilities also
employ filters in the manufacturing process.

37
 Fig: -25 Oil Filters

STAGE 14

1. Fitment of fuel filter. 2.

Fitment of self-starter.

STARTER MOTOR

To start the automobile engine, the crankshaft must turn fast enough for air-fuel mixture

to enter the cylinders. An electric starter or staring motor does this job. It converts

electrical energy from the battery into mechanical energy that rotates the crankshaft. The

self-starter motor draws high cranking current from the battery to produce a high torque

on the flywheel ring so as to turn the crankshaft with the required speed. The starter

motor has an overrunning clutch that transmits torque in the direction and turns freely in

other direction When armature turns, the clutch locks and transmits cranking torque to the

ring gear. As soon as the engine starts, it spins the pinion faster than the armature. This

prevents damage to the armature from spinning at high speed.

38
 Fig. 26 Stator motor

CHAPTER-5:
ENGINE TESTING

After assembly the engine is passed to the Engine Testing where engine is tested with the
Dynamometer. The dynamometer which is used for testing purpose is the Hydraulic
dynamometer.

The Engine is fastened on the test bed after that the Fan belt, Water Hoses, Top exhaust
mountings, fuel connections is done, then the engine is coupled with the Dynamometer
with the help of Cardon shaft. Specified adjustment along on cylinder head torque/tappet
fly up RPM and oil Pressure Leakage. Defected component is checked which will be
removed or repaired.

Cardon shaft of dynamometer is assembled to the flywheel with bolt &nuts. Connection
of the fuel pipe to the feed pump. Double stage fuel filter to be filled with fuel. Air
cleaner connected to manifold. Water mixing tank to the engine water pump and engine
return line. Water gauge connected with the engine gallery. Throttle lever to the F.I.P with
thrilled control lever.

39
 Fig 27 Testing machine

The parameters which are done in the Testing.

1. Speed in RPM
2. Torque in Nm
3. Engine Inlet Temp.
4. Engine Water Outlet
5. Engine Lube. Oil
6. Engine Exhaust Gas

Calculations done: -
1. Specific Fuel Consumption
2. Brake Horse Power
3. Torque Back Up

Checking and Tests on the Different Tractors

DOMESTIC ENGINES - 55 MIN.

Engine run for 25 min at diff. RPM
1. 5min – without Load at 700 rpm
2. 10min – with 25% load at 1000 rpm
40
3. 5min – with 50% load at 1500 rpm
4. 5min – with 75% load at 1800 rpm

Then tappet clearance will check with the filler gauge that is of 0.25

Again engine start for 30 min

1. 5min – with 50% load at 1000 rpm

2. 5min – with 80% load at 1800 rpm

3. 15min – with 100% load at 2000 rpm

4. 5min – without load at IDIe Speed.

EXPORT ENGINES – 35 MIN.

Engine run for 20 min

1. 5min – without load at 700 rpm

2. 5min – 25% load at 1000 rpm

3. 5min – 50% load at 1500 rpm

4. 5min – 75% load at 1800 rpm

Then tappet clearance will check with the filler gauge. Again engine start for 15 min

1. 5min – with 50% load at 1000rpm

2. 10min – with 100% load at 1800/2000/2100 rpm.

41
 CHAPTER-6: ENGINE REWORK

6.1 INTRODUCTION: -
Rework on engine of any kind in International Tractors Limited (ITL) is done in Engine
Rework department. Engine Rework department is the sub-department of Engine
Division in ITL. Rework on engine's mainly done are for: -

1. Rejected/Faulty engines.

2. Export engines.

3. Research & Development engines.

The condition of rework on assembled engine arise when engine has defects which are
caught in Engine Testing. The assembled engine is sent to Engine Testing section where
engine is checked for proper functioning. Fault's in engine are caught when engine is run
by assembling with Dynamometer. These defects are written on pink card and engine is
sent to rework section. Here problem in engine is sorted out and engine is again sent to
testing section for testing with green card on written ready for testing (R.F.T).

6.2 Cause for Rework on Engine: -

42
1. High SFC :-In high specific fuel consumption, there are 3 main areas of concern
with which fuel consumption per unit of power production is high. The area of concern
in engine for high SFC are:
a) Fuel Injection Pump (FIP) problem
b) Valves seating problem
c) Injector problem

2. Leakage: - Leakage in engine is detected by supply of air and spraying diesel on

engine, then inspection is done with UV light. The spot of leakage leaves bubbles and
hence leakage spot is found. Cause of Leakage: - a) Blow hole
b) Improper seating of valves
c) Cracks
d) Damaged Gasket
3. Oil pressure nil: - Lubrication oil pressure is maintained with oil pump. Oil pump
is actuated with bottom intermediate gear.
Problem of nil oil pressure can be due to:
a) Blockage in suction strainer
b) Low level of lubrication oil
c) Oil pump problem
d) Filter problem

4. Fuel Timing Problem: - For proper functioning of engine, it is necessary that

injection timing of fuel is accurate. With improper timing of fuel injection there will be
problems like less efficiency, high SFC, noisy operation, vibrations, etc. Cause of
Improper Fuel Timing are: a) Fuel Injectors
b) Gear Train
c) FIP
d) Fuel timing incorrect

5. Water Circulation Problem: - For efficient functioning of engine it is necessary

to maintain engine at working temperature, to do this cooling of engine is done with
help of water pump.

Causes related to water circulation:

a) Low coolant level
43
b) Water pump problem
c) Leakage in pipeline

6. Timing Gear Noise: - Timing gear is installed in gear train which actuates other gears.
Sometimes this TIG gear makes noise

Reasons for TIG noise:

a) Improper gear fitting
b) Teeth meshing not proper
c) Low gear quality

6. FIP hunting: - Hunting means variation of RPM in ideal position of tractor. The RPM
should be same so that to prevent the zigzag noise from engine.
Reasons for hunting in FIP: -
a) Improper function of the rack

Other Rework Problems: -

Fuel Timing Set, EGR assembly, Crankcase change, Change of Piston rings, Cylinder
liner change, Alternator change, Rocker arm adjustment, TDC check, Water pump hose
change,
Grinding, Oil pump change, Gasket fitment, Change of crankshaft, Gear train adjustment,
Camshaft fitment, Exhaust pipe cleaning, Push rod fitment, Fuel filter change.

44
 CHAPTER-7 PROJECT WORK

Training work: -Work on engine model and its various stages

Purpose/AIM: -To acquire knowledge about engine

Training Chief: - This project work is assigned by ER. Malkit Singh

7.1 INTRODUCTION
Engine is simply a machine which converts heat energy into a useful mechanical work.

There are mainly two types of engine used in automobile industries:

 Internal Combustion(IC) Engine 

External Combustion(EC) Engine

An Internal Combustion Engine (IC Engine) is a type of engine that converts chemical
energy into thermal energy, to produce useful mechanical work. In an IC engine,
combustion chamber is an integral part of the working fluid circuit. The internal
combustion engines are the engines in which the combustion of a fuel occurs with an
oxidizer (usually air) in a combustion chamber that is an integral part of the working fluid
flow circuit. In an internal combustion engine, the expansion of the high temperature and
high pressure gases produced by combustion apply direct force to some component of the
engine. The force is applied typically to pistons, turbine blades or a nozzle. The internal

45
combustion engine is an engine in which the burning of a fuel occurs in a confined space
called a combustion chamber. This exothermic reaction of a with an oxidizer creates gases
of high temperature and, which are permitted to expand. The defining feature of an
internal combustion engine is that useful work is performed by the expanding hot gases
acting directly to cause movement, for example by acting on pistons, rotors, or even by
pressing on and moving the entire. This contrasts with external combustion engines,
such as which use the combustion process to heat a separate working fluid, typically
water or steam, which then in turn does work, for example by pressing on a steam
actuated piston.

Principle of operation:
Air-fuel mixture in the combustion chamber (inside the cylinder) is ignited, either by a
spark plug (in case of Spark Ignition Engines) or by compression (in case of Compression
Ignition engines). This ignition produces tremendous amount of heat and pressure inside
the cylinder. This induces reciprocating motion in the piston. Power of the piston is
transmitted to a crankshaft which undergoes rotary motion. The rotary motion is
ultimately transmitted to the wheels of the, via a transmission system, to produce
propulsion in the vehicle. As the combustion takes place internally inside the cylinder (a
part of working fluid circuit), the engine is called internal combustion engine.

7.2 Comparison of SI and CI Engine:

S.No Parameter SI Engine CI Engine

1 Definition It is an engine in It is and engine in
which the spark is which heat of
used to burn the fuel. compressed air is
used to burn the fuel.
2 Fuel used Petrol is used as fuel. Diesel is used as fuel.
3 Operating cycle It operates on Otto It operates on Diesel
cycle. cycle.
4 Compression ratio Low Compression High Compression
ratio. ratio.
5 Thermal Efficiency High Thermal Less Thermal
Efficiency Efficiency

46
 6 Method of ignition Spark plug is used to Heat of compressed
produce spark for the air is used for the
ignition. ignition.
7 Constant parameter during cycle Constant Volume Constant Pressure
cycle. cycle.
8 Intake Air+Fuel Only Air.
9 Noise production It produces less It produces more
noise. noise.
10 Maintenance cost Low High
11 Fuel supply Carburetor Injector
12 Vibration problem Less Very High
13 Cost of engine Less High
14 Weight of engine Less Heavy
15 Application It is used in It is used in heavy
commercial vehicles duty vehicles .
Table No -5

7.3 CLASSIFICATION OF ENGINES

Automotive Engines are generally classified according to following different categories: -

Classification Tree:
According to number of stroke:

1. Two stroke engine 2. Four stroke engine

According to design of engine:

1. Reciprocating engine (piston engine)

2. Rotary engine (Winkle engine) Fig No.
28

According to fuel used:

1. Diesel engine
2. Petrol engine
3. Gas engine
4. Electric engine
Fig No. 29
According to method of ignition:
47
 1. Compression ignition engine
2. Spark ignition engine

According to number of cylinder:

1. Single cylinder engine
2. Multi-cylinder engine

According to arrangement of cylinder:

1. In-line engine

2. V-type engine

3. Opposed cylinder engine 4.W-type engine

5. Opposite piston engine

6. Radial engine According to air intake process:

1. Naturally aspirated2. Supercharged engine

3. Turbocharged engine

Fig No. 30
7.4 VALVES

There are two types of valves

1. Inlet valve
2. Exhaust valve

48
 Fig No. 31 Valves

1. Inlet valve: These valves are used to allow fresh air or mixture into cylinder.
There is at least only one inlet valve on each cylinder head. On equal number
valve heads inlet valves are larger in diameter than exhaust valves.
2. Exhaust valve: These are used to allow burnt and unburnt gasses to escape atmosphere.
Exhaust valves are normally smaller than inlet valves in diameter.
There must be at least one exhaust valve for each cylinder.

The bigger valve is the inlet valve and the smaller one is the exhaust valve. The spark
plug lies between the two.

Difference between both is diameter.

The main reason for the size difference is to avoid pre-ignition and knocking.

The exhaust valve is the hottest part of the engine.

49
 Different Valve assemblies

Fig no: - 32 Valve assembly parts.

Both inlet and exhaust ports are shaped to curve upwards and outwards emerging from
one or both sides of the cylinder head. It is normal to have one inlet and one exhaust
valve and porter cylinder. However, twin inlet and exhaust valve-and-port layouts are
also adopted for some high-performance or large capacity engines adopted.

50
 Fig No. 33 Valves

7.5 CHARGE STRATIFICATION

A stratified charge engine describes a certain type of internal combustion engine, usually
spark ignition (SI) engine that can be used in trucks, automobiles, portable and stationary
equipment. The term "stratified charge" refers to the working fluids and fuel vapors
entering the cylinder. Usually the fuel is injected into the cylinder or enters as a fuel rich
vapor where a spark or other means are used to initiate ignition where the fuel rich zone
interacts with the air to promote complete combustion. A stratified charge can allow
for slightly higher compression ratios without "knock," and leaner air/fuel ratio than in
conventional internal combustion engines.

Charge stratification diagram: -

51
 Fig No. 34 Charge stratification

1. Homogeneous charge:

Homogeneous charge compression ignition (HCCI) is a form of internal combustion in

which well-mixed fuel and oxidizer are compressed to the point of auto-ignition. As in
other forms of combustion, this exothermic reaction releases energy that can be
transformed in an engine into work and heat.

2. Stratified charge:

i. Carburetion:

A carburetor is a device that mixes air and fuel for internal combustion engines in the

52
 proper ratio for combustion. To carburet (and thus carburetion or carburetion,
respectively) means to mix the air and fuel or to equip (an engine) with a carburetor for
that purpose.

ii. Fuel injection:

Fuel injection is having largely been supplanted in the automotive and, to a lesser extent,
aviation industries by fuel injection. They are still common on small engines for lawn
mowers, rot tillers and other equipment.

The introduction of fuel in an internal combustion engine, most commonly automotive

engines, by the means of an injector.

All diesel engines use fuel injection by design. Petrol engines can use gasoline direct
injection, where the fuel is directly delivered into the combustion chamber, or indirect
injection where the fuel is mixed with air before the intake stroke.

On petrol engines, fuel injection replaced carburetors from the 1980s onward. The
primary difference between carburetors and fuel injection is that fuel injection atomizes
the fuel through a small nozzle under high pressure, while a carburetor relies on suction
created by intake air accelerated through a Venture tube to draw the fuel into the
airstream.

7.6 ENVIRONMENTAL CONCERN

The diesel engine is the most efficient prime mover commonly available today. Diesel engines
move a large portion of the world's goods, power much of the world's equipment, and generate
electricity more economically than any other device in their size range. But the diesel is one of
the largest contributors to environmental pollution problems worldwide, and will remain so, with
large increases expected in vehicle population and vehicle miles traveled (VMT) causing ever-
increasing global emissions. Diesel emissions contribute to the development of cancer;
cardiovascular and respiratory health effects; pollution of air, water, and soil; soiling; reductions
in visibility; and global climate change. Where instituted, control programs have been effective
in reducing diesel fleet emissions. Significantly reducing this sulfur content would reduce
secondary particulate matter (PM) formation and allow the use of control technologies that have

53
proven effective in the on-road arena. The use of essentially zero-sulfur fuels, such as natural
gas, in heavy-duty applications is also expected to continue. Technology changes, such as engine
modifications, exhaust gas recirculation, and catalytic after treatment, take longer to fully
implement, due to slow fleet turnover. Lastly, the turnover of trucks and especially off-road
equipment is slow; pollution control agencies need to address existing emissions with in-use
programs, such as exhaust trap retrofits and smoke inspections. Such a program is underway in
California. These and other steps that can be continued and improved will allow the use of the
diesel engine, with its superior fuel consumption, to continue to benefit society while greatly
reducing its negative environmental and health impacts. The next ten years can and must become
the "Decade of Clean Diesel."

54
 CONCLUSION

The six weeks industrial training proved to be golden opportunity for me in letting me
understand various procedures involved in machinery designing and soughing out different
problem regarding it in engine department. In this training I learnt various aspects and analysis
which we carried out in industry at the same time we learnt how to follow rules and regulations
in industry. I had the pleasure to work with one of the most reputed manufacturers in their field. I
received experience in private sector. It was a good learning time during my training. In the end,
I would like to thank all the people who helped me throughout my training to enhanced my
experience.

55
 REFERENCES

• During Training work/ report carried out by me at SONALIKA ITL o In EDC o

In HRD o In Plant  Wikipedia.org
• Sonalika website
• Daily report diary

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