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1
TEST REPORT INDIAN COMBINE HARVESTER
SWARAJ-8100
BY
AGRICULTURAL MECHANIZATION RESEARCH INSTITUTE (AMRI), MULTAN GOVERNMENT OF THE PUNJAB, AGRICULTURE DEPARTMENT, LAHORE (June, 2014)
2
TEST REPORT OF INDIAN COMBINE HARVESTER
SWARAJ-8100
Report Indian Combine/AMRI/2014
Test period 20-04-2014 to 10-05-2014
Name & Model of Combine INDIAN COMBINE HARVESTER
Harvester SWARAJ-8100
Manufactured by Punjab Tractors Ltd., India
Tested by Agricultural Mechanization Research Institute (AMRI), Multan, Government of the Punjab, Agriculture Department, Lahore
3
CONTENTS
Sr. # Title Page #
1. Introduction 1
2. Brief Description
1
3. Specifications
3
4. Test Observations
8
5. Results and Discussion 8
6. Conclusion and Recommendations 12
7. Annexure I 14
8. Annexure II 15-16
4
PERFORMANCE TEST CERTIFICATE
The performance evaluation data and results of INDIAN COMBINE
HARVESTER “SWARAJ-8100” presented in the report has been carried out
without any prejudice and favour to the manufacturer. The testing institution,
anyhow do not accept any responsibility whether expressed or implied to the
extent of combine harvester performance not commensurating with the data in
the test report, which may be due to variation in working environment and
operating conditions.
Sd/- Sd/-
Asstt. Agril. Engineer(T&T), Asstt. Agril. Engineer (D&D),
Agricultural Mechanization Agricultural Mechanization
Research Institute, Multan Research Institute, Multan
Sd/- Sd/-
Agricultural Engineer (T&T), Director,
Agricultural Mechanization Agricultural Mechanization
Research Institute, Multan Research Institute, Multan
5
1. INTRODUCTION
Swaraj-8100 is indigenous Combine Harvester, manufactured by Punjab Tractors
Limited, India. It operates according to the longitudinal flow principle with proper
attachments for harvesting of wheat, paddy, sunflower, gram, mustard, soya bean
and safflower crop. The machine was gifted by Indian Chief Minister Punjab,
Parkash Singh Badal to the Chief Minister Punjab (Pakistan), Mian Muhammad
Shahbaz Sharif. The testing of the combine harvester was conducted by the AMRI
Engineers with the following objectives:
1. To assess combine harvester field performance, general condition, durability, repair and maintenance requirements under local agro climatic conditions.
2. To check the fuel consumption and hourly production of the combine harvester under different working conditions.
3. To obtain operator views regarding suitability of combine harvester.
2. BRIEF DESCRIPTION
The brief description of the machine is as under.
2.1 HARVESTER
It consists of the following:
a) Engine
b) Intermediate Drive Assembly
c) Gear Box, Clutch, Reduction and Brake Assembly
d) Front Wheels (Driven)
e) Rear Wheels (Steered)
f) Guide and Threshing Drum Assemblies
g) Feeder Conveyor Assembly
h) Cleaning System: Stepped Floor, Sieves Blower and Straw Walkers
i) Elevator Conveyor Assembly
j) Grain Bin
k) Discharging Unit
l) Hydraulic System
m) Electrical Equipment
6
2.2 CUTTER BAR
It consists of the following:
a) Cutting Blade Assembly. 4.2 meters long (14ft) b) Reel Assembly. c) Conveyor Worm Assembly. d) Trailer Assembly.
2.3 INDICATORS
a) Engine speedometer: This meter directly indicates the speed of engine, and records hours run by the engine.
b) Threshing Drum Speedometer: This speedometer indicates the speed of Threshing Drum.
c) Oil Pressure Gauge: This gauge indicates the pressure of the lubricating oil of the engine.
d) Ampere Meter: It indicates charging/discharging of the batteries. e) Water Temperature Gauge: It indicates the water temperature
2.4 ELECTRICAL INDICATORS
a) Ignition switch b) Indicator switch c) Horn switch d) Dipper switch e) Switch for parking of combine on road side f) Switch for grain discharge light
2.5 CONTROLS
There are various controls provided on the operator’s platform so that the operator may have an easy approach for each control for the prompt functioning of the Combine Harvester. These are as under:-
a) Accelerator Control Lever b) Cutter Bar Height Control Lever c) High Low Lever d) Gear Selection Lever e) Hand Crank Lever f) Reel Speed Variation Lever g) Engine Stop Lever h) Clutch Levers i) Cutter Clutch Lever j) Thresher Clutch Lever k) Concave Adjustment Lever l) Hand Lever m) Grain Discharge Lever
7
3. SPECIFICATIONS 3.1 ENGINE
Type ASHOK LEYLAND Bs III (Turbo charged)
Modle ALU-400 Direct Injection, four strokes, 6 cylinder, overhead valve Water cooled
Rated H.P 128 (B.S.)
Electrical equipment
Voltage 24 V
Storage batteries 12V / 120 Amp hr; 2 Nos.
3.2 SWEPT VOLUME Bore 107.18 mm (4.22”)
Stroke 120.65 mm (4.75”)
Compression ratio 16 : 1
Firing order 153624
F.I. Pump MICO (Plunger type)
3.3 CUTTING MECHANISM.
3.3.1 Cutter Bar
Width 4.2 m (14’)
No. of knives 58
Blade Speed 1.50 m/sec.
3.3.2 Cutter Bar Platform
Height adjustment Hydraulic control from Operator’s seat
Min. cutting height 60 mm
3.3.3 Reel
Diameter 1000 mm
Speed adjustment Variable through Mechanical variator
Speed range 15 – 48 rpm
Vertical height Adjustment Hydraulic controlled from Operators seat
Longitudinal position Adjustment
Mechanical
8
3.4 THRESHING AND CLEANING MECHANISM
3.4.1 Threshing Drum:
Width 1274 mm
Diameter 600 mm
No. of rasp bars (Wheat) 8
No. of spikes (Paddy) 120 (8 x 15)
Speed adjustment Variable through Mechanical variator controlled from Operators seat.
Speed range (standard) 525 – 1125 rpm
3.4.2 Concave
No. of spikes (paddy) 31
First time 16
Second time 15
Bar Nos. 3 Big
Bar Channels 3 small
3.4.3 Straw Walkers:
No 5
Number of steps 5
Area 5.2 m
3.4.4 Cleaning Sieves.:
Upper sieve area 2.28 m
Lower sieve area 1.55 m
3.4.5 Blower:
No. of blades 6
Speed adjustment Variable
Speed range 350 – 1000 rpm
Direction adjustment Mechanically operated deflector
3.5 GROUND DRIVE
3.5.1 Clutch 13”Single Plate: Mechanical .
9
3.5.2 Gear Box:
No. of gears
Forward 3
Reverse 1
Speed variation Infinitely adjustable in Each Gear through Hydraulic Control operated From Operator’s seat
3.6 Tyres.
Front (Driving) 18.4 – 15/30 12 PR
Rear (Steering) 7.50 – 16-12 PR
3.6.1 Road Speeds:
Forward:
1st gear 1.5-3.5 km/hr
2nd gear 2.3 – 8.5 km/hr
3rd geat 8.5 – 20 Km/hr
Reverse 3.5 Km/hr
3.7 STEERING AND BRAKES:
Wheel track Front 2400 mm
Wheel Base 3600 mm
Steering Hydraulically assisted Finger tip control
Brakes Disc brakes, mechanically Operated Wheels can be Braked independently or together
3.8 CAPACITIES;
Grain tank 2.0 m3
Fuel tank 245 liter
Hyd. Tank 15 liter
Engine sump 13.60 liter
Main gear box 18 liter
Reduction drives 1.5 liters each
10
3.9 OVERALL DIMENSIONS:
3.9.1 Width.
Transport position 2950 mm
Working position 4600 mm
3.9.2 Length
Working position 8100 mm
Transport position with trailer
12500 mm
Transport position without trailer
7300 mm
3.9.3 Height:
Maximum 3950 mm
3.9.4 Ground clearance: Minimum 370 mm
4. TEST OBSERVATIONS:
The combine harvester Swaraj- 8100 was tested for 75 hours in different fields
and different wheat varieties in district Multan and Muzzafargarh. The test
observations are given in Annexure I &II.
5. RESULTS AND DISCUSSION
The Indian Combine harvester Swaraj- 8100 was tested in the field for the total of
75 working hours. Test observations recorded are discussed below:
5.1 Overall performance
The machine was operated in first gear at 1850 engine rpm. The operating
speed was 2 to 3 km/hr. The overall performance of the combine harvester
was found satisfactory at the testing sites as some minor defects were
observed during the testing.
11
5.2 General Condition and Durability:
The general conditions of the machine at the testing period was found
satisfactory as some minor damages/abnormal wear of different components
was observed. Engine performance at low and high idle rpm was observed
to be satisfactory and no abnormal exhaust gases/color was observed. All
the control levers jammed together. The bushes, brackets, knives, lower
sieve were damaged during the testing.
5.3 Repair and Maintenance
a) The break lock of the combine harvester was jammed during the
operation in the field which was replaced
b) The belt of the main pulley was dislocated from its original position
which was adjusted.
c) The brackets of the bearing were broken during the operation in the
field.
d) The clutch lever was jammed during operation.
e) The rubber bushes of different brackets were damaged which were
replaced with new ones time to time.
f) The lower sieve was cracked and dislocated.
g) The nylon bushes of the reel were adjusted due to misalignment.
h) The grain tank auger conveyor was not properly functioning due to
which loss of grain was observed during unloading.
i) It was observed that once the machine started, all the system attached
automatically started which caused wear & tear, overloading and loss of
fuel. During traveling from one place to another place the whole system
of machine remained engaged to the main system. Despite of number
of efforts, the system could not be disengaged.
j) The cutter bar and knives of the machine were damaged during
operation which were replaced at AMRI workshop.
k) The speedometer of the threshing drum stopped working just after few
hours of operation.
5.4 Grain Losses
The following losses were observed during the testing of the combine
harvester.
12
a) Grain breakage from the main outlet was from 1.1% ranging to 3.6 %.
b) Shattering of grain was observed in the laid down crop during
harvesting.
c) Unthreshed ears were observed from straw walker which was
recovered by increasing the speed of the threshing drum.
d) Falling down of the head of the cut crop was ignorable.
e) Grain losses were observed occasionally during the field operation
which was reduced by rechecking and adjusting the blower, threshing
drum and forward speed of the machine. It was also recorded that
initially the grain breakage percentage during harvesting was higher.
The machine was adjusted accordingly to minimize the grain breakage.
5.5 Fuel Consumption:
The fuel consumption was checked under variable working conditions in
different fields. It was observed 9.5 lit/hr on an average at 1850 rpm during
harvesting. The fuel consumption for marching was observed 7.5 lit/hr on
average during road marching. The machine was operated in first forward
gear.
5.6 Actual Hourly Rate of Work:
Actual hourly rate of work that is harvesting capacity of the machine was
calculated at twelve sites for different duration of tests. The average hourly
rate of work was found 0.95 ha/hr as the machine was operated in first gear
at 1850 rpm.
5.7 Operator Comments:
The operator of the machine and allied staff were interviewed regarding
their opinion about the overall performance of the combine harvester. In
general they offered satisfactory remarks about the machine performance in
special reference to the following.
Controllability
Control lever for different machine operations should be easy and
comfortable to operate.
13
Foot Rest:
Foot rest should be provided for operator safety and comfort.
Silencer Noise:
The silencer noise level should be reduced.
Alarm system:
There is no indication system for the operator during breakage of
parts/choking of system.
5.8 Cost of Operation:
The cost of operation of Indian combine harvester Swaraj 8100 was
calculated on the basis of 10000 hours of operational life.
Capital Cost: (P), Rs. 2600000
Salvage Value (S) @ 10% of P, Rs. 260000 Total Life (L) in hours 2000 Annual Use in hours 200
Fixed cost (A)
Depreciation (P-S)/L, Rs/hr 1170
Interest I= {(P+S)/2 x interest rate/annual use}
@10%,Rs/hr 715
Insurance, Taxes & Shelter = {(P+S)/2 x insurance
rate/annual use} @2%,Rs/hr 143
Total fixed cost (A) = 1170+715+143 2028
Variable Cost (B) Repair & maintenance cost @ 25% of P/L, Rs/hr 325
14
Fuel cost @ 9.5 Lit/hr and @ Rs.116/lit (avg.), Rs./hr 1102
Lubricants @ 2% of fuel cost, Rs/hr 22
Wages of Operational Staff, Rs/hr. 200
Total variable cost (B) = 325+1102+22.04+200 1649
Total Operational Cost Rs./hr (A+B) 3677
Harvesting Capacity, ha/hr 0.95
Cost of operation, Rs/ha. (3677 x 0.95) 3494
Cost of operation Rs./ac (3494/2.47) 1414
6. CONCLUSION AND RECOMMENDATIONS:
Overall performance of the Indian combine harvester Swaraj-8100 was found
satisfactory after testing of 75 hours. The following recommendations /
suggestions need to be considered for improvement of the operational capability
of the combine harvester.
a) The quality of the workmanship requires improvement.
b) The noise level causes fatigue to the operator which may be reduced.
c) The operation manual should be updated according to the machine.
d) The unloading grain auger should be hydraulically controlled.
e) The operator cabin must be air conditioned and seat should be made more
comfortable in order to operate the machine for longer time.
f) The grain tank capacity of the machine should be increased.
g) All the systems attached to the machine should be easily engage and
disengage.
h) Indication system or alarm may be provided near the operator seat during
any breakage or any other abnormality.
15
ANNEXURE-I
FIELD TEST DATA SHEET
Test No.
Date of test
Duration of test
(Working hrs.)
Travel Speed Rate of Work
Fuel Consumption (Avg)
Pre
harv
es
t lo
ss
(kg
/ha
)
Po
sth
arv
es
t L
osse
s
(Kg
/ha
)
Cro
p t
hro
ug
hp
ut
(t/h
r)
Gra
in B
rea
ka
ge
in
Main
Ou
tle
t(%
)
Ge
ar
Use
d
Sp
ee
d (
km
ph
)
Are
a C
ov
ere
d (
ha/h
r)
Gra
in o
utp
ut
(kg
/hr)
Str
aw
(kg
/ha)
lit/hr lit/ha
1 25-04-2014 4 1st 2 to 3 0.97 3840 3667 9.0 9.27 8.8 122 3.84 2.5
2 26-04-2014 10 1st 2 to 3 0.97 3780 3610 10.0 10.3 8.9 120 3.78 3.6
3 27-04-2014 8 1st 2 to 3 1.1 3810 3604 9.7 8.81 9.3 118 3.81 2.1
4 28-04-2014 5 1st 2 to 3 0.93 3750 3487 9.8 10.53 9.4 117 3.75 1.5
5 29-04-2014 8 1st 2 to 3 0.93 4017 3840 10.0 10.75 9.5 125 4.02 1.7
6 2/5/2014 6 1st 2 to 3 0.97 4210 3950 9.0 9.27 9.1 115 4.21 1.2
7 3/5/2014 7 1st 2 to 3 0.9 4180 3900 9.5 10.6 10.1 112 4.15 1.3
8 6/5/2014 4 1st 2 to 3 0.86 4050 3720 8.7 10.11 10.4 117 4.05 1.4
9 7/5/2014 5 1st 2 to 3 0.86 4030 3770 8.8 10.2 10.6 126 4.03 1.4
10 8/5/2014 7 1st 2 to 3 0.97 3850 3680 10.0 10.3 10.9 126 3.85 1.7
11 9/5/2014 6 1st 2 to 3 0.93 3960 3720 9.5 10.2 10.5 118 3.96 1.1
12 10/5/2014 5 1st 2 to 3 0.93 3910 3705 10.0 10.75 10.8 120 3.91 1.1
16
ANNEXURE-II
Performance test/practical field test under actual field condition
Particulars Practical field test
1 2 3 4 5 6 7 8 9 10
A- Test Conditions. (a) Conditions of crop (with reference to field to be harvested.
Rip
ened
Rip
ened
R
ipen
ed
Rip
ened
R
ipen
ed
Rip
ened
R
ipen
ed
Rip
ened
R
ipen
ed
Rip
ened
1- Crop and variety. Sehar Sehar Lasani Lasani Sehar Punjab11 Aas Aas Lasani Sehar
2- Whether susceptible to shattering at maturity Yes/No. No No No No No No No No No No
3- Date of sowing/planting Seed Rate. Kg/acre
15.11.13 60
18.11.13 50
20.11.13 60
15.11.13 60
21.11.13 50
18.11.13 55
16.11.13 60
24.11.13 70
29.11.13 75
26.11.13 60
4- Normal period of maturity days after sowing. 150 150 145 135 150 130 130 145 150 135
5- Plant height. Cm (average of 10 readings.) 70 68 70 72 73 70 69 67 70 70
6- Inclined angle of plant. (average of 10 readings) 6o 7o 10o 9o 7o 6o 9o 10o 10o 7o
7- Plant population per square meter. (average of observation taken randomly at 10 places)
215 220 210 217 200 220 190 195 205 210
8- Moisture content of grain. 10.2 10.4 11.2 11 10.6 10.4 10.8 10.9 11 11
9- Temperature. 38oC 38oC 39oC 40oC 42oC 41oC 37oC 39oC 40oC 42oC
10- Wind velocity (km/hr) 15 13 12 12 12 14 15 13 14 15
11- Cloud cover. mild nill nill nill mild nill nill nill nill mild
Contd…………..
17
ANNEXURE-II
Particulars Practical field test
1 2 3 4 5 6 7 8 9 10
Data Sheet for Noise Measurement.
Sound level at driver's ear . 88db 88db 88db 88db 88db 88db 88db 88db 88db 88db
Detail of the Test Site. Field Field Field Field Field Field Field Field Field Field
Gear used 1st 1st 1st 1st 1st 1st 1st 1st 1st 1st
Travelling speed( Km/h) 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3
Labour requirement. 2 2 2 2 2 2 2 2 2 2
Number and man hours of persons employed during test:- 1) Operator.
4 10 8 5 8 6 7 4 5 7
2) Number of man hours used (Labour). 8 20 16 10 16 12 14 8 10 14
Ease of operation of machine (easy, manageable, difficult).
Ma
nag
eab
le
Ma
nag
eab
le
Ma
nag
eab
le
Ma
nag
eab
le
Ma
nag
eab
le
Ma
nag
eab
le
Ma
nag
eab
le
Ma
nag
eab
le
Ma
nag
eab
le
Ma
nag
eab
le
Ease of adjustment and precision of machine (good acceptable poor)
Acc
epta
ble
Acc
epta
ble
Acc
epta
ble
Acc
epta
ble
Acc
epta
ble
Acc
epta
ble
Acc
epta
ble
Acc
epta
ble
Acc
epta
ble
Acc
epta
ble
18
DIRECTOR GENERAL AGRICULTURE (FIELD) PUNJAB & DIRECTOR AMRI VISITING THE TEST SITE
DIRECTOR GENERAL AGRICULTURE (FIELD) PUNJAB & DIRECTOR AMRI VISITING THE TEST SITE
19
FIELD TEST TO DETERMINE GRAIN LOSS AND OTHER OBSERVATIONS
UNLOADING GRAIN FROM THE COMBINE HARVESTER