REPORTOFPROJECT SEMESTER TRAININGCOMPLETED AT

ESCORTS AGRI MACHINARY CHD PLANTWITHPROJECT- MANUFACTURING AND TESTING OF ADDC BODY

SUBMITTED IN PARTIAL FULFILLMENT FOR AWARD OF DEGREE OFBACHELOR OF TECHNOLOGYINMECHANICAL ENGINEERING

BYJAGSIR SINGH (20903035)

MECHANICAL ENGINEERING SECTIONYADAVINDRA COLLEGE OF ENGINEERINGPUNJABI UNIVERSITY, GURU KASHI CAMPUS,TALWANDI SABO 151302 (PUNJAB), INDIAMAY 2013

ACKNOWLEDGEMENTFirst of all I would like to thank Mr. BIPAN SHARMA head of employees relation ,for giving me this opportunity to be trained in this reputed company. I worked under the super vision of Mr. R MAHAJAN section incharge of hydraulics department. He motivated me at each step and made this training a great learning experience . I would like to thank Mr. SHAMBHU , who provided me with all the necessary resources that I required during my project work in Escort. Last but not the least all the workers of the shop floor who were always eager to help me and were very patient inspite of the fact that I had to interrupt them time and time again for my queries.

Jagsir singh

ABSTRACT

Industrial exposure is the most crucial part of the technical studies in which a student is able tosynchronize his technical knowledge with practical knowledge gained in any of the organization in which he gets his training from. I was allotted a projecttitled, Manufacturing and testing of ADDC body , in ESCORTS LTD, CRANK SHAFT AND HYDRAULIC DIVISION.I hope that the word of my project communicates the actual experience gained with subtlety and precision, which is unapproachable, by any other means. From the medium of this project report, I would like to thank each and every honourable employee of ESCORTS LTD, CRANK SHAFT AND HYDRAULIC DIVISION, who has helped me to gain all the knowledge in the respective production shop, where production process was involved.

TABLE OF CONTENTS

Company profile Introduction about project Manufacturing operations Inspection Assembly Testing Problems

COMPANY PROFILE

ABOUT THE COMPANY

The Escorts Group is among India's leading engineering conglomerates operating in the high growth sectors of agri-machinery, construction & material handling equipment, railway equipment and auto components. Having pioneered farm mechanization in the country, Escorts has played a pivotal role in the agricultural growth of India for over five decades. One of the leading tractor manufacturers of the country, Escorts offers a comprehensive range of tractors, more than 45 variants starting from 25 to 80 HP. Escort, Farmtrac and Powertrac are the widely accepted and preferred brands of tractors from the house of Escorts. A leading material handling and construction equipment manufacturer, we manufacture and market a diverse range of equipment like cranes, loaders, vibratory rollers and forklifts. Escorts today is the world's largest Pick 'n' Carry Hydraulic Mobile Crane manufacturer. Escorts has been a major player in the railway equipment business in India for nearly five decades. Our product offering includes brakes, couplers, shock absorbers, rail fastening systems,composite brake blocks and vulcanized rubber parts. In the auto components segment, Escorts is a leading manufacturer of auto suspension products including shock absorbers and telescopic front forks. Over the years, with continuous development and improvement in manufacturing technology and design, new reliable products have been introduced.Throughout the evolution of Escorts, technology has always been its greatest ally for growth. In the over six decades of our inception, Escorts has been much more than just being one of India's largest engineering companies. It has been a harbinger of new technology, a prime mover on the industrial front, at every stage introducing products and technologies that helped take the country forward in key growth areas. Over a million tractors and over 16,000 construction and material handling equipment that have rolled out from the facilities of Escorts, complemented by a highly satisfied customer base, are testimony to the manufacturing excellence of Escorts. Following the globally accepted best manufacturing practices with relentless focus on research and development, Escorts is today in the league of premier corporate entities in India. Technological and business collaboration with world leaders over the years, Globally competitive indigenous engineering capabilities, over 1600 sales and service outlets and footprints in over 40 countries have been instrumental in making Escorts the Indian multinational. At a time when the world is looking at India as an outsourcing destination, Escorts is rightly placed to be the dependable outsourcing partner of world's leading engineering corporations looking at outsourcing manufacture of engines, transmissions, gears, hydraulics, implements and attachments to tractors, and shock absorbers for heavy trailers. In today's Global Market Place, Escorts is fast on the path of an internal transformation, which will help it to be a key driver of manufacturing excellence in the global arena. For this we are going beyond just adhering to prevailing norms, we are setting our own standards and relentlessly pursuing them to achieve our desired benchmarks of excellence.THE FOUNDING PHILOSOPHY

Over six decades back two young men set out on a journey together armed with little beyond intelligence, business acumen and determination and dreams aplenty. They believed that India could only achieve total freedom with a breakthrough in the field of agriculture and mechanization would have to rule the fields. Their youthful enthusiasm had kindled the hope that one day they would make a mark of their own. They were in fact writing the first chapter of what has come to be widely recognized as one of the greatest success stories in Indian industry. Escorts came into being with a vision. A vision that eschewed easy paths to profitability, and sought instead for ways to make a contribution. A vision that led two young brothers, Yudi and Hari Nanda, to branch out of their family's prospering transport business and institute ventures that were to become the foundations of Escorts Limited. On 17th October 1944, Escorts Agents Limited was born at Lahore (now in Pakistan) with Mr. Yudi Nanda as Managing Director and Mr. Hari Nanda as Chairman. It was a trendsetting marketing house driven by the same business philosophy, which had given their family enterprise an unrivalled reputation: customer concern. Not long afterwards, this driving ambition to go beyond the expected led Hari Nanda to the first of his many successful business insights - the discovery of the great business potential that lay in India's villages. This led to the launch, in 1948, of Escorts (Agriculture and Machines) Ltd., with Yudi Nanda as Director. Though separate business entities then, both companies had two great strengths in common: the dynamic Nanda brothers and the unifying force of the name they gave their companies; Escorts, literally 'escorting' their products and services to the customer while most other businessmen were just selling. Tragically, Mr. Yudi Nanda died in an accident in 1952 - but his spirit remained embedded in the foundations of the company. Mr. H P Nanda then took on the mantle to realize the dreams which he had always seen with his brother.Escorts (Agents) Ltd. and Escorts (Agriculture and Machines) Ltd. merged in 1953 to create a single entity -Escorts Agents Pvt Ltd. Having initially started with a franchise for Westinghouse domestic appliances, by this time the Company had already expanded its marketing and service operations, representing internationally known German and American organizations such as MAN, AEG, Haniel & Leug, Knorr Bremse, MIAG and BMA for sophisticated electrical and mechanical engineering equipment and Minneapolis Moline and Wisconsin for agricultural tractors, implements and engines. Escorts made a major thrust into the agricultural arena by taking on the marketing and service franchise for Massey Ferguson tractors in Northern India, which soon comprised 75% of MF's all-India sales - a signal tribute to Escorts' inherent strengths. Its first industrial venture came up in 1954, in partnership with Goetzewerke of Germany for the manufacture of piston rings and cylinder liners - followed by production of pistons in collaboration with MAHLE, also of Germany, in 1960. The company's incorporation in its present name, Escorts Limited, was effected on 18th January, 1960. Escorts' next major industrial activity was the assembly of tractors in 1961 in technical cooperation with URSUS of Poland. Subsequently this led to the manufacture of the country's first indigenous tractors under Escorts' own brand name, which were to play a pivotal role in the Green Revolution. This went on to lay the foundations that even today are the Company's core strengths -relevant, world-standard technology through strategic international alliances; a broadbased marketing and service network yet unrivalled. Beyond the growth of the organization, these principles have ensured that Mr. H. P. Nanda's contribution to the cause of industry and the consumer will endure. He pioneered the revolutionary concept of 'interdependence' between ancillary and large industries, institutionalizing vendor development and in the process building Faridabad and the entire belt of townships in the region. He introduced the discipline of service going before marketing, reassuring the customer that Escorts would stay with them, that they were here for the long run. He built lasting alliances with an array of the world's most respected names in tractors, industrial equipment, two-wheelers, construction equipment and telecommunications. Going further, he created institutions devoted to value engineering and training, not only as investments in the company's future but also as catalysts for the enhancement of Indian industry as a whole the Escorts R&D Centre and the unique Escorts Institute of Farm Mechanization. His concern extended to the society in which he worked, and he manifested it by establishing the Escorts Medical Centre at Faridabad, Escorts Heart Institute and Research Centre at New Delhi, as well as numerous village development programmes. And above all, he imbued the corporation with his own pioneering. Escorts is testimony to the valor, vision and values of its Founder Mr. H P Nanda. He remains the inspiration for our courage, spirit of adventure and ability to Think Big. These qualities are his enduring legacy and have inspired and encouraged us down the decades and will continue doing so in all our endeavors.

Background In 1960, our parent company, Escorts, set up the strategic Agri Machinery Group (AMG) to venture into tractors.

In 1965, we rolled out our first batch of tractors under the brand name of Escort.

In 1969 a separate company, Escorts Tractors Ltd., was established with equity participation of Ford Motor Co., Basildon, UK for the manufacture of Ford agricultural tractors in India.

In the year 1996 Escorts Tractors Ltd. formally merged with the parent company, Escorts Ltd.

Since inception, we have manufactured over 1 million tractors.

Overview Manufacturing Escorts - AMG has Tractor manufacturing capacity of 98,940 trs / annum which is the highest in Asia at one location. Its manufacturing operations are divided in three plants as :- Component Plant consists of Machine shops in which all major castings such as Engine blocks, Gear Box housings, Differential housings are being machined along with Gears & Shafts. Machine shop consists of State of the Art machines such as CNC Horizontal Machining Centers, CNC Turning Centers and variety of other precision machines, including Gear Hobbing and Shaving machines, etc. It is important to note that all critical components are machined in house. Tractor Assembly Plant is divided into two lines as Farmtrac Line and the Powertrac Line. Farmtrac Line is a composite line that has machining as well as assembly activities of Engine, Transmission & Tractor whereas on Powertrac line only Assembly activities of Engine, Transnmission& Tractor are being carried out. Tractor Assembly Plant has State of the Art Paint Shop that has CED paint shop facilities. Engine Shop has State of the Art testing facilities that includes AVL make Eddy Current Dynamometers in Engine Test House. Crankshaft & Hydraulic Plant is divided into two parts as Crankshaft Line and Hydraulics Line. Crankshaft line consists of machine shop where crankshafts of all Tractor models are being machined. It has State of the Art machines such as Rotary Miller, Pin Grinder, Journal Grinder, etc. Hydraulic line consists of Machining as well as Assembly activities where critical parts of tractor hydraulics such as Distributor, Hydraulic Cylinder, etc are being machined and assembled. It has State of the Art Honing and other precision machines

INTRODUCTIONTractors have two main things one is its engine and second is lift. Both parts show the power and capacity of tractor. The user need both of these part have good efficiency. In tractor the lift is major part because tractor is use for agriculture purpose so in large use of lifting the bodies and material. my project was about the manufacturing and testing of ADDC body use in powertrac. ADDC- Automatic Depth And Draft Control.It is an hydraulic component made of mild steel. The forged body comes in shop having weight 5kg. 59 operations will done on the body. after all operations body weight is reduce to 2.7-2.8 kg.It can lift upto 1000-1300 kg load .From name it is automatic depth control. Generally hydraulic lift is used for remove the chance of effect on harrow by lift up the harrow .it is an automatic quality when any obstacles are in the ways it automatically lift up the harrow. It does not need any command.Hence it helps to maintain less load on engine of the tractor and farmer can do their work easily without his physical effort.For the manufacturing of this product I have to go to each manufacturing division of the company to find out what materials are involved at each stage and what processes they do undergo in their respective division. This process starts with procurement of the material and ends with the dispatch of final product.

ADDC body have cubic shape.dimensions of body are shown in fig. so body have six face. for easy to understand the futher operations consider the faces.Face A,B :- 110.4*82.4Face C,D :- 57*82.4Face E,F :- 110.4*57Now we discuss the all operations done in manufacturing the addc body.

FORGINGOPERATION DESCRIPTION :- Receive and inspect forgings.NOTE:-1. Normalized to hardness 175 to 225 HB.2. Draft angle should be 7 degree.3. Shot blast.4. Forging to be closed dia forged.5. Material steel is 45C8.

MILLINGOperation description:- Mill three faces in setup 1. Mill other three faces in setup 2. After milling length:- 110.4, width :- 82.4 and height :- 57mm.Machine used :- HMT triple X milling machine.NOTE:-1. Flatness of milled faces should be within 0.05mm.2. RPM of cutters top = 300rpm, sides = 472 rpm.3. Cutting speed = 148 M/min, Feed = 201 mm/min.4. Sqaureness of adjoining faces to be within 0.01 mm maximum at extreme points.

SURFACE GRINDING

Operation description:- Finish grind face E and F.Machine used :- Rotary surface finish.Note :-1. Width of body after grinding should be 82mm. 2. Surface finish of ground surfaces to be within 2.5 ucla (max.) DEBURRING & PUNCHINGOperation description:- Deburring process is mainly done to smooth the sharp edges of the mild steel body in order to prevent cuts on hands of operators while handling the body or placing it on fixtures provided on each machine. Two no.s are punched on F side of the body.one no. describe the month and other is the piece no.Machine used:- Surface chamfering machine & hammer punching.Note:- Chamfer of 0.2*45 degree is provided to sharp edges.

CNC DRILLINGOperation description:- ON FACE A Hole no.1 4mm centre dril drill 7.8*8mmdrill 6*36mm ream 8*8mm. Hole no.2 4mm centre drill slot 10.2*6mm. Hole no.3 4mm centre drilldrill 7.8*8 drill 6*32mm ream 8*9mm. Hole no.4 4mm centre drilldrill 7.8*8. Hole no.5 4mm centre drillslot 10.2*9mm ream 10.5*9mm.Machine used:- VA 35 COOPER CNC DRILLING MACHINE. 2 pieces can be machined at a time.

FAUNIC DRILLINGOperation description:- ON FACE C Hole no.1 drill 23.5*37.2mm +0.1 drill 8*46mm +0.5. Hole no.2 drill 18.5*32mm +0.1 drill 8*97mm +0.5. Hole no.3 drill 16*1.4mm +0.1.Machine used:- VOLTAS FAUNIC DRILL CENTRE. 4 pieces can be machined at a time.

CAPSTON LATHEOperation description:- ON FACE C Hole no.4 drill a through hole from face C to D of dia 23.5mm.Machine used:- CAPSTON LATHE MACHINE. 1 piece can be machined at a time.Operation description:- ON FACE D Bore the dia of hole no.4 (THROUGH HOLE) from D face by 28.576/28.376*29mm deep. After boring tapping operation is done in that hole by M30*1.5*18mm deep. Upper top corner oh tapped hole is chamfered by 30*0.75mm.

RADIAL DRILL MACHINEOperation description:- ON FACE E Hole no.1 drill 5*20.5 mm deep. Hole no.2 and 2* drill dia 6.8*16.5/16.0 mm deep. Hole no.3 drill dia 7*66 mm deep. Hole no. 4 drill 10.2*9 mm ream dia 10.5*9 mm. Hole no.5 drill 16*9 mm flat drill 16.25+-0.15*14mm drill dia 8*29/19 mm. Hole no.6 drill 16*9 mm flat drill 16.25+-0.15*14mm drill dia 10*28 mm deep.

Machine used:- RADIAL DRILL MACHINE RADIAL DRILL MACHINEOperation description:- ON FACE F Hole no.1 drill 16*59.5 mm deep drill 5.5*76 mm deep core drillDia 18.25*25 mm deep Hole no. 2 drill 6*55 mm drill dia 7.8*8 mm ream dia 8*8 mm. Hole no.3 drill 16.25*14 mm drill dia 7*50 mmMachine used:- RADIAL DRILL MACHINE

DECKEL JIG BORING MACHINEOperation description:- ON FACE A Through hole from face A to B Hole no.1 center drill 4.8*11.1 mm twist drill dia 12 mm core drill dia 13.96 mm reamer dia 13.96

CRANK DRILL BORING MACHINEOperation description:- ON FACE C Here two setup for drilling Setup 1 :- Hole no.1 drill 6*72+0.5 mm flat drill dia 7.8*8.5 mmream 8*8.5 mm

Setup 2 :- Hole no.2 drill dia 6*64 mm Hole no.3drill dia 6.8*18 mm ( 5 HOLE)

ANGULAR DRILLINGOperation description:- Drill a throughout hole of dia 2 at 45degree from face F to D. Drill a hole of dia 6*52 mm at 75 degree from 10.2 mm hole at face E which will open in 23.5 mm hole at face C. Drill a hole of dia 6*55 mm at 65 degree from 10.5 mm hole at face A to 16.25 mm hole at face E.

Machine used:- PILLAR DRILLING MACHINE

XLO BORING MACHINEOperation description:- ON FACE C XLO machine is used to provide exact size as required. Hole no.1 Bore dia 25.991/25.970 throughout.. Hole no.2 Bore dia 20.065/20.117*32 mm +0.1 hole no.3 Bore dia 25.065/25.117*37mm +0.1 RADIAL DRILL MACHINEOperation description:- ON FACE B Hole no.1 drill dia 10*5 mm deep. Hole no. 2 drill dia10*10 mm ream dia 10.5 mm drill dia 8*46 mm

RADIAL DRILL MACHINEOperation description:- ON FACE C Tapping Tapping dia 8*12 mm deep in five holes on face c on which the cover plate is fitted.

Operation description:- ON FACE E Tapping Hole no.1 and 1* Tapping dia 18*12 mm deep Hole no.2 and 2* Tapping dia 18*12 mm deep

Operation description:- ON FACE F Tapping Hole no.1 and 1* Tapping dia 20*20 mm deep

Here all the machining operations are completed . now body goes in inspection.After the tapping deburring of body will done.all the burrs are removed by file or some other tools.Then chamfering is done on face c.After that the final inspections starts. In this all the holes dia are measure and check the dimensionsINSPECTION OF AUTOMATIC DEPTH AND DRAFT CONTROL BODY

Serial no.InspectionMethod of inspectionFrequency

1I.D 25 D9 (25.117/25.065)Plug guage100%

2I.D 20 D9 (20.117/20.065)Plug guage100%

3I.D 25.991/25.970Plug guage100%

4Depth 32Plug guage100%

5Depth 37.2Plug guage100%

6Crankbore dia 13.96Plug guage100%

THREADING

7M8*1.25- 11mm Deep (depth 18mm) 5 holesThread plug guage10%

8M8*1.5- 11mm Deep (depth 4 mm)Thread plug guage10%

9M20*1.5-20mm deep (depth- 25 mm)Thread plug guage10%

10M30*1.5-18mm deep (depth 29 mm)Thread plug guage10%

HOLE OPENING

11Dia 8*97 mm opening in external circuitVisual100%

12Dia 6*64 mm opening in dia 7*66 mm.Visual100%

13Dia 6*72 mm opening in dia 6*32 mmVisual100%

14Dia 5.5*76 mm opening in dia 6 mm angle holeVisual100%

15Dia 16*59.5 mm deepVisual100%

16Dia 7*50 mm opening in dia 20 mm depth 9 mmVisual100%

17Dia 6*55 mm opening in dia 8*97 mmVisual100%

18Dia 10*28 mm opening in dia 8*97 mmVisual100%

19Dia 8*20 mm (eccentric hole) opening in crank boreVisual100%

20Dia 6 mm angle hole opening in dia 6*72 mmVisual100%

21Dia 6*32 mm opening in dia 25.97 mmVisual100%

22Dia 6*38 mm opening in dia 25.97 mmVisual100%

23Dia 10*6 mm opening in dia 25d9Visual100%

24Dia 7.8*8 mm opening in dia 16*59.5 mmVisual100%

25Dia 6*55 angle hole opening in M8 (inlet hole)Visual100%

26Dia 8*46mm opening in dia 8*46 mmVisual100%

27Dia 10 mm opening in M30Visual100%

28Dia 2 angle hole for sealingVisual100%

29Dia 10.5h8*9 mm deepVisual100%

30Dia 8h8*8 mm deepVisual100%

This inspection is shown in figure below

Note :-1. All operations are completed.2. Proper filing and debering of all surfaces.3. Chamfer on dia 20 D9, dia 25 D9, dia 25.97 and crank bore should be smooth.4. Step groove in bottom of dia 20 D9 and dia 25 D9.5. Undesired hole opening and hole interconnection.

Operation description:- Blackening of distributor body.This operation is mainly used to remove some scrap left inside the holes and proper cleaning of interconnected holes. In this body is kept in three different tanks with certain time period as given below:-TANK 1TANK 2TANK 3

Degrease 88Metaphose -140 temperature range( 80-100%)E.C. 10

Fill 10% after every 15 daysFill 10% after every 15 daysFill 10% after every 15 days

Time period: 2-5 min Time period : 25-30 minTime period: 2-5 min

Machine used:- Electrode Welding SetupOperation description:- Electrode welding is done over the sector shown in blue color. In this operation firstly sector is placed at a distance of 3 mm from the crank bore with the help of fixture and then glue is applied on the surface to place the sector at a particular position and then electrode welding is done at the two ends of the sector. 10.5 mm plug dia is fixed over the crank bore. The main purpose of this sector is to provide proper position to crank lever assembly for lifting up of harrow and trolley.

ASSEMBLYAfter completions of welding procees the body comes in assembly line.the parts which are to be assembled are given below.

Screw Cover Spring lock valve Seal Sealing ring Seat valve Plunger Ball Ball seat Spring non return valve Seat valve Circlip Lever agro control Dowel pin Handle oil flow direction control Shaft Plug Distributor body Ring Spring slide valve Plug Spring small Ball pressure relief valve Seat valve Spring Shim Seat slide valve Sleeve slide valve Slide valve

Nagel Honing Machine.Operation description:- This operation is used to create through dia in microns as required by the type of bush and crank. This operation is called semi finishing operation.Eq:- when O.D. of slider bush is checked on baker air electronic convertor and 30+ micron size is written over it , according to the size written on the slider bush , honing of 30 micron is done over done on a dia of 25.991/25.970) and same is the case with crank bore. This machine provides accuracy between 8-16 microns.

DOWEL INSERTOperation description:- Fitting of plug dia 10.5 and 8 mm as shown by black color in figure below.Tools used :-HammerMachine used :- This operation is performed manually using hammer by worker.

Machine used:- Press fitting machine.Operation description:- This operation is used to fit slider bush inside through hole of 25.991/25.970. The slider bush fitted inside the body is shown in red color in figure below:-

LAPPINGMachine used:- Laping Machine.Operation description:- Laping of inner dia of the slider bush in order to remove ovality and clearence between slider shaft and inner dia of the slider bush should be between 3-10 microns. This operation is shown in red color in figure below:

After completing the lapping process body comes on assembly table.Here, first of all the safty valve can be fitted into the body .On face-F the valve is fitted into the hole have dia 16.25 mm. as shown in assembly fig.in this Step 1 put the ball (8 mm dia ) in hole. Step 2coining Step3 then put the seat valve Step 4 put the spring on seat Step 5 place shim on the spring Step 6 now fit the RVOP plug on this So valve is assembled with body After that we fitted the two valve on face C. on face c we have 4 holes one is 25.991 mm, second is 20 mm,and third is spot only 16 mm, and fourth is through out hole of dia 25.01 mm.as shown in assembly fig.Now first of all fit the valve in hole have dia 25.991 mm Step 1first place aa o ring in hole Step 2 also put the o ring on the insert Step 3 then put the seat in hole Step 4 again place oring on it Step 5put the ball (10 mm dia) Step 6then place the insert on seat Step 7then put the o ring on upper side of insert Step 8 place the spring on itAfter that in hole have dia 20 mm fit the non return valve. Step 1first place o ring Step 2place o ring on seat Step 3put the seat in hole Step 4 place ball on seat (10 mm dia) Step 5 place o ring on upper side of seat Step 6 put spring on itThen put only o ring on the spot of dia 16 mm.Then cover plate is fitted on face C by screw.in this 5 screw is used for fit the plate as shown in fig . Then crank is fitted in the body. Crank is inserted from the face F in throughout hole. As shown in figure. Step 1crank is grinded according hole size Step 2 then make a small dia pin at the end of crank where handle is fitted Step 5Crank handle is fitted with the help of a pin. Step 6Then a lever is fitted on crank handle with wire lock.

A slider is prepared to be fitted inside the bush. And then washing of body with oil takes for removing any rust particle.After that body again comes to assembly bench for final assembling. Step 1Ring lock is inserted on the other side of the crank that doesnt allow the crank to came out from hole. Step 2Wire lock is fitted in the groove of slider. Step 3Slider is inserted inside the bush. Step 4A spring of large dia and small length is kept inside the plug, another spring of small dia and large length is kept on plug pin inside the the first spring. Step 5Then screw tight this plug by compressing the springs.

Now whole body is assembled and ready for testing.

TESTINGIn this section body is tested under fluid pressure. First check all the parts are assembled . Here checked the pressure which can generate the body. First check the relief valve , in this limt of pressure is set upto 195-200 kg/cm square.if pressure is above that then loose the valve plug and if pressure is below that limt then tight the valve plug. Sometimes pressure not reached at desired limt even after tight the plug then open the plug and insert shim and tight again.Then check the fluid leakage through any holes. Also check the non return valve ,if valve not properly work then pressure will drop and body will not work.If the clearance between slider and bush more then 4-8 microns then also pressure drop fast and body will not work.Testing specifications:- Fluid pressure is 200kg/cm square. Temperature is 55-60 degree celicus. Flow rate is 28L/min. Pump RPM is 1200-1400.

Problems causing in testing1) Pressure drop fast Due to clearance is more then 8 microns between slider and bush If fluid will comes back fastly in the non return valve.

2) Pressure drop slow If fluid will comes back slowly in the non return valve. Ball in relief valve not properly coined.Customer problems Dust on ball Burr in cover plate Steplar pin mesh with RVOP plug Rust material in plug O ring merge with flash body Oring mesh with spring

After complete assembly and testing

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