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Parts Failure Frequency of Small Engines Used in Agriculture

AKM Saiful Islam
Senior Scientific Officer
Farm Machinery and Postharvest Technology Division, Bangladesh Rice Research Institute, Gazipur-1701.

JK Saha
Post graduate student
Department of Farm Power and Machinery, Bangladesh Agricultural University, Mymensingh-2202.

Abstract/ Executive Summary:

Normal and reliable operation of engines used in agriculture depends upon a correct service and good maintenance, which, in turn, will prolong the life of the engine. The average annual use was observed to be 954 hr, 862 hr, 755 hr and 231hr for the engines used in power tiller, trolley, irrigation and huller respectively. Depending on the replacement frequency, the engine components were divided into slow replacement and fast replacement groups. Crankshaft, camshaft, piston, valve guide, connecting rod, camshaft bearing were found to be the slow replacement parts and replaced rarely. Fast replacement parts were categorized as plunger, injector nozzle, engine head gasket, piston ring, cylinder liner, fuel filter and piston. The frequency of replacement of plunger, injector, nozzle, engine head gasket, piston ring, cylinder liner, fuel filter and piston was found higher among the engine parts irrespective of the use of engine. The replacement frequency was increased after first year replacement. Improper casting significantly influenced the replacement rate of cylinder liner. Replacement schedule of engine parts was depended on the annual use of engine. Replacement schedule was also varied on the type of engine use.

Keywords: Engine parts, First replacement, Slow replacement, Replacement rate and schedule

Location: Tangail sadar,Tangail

Start Date: 01-06-2001

End Date: 31-12-2001

Program Area: Farm Mechanization

Commodity: Farm machineries

Objectives:

To investigate the parts failure frequency and replacement schedule of small engines used in power tiller, trolley, irrigation pumps and hullers.

Methodology:

The present study was based upon field survey where primary data were collected systematically by means of a questionnaire from individual owner of small engines. Data were also collected from mechanics to validate the data obtained from engine owner. Forty four owner of small engine used in power tiller, trolley, irrigation pumps and hullers were randomly selected for the study. Person to person contact survey (Delphi) method was followed for data collection. The information about total number of repairing/replacement of the parts, number of repairs and availability of spare parts were collected by interviewing owners and operators. The number of parts replaceable/repairable in each time was identified from the data. Parts replacement rate was calculated from the total number of each parts failure in each year divided by the total number of engine in operation. Parts replacement was categorized as slow replacement and fast replacement depending on the failure frequency. Replacement schedule of engine parts was done for prediction of parts failure.

Source of Information: Int. J. Sustain. Agril. Tech. 2(4):36-41. BRRI Annual Review, 2001-2002

Article Link (Online Journal):

Funding Source:

1. Government

Budget:

Total Budget (Tk.) :

Achievement/Findings:

The average annual use was observed to be 954 hr, 862 hr, 755 hr and 231 hr for the engines used in power tiller, trolley, irrigation and huller respectively. Depending on the failure frequency, engine parts have been divided into two groups: slow replacement and fast replacement groups. Crankshaft, camshaft, piston, valve guide, connecting rod, camshaft bearing were found to be the slow replacement parts and replaced rarely. First replacement parts were categorized as plunger, injector nozzle, cylinder head gasket, piston ring, cylinder liner, fuel filter and piston. The frequency of replacement of plunger, injector, nozzle, cylinder head gasket, piston ring, cylinder liner, fuel filter and piston was found higher among the engine parts irrespective of the use of engine. The replacement frequency was increased after first replacement. Replacement rate is dependent on the annual use of engine. Plunger replacement was found to be faster than other parts. Plunger was worn-out due to presence of dust in the fuel. Injector nozzle set was replaced due to change of plunger. Replacement of cylinder head gasket for the successive years was highest for both power tiller engine and trolley engine than those of irrigation engine and static huller engine. This was due to increased opening of cylinder head for repairing/replacing piston ring, liner or piston of power tiller and trolley engine. Piston ring replacement rate in power tiller and trolley engine was obtained as highest as of engines used in irrigation and static huller. Cylinder liners were manufactured locally through casting. Improper casting significantly influenced the replacement rate of cylinder liner. Engine owner thought that engine failure occurred due to presence of dust in the fuel. Replacement schedule of engine parts was depended on annual use of engine. Replacement schedule was also varied on the type of engine use.

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