Analysis & improvement in the methodologies

for maintenance of heavy equipment

Monthly Report
Jan-2015

Submitted by

Avinay Sharma
(Reg. No. 110109044)

Under the Supervision of -

Mr. Shashank Bajpai

(Mechanical Engineer)

Department of Mechanical Engineering

MANIPAL UNIVERSITY JAIPUR
JAIPUR, RAJASTHAN-303007

January 2015 - In progress

Activity: Company overview & basic understanding of servicing
Description: How the company is segmented; how heavy equipment are serviced.
Table of contents:
1.
2.
3.
4.

Description
Introduction & basics of maintenance records
Plant Layout & Segmentation of Amrapali Infrastructure, Golf Homes Site
Tools Required
Conclusions

Page No.

1. Introduction
Heavy equipment refers to heavy-duty vehicles, specially designed for executing construction tasks,
most frequently ones involving earthwork operations. They are also known as, heavy machines, heavy
trucks, construction equipment, engineering equipment, heavy vehicles, or heavy hydraulics. They
usually comprise five equipment systems: implement, traction, structure, power train, control and
information. Heavy equipment functions through the mechanical advantage of a simple machine, the
ratio between input force applied and force exerted is multiplied. Currently most equipment use
hydraulic drives as a primary source of motion.
For a construction company like Amrapali, it would be highly inconvenient to take heavy equipment to
a company authorized repair shop, so maintenance team make repairs on a company site, which is
located centrally to all the ongoing projects of the company. These are heart and soul of construction,
agriculture, mining, cement and steel industry. Their maintenance involves an understanding of all the
systems found on large trucks, bulldozers, cranes, etc. Systems usually includes - hydraulics, large
engines and many connected parts and thus require specialized maintenance and repair techniques.
Objectives of maintenance system:
* To keep the vehicle available for protective work for maximum period.
* To extract optimum life for the vehicle.
* To get maximum utilization of vehicle at minimum cost.
Types of maintenance systems:

Planned Preventive Maintenance (PPM): Also known as Planned Maintenance (PM) or

Scheduled Maintenance is any variety of scheduled maintenance to an equipment. Specifically,
Planned Maintenance is a scheduled service visit carried out to ensure that an item of
equipment is operating correctly and to therefore avoid any unscheduled breakdown and
downtime.

Corrective Maintenance (CM): The most commonly used approach, but it is easy to see its
limitations. When equipment fails, it often leads to downtime in production. Work is to
identify, isolate, and rectify a fault so that the failed equipment, machine, or system can be
restored to an operational condition within the tolerances or limits established for in-service
operations.

Condition-based Maintenance (CBM): It is maintenance when need arises. This maintenance is

performed after one or more indicators show that equipment is going to fail or that equipment
performance is deteriorating. This concept is applicable to mission critical systems that
incorporate active redundancy and fault reporting. It is also applicable to non-mission critical
systems that lack redundancy and fault reporting. Condition-based maintenance was introduced
to try to maintain the correct equipment at the right time. CBM is based on using real-time data
to prioritize and optimize maintenance resources.

Periodic Maintenance Check Sheet (Sample):

Dealer:
Ro No:
Place:
Mileage:
Kms:
Date of Sale:
SERVICE TYPE
Mileage(Kms) 10000 30000 50000 70000 90000
Service type
Mileage(Kms) 170000 190000 210000 230000 250000
Service type
Mileage(Kms) 330000 350000 370000 390000 410000
Service type
Mileage(Kms) 490000 510000 530000 550000 570000
Service type
S. No CHECK ITEM
CHECK
1
BASIC ENGINE COMPONENETS
Engine Oil
R
Engine oil filter
R
2
IGNITION SYSTEM
Battery
T
3
FUEL AND EMISSION CONTROL
Pre-filter
R
Water sediment filter
CA
C
Air cleaner filter
4

CHASSIS AND BODY

Brake pedal, Parking brake
Brake pads and discs
Brake linings and Brake drums
Brake line pipes and hoses
Brake fluid
Clutch
Power steering fluid
Ball Joints and dust covers
Tyres and inflation pressures
Lights, horns, wipers
Steering wheel linkage and gear box oil
Front and rear suspension
Tightening of bolts and nuts

Ro Date:
Engine No.
Fraame No:
110000 130000 150000
270000 290000 310000
430000 450000 470000
590000 610000 630000
STATUS

CA
CA
CA
CR
R
CA
CR
CR
CA
CA
CA
CA
T

5
AC / Cooler Refrigerant
NA
C-Clean; R-Replace; CA-Check& Adjust; CR-Check & Replace; T-Tighten
ADDITIONAL JOB:
MILEAGE
1.50,000
4,50,000
TIMING BELT
Replace
Replace
Name of the Inspector
Signature

REMARKS

The periodic maintenance check sheet is used to record the inspection status made during the
maintenance check operation. It contains various details such as the dealer name, place, date of sale,
manufacturers name, mileage, frame number, chassis number etc. the mileage and service type are
indicated in the various cells of the check sheet. The check sheet also contains the check item name,
status and remarks.

In month of January I was given an overview on Amrapali Infrastructure (Golf Homes Site). This
month includes a brief introduction to working of the organization, various manufacturing processes,
etc. Some of the main tasks included:
Plant visit and understanding of each segment of the site
Preparation of required tool list by going to every technical department of the company.
Find out the various mechanical systems, applicable in heavy equipment.

2. Plant location & layout

1. Staff quarters
2. Concrete pump repairing shop
3. Paint shop
4. Engine room
5. Shop for minor breakdown treatment
6. Shop for major breakdown treatment
7. Service shop
8. Welding & Body shop
9. Workshop staff rooms
10. Electrical shop
11. Pantry
12. Toilet
13. Staff quarters

3. Tools required
WRENCHES
1 1/2 Drive socket set:
- Sockets, 3/8 to 1-1/14, 6 point, shallow well
- Sockets, 7/16 to 1-1/8, 6 point, deep well
- Sockets, 10mm to 32 mm, 6 point, shallow well
- Ratchet

14. Mess
15. Engineers room
16. HR office
17. RMC office
18. Spare parts store
19. Repairing store
20. Lubricants & oil store
21. Concrete pump store
22. Puncture shop
23. RMC Plant
24. Bar bending & cutting shop
25. DG room
26. Scaffolding yard

- Breaker Bar
- Drive Extensions: 1-1/2, 3, 5, 10, and 15
- Drive Adapter: 1/2 to 3/8
- 250 lb. Torque Wrench, Micrometer adjust
- Impact Wrench, 3/4 or 1/2, Pneumatic or Battery
- Universal Joint
1 3/8 Drive socket set:
- Sockets, 1/4" to 15/16, 6 point, shallow well
- Sockets, 6mm to 19mm, 6 point shallow well
- Universal Sockets, 3/8 to 3/4", 6 point shallow well
- Sockets, T30 to T55, Drivers
- Spark plug Sockets, 5/8 and 13/16
- Ratchet
- Breaker bar
- Drive extensions: 1-1/2, 3, 6,10
- Universal Joint
1 1/4 Drive socket set:
- Sockets, 3/16 to 9/16, 6 point, shallow well
- Sockets, 3/16 to 9/16, 6 point, deep well
- Sockets, 5.5mm to 14mm, 6 point, shallow well
- Sockets, 5.5mm to 14mm, 6 point, deep well
- Sockets, T8 to T27, Drivers
- Ratchet
- Drive extensions: 2, 4, 6
- Universal Joint
1 Combination End set:
- 1/4" to 1-1/4, Long
- 6mm to 24mm, Long
1 Flare Nut set:
- 1/4" to 13/16
- 9mm to 21mm
1 Ratcheting Box End:
- 1/4 x 3/8 and 3/16 x 5/16, Square, Air Conditioning
1 8 Adjustable Wrench
1 14 Pipe Wrench
1 Hex Key set:
- 5/64 to 3/8, Long Arm
-1.5mm to 13mm, Long Arm
SCREWDRIVERS
1 Flat Tip Screwdriver set:
- 1/4" x 1-1/2
- 3/16 x 3
- 1/4" x 4

1 Phillips Screwdrivers set:

- #1 x 3
- #2 x 1-1/2
- #2 x 4
PLIERS
1 Needle Nose Pliers, 8
1 Diagonal Cutting Pliers, 8
1 Multi-purpose, Tongue & Groove pliers (Channel-Lock style), 10
1 Slip Joint pliers, 10
1 Vise Grip Pliers, 10 curved jaw
1 Internal/External Snap Ring Pliers set:
- .038 x 6
- .047 x 6
HAMMERS, CHISELS, & PUNCHES
1 Ball Peen Hammers:
- 16 oz.
- 48 oz.
1 Dead Blow Hammer, 42 oz.
1 Punch and Chisel Holder
1 Center Punch, 1/4"
1 Brass Punch, 1/2 x 10
1 Pin Punch set:
- 1/8 x 5
- 3/16 x 5
1 Cold Chisel:
- 5/16 x 5
- 3/8 x 5
BRAKE TOOLS
1 HD Air Brake Adjusting Tool
1 HD Brake Spring Pliers
MEASUREMENT
1 25 Steel Tape Measure
1 Feeler Gauges, all purpose, Go-No-Go blades
1 6 Steel Ruler
1 Tire Gauge, 120psi
1 Anti-Freeze Tester
1 6 Dial Caliper

TEST & ELECTRICAL

1 Digital Volt/Ohm Meter
1 Battery Service Kit:
- Battery Pliers
- Battery Clamp puller
- Terminal Cleaner
1 Remote Starter Switch
2 Jumper wires (can be made by using 24 of #12 gauge wire & alligator clip ends)
1 Long Probe Test Light
MISCELLANEOUS
3 Male Stems for ARO Quick Couplings
1 Dual Straight-on Air Chuck
1 Air Blow Gun, OSHA Safety Tip
1 File set:
- Flat, with handle, 10
- Round, with handle, 10
- Half-round, with handle, 10
1 Telescoping Inspection Mirror, 2-1/4
1 Rolling Head or Lady Foot Pry Bar, 21
1 Pry Bar Set: 8, 12, 18, & 24
1 Welders Gloves
1 Welders Goggles
1 Welding Chipping Hammer
1 Leather Work Gloves
1 Steel Toed Boots
1 Pair Safety Glasses
1 Cordless Droplight (LED)
TOOL CABINETS
1BaseCabinet,13Drawers,41Wide

4. Conclusions:

Analyzed and understood each segment of the site

Prepared required tool list by going to every technical department of the company.
Found out the various mechanical systems, applicable in heavy equipment.
Gathered the basic concepts of maintenance & records.