A

TRAINING REPORT ON
VACATIONAL IN-PLANT TRAINING
AT
♣♣

ACKNOLEDGEMENT

It gives us an immense pleasure in presenting the

industrial report on

We take opportunity to acknowledge the enormous

assistance and excellent co-operation extended to us
by all concerned in department.

First we would like to express to thanks all industrial

members for this valuable guidance.
CONTENTS
►ABOUT THE COMPANY

►QUALITY CONTROL & INSPECTION

►MACHINE SHOP

►ASSEMBLY

►TESTING

►PAINTING, REFITTING, PACKING-DISPATCH

ABOUT THE COMPANY
is reputed district in the state of Maharashtra. Also
well known for cultural heritage and industrial
development.In the Maharashtra there
are so many well established M.I.D.C.’s one of them
is which is situated near “.” is situated in.
It was established in 1960.The main product of this
co. is -
DIESEL ENGINE
Portable engine series (3.5HP-8HP)
Conventional engine series (5HP-26HP)

In conventional engine series (5HP-14HP) are single

cylinder engines. And (13HP-26HP) are multi
(double) cylinder engines. The total production of the
co. -

The brand name of co. is”

The main customer of co. is.’ other applications are –
Pump set
-D.G. set
-Stone crusher

ASSEMBLY
Guidance_

.
There are two sections of assembly one for
portable engine and other for conventional engine.
The cooling systems for both engines are –
Air cooled engine
Water cooled engine
The assembly of the portable air & water
cooled engine and the conventional air & water
cooled engine is done on the same assembly section.

1. Crank-case assembly
The machined crank-case is first cleaned by
water injection. Then stud fitment is done after that
the taper roller bearing which is heated by induction
heat treatment assembled on crank-shaft fitted in
crank-case by tapping process. Then fulcrum pin,
drain plug, shims & shims housing, lubricating oil
pipe etc. parts are assembled by using proper studs,
screws &nuts. This transferred for further assembly.

2. Gear cover assembly

For the protection of crank gear & cam gear
the gear covers are used. It contains the assembly of
gasket packing gear cover plate, gear cover port, oil
seals & washers by using proper nuts and screws.

3. Pump bracket & Inspection cover assembly

The parts of assembly for this are fuel
pump bracket, fuel pump rocker lever, gasket packing
inspection cover, ‘o’ ring, fuel rocker spindle etc.
pump bracket is used for the actuation of fuel pump.

4. Cylinder block & liner assembly

The air cooled & water cooled cylinder
blocks are of different types. The assembly of water
cooled block contains port, liner, shims, blanking
flange, push rod cover.

5. Cylinder head assembly

The design of cylinder head of air &
water cooled engines are also different. The assembly
of water cooled cylinder head contains gasket, valve
guide port, spring & inlet-exhaust valve port, core
plug, head breather tube port, washers etc.
6. Rocker box & Fuel tank assembly
The purpose of rocker mechanism is the
movement of inlet & exhaust valve at the correct
timing. Fuel tank is used to provide fuel to Bosch
pump. The assembled parts are regulator port, tank
bracket, strainer, tank cap, bush, rocker box port,
gasket, rocker shaft port etc.

7. Crank shaft & flywheel assembly

Crank shaft is fitted in crank case & purpose
of fly wheel is to store energy. The assembly parts
are ports, keys, taper roller baring, woodruff key,
strainer, crank gear, washers, etc.

8. Piston & connecting rod assembly

Piston is reciprocating in cylinder &
connecting rod connects piston & crank gear with the
help of gudgeon pin. The assembly contains piston,
piston rings, connecting rod, gudgeon pin, bolts, etc.

9. Cam shaft with gear assembly

Cam shaft connected to crank shaft with
gears. The purpose of cam shaft is the valve timing
actuation. The assembly contains cam shaft, cam
gear, governor push rod, valve tappet, extension
shaft, governor weights, spring, bush cam, etc.
 10. Bearing housing & Gov. bracket assembly
Bearing housing is provided for carrying
bearing. It contains the flywheel pointer, gasket,
adopter plate, oil seal, bearing cup, plastic grip, etc.

11. Fuel injection & filter assembly

Fuel injection contains multi hole nozzle, a
filter is used for filtering of oil & air. The assembly
contains Bosch fuel pump, speeder spring, nozzle
with holder, pipes, shims, fuel filter assembly,
washers, etc.

12. Manifold & starting handle assembly

The assembly contains air cleaner
assembly, air inlet manifold, gasket, exhaust
silencer, water inlet & outlet manifold, starting
handle assembly etc.

13. Cylinder liner or block assembly

Cylinder liner for air cooling & water
cooling is different. The assembly for air cooled
engine contains cylinder liner, gasket for push rod,
rubber bush, shims, washers, etc.

14. Cylinder head assembly

The construction of cylinder head for air
& water cooling is different. The assembly air cooled
cylinder head contains cylinder head, inlet & exhaust
valve, valve guide port, spring valve port, valve cup,
nozzle chamber & cover, head breather tube port, etc.

15. Cowling assembly

The construction of cowling for air &
water cooled engine is also different. The assembly
of air cooled engine contains cowling set, washers,
screws, etc.

16. Centrifugal water pump spares assembly

This one of the major application of the
diesel engine set. The pump assembly contains pump
housing, impeller shaft, flange, water deflector,
grease cup, ball bearing & cap, impeller, pump
casing, etc.

The assembly process flow diagram of

portable engine (3.5HP A/C to 5.0HP
A/C)&(3.5HP W/C to 8.0HP W/C) is shown.

TESTING
Guidance Date-22/06/2010.
 After the assembly of engines both
portable & conventional the same is transferred to the
testing department. In this department the
performance testing of each engine is done with the
help of dynamometers.
For portable type engines –water type
dynamometer is used.
For conventional type engines –eddy
current type dynamometer is used.

The various types of performance tests

are as follows-
1. Valve timing checking.
2. Oil checking.
3. Brake power checking.
In this, the brake power is
calculated at no load, half load and full load (for
predetermined time) according to the engine power
i.e.HP(given in chart).The other calculations are
-Specific fuel consumption.
-Lubricating oil consumption.
-RPM i.e. governing.
If any error detected the
yellow color tag with the error written on this tag is
transferred for the elimination of error e.g. if there is
oil leakage the tag can be written like –crank case
error.
 After the checking of all
parameters the engines is transferred for the painting
purpose.