A

TRAINING REPORT

ON

Greaves Cotton Limited

Volvo Trucks

Volvo Construction Equipment

Metso

Wirtgen group

SUBMITTED TO SUBMITTED BY

Head Office PUTHA NANDA KISHORE REDDY

Kalinga Commercial Corporation Limited Graduate Engineer Trainee, KCCL

Bhubaneswar (B.Tech Mechanical Engineering)

 ACKNOWLEDGEMENT

I would like to thank all those people who contributed for the completion of my training, Which
was an enjoyable experience for me.

First of all, I would like to express my deepest sense of gratitude to Mr. S.R. Samal founder of
Kalinga Commercial Corporation Limited for his patient, support, encouragement throughout
my training time.

I would also like to extend my thanks to Mr. James Joshep, DP KCCL. for providing me
required data and continuously guiding me throughout this training.

PUTHA NANDA KISHORE REDDY

GET KCCL
 GREAVES COTTON LTD

Greaves Cotton Limited is a diversified engineering

company that is a leading manufacturer of diesel engines,
petrol engines, generator sets, pump sets and construction
equipment. They find their product applications in ACs in
Railways, brick kiln mixing, concrete road cutting, marine
engines, Light agriculture, construction, Genset, Reaper-
binder, mini-tractors, sprinklers, concrete mixer, light tower, compactors and fire fighting
pumpset engines.

BUSINESS :

Greaves Engines:

Automotive Engines : Diesel Engines (Single/Multi cylinder), CNG/LPG Engines, Petrol

Engines with variable HP and maximum torque.
Non-Automotive Small Engines : Agriculture, construction and marine industry with variable
HP.
Industrial Engines: 30-700 HP V type or Inline configuration engines with applications in
pumps, agriculture, construction, marine, railways and defence.

Greaves lightweight diesel/gasoline engines are highly fuel efficient and come with very low
cost of ownership. These engines meet the compliance norms which are ideal for automotive
engine applications such as 3 wheeler and small 4 wheeler commercial vehicles. In addition to
this, there is a reliable range of bigger engines catering to the usage of wider industrial
applications.

Greaves Power:

Portable Gensets : Greaves has a range of portable generator sets for power requirements in
residential and commercial complexes. They are compact, reliable gensets which can be moved
easily from one place to another.
Industrial Gensets : These generator sets include 24x7 backup service and spares facility to
support industries running for long hours, hospitals etc.
Lighting Tower : They provide brightness range of 100W-1000 W and find application in
industries like manufacturing, infrastructure, construction, railway, defence, retail and
government.
Greaves manufactures a wide range of generator sets in the range of 2.5 kVA to 500 kVA. These
products are manufactured at the Greaves Plant in Chakan, an ISO 9001-2000 certified facility,
powering critical installations and multifarious applications benefiting everyday life.
Greaves Agriculture:

Pumpsets (petrol-kerosene pumpsets/ electric pumpsets), power tillers, light agriculture

equipment (rice transplanter, power weeder, brush cutter, sprayer, rotavator, reaper, harvestor
etc) and irrigation solutions (drip/sprinkler irrigation)
Greaves manufactures a wide range of pumpsets, power tillers and light agri equipment that are
powerful, reliable and fuel efficient. These products are made-in-India and require low
maintenance. Now, mechanised farming has become simpler using Greaves light agri equipment
which includes the brush cutter, the reaper, the weeder, the sprayer and the mini power tiller.
Thus, right from land preparation to harvesting, we enhance productivity at every stage of the
crop cycle with mechanised equipment to help farmers.

Greaves Spare:

Engine parts, electrical parts, lubricants, filters, AMSOIL oil.

Greaves cotton employs PFMEA (Potential Failure mode engine analysis) and TPM (Total
productive maintenance) as their principles in manufacturing of diesel engines or gensets. They
use CNC controlled machines, cellular manufacturing methods, LEAN principles to reduce the
manufacturing lead time by removing non value addition parts.
Greaves manufactures a wide range of trusted, genuine and affordable spares which are available
across the country. It supports the proposition of care in the after-market domain for all product
lines. Greaves also provides guaranteed assurance to all customers to go anywhere, do anything
and still completely rely on it. Our Greaves auto part store is a one stop shop for all your spare
part needs across various brands.

Greaves cotton makes an engine of different series as G series and D series. Company take parts
from different vendors and assemble them to make a successful engine, it takes 5C components
as

connecting rod, camshaft, cylinder block

crankshaft, cylinder head.

Engine is undergone to cold and hot testing, and is tested under

different parameters, as in cold testing engine is driven by the
electric motor to check the leakages while in hot testing engine
parameters like rpm, load graphs, brake horse power are tested

GENERATOR SETS:

An engine generator is a combination of an electrical generator and an engine (prime mover)

mounted together to form single equipment. In addition to the engine and generator gensets
include a fuel supply, a constant engine speed regulator, cooling and exhaust systems and
lubrication systems.

It has two methods of starting:

 STAR-DELTA
 DIRECT ONLINE

It consists of engine, alternator, radiator, pre-cleaner and an air cleaning unit. Industrial gensets
are divided into smart series (10-45 KVA), genius series (50-250 KVA), dynamic series (250-
500 KVA) and mega series (above 500 KVA).

Model: GPWII-500
No of phases: 3
Voltage range: 415V
Power factor: 0.8
Current (@0.8 PF): 695.6 ampere
During training we were taught about engine components such as –camshaft, push-rod, rocker-
arm, spring controlled valves, piston, piston rings, cylinder liner, connecting rod, crankcase,
crankshaft, flywheel, crank and gudgeon pins, cylinder gasket, cylinder head and cylinder block.
Timing and gear arrangement and electronic governor control the rate of fuel injection and firing
order is fixed (for eg. it’s 1-5-3-6-2-4 for six cylinder engine) for engine balancing.

Engine functioning is divided into-

 Lubrication system
 Air Intake/Exhaust system
 Fuel System
 Cooling system

Common problems of engine include knocking, fuel oil mixing, misfiring, coolant in oil, smoke
color (blue, black, white), water in exhaust, overheating, vibration, excessive noise, starting
problem, filter choking etc

We were also told about APFC (Automatic Power Factor Controllers) and DG synchronization.
Quality testing inside the assembly unit for process inspection:

 Machine shop: Process audit, product audit and SPC technique.

 Millipox testing: testing of critical components for internal circuit or critical passage of
fuel and oil gallery.
 Engine assembly: assembly data lodging & traceability system through digital signage
system.
 VOLVO GROUP

Volvo is a Swedish multinational manufacturing company headquartered in Gothenburg.

Products include trucks, buses, construction equipment, marine and industrial engines, financial
services etc. Subsidiaries are Volvo Trucks, Mack Trucks, Terex Trucks, Renault Trucks, UD
Trucks, Volvo Construction, Volvo Buses and Volvo Penta. “Volvo” is a Latin word which
means I Roll. Volvo values include quality, safety and environmental care.

Volvo truck models commonly used at mining sites are-

Volvo FMX: Engine configurations are-

D11K: 320,380,430,460 HP
D13K: 420,460,500,540 HP

The first mining truck to be made was FM400. Most used model these days is FMX 460 8x4
which means it’s engine provides 460 HP and has 8x4 configuration (total 8 wheels with front 4
steerable wheels and rear 2 drive axles). Maximum torque achieved is 2300 Nm and speed range
is from 1400-1900 rpm. Gross vehicle weight (GVW) is 51 tons. ‘X’ stands for extra off-road
features for mining and construction work. They have EHB (Exhaust heated body) for carrying
coal, iron ore and OB. Extra features include rear air suspension, automatic traction control and
tandem axle lift. Cabin type is day cabin. ‘M’ in FMX stands medium height cabin.

As government of India is introducing BS6 norms in year 2020 so more focus is being laid upon
EATS (Exhaust after treatment system) and following methods are being adopted:

 DPF (Diesel Particulate Filter)

 EGR (Exhaust gas recirculation)
 SCR (Selective catalytic reduction)

DPF is a device designed to diesel particulate matter or soot from exhaust gas of a diesel engine.
EGR aims to recirculate a portion of engine’s exhaust gas back to the engine cylinders to allow
significant NOx emission reductions in petrol/diesel engines.
SCR system uses DEF/Adblue solution (35 liter) which releases ammonia after exhaust
temperature reaches 200oC which reacts with NOx in presence of catalyst to form nitogen and
water.

Gearbox configuration: I Shift AT2612D

Max incoming torque: 2600 Nm
Type: Automatic Splitter/range change transmission
Number of forward gears: 12
Number of reverse gears: 4
Gear selector positions: R/N/A/M
Driving programs: Economy/Performance
1’st gear/crawler gear is used for high starting torque and low speed and as we move on to 12’th
gear speed increases and torque reduces.

Volvo trucks are divided into functional groups as-

Engine
Electrical system (TEA- Truck Electronic Architecture)
Power transmission
Brakes
Front axle, steering
Frame, suspension, wheels and hubs
Cab, interior rim
Auxiliary equipment

Various sensors used in lubrication, cooling and fuel systems include-

 Water and fuel sensor

 Oil level and temperature sensor
 Fuel pressure
 Coolant level and temperature sensor
 Boost pressure and temperature sensor
 Camshaft speed sensor
 Vacuum sensor
 Flywheel speed sensor
 Oil pressure sensor
 Crankcase pressure sensor

Sensors used in transmission systems are-

Vehicle speed sensor
Wheel speed sensor
Accelerator pedal position
Folk position sensor
Inclination sensor
Load sensor
Main shaft and countershaft speed sensor
Gearbox temperature sensor
Air pressure sensor
PLCD sensor (checks clutch position)

Dynafleet positioning system for tracking of tippers was also explained through an activity.
ECU’s installed in FMX 460 are-

ACM- After-treatment Control Module

APM- Air Production Modulator
BBM- Body Builder Module
CCIOM- Central Chassis I/O Module
CCM- Climate Control Module
ECM- Engine Control Module
FCIOM- Front Chassis I/O Module
HMIIOM- Human Machine Interface I/O Module
IECU- Instrument cluster
PDM- Passenger Door Module
RCIOM- Rear Chassis I/O Module
TECU- Transmission Electronic Control Unit
TGW- Telematics Gateway
VMCU- Vehicle Master Control Unit

DUMP TRUCK :

Dump trucks play an important role in carrying materials such as ore from the working areas to
the dumping ground. Dump trucks can be electrical, mechanical or hydraulically controlled but
the main prime mover is a diesel engine. Here in Gandhamardhan block B operated by KCCL,
VOLVO tippers are used of various specifications such as FM 440, FMX 460 for dumping the
overburden in the dump yard. For loading of the ore to stockpile BHARATBENZ tippers are
used.

Though in HIM various types of tippers are used, lets discuss about the various components of
FMX 460 tipper manufactured by VOLVO (SWEDEN).

Steering system

Steering system of the mine truck is provided to steering the vehicle in the mines, in all road
condition. In the dump truck the steering system is fully hydraulically powered. The dumper is
steered by the steering cylinder with the help of steering valve. There are three types of steering
activities, steering left, steering right, steering neutral. Ackerman steering gear mechanism is
provided to the dump truck for the steering action.
Braking system

Braking system is provided to the vehicle to be capable

of bringing into a complete halt even under fully
loaded downhill condition. The tipper is equipped with
drum brake system which is connected to the wheels.

The mine truck is provided with three types of brakes

which are capable of applying brakes
whenever necessary. They are

• Service brake

• EPG

• Parking brake

Power transmission system

Engine Clutch Gear box Propeller
shaft

Vestibulum
congue tempus
Wheel hub Rear axel Differential

Frame and body

The job of the frame is to support the power train , the cab and the body.

The chassis frames are made of high-tensile steel.

C channel
Made of high strength steel

Cross section-300mm x 90mm x8mm

Inner reinforcement – 5mm

Vehicle Specification (VOLVO FMX 460) :

ENGINE

1. 6 cylinder inline direct injection system

2. SCR technology with adblue tank

3. Displacement -12.8 ltr

4. Compression ratio – 17.8:1

5. Max power-460hp@1400-1900 rpm

6. Max torque-2300Nm@1000-1400 rpm

7. Emission BS4

8. Max brake power 503hp

Brakes

1. Dual line air brake system

2. Z-cam drum brake with automatic adjustment.

3. Electronic parking brake activation.

STEERING

1. Hydraulic power steering with VD pump.

2. Steering wheel dia. = 500mm

 GEAR BOX

1. I-shift (automated range and spilter)

2. No of gears 12+4

CHASSIS &FRAME

C channel

Made of high strength steel

Cross section-300mm x 90mm x8mm

Inner reinforcement – 5mm

Lubrication system

Components of lubrication system

Valves

 Reducing valve

 Safety valve
  Thermostat valve for oil cooler

 Over flow valve for full flow filter

 Opening valve for piston cooling

 Piston cooling control valve

 Pressure sensor

Lubricants used (Volvo tippers)

Engine

VDS (VOLVO DRAIN SPECIFICATION) 4

Gear Box

Transmission oil- volvo transmission oil 97305,97307,97315

engine oil- API CE/CF

ACEA E2/E3

Rear axel

SAE J 2360, API GL-5

TRANSMISSION OIL – 97312

Front axel

ATF oil , type Dexron iii

Coolant - VCS ( VOLVO COOLANT SPECIFICATION)

ELECTRICALS:

Battery, Alternator, Starter motor, cable harnesses, fuses, relays, switches etc
 VOLVO CONSTRUCTION EQUIPMENT

Volvo Construction Equipment is one of the leading manufacturers of excavators, wheel loaders,
articulated haulers, road development machines (Asphalt Pavers) and compact construction
equipment (Compactors)

HYDRAULIC EXCAVATORS

It is a large digging vehicle designed for excavation and demolition purposes. Its main parts
include boom, bucket, arm, and chassis and move on sprocket chains which transfer motion to
crawlers. Hydraulic motors (variable displacement type), two main pumps and pilot pump
control hydraulics required for boom and arm operation. Main control valve (MCV) and electro-
hydraulic system control flow for need of high productivity and high digging capacity with better
fuel economy.

Configuration: EC300D where 300/10=30 ton designates the operating weight of excavator
which is sum of weight of empty bucket, operator and machine parts with all lubricants filled
upto maximum level.

An excavator is divided into three basic parts:

 Carriage
 Superstructure
 Front Attachment

Carrier rollers and idlers take weight of machine and provide stability during movement to
support track chain movement to reduce effort given by motor/engine.

In middle there is swing motor and gearbox which provides 360o rotation to arm. There is a
central joint where all hoses are connected. A fuel and hydraulic tank is present with AC unit,
intercooler, turbocharger, hydraulic oil cooler, condenser, engine oil cooler and radiator.

Some common configurations are: EC 250D, EC 300D, EC 350D, EC 380D, EC 480D

EC 750D, EC 950E

AIR LINE

Oil Bath-Air Filter-turbocharger-intercooler-intake manifold-exhaust manifold-turbocharger-

muffler.

FUEL LINE

Fuel Tank-water separator-feed pump-main filter-feed pressure sensor-engine ecu-FCU (fuel

control unit) - 2 high pressure piston pump-rail/accumulator.
Hydraulics governing formulae:

Flow = Displacement x RPM

Hydraulic horsepower = Pressure x Discharge

For power balancing: Hydraulic horse power < Engine horse power

The left side pump P1 deals with swing, arm and travel and the right side pump P2 deals with
travel, boom, bucket and arm. Priority function for P1 is arm and for P2 is boom.

Electric power used to drive is 3 phase DC and 2 batteries used are of lead acid type (12 V).
After engine starts alternator activates and battery starts charging. Solenoids, sensors, motors,
switches and relays are provided for electrical work. When hydraulic motor speed is varied
displacement changes.

The whole excavator is divided into General, Engine, Electrical, Power transmission, Brake,
Steering, Frame/Track/Wheel, Cabin/AC and Hydraulics. Main pumps are of piston type variable
displacement and pilot pump is of gear type. The track brakes are multi-disc. Spring-applied and
hydraulic released. The travel motor, brake and planetary gears are well protected within the
track frame

Some of the abbreviations include:

RE- Relay
SE- Sensor
SW- Switch
MO- Motor
AL- Alternator
BA- Battery
LA- Lamp
PWM- Pulse width modulation
SA- Sound audible
MA- magnetic actuator
R- Resistor
C- Capacity
DI- Diode

Mainly three ECU’s with their functions are-

Engine ECU- maintains engine rpm according to operator and acts for the protection of engine in
case of malfunctioning and high engine coolant temperature.
VECU- maintains flow in hydraulics by variable displacement and is responsible for HP
balancing.
IECU- collects and displays information on screen.
ECU’s transfer data through CAN Bus system which has two wires basically named as CAN
Low and CAN High with voltage ranges as (1.5-2.5V) and (2.5-3V). It has terminating resistors
of 120 ohm each connected in parallel producing 60 ohm. During faults of broken wire isolation
test is applied to detect the problem.

WHEEL LOADERS: They are used to load/unload the ore body from tippers or dumpers.
Some of the common configurations are:

L 350H, L 260H, L 220H, L 180H, L 150H, L 120GZ, L120F, L 90GZ

We also experienced driving simulators of excavators and loaders.

A loader is a heavy earth moving machinery used to move aside or load materials into other
machinery. It is a type of tractor, usually wheeled, sometimes on tracks, that has a front-mounted
square wide bucket connected to the end of two booms (arms) to scoop up loose material from
the ground. It is typically used to move asphalt, dirt, feed, logs, raw minerals, rock etc. onto
another type of machinery such as a dumper, conveyor belt, feed-hopper etc.

Most loaders are wheeled and not tracked, although track loaders are common in larger scale
machines. Track loaders are used where sharp edged materials in debris would damage rubber
wheels, or where the ground is soft and muddy. Wheels provide better mobility and speed and do
not damage paved roads as much as tracks, but provide less traction.

Main components of a Wheel Loader are as listed

below.

 Linkage

Linkage is the mechanism which controls the lifting and

movement the bucket and boom. In a wheel loader, two
main types of linkage is found in the market. The Z-bar
linkage is the most traditional and has been around since
the wheel loader was invented.

Named for the Z shape of the tilt cylinder, lever and link
layout, it also has the advantage of simplicity and the least number of pins, links and levers to
maintain and has the disadvantage of less visibility due to size of the linkage. Parallel-lift
linkages offer the best operator visibility. The links are mounted on the lift arms themselves
directly above the lift arms, so the view down the middle of the machine is unobstructed.
Another advantage is as its name suggests, the front attachment will remain parallel as it is raised
in the air on a wheel loader with parallel-lift linkage whereas on a machine with Z-bar linkage,
the attachment will roll or rock back when raised.

Volvo has created its own linkage called Torque Parallel (TP) Linkage. In TP Linkage, Volvo’s
patented lift arm system combines the benefit of parallel and Z-bar linkage, which gives high
breakout torque and parallel action throughout the entire lifting range.

Currently here, Volvo L90F, L120H, L150H, L220H is equipped with TP Linkage.

Whereas Volvo L260H as well as SDLG LG-958L has the Z Bar linkage in the front attachment.
Another special feature of Volvo wheel loader is that it comes with the feature of boom
suspension system which enables the loader to ride smooth and comfortable in rough ground
without transferring the front attachment vibration to the cabin.

 Front Attachment

Front attachment is the part of the wheel loader

which is used to dig and load the loose material to
the dump truck. It consists of various parts as
shown.

A. Bucket
B. Bucket Link
C. Bell Crank
D. Bucket Tilt Cylinder
E. Boom
F. Boom Lift Cylind
Volvo uses both torque parallel linkage and Z bar linkage for higher breakout force in different
loader according to capacity, whereas SDLG loader having only Z bar linkage in the bucket
attachment.

Bucket

In front attachment, bucket is the most important part

which induces high wear and stresses. Thus bucket
selection is the most crucial part in wheel loader. For
rock handling generally two types of bucket is used
namely straight edge and spade nose. Straight edge is
heavy-duty, wear resistant bucket. Optimized for
loading shot rock or easily broken material from the
bank with high breakout capability, it is fitted with welded teeth. Spade nose is best choice for
breaking out hard and stony material and shot rocks. Mainly used for ores, bucket teeth is fitted
with bolt-on edge method.

POWER TRAIN

The Power train of a typical wheel loader

consists mainly of following components:

 Diesel Engine
 Hydraulic Transmission Pumps
 Torque Converter
 Transmission Gearbox
 Drive Shaft (Front and Rear)
 Universal Coupling
 Front and Rear Axle
 Front and Rear Differential
 Wheel End Hub Reduction
 Engine

Wheel loaders generally employ 4 stroke 6 cylinder inline diesel turbocharged engines.

In case of Volvo, L90F uses D6E LAE3 engine, L120F uses D7E engine, L150H and L220H
uses D13F engine and L260H uses D13J engine. In case of SDLG, Deutz BF6M1013FC engine
is used. In earlier engines mechanical governors were used to control fuel consumption.

Nowadays electronic engine governor or EMR is used. The EMR is an engine control system
that obtains information from the engine, from sensors and from the driver, and adjusts the
optimum fueling rate while maintaining emission control norms.

Torque Converter

A torque converter is a form of fluid coupling device

which is used in automatic transmission

It transfers the engines drive to the wheels without any

inter meshing gear arrangement, rather uses a fluid loop
mechanism to transmit power. Unlike fluid coupling
however, it contains an stator between impeller and
turbine. This helps to multiply torque by 2 to 3 times
when needed like starting of engine or heavy load operation.

The impeller receives power from the engine and

rotates the fluid in it. Initially when the speed is low or
stalled condition, the impeller rotates the fluid but the
turbine doesn’t rotate. In this case, the stator redirects the fluid in direction of the stators rotation,
thus multiplying torque. As the impeller and turbine speed reaches 90% to 95% synchronization,
the torque multiplication ceases and it behaves like a fluid coupling. VOLVO is equipped with a
"lockup" mechanism which rigidly binds the engine to the transmission when their speeds are
nearly equal, to avoid slippage and a resulting loss of efficiency.
Transmission Gearbox

Wheel loaders generally employ a synchromesh gearbox to

change speed. Volvo employs a full power shift transmission
system with single lever control. It has 4 forward and 4 reverse
gears. Fast and smooth shifting of gears is achieved by
hydraulics and is done using electronically controlled solenoid
valve with Pulse Width Modulation (PWM). It employs
Automatic Power Shift (APS) with fully automatic shifting
from 1 to 4 and mode selector with 4 different gear shifting
programs.

Drive shaft and universal coupling

The drive shaft transfers the power from the engine and
transmission system to the live axles differential. In wheel loader,
power is to be transmitted to both front and rear axles so two
drive shaft is present for either side. A universal joint is a type of
joint that connects two rods whose axes are inclined to each other
at an angle. Since it results in jerky behavior or vibration due to
the changing angular velocity, they are usually used in pairs making both shafts parallel to each
other.

Differential

Differential is a device which transfers the power from the drive

shaft to the wheels perpendicular to the shaft while allowing them
to follow paths of different length.

Wheel loader is all wheel drive machine, it is having two

differentials which drive the wheel of the equipment.

Differential has 3 main jobs:

To aim the engine power at the wheels.

To act as another level of gear reduction in the vehicle.

To transmit the power to the wheels while allowing them to rotate at different speeds.

Components of differential system are pinion gear, ring gear, side gear, spider gear, right axle
shaft, left axle shaft and the differential casing.

On a straight road, the differential imparts equal power to both wheels. But when taking a turn, it
shifts a part of the power from the inner wheel to the outer wheel, resulting in decreased speed in
inner wheel and increased speed in outer wheel.

In case of slippery surface, the differential is locked so as it imparts equal power on both side.
Since the speed of the wheels remain same, unequal torque is applied on each wheel which helps
circumvent jam.

Volvo wheel loader has a differential lock in the front wheel.

Wheel end hub reduction

At the end of power train, the final torque multiplication is done at the wheels using a device
called hub reduction. It consists of

Final Drive (crown wheel and pinion)

Axle Shaft

Axle Hub

This is normally achieved by a pinion and crown wheel gear set.

Depending on the number of teeth on the pinion and the crown wheel, revolutions can be
typically reduced from 3 to 7 times.
Hydraulic Power Train

Hydraulic Pump

In Volvo wheel loaders, the entire hydraulic system is

driven by three axial piston pumps namely Pump 1,
Pump 2 and Pump 3.

These pumps are variable displacement swash plate

type axial piston pumps which receives power from
the diesel engine.

It consists of 7 or 9 pistons in cylinders arranged parallel to each other and rotating around a
central shaft. A swashplate at one end is connected in a particular angle to the pistons. By
changing the swash plate angle, flow can be controlled. The three pumps each control a certain
aspect of the hydraulic system and is connected to main control valve.
Load Sensing System

 A conventional hydraulic system with a fixed-displacement pump provides a constant

flow through the system.

 When the system develops the set pressure, the pump flow is bypassed through the
associated pressure relief valve.

 As a consequence, the system generates tremendous amount of heat. Even when a

variable displacement pump is employed, the system produces considerable heat.

 The hydraulic system with a load sensing feature provides only the flow and the pressure
as required by the connected load.

 Controlling both the pressure and the flow allows for a significant reduction in losses,
improvement of circuit efficiencies, and enhancement of the service life of the system
 The load sensing system for the control of a hydraulic actuator consists of a variable-
displacement pump, a compensator block, and a load-sensing closed center directional control
valve.
 The 20 bar spring of the compensator forces the pressure-flow compensator spool
towards the left when there is no pressure in the system.
 This normal position of the spool provides for the fluid a direct passage from the cam
plate control piston to flow to the reservoir.
 As there is no fluid pressure acting on the control piston of the pump, the cam plate of the
pump is forced to move to its maximum angle position thus providing maximum flow.

Steering System

For steering, a typical wheel loader contains an articulated hydraulic steering system.

A vehicle with articulated steering is split into front and rear halves which are connected by a
vertical hinge in between.

The front and rear halves are connected with two hydraulic cylinders on each side that change
the angle between the halves, including the front and rear axles and wheels, thus steering the
vehicle.
Volvo wheel loaders are equipped with load-sensing hydrostatic articulated steering system
controlled by two double acting hydraulic cylinders allowing a steerability of ±37°.

Volvo also includes a secondary steering system using an electric pump if necessary, like in case
the engine stopped working.

Brake System

In any typical wheel loader, two main types of brakes are used. They are Service Brake and
Parking Brake.

Service brake is used when the operator wishes to slow

down or stop the machine.

On the other hand, parking brake is applied when as

the name suggests, parking the vehicle. It is usually
applied after the vehicle has been brought to still.

It is also called emergency brake as it is also used in

case service brakes are not working effectively.

Volvo wheel loaders also provides two alternate modes of braking namely auxiliary brakes and
reverse by braking.

The auxiliary brake (engine brake) is used in assistance to service brake which increases engine’s
resistance through increased load in fan pump.

Reverse by Braking (RBB) is used when changing direction to brake using the wheel brake and
then opposite direction gear is engaged.

Both service and parking brake utilizes single or multi disc brake to stop the machine.

In a disc brake, when the operator engages the brakes, the hydraulic system pushes the piston
outward, pushing the brake pads against the disc.

As more pressure is exerted, the caliper presses the pads towards the disc on both sides together.
This results in high friction against the disc and the brake liner on the brake pad, thus slowing
down the machine to a halt.

This generates a lot of heat, which is why the discs are often immersed in oil, called wet disc
brakes.

Volvo uses dual circuit hydraulic wet disc brakes in service brakes and electro-hydraulically
operated, spring applied dry disc brake in parking brake.

Electrical System

The electrical system comprises of all devices and sensors operated by electricity.

This includes engine starter motor, different headlights, ECUs, wipers, rear/front cameras,
solenoid valves, instrument panel, display unit, regeneration, horn etc.

Volvo wheel loaders have 24V DC requirement which is supplied by two 12V batteries of 170
Ah capacity each in series.

When the vehicle is in operation, the battery is charged using an alternator driven by the engine.
 METSO

Metso is an industrial company forming product finding applications in mining, recycling,

aggregates and process industries. With unique solutions it helps in customers to improve their
functional efficiency, reduce hazards and increase economy.

Products under mining include: Jaw crusher, cone crusher, vibrating screens, grizzly feeder,
apron feeder, dewatering equipment’s

Products under aggregates include: wear/spare parts, crushers, feeders, conveyors, portable
plants, stationary plants.

Products under valves include: Control valves, butterfly valves, actuators, emergency shutdown
valves, on-off controllers.

Products under slurry pumping include: horizontal/vertical slurry pumps, slurry hose and pipe
systems.

Working principles of common equipment’s:

Jaw Crusher: It is a heavy duty machine commonly used to break large boulders into smaller
pieces. It consists of moving and fixed plates, eccentric shaft, bearing, toggle, pitman, flywheel
and motor. One of the jaw is fixed while other reciprocates by a cam or pitman mechanism as the
eccentric shaft is rotated by the flywheel driven through motor. The cavity between two jaws is
called crushing chamber. The jaws are constructed of cast steel and are fitted with replaceable
liners which are made of manganese steel, or Ni-Cr alloy
Cone crusher: It is a compression type
machine which reduces rock size into smaller
pieces by squeezing or compressing the feed
material between moving piece of steel
(mantle) and stationary cone shape outer
body. It consists of feed bowl hopper, mantle,
main shaft, counter shaft, eccentric shaft, gear
and pinion and hydraulic motor. Final size of
ore or reduction is controlled by the closed
side setting (CSS) or the gap between
crushing parts at lowest point

Double/Triple Deck Scalping

Screen: They are used to separate
granulated ore material into multiple
grades by particle size using different
size wire mesh made of synthetic
media like rubber or polyurethane. It
consists of cardan shaft, frame,
springs, screen, V belt pulley and
motor.

Vibro Feeder: They use strong linear

motion to forward the material from hopper
to jaw/cone crusher or belt conveyors. The
mechanism consists of modular vibrators
(MV) which have eccentric counterweights
to create rotating unbalance and desired
vibration for the wanted stroke.
 Wirtgen Group
It is a group of companies which include brands such as Writgen, Vogele, Hamm, Kleemann and
Benninghoven. It manufactures ore handling equipment’s such as mobile screening plants,
mobile jaw/cone crusher, combined crusher and screening assemblies and mobile impact
crushers. It also laid it’s mark in compaction, paving, mixing, construction of roads and has
given equipment’s like soil/asphalt compactors, concrete pavers etc

MOBISCREEN: Its models are MS702EVO, MS703EVO, MS952EVO and MS953EVO.

Tonnage capacity varies from 350 to 500 tph. Difference between MS952 and MS953 is in the
number of decks that are 2 and 3 respectively.

It’s major parts are 6

cylinder diesel engine
(Deutz), gear pumps,
hydraulic motors,
splitter gearbox
conveyor belts steel
wire mesh screens,
hopper and controlling
panel at the front. It’s
usage comes when we
have to obtain material
of different grain
sizes.

Conveyors are hopper

feeding conveyor, main feeding conveyor, upper/middle/lower deck conveyor and main
discharge conveyor (fines). Angle of inclination is adjustable and varies from 20o to 30o. Screen
area is 9.5 m2.

As screen angle inclination increases aperture size decreases.

Low inclination- high efficiency + low capacity

High inclination- high capacity + low efficiency

Jaw and cone crusher working, designing and its application was discussed.

Jaw crusher as it is direct drive machine, coupled with fluid coupling that drives the flywheel,
metal detecting system as a option comes with the system also called as CLS system most of the
machine in kleemann are electronic, hydraulic used only in some parts like crawling and fixing
arrangement of crusher. There is an unbabalnced motor which drives the pan feeder in the
system.
Cone crusher is a secondary crusher used in line with the jaw crusher. It has also called as
mobicone employed for medium to hard as well as abrasive material. It gives very good cubic
results in the secondary stage, it generally links with primary crushers and screen plant system.

Set the CSS in the crushers, it is generally 1.8 times of the required size.it has a separate display
arrangement to set the css and other parameters of the machine.

Kleemann mobiscreen

Topics covered in screens:

 Overview of the screen

 Principles of screen
 Size calculation
 Problems in screens
 Machine maintenance

Screens are classified as classifier and scalpers, classifiers are the final screens where we get
finer product majorly used in the end of the production line. Whereas in scalper we get the size
of moderate size it generally used to reduce the load to the crusher by bypassing the smaller
product from the crusher. It all depend on the gradation of the material if we want more finer
product the classifier screens are used otherwise we can use the scalper.

Mobiscreen EVO-953 is the mobile screen, and 953 is the dimension of the screen like 15.5m *
6m leads to approximately 9.53m2 area, whereas EVO means evolution it is a type of generation.
EVO are basically a compact machine which are easy to transport.

EVO953 having a hopper, feeding conveyor, main feeding conveyor, feeding screen box, upper
deck conveyor, middle deck transport conveyor, lower deck conveyor, main discharge conveyor,
power pack, also having a option of recirculation conveyor. These are circulatory motion screen.

Screen mesh calculation:

Mesh size/1.2 = Product size

Needed mesh size = biggest grain size * 1.2

If open surface area is about 68% it gives more life and the mesh is also robust whereas in 77%
open surface area it gives shorter mesh life with less reluctance. For open surface area to avoid
blanking s-type mesh is used it is a self-cleaning mesh that add on to the production.

Terms in screen jamming

  Blanking- reduces the surface area
 Blinding-corners of mesh get chocked
 Pegging-clog in the wire mesh

Maintenance of screen consists of various parts.

Topics covered:

 Greasing
 Engine
 Hydraulics
 Transmission
 Capacity and specification

In greasing, plumber block lubricate 1stroke/yr, change of grease in 2000hrs, flange bearing
1stroke/yr, screen box bearing classifying screen lubricate 10g/50hrs.

Engine daily check, 500hrs: check v belt, oil change. For 300hrs change tooth belt.

Hydraulics: checking of hydraulic oil and filters, checking of popup indicators of return filter,
breathing filter and pressure filter. Hydraulic oil first change in 500hrs then after every 1000hrs.

Transmission and track system: checking of splitting gear box oil level, changing of track oil first
in 500hrs then after every 2000hrs.