is i 9019 • 1979 indian standard
TRANSCRIPT
IS I 9019 • 1979
Indian Standard
CODE OF PRACTICE FORINSTALLATION, OPERATION AND PREVENTIVE
MAINTENANCE OF POWER THRESHERS
First Reprint NOVEMBER 1982( Incorporating Amendment No. I )
(0 Copyright 1982
INDIAN STANDARDS INSTITUTIONMANAK SHAVAN.9 BAHADUR SHAH ZAFAR MARG
NEW DELHI JlOOO2
Gr 3 March 1919
IS : 9019 • 1979
Indian Standard
CODE OF PRACTICE FOR
INSTALLATION, OPERATION AND PREVENTIVE
MAINTENANCE OF POWER THRESHERS
Harvesting. Threshing and Transport EquipmentSectional Committee, AFDC 51
ReJWfsmJU.I
Punjab Agricultural Univerlity, Ludbiana
Department of ａ ｧ ｲ ｪ ｣ ｵ ｬ ｴ ｵ ｲ ｾ Ｌ Government oCU. P. tLucknow
Vicon Limited, ｂ ｡ ｮ ｧ ｡ ｬ ｯ ｲ ｾNational Dairy Research Institute (ICAR).
Karnal
Tractor TrainiDI & Testing Station (Ministry ofAgriculture and Irrigation). BudAi
State Farms Corporation of ludia Ltd, New Delhi
CANau.r.a
DB S. R. VsaM.
M..-s
Sa.1 A. M. ｃ ｂ ａ Ｎ ｕ ｂ ｾ (.4ltmutt, toDr S. R. Verma)
SBBI Jl. K. AGARWAL
SRRI R. C. GOEL Ｈ ｾ ｬ Ｇ Ｇ Ｇ Ｇ Ｇ Ｇ Ｇ Ｇ Ｇ Ｉ5.8. M. R. ABLADA RAOSII&I V. P. ａＡｬｊｴＮｾ A
D. S. P. AOAIlWAL4 (.Alumou)5.8. S. S. BAlNa
SHal P. P. DAB GUPTA
SIUU VINOD DUItfOR.&
Department or Agriculture, Governnlrnt orPunjab, Chandigarh
Dunlop India Limited, CalcuttaESPI Agricultural MacbiDeries Pvt Ltd,
Far ida badSHal V moo RITEA.J (All.-,,)
DUl:l:CTOB Tractor Training Centre ( Mini.try of Agricultureand Irrigation ), Hi,aar
Sanoa TOT ENOUfZKa Ｈ ｍ ｾ ＩS..I A. K.. G.uo MahiDdra OweD Ltd. Pune
S.al A. D. ｄｾｉ (MUIJIIjU) .SIl&I K.. N. GAva CeDtral Mechanical EDgineering Research
Institute (CSIR ). DurgapurS.., R.. K.. VKaIU ( AI,."..,.)
Saal O. S. GUftA .5..11. ｐ Ｎ ｾ Ｘ ａ ｄ (M'"",,)
SJ!Jl1R.. It. GurrAS..I G. B.Jo••J (.db""')
( Ctmti"ued till Ｏ ｊ ｴ ｊ Ｑ ｾ 2 )
@ C.gn," 1979
INDIAN STANDARDS lNSTITtrrION
Thia pubJlcatioD iI prolected UDd. the ,JUlia CD/JYri,hJ Act (XIV of 1957) and
repradacdoD ba wbole or ill pari by aD, meaDi except with wriUnI permission of the
pabl...... IbaII be deemed to be aD bafriDpmeac of copyright UDder tbe said Act.
ｉｓｉＧｏｉＧＮｬｾ
Sunl INDEan'l' 51110. UDioa ForliJa... LudbiaaaSIIRI P.BAJI.JIT 51.0. Ｈ ｾ Ｌ Ｎ Ｎ Ｎ Ｎ Ｌ Ｎ )
PRor A. C. PANDYA CeDtral Institute or AFicultural EDpDeeI'iDl(ICAR. l. Bhopal
SIUtl P. N. PAKOOTB£ Ministry of Alriculture aDd Irri.atioD (Depart-ment of Agriculture)
D1& J. S. PAlCWAa Indian AJricultural Research Institute (ICAR),New Delbi
Dn G. S,NOH (.AllmtIIU )Sllkl K. M. PATEL
SUKI K. K. PA.,..L (.,41"""",)SURJ E. C. PETEa
DR M. S. ｐ｡ＢｄＮｾ
Jyoti Limited, Vadodara
BaryaDa Alro-Iudultries Corporation, CI&IIdiCarbNational Ap'icultural Co-operative MarkeliDI
FederatioD of ladia Ltd, New DelhiSHRI BHuJtENDaA ( Jill..,. )
5Hlt1 K. RAMAKRISHNA R.AO ladia Investment Centre, New DelhiSURf RJPUA)IAN SINOR Escort. Limited, FaridaJ.d
SHItJ Gual'AL VERMA (AI'""",)SlIln It. K. SABHARWAL Hindlons Private Ltd, PatialaDu K. N. SINGH Govind BaJlabh Pant UDivenity of A-rriculture •
Technology, PantDasar ( Dist Nainital )SURt R. S. YAIJAV U. P. State Al"o-Jndustriai CorporatioD Ltd.
LucknowSuru T. ｲ ｦ ﾷ ｊ ｬ ｾ ａ ｾ ａ ｙ ｄ ａ ｍ Ｌ Director General, lSI (&•• M... )
l)eptat)" Director ( Agri It Food )
ｓﾫｲｾ
SaRI R. N. SR.....Deputy Director ( Asri A Food ). lSI
2
AMENDMENT NO. 1 JUNE 1980
TO
15:9019-1979 CODE OF PRACTICE FORINSTALLATION, OPERATION AND PREVENTIVE
MAINTENANCE OF POWER THRESHERS
Alterations-------(Page 3. clausB ｏ Ｎ ｾ Ｎ Za.t .antenaa) -
Substitute the following tor the existingsentence:
"The third Indian Standard. ｉ ｓ Ｚ Ｙ Ｑ Ｒ Ｙ ｾ Ｑ Ｙ Ｗ Ｙ
'Technical requirements tor Bate feedingsystems tor pover threshers' covers the teeh-nieal requirements tor sate feeding 87stemstor pover threshers."
(Page 7. cZause 9.1) ｾ ｓ ｾ ｢ Ｎ ｴ Ｑ ｴ ｵ ｴ ･ 'tamper'to,. 'temper'.
(APDC 51)
aeproarapbr Unit, lSI. Bev Delhi
AMENDMENT NO. 2 JUNE 1996TO
IS 9019: 1979 CODE ｏ ｾ .. PRACTICE FORINSTAl.JLATION, OPERATION AND PREVENTIVE
MAINTENANCE OF POWER TIIRESHERS
( Page 7, cia lise 8.2.1 ) - Delete.
(FAD 59)Ｍ Ｍ Ｍ Ｍ Ｍ Ｍ Ｍ Ｍ Ｍ Ｍ Ｍ ｾ
Reprograpby Unit. rns. New Delhi. India
IS 1 9019 • 1979
Indian Standard
CODE OF PRACTICE FOR
INSTALLATION, OPERATION AND PREVENTIVE
MAINTENANCE OF POWER THRESHERS
0. FOREWORD
0.1 This Indian Standard was adopted by the Indian Standards Institu-tion on 16 February 1979, after the draft finalized by the Harvesting,Threshing and Transport Equipment Sectional Committee had beenapproved by the Agricultural and Food Products Division Council.
0.2 Mechanization of the threshing operations which played a pivotalrole in ushering in an era of grc<-n revolution in the country also broughtin its wake a chain of accidents to farm workers resulting in theirtemporary or permanent disability. This brought to the fore the need forsome immediate measures to safeguard the far m workers against avoidableaccidents be it due to any of the vu'lner'able factors of machine, man, etc,As a number of reports of many farm workers specially the young losinr;their limbs poured in. the urgency to provide for safety provisions be-carne more pronounced.
0.2.1 Punjab Agricultural University, Ludhiana conducted a survey onthe accidents during the wheat threshing season of 19i6. As many as294 cases ｷ ｾ ｲ ･ examined and it was observed that the factors responsiblefor accidents are as under:
Factors of Accidents Percentag«
i) Human 72-9ii) Machine 12'9
iii) Crop g-Oiv) Situational 5-2
0.3 Safety provisions for all the above factors of accidents are covered inthree separate Indian Standards. This standard ｃ ｏ ｜ ｏ ｾ ｲ ｳ rhe human, cropand situational factors. The other standard JS : 9020-19i9· covers genera]and sarety aspects of machine factor. Another standard covering thetechnical requirements for safe feeding devices for po\ver threshers is underprrparation.
ｾ ･ ｲ ｡ ｉ .ad .'ety ｲ ･ ｱ ｵ ｩ ｾ ･ ｭ ･ ｮ ｴ ｬ or power threshers.
3
IS,901'-1'7'
0.4 In preparation of this standard. assistaDce has been derived fromTractor Training Centre (Ministry of Agriculture and Irrigation), Hissar.
0.5 For the purpose of deciding whether a particular requirement ofthilstandard is complied with, the final value, observed or calculated, express-ing the result of a test or analysis. shall be rounded off in accordancewith IS: 2-1960·. The number of significant places retained in therounded off value should be the same as that of the specified value in thisstandard.
1. SCOPE
1.1 This standard coven the recommendations for insta)]ation, operationand preventive maintenance of power threshers.
2. TERMINOLOGY
2.1 For the purpose of this standard, the terms and definitions given inIS: 9020-1979t shall apply.
3. RECOMMENDATION FOR THRESHING YARD
3.1 The threshing yard shall be kept relatively free from all kind. ofobstructions. However, some shade should be provided for workers.
3.2 As far as possible, the threshing yard should be away from theresidential area. It shall not be located near the railway tracks and underthe power transmission Jines.
3.3 A first aid box or kit shall be provided at the site.
3.4 Adequate fire protection facilities shall be provided. It may be somebuckets of sand and water and two 5-kg dry powder fire extinguisher.conforming to IS : 2171-1972:. The extinguisher shall be in a serviceablecondition. It shall also be ensured that these extinguishers are inspectedand maintained properly and that all the workers are well conversantｾ ｶ ｩ ｴ ｨ the method of operation.
3.5 In case the threshing is to be done in night, proper arrangement shallbe made for light. In case of electrical jostaJJation, it .baJJbe in aecer-dar-ce with IS: 132..1963§ and to the requirements of Indian ElectricityRules.
·Rules lor roundmr off" numerical value. (H""tI).tGcneraJ and safety requirements (or power threshen.:Spt'cifiC'ation for portable fire extinguishers, dry powder type (jinI,.,u;.).§Code of practice Cor electrical wiring instanatioDJ (.y.tem voltqe Dot exceediftl
650 volrs ) ("t'v;sed).
4
IS I 9019 • 1979
4. INSTALLATION OF PRIME MOVER
".1 The prime mover, unless directly mounted on the thresher, shall beIocared such that the straw ( BHUSA ) being blown from the thresher doesDot fallon it.
4.2 As far as possible, the prime mover should be kept at a safe distancefrom the feeding mechanism or feeding platform.
".3 In case of the prime mover mounted on the threshers, protectionshould be provided from the straw and dust falling on it.
4.4 The prime mover shall be level both longitudinally as well aslaterally..
4.5 The exhaust pipe of the tractor shall be fixed ve-rtically upward andnever under the chasis. The tractor shall be installed at a safe distancefrom the crop heap.
4.6 In case of permanent installation of electrical motors. assistanceshould be taken from IS: 900-1965*. Even for temporary insta llation ofmotors, the points given under 7 of IS : 900-1965· should be observed,The main..switch of the motor should be fixed within easy reach of theoperator.
5. DETAILS TO BE CHECKED BY THE BUYER OF THETHRESHER
5.1 While purchasing the thresher, the purchaser should check thefollowing:
a) The power required for the thresher is in accordance with thesource of po\\'er available with him.
h) The direction of rotation and the number of rev/min has beenmarked on the thresher,
c) The safety provisions (Ite IS: 9020-1979t) have been providedin the thresher.
d) ｗｨ･ｴｨｾｲ the thresher has been certified by any certifyingagencies, such as lSI or it has been ｴ ･ ｳ ｴ ｾ ､ by any independenttesting authority.
e) The operator's manual in a language understood by him and thathe understands the meaning, has been provided.
f) The special tools and accessories, if any, have been supplied bythe manufacturer.
g) The after-sale service facility is available,
-Code or practice Cor instaJJation and mainlenancp. or induction molon ( ,,,.iJltl ).!General and I.fety requirement. (or power threshers.
IS J 9819 • 1971
5.2 The buyer shall familiarize ｨ ｩ ｭ ｳ ｾ ｬ ｦ about the operation and control.of the threshers,
5.3 Before purchasing, the thresher shall be run idle and the presence ofany undue knocking or rattling sound. alignment and tension of drive beltsto avoid slippage, unusual vibration of thresher and smooth running offan and oscillation of sieve should be checked, .
6. INSTALLATION OF POWER. THRESHER
6.1 The direction of the thresher should be set in consonance with thedirection of t he prevailing wind. that is, straw ( BHlJS.1) outlet should bekept in the same direction as that of the wind and not against the wind,
6.2 The thresher shall be properly anchored in the ground or the wheelshould be grounded firmly to ensure the stability during the operation,
6.3 The thresher should be set level both longitudinally as Ｌ｜ＧｾＱｉ asIateratly.
6.4 'The main drive of the power thresher should be aligned with the driveof the power unit.
6.5 The direction of the movement or the belt should be adjusted to suitthe d irection of rotation of the threshing drum.
6.6 The proper tension of the driving belt should be maintained,
6.7 .*\11 components including guard! and other safety devices should beintact. T'he fasteners should be checked and tightened, if required. AJIthe lubrication points should be properly greased or oiled as ｾ ｲ therna nufacturer's recommendation.
6.8 Proper platform should he made for facilitating smooth fcc-ding of thecrop and for preventing the falling down of the operator.
7. CROP CONDITION
7.1 For efficient operation and to avoid sparking hazard inside the thre-sh-inA' drum. care should be exercised to ensure that the crop to be threshedis in proper condition. For "heat thresher in vogue, the crop should besufficient I)' dry.
8. OPERATIONAL CONDmONS
'.1 Concave clearance, slope of the sieve, rcxrntricity of the shakingmechanism should be checked and adjlatecl in accont.nce with the Qlan,,·facturer's recommendation.
6
IS J 9019 • 1979
8.2 The thresher should be operated at the speed recommended by themanufacturer for a given crop. The size of the main pulley to be fittedon the thresher may be calculated using the following formula:
Dr _ D p ｾｾ- .A'T
D T == diameter of the thresher pulley, mm;
D p - diameter of the prime mover pulley, rnm;
N p == speed of prime mover pulley, rev/min; and
,.;'''T = speed of thresher pulley, rev/min.
8.2.1 The recommended speed for some of the crop is given in Table 1for guidance:
TABLE I RECOMMENDED SPEED OF THRESHING DRUM
Sr.. t:HOP ｓ ｐ ｴ ｾ Ｂ ［ ｄ uF THE ｄ ｊ ｴ ｬ Ｚ ｾ ｦ
No.ｾ｟ＭＭＭａＮ ____ ｾ
ｲ ｾ ｜ Ｇ Ｎ Ｇ ｮ ｬ ｩ ｮ m 's
(I) (2) (3) (-I)
i) \\·heal 550 to I 100 20 to 30
ii) ｮ ｡ ｲ ｊ ｾ Ｉ ﾷ 740 to I 080 20 to 2G
iii) Paddy 675 to I 000 H, to 1:)
j\") Bajra 400 10 550 12 to IG
\') Juwar 400 to 6i5 J:? to 20
vi ) (;r.£rn 400 to 750 12 to 2:!
vii) Peas 430 to 150 13 to 22
8.3 The speed 01 the blower, separating and cleaning mechanism, etc,should be checked and adjusted in accordance with the manufacturer'srecommendations,
8.4 Before starting the prime mover, the main thresher pulley should Ｑ Ｉ ｾ
turned by hand to ensure that there is no obstruction inside the thresher.
8.5 The crop should be fed continuously and uniformly.
9. SAFETY PRECAUTIONS IN OPERATION
'.1 Do not temper with or remove the guards or safety devices,
'.2 Do not wear loose dress, band bangles, wrist watch, etc, whileworking.
1
11.101••1171
'.3 Do Dot smoke and light fire near threshing yard and thresher,
9.4 Never operate the thresher under the influence of intoxicants, likeliquor, opium, etc.
9.5 Do not staDd on the thresher.
'.6 Do not cross over the belts,
9.7 Do not work if you feel tired.
,.I Only skilled and trained workers should be employed for feeding thecrop. Children below 16 years of age and elderly people above 50 yearslacking physical stamina should be discouraged to work specially forfeeding the crop.
9.9 While feeding the earheads or threshing such crops where onlyearheads are required to be fed, due care should be exercised to keep tbehand at a safe distance. To ensure proper feeding, suitable pushing devicemay 11C used instead of hand for pushing.
9.10 Be always attentive while feeding the crop and avoid too much oftalking.
9.11 Due care shall be taken to keep the hand at a safe distance whilefeeding.
9.12 To reach the chute for feeding the crop, do not stand on a bundle ofcrop or bullock cart or trolley, In case cart or trolley is used as feedingplatform obstruction should be provided to the wheels so that it shouldnot move. The cart or trolley should be level.
9.13 Excepting those adjustments which are required to be carried outwhen the thresher is being operated, any adjustment to be carried outshould be done after switching off the prime mover.
10. PREVENTIVE MAINTENANCE
10.1 Make sure that the tension of the belts is proper.
10.2 Check aU the fastening bolts and screws, and make sure that theyare tight.
10.3 In case of pneumatic tyres, the inflation shall be according to therecommendation of the manufacturer.
10•• Remove foreign matter, if any, from the hopper, threshing anddeaDina ubit.
11-5 Check aDd repair aDy damaged or bent partl.
8
11,901'.1979
18.1 Before starting thresher, check various parts to ensure free rotationof components like drum. Can and sieve.
10.7 Occasionally check the sieves and clean if openings are clogged.
IO.a Clean and grease the lubricating points according to the .recommen-dation of the manufacturer.
11. DIAGNOSIS OF COMMON.FAULTS AND THEIR REMEDIES
11.1 Information in regard to some of the common faults) their causes andremedies is giveD in Appendix A.
12. TRAINING AND FAMILIAJUZATION
12.1 Generally, the farm workers are not conversant with the operationand controls of power thresher. The care shall, therefore, be taken toensure that each worker understands the safe operation of the thresherand the safety precautions particularly the following:
a) The method of stopping and starting the prime mover;
b) The hazards which are known to arise in the course of normalworking;
c) The hazards liable to arise from bad practices, inattention andmisuse of controls;
d) The hazard liable to arise from the use of intoxicant;
e) The purpose of guard and safety device and how they may fail;
f) The ability to recognize over loading or abnormal loadingconditions; and
g) The necessity of immediately informing the person inchargc ifany fault or defect arises and the danger to the worker inattempting to correct the fault.
12.2 Clear instructions shall be given to the workers that guard or safetydevices shan not be tempered with, removed or altered in any way andthat adjustable guards shall be re-adjusted only by the authorized person.
12.3 The owner and the operators of the thresher should be conversantwith the rights of workers regarding compensation in case of Jive accidentswhich they may suffer during operation; legislation, if any; suitableinsurance coverage; etc.
13. INSTR.UCTION FOR OFF-SEASON STORAGE
13.0 The points given below should be observed for storing the thresherduring off-season.
13.1 After the work is over, run the thresher idle for some time so thatpractically all the material fed are removed.
9
IStlllt.lm
13.2 Disconnect the power source and remove manually a)) the grains andstraw.
13.3 Remove all belts. clean them and store in a sare place to preventtheir spoilage from heat. dUlt and rain,
13.4 Wash, clean and dry the thresher completely.
13.5 Check the condition of the parts. Undertake necessary repairs and/orreplacements to get the thresher in ｰｲｯｾｲ condition for the next sealOD.
J3.& Repaint the thresher where necessary, or apply a coat of grease orused engine oil to avoid rusting.
13.7 Dismantle the sieve and repaint, it necessary, or apply a coat ofgrease or used engine oil.
13.8 Clean all the luhricating points specially grease cups and bearingswith kerosene or diesel oil and lubricate them with fresh oil or grease.
13.9 Close all the passages through which it might be possible (or virminsto get in. .
13.10 Store the thresher inside a dry shed, No water should fall overthe thresher during rainy season. In case shed is not available, thethresher should be completely covered with waterproof canvas, plastic ortarpaulin.
13.11 Jack the thresher era me horizontally on wooden blocks or bricks incase of pneumatic lyres. If water is filled in tyres, drain the same.
APPENDIX A
( CIause 11.1 )
THRESHER TROUBLE SHOOTING
51 No. Trouble R'lIlon
(1) (2) (3)
i) Blockage of the drum OverfeedingBelt loose
Drum speed tooIow
JO
R,m,tl,7
(4)
Avoid overfeedingCheck all the belts for
proper tension
I Decease the speed torecommended numberby changing drumpulley or by adjustingbelt teRlioa
IS I 9019 • 1979
Increase cylinder speed
Decrease coaeave dear-ance
Install the threaherproperly
Tighten the fastcDen.change or tighten bear-ings
Repair or replace thecomponents
Adjust the proper speed
Adjust the proper fanspeed
Use ｰ ｲ ｯ ｰ ｾ ｲ size of sievesand make properadjustmcnts
Proper and uniform feed-ing
Clean the concave
Clean upper sieve
Adjust proper lieve dope
Use proper size of sieve
Decrease shaking speed
Rnned,1
(4)
Await proper drying ofthe crop
Remove the weeds as faras possible
Adjust the proper clear-ance
Decrease the drum speedto the required number
Adjust the proper clear-ance
Adjust the proper fanspeed
Clean the sieve holes
Improper sizeand adjustmentof sieves
Too much anduneven feeding
Concave may beblocked
Low shakingspeed
Upper sieve bloc-ked
Improper sieveslope
Improper size ofSIeve
High shating.peed
Low cylinderspeed
High concaveclearance
Improper instal.Jation
Fastenen andbeariDgs areIooIe
Worn out com-ponents
II
Concave clear-ance is less
with High fan speed
Blocked sieveholes
Low fan speed
Troubl,
(2)
iv) Straw with grain
iii) Grain blowsstraw
R,lUOft
(3)
Crop is moist
Crop is infestedwith weeds
Concave clear-ance is less
ii) Breakage or the grain High drum speed
vii) Vibration in thresherduring operation
v) Grain with tailings
. vi) Too many unthrc-shed head.
SlXo.(1)
IMTEBNA.TlONAL SYSTEM OF UNn'S (81 UNITS)
... u....
Q,u.1r!TJ"Y U.rr S71DOl
LeDlth metre m
M.. kilop-am qTime seeead I
Electric CUITeDl ampere A
Thermodynamic kelvin K.te.mpet'At "",e
LuminoUi intensity candela cd
AmouDt orlubstance molt' mol
Sapple.elltU7 U.lt.
Q,cAltnTY UJflT ';rlfBol
PlaaeaDIJe radian rad
Solid ADlle .reradian It
Denv•• DaI.e
QuAlftTrY UNIT SYMBOL o ZWINIT ｾ 0 M
Force newton N IN I kg.nl/. I
Eoergy joule J I J I N.m
PoweT wan W IW 1 J/'Flus weber Wh 1 Wb 1 V.I
Flus deaahy leala 'r IT I Wb/m'FrequeDcy hertz Hz 1 Hz 1 ell (I_I)
Electric coDductaDce sierneru S I S =t t AIVElectromotive force volt V IV 1 WJAPre-asure. Itre. pa..4Ical Pa I Pa - 1 N/m l
INDIAN STANDARDS INSTITUTION
2 03 112 16 41
e 27 l'5 36 2728320
22 10 83
e 18 SI8 12 72
I 28 0132 27
BOMBAY 400007
CALCUTTA 700072
MADRAS 800020
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