Summer Training

Bharat Coking Coal limited

Sinidih Central Excavation workshop
Summer Training

“Overhauling of
Engine and Transmission
of Heavy Earth moving Machineries”

Presented by:-
Ashwini Kumar
2013JE0777
IIT (ISM), Dhanbad
Overhauling
 Overhauling process is the process to repair or
improve something so that every part of it works
as it should.
 Sinidih workshop takes care of big and small
failure in different parts of heavy earth moving
machineries used in BCCL all around.
 The workshop performs both repair and
maintenance of engines and transmission of
Dumpers, Loaders, Dozers, etc.
Steps involved in Overhauling process

 The overhauling process in the shop is done in

five steps:-
a. Dismantling of the engine/transmission
b. Cleaning of the components
c. Repairing or Replacement of defective
components
d. Assembling of components
e. Trial run
Engine Models
 NT/NTA-495
 NT/NTA-855
 KT/KTA-1150
 KT 2300
 SG D170
 CAT 3406
Engine main components
 Engine block
 Cylinder liner
 Camshaft
 Crankshaft
 Piston, Connecting rod
 Engine head
 Rocker assembly
 Inlet and Exhaust manifold
 Turbocharger
 Oil pump
 Radiator
 Flywheel
Transmission Model
 CLBT-754
 CLT-74
 D15TR
 D355
 HD-78-2
 D15 TC
Transmission main components
 Torque convertor
 Planetary gear set
 Hydraulic system
 Clutch packs
 Band
 Seals and gaskets
Dismantling of Engine and Transmission

 A particular sequence is followed while

dismantling.
 In engine, firstly the coupling is disconnected,
followed by removal of outer components like self
starter, manifolds, radiator, belts, flywheel, etc to
the removal of inner components like rocker,
valves, piston, crankshaft, camshaft, etc.
 In transmission, firstly torque converter is removed
followed by planetary gear set, hydraulic system,
etc.
Cleaning of components
 In engine, firstly radiator water lines are throughly
flushed with pressurised water. Turbocharger unit
is cleaned using compressed air. Most of other
components are cleaned using diesel oil to
remove carbon, grease and other foreign
materials.
 The components of transmission is mainly cleaned
using compressed air.
Repairing or replacement of the
defective components
 After cleaning, the conditions of the components
are inspected, so as to either repair if possible or
to replace it with a new one.
 The piston rings, spring and filter elements of
engine are generally replaced.
 All the Gaskets and seal rings are generally
replaced with a new one.
Gaskets
Assembling of components
 For the assembling of components, different types
of tools used are torque wrenches, filler gauges,
spanner set, micrometer and inside dial
micrometer.
 After assembly, filling of diesel fuel, lubricating oil
and water is done.
 As soon as the engine starts, the engine is
inspected by checking the sound, vibration and
leakage of water, lubrication oil or fuel if any.
Trial run
 The engine is run at different load for 2-3 hours,
the temperature is measured using thermocouple
and the pressure is measured using pressure
gauge to check value to be less than the
maximum value.
 If found to be function properly, the engine is
certified fit for operation.
Trial run (Engine)
Load Run Time Max. Water Max. Oil Oil Pressure
(in hour) Temp. (°C) Temp. (°C) max. (kg/cm2)
No Load 2-3 85 90 4.0
25% 3-4 85 90 5.0
50% 3-4 85 90 5.0
75% 3-4 85 90 5.5
Full Load 3-4 85 90 6.0

Trial run (transmission)

Max. Temp Max. Temp. Pressure Pressure Pressure
@ Neutral @ Load @ Forward @Reverse @Neutral
(°C) (°C) (kg/cm2) (kg/cm2) (kg/cm2)
70 80 1-5 18-20 12-17
Engine Testing
Transmission Testing
General maintenance schemes
 Daily maintenance
 250 hour maintenance
 1500 hour maintenance
 4500 hour maintenance