Course Objectives

• To assist an applicant to acquire the knowledge, understanding, and specific skill necessary to obtain over HEMM Heavy machinery like excavator, wheel loader, backhoe loader, soil compactor, grader and bulldozer, etc.
• To give more emphasis on safety during attending the machine or work in a workshop in  Industrial core value Safety, quality, and environmental care.
• Mainly explore the practical consequences of the Diesel engine system, Hydraulic system, Electrical and electronic system, Use of special tools, Pre-delivery Inspection.
• Foundation with a conceptual understanding of the engine (4 & 6 cylinders) along with precision measurement of all internal components.

Learning Outcomes

• Performance and procedure to be meet with industrial standard specification (Satisfactory).
• Complete overhaul the engine (Inline 6 – cylinder with turbocharger and intercooler 4-stroke diesel engine as well 3 & 4 cylinder engine). Components replacement with 1^st, 2^nd and 3^rd oversize.
• Easy way to interpret the ISO symbols and schematic circuit diagram of hydraulic & electrical systems.
• Fault finding procedure and process (troubleshooting) as well as repair.
• Able to understand interval mandatory service maintenance of the machine.

Course Syllabus

Module 1 Safety

Personal safety, Machine or Component safety, and environmental safety.

Module 2

Overview and introduction of the heavy earthmoving machine, Application with the different attachment, Purpose, maintain with running condition and high productivity, machine model category, and identification of all systems and components.

MODULE 3  Diesel engine system.

Introduction, Fundamental of a diesel engine, Overview construction of diesel engine System of the Diesel engine, Engine electrical system

Practice: - Demonstration and identification of all attachment components.

Practice: - Complete dismantle and assemble the engine with procedure by following the respective service manual.

Practice: - Use of engine special tools.

Practice: - Precision measurement of all components.

Practice: - Engine electrical fault finding.

Measure engine components.

Piston, Crankshaft, connecting rod, gudgen pin, camshaft, rocker arm, pushrod, valve guide, block deck test, engine cylinder, oil clearance between main journal bearing and crank throw shaft, valve adjustment, crankshaft endplay, etc.

MODULE 4: Hydraulic system.

Introduction, Fluid power physics, ISO symbols (International standardization for organization).

Major system or components identification

Practice: - Inspection of the hydraulic system.

Practice: - dismantle and assemble the hydraulic cylinder (Seal kit replacement).

Practice: - System pressure checking.

Practice: - Use of hydraulic special tools.

Practice: - Operation method.

Project -Phase 2 (3HRS).

Replacement of the hydraulic cylinder seal kit.

MODULE 5: Electrical and electronic system.

Introduction,basics of automobile electrical component,ISO symbols (International standardization for organization),Lighting system (Interior & Exterior).

Practice- identification of electrical components (Fuse, relay, Battery, Relay, Fuse, Diode, Resister, Capacitor, Switch, Transistor, Solenoid, Harness connector, Sensors.

Practice: - Troubleshooting in the starting and charging system.

Practice: - Use of multimeter, Thermometer.

Practice: - Diagnose the lighting system (interior & Exterior).

Project -Phase 3 (3HRS).

Diagnose battery to starter motor supply

MODULE 6: Machine undercarriage system.

Introduction, Chassiss configuration,Track chain assembly.

Practice: - Dismantle and assemble the track chain assembly.

Practice: - Measurement of Track shoe, pin and link of the track chain.

MODULE 7: Drive train system.

Introduction.

Basics of gear configuration.

Types of gear.

Drive train assembly.

Practice: - Identification of different types of gears.

Practice: - Speed and torque distribution of the gear assembly (Epicyclic gear train).

Practice: - Track motor and hub reduction gear assembly.

MODULE 8: Use of Special tools.

Introduction.

Practice:- Vernier caliper, Outer/inner micrometer, Dial indicator gauge, Bore gauge, Filler gauge, Radius gauge, Pressure gauge, Straight edge, Torque wrench, Ring compressor, magnetic Protector, Flow meter, Digital Tachometer, Digital thermometer.

MODULE 9: Pre-delivery inspection.

Practice: - Inspection of the new machine before delivery to the customer.

Practice: - Preparation of service report.

Project -Phase 4 (3HRS).

Fully inspection of the machine and prepare service report along with model, serial no, HMR, and condition of the machine.

References :

Session Plan

Session 1

LECTURE (3 hrs)

Personal safety, Machine or Component safety and environmental safety.

WEBLINKS:

https://www.youtube.com/watch?v=7tdfizoornI

Session 2

LECTURE (3 hrs)

Overview and introduction of the heavy earthmoving machine.

Application with the different attachment, Purpose, maintain with running condition and high productivity, machine model category and identification of all system and components.

WEBLINKS:

https://www.youtube.com/watch?v=1fzYeJaQ5MA

Session 3

LECTURE (3 hrs) Diesel engine system.

Introduction, Fundamental of diesel engine, Overview construction of diesel engine, System of Diesel engine, Engine electrical system.

WEBLINKS:

https://www.youtube.com/watch?v=fTAUq6G9apg

Session 4,5,6

Practice cum project :

Project -Phase 1  Student submit a report and presentation

Practice: - Demonstration and identification of all attachment components.

Practice: - Complete dismantle and assemble the engine with the procedure by following the respective service manual.

Practice: - Use of engine special tools.

Practice: - Precision measurement of all components.

Practice: - Engine electrical fault finding.

LECTURE: Measure engine components.

Piston, Crankshaft, connecting rod, gudgen pin, camshaft, rocker arm, pushrod, valve guide, block deck test, engine cylinder, oil clearance between main journal bearing and crank throw shaft, valve adjustment, crankshaft endplay etc.

WEBLINKS:

https://www.youtube.com/watch?v=zPDDI3OomQg

https://www.youtube.com/watch?v=lR6ku_g_eNI

Session 7

Practice:

Demonstration and identification of all attachment components.

Session 8

Practice:

Use of engine special tools.

Precision measurement of all components.

Session 9,10

Practice:

Engine electrical fault finding.

LECTURE: Measure engine components.

Piston, Crankshaft, connecting rod, gudgen pin, camshaft, rocker arm, push rod, valve guide, block deck test, engine cylinder, oil clearance between main journal bearing and crank throw shaft, valve adjustment, crankshaft endplay etc.

Session 11

LECTURE: Hydraulic system.

Introduction.Fluid power physics.ISO symbols (International standardization for organization).Major system or components identification.

Session 13

Practice:

Inspection of the hydraulic system.

Dismantle and assemble the hydraulic cylinder (Seal kit replacement).

Session 14

Practice:

System pressure checking

Session 15,16

Practice:

Use of hydraulic special tools.

Operation method

Session 17,18

Project - (3HRS).

Replacement of the hydraulic cylinder seal kit.

Session 19

LECTURE:  Electrical and electronic system.

Introduction, Basics of automobile electrical component,ISO symbols,Lighting system (Interior & Exterior).

Session 20

Practice:

Identification of electrical components  Fuse, relay, Battery, Relay, Fuse, Diode, Resistor, Capacitor, Switch, Transistor, Solenoid, Harness connector, Sensors etc.

Session 21

Practice:

Troubleshooting in the starting and charging system.

Session 22

Practice:

Use of multimeter, Thermometer

Session 23

Practice:

Diagnose the lighting system (interior & Exterior

Session 24

Project -Phase 3

Diagnose battery to starter motor supply.

Session 25

LECTURE: Machine undercarriage system

Introduction.Chassiss configuration.Track chain assembly

Session 26

Practice:

Dismantle and assemble the track chain assembly

Session 27

Lecture: Drive train system

Introduction, Basics of gear configuration, Types of gear,

Session 28

Practice:

Measurement of Track shoe, pin, and link of the track chain.

Identification of different types of gears.

Session 29

Practice:

Speed and torque distribution of the gear assembly (Epicyclic gear train)

Track motor and hub reduction gear assembly

Case Studies

Case Studies