A REPORT

ON

HEAVY MACHINERY AND GENERATOR SET

BY

ARUN BHASKAR 2017A4PS0273U MECH

AT

Mohamed Abdulrahman Al-Bahar

Sharjah, U.A.E

A Practice School – I Station of

BITS Pilani, Dubai Campus

Dubai International Academic City (DIAC)
Dubai, U.A.E
(JUNE 2019 - JULY 2019)

I
 A REPORT

ON

HEAVY MACHINERY AND GENERATOR SETS

BY

ARUN BHASKAR 2017A4PS0273U MECH

Prepared in Partial Fulfillment of the

Practice School – I Course

AT

Mohamed Abdulrahman Al-Bahar

Sharjah, U.A.E

A Practice School – I Station of

BITS Pilani, Dubai Campus

Dubai International Academic City (DIAC)
Dubai, U.A.E

(JUNE 2019 - JULY 2019)

II
 BITS Pilani, Dubai Campus

Dubai International Academic City (DIAC)

Dubai, U.A.E

Station: Mohamed Abdulrahman Al-Bahar Location: Sharjah

Duration: 02-Jun-2019 to 31-Jul-2019 Date of Start: 02-Jun-2019
Date of Submission: 31-Jul-2019
Title of the Project: Heavy Machinery and Generator Sets.
Student Name: Arun Bhaskar Student ID: 2017A4PS0273U
Discipline of Student: Mechanical Engineering
Name and Designation of Experts: Mr. Thulasi Krishnan (QHSE Manager)
Name of the Faculty: Dr. B. Gulyani
Key Words: QHSE (Quality Health Safety Environment)
Project Areas: Machinery and Power Generation
Abstract:

In this report the main topic will revolve around heavy machineries and power generating
systems. In heavy machineries, two different machineries will be discussed (Vibratory
Compactor and Wheel Loader). In the later sections of this report, Generator sets will be
discussed regarding how the power is generated and what kind of testing is done on it in
order to assure optimal performance.

Signature of the Student Signature of PS Faculty

Date: 31-Jul-2019 Date: 31-Jul-2019

III
 ACKNOWLEDGEMENTS

Firstly, I would like to express my heartfelt gratitude to Prof. R. N. Saha, Director BPDC who has given
us an opportunity to apply and understand our engineering concepts in a practical atmosphere.

I am grateful to Mr. Thulasi Krishnan – QHSE Manager, for assisting me by providing the required
information about the organization.

I would also like to thank Dr. Muralidharan, Associate Dean - Practice School, for giving us this
opportunity to work and apply our knowledge in the technical field and gain firsthand experience.

My sincere gratitude to Dr. B. Gulyani, our PS Faculty, for providing me with all the assistance required
for successful completion of this report

Signature of the Student

Date: 31-Jul-2019

IV
 CONTENTS
Abstract
Acknowledgement
Table of contents
List of Figures
List of tables

Chapter 1: AN OVERVIEW OF Al Bahar

1.1 INTRODUCTION...................................................................................................1
1.2 SERVICE INFORMATIONSYSTEM......................................................................2

Chapter 2: Heavy Machinery and Power generation systems

2.1 HEAVY MACHINERY...........................................................................................3
2.1.1 VIBRATORY COMPACTOR.....................................................................3
2.1.2 WHEEL LOADER …………………………………………………………….7

2.2 GENERATOR SET…………………………………………………………………….9

2.2.1 ENGINE ………………………………………………………………………...9
2.2.2 ALTERNATOR ………………………………………………………………12

Chapter 3: Conclusions...................................................................................14

References

V
LIST OF FIGURES

Figure 1: Vibratory Compactor ………………………………………………………….3

Figure 2: Faulty Coupling Motor ………………………………………………………...3
Figure 3: Wheel Loader ………………………………………………………………….7
Figure 4: Bucket(Implement)………………………………………………………….....7
Figure 5: HMU Steering ………………………………………………………………....8
Figure 6: Generator Set ……………………………………………………………..…..9
Figure 7: Cylinder block and cylinder head ……………………………………….…..9
Figure 8: Piston ring …………………………………………………………………….10
Figure 9: Piston ………………………………………………………………………….10
Figure 10: Camshaft …………………………………………………………………….10
Figure 11: Crankshaft ………………………………………………………………..….10
Figure 12: Rocker arm and lifter rod …………………………………………………...11
Figure 13: Fuel Injection Pump ………………………………………………………....11
Figure 14: Alternator ……………………………………………………………………..12
Figure 15: Various Components of alternator …………………………………………12
Figure 16: Load Bank …………………………………………………………………….13

VI
 CHAPTER-1
An Overview of Al-Bahar

1.1 Introduction

Mohamed Abdul Rahman Al-Bahar is a reputed company dealing in CAT machinery

and heavy equipment. It has been established for more than 75 years in the country.
The company is divided into three sections namely General Repair, Component
Rebuild and Power Generation. They lend their expertise and equipment for a large
number of applications which include building construction, mining, waste handling,
generation of power, etc.

Vision

Be the No.1 provider of customer value in construction equipment, energy and

transportation, and materials handling.

Mission

Strengthening the market leadership by creating dynamic and profitable relationships

with customers and suppliers through innovative solutions and committed
employees.

Core Values

1) Safety and Environmental Care

2) Integrity
3) Excellence
4) Innovation
5) Flexibility and Agility
6) Initiative

The Management of Al- Bahar is QHSE (QUALITY HEALTH SERVICE

ENVIRONMENT) type Management.

1
1.2 Service Information System

SIS Web is an electronic service tool which Caterpillar dealers, customers and
employees rely for parts and service information needs.
The advantage of SIS is that more than 17000 publications on various CAT engines
and machines are available. SIS includes:

 Breakdowns and identification of Parts

 Operation & Maintenance Manuals

 Assembly-Disassembly Manuals

 Special Instructions

 Over 2 million Parts Graphics

 Engine News

 Tool Guides

2
 CHAPTER 2
Heavy Machinery and Generator Sets

2.1Heavy Machineries

During my time at Al-Bahar, I had the opportunity to study about the working and
functioning of the heavy machineries in the company. Two of which were; Vibratory
Compactor and a Wheel Loader.

2.1.1 Vibratory Compactor

Figure 1: Vibratory Compactor

A vibratory Compactor is a machine which is used for compacting soil for

construction purpose. During inspection, it was found out that the rear right drum had
a crack. As further inspection was done, there was a problem with its vibratory
system. It had a faulty coupling motor which was due to a missing Woodruff key as
this caused the damage to it. A coupling motor is the driving motor of the eccentric
weight which causes the drum to vibrate.

Figure 2: Faulty Coupling motor

3
Different Systems of the Heavy Machinery were studied using SIS

Fuel System
A fuel transfer pump is used to pump the fuel from the fuel tank and fuel passes
through water Separator. From here the fuel is passed through a fuel filter and then
passes on to a fuel injection nozzle. A fuel injection pump is a pressurized unit that
sends fuel to the injection nozzle that sprays fuel with high pressure to the cylinders.
With the help of a governor the fuel injection is regulated and thereby regulating the
rpm as per the needs of the engine.

Lubricating System
Oil flows from the gerotor pump (oil pump) ---->Oil Filter head--->Oil Cooler---->Back
to Oil Filter Head ----->Oil Filter

From the oil filter the oil flows to the oil gallery

From Oil Gallery---->Crankshaft (main Bearings) ----->Connecting rod------->Sprays

onto the underside of the piston and the cylinder head

From the Crankshaft main bearings-----> Journals of the Camshaft---> Second

journal of the Camshaft-----> Cylinder Head------> Rocker arm shaft-----> Rocker arm
levers---->Valve Groups

Cooling System
Coolant flows from the bottom of the radiator to the water pump. The water pump is
a centrifugal water pump which pumps coolant across the lubricating system and is
operated by the fuel pump gear.

A thermostat, which is present, is a valve that operates on the temperature of the

coolant. If the coolant is cool the bypass valve of the thermostat is open and the
coolant bypasses the radiator and circulates through the engine. When the coolant
becomes hot the bypass valve opens and the coolant passes through the radiator
The Coolant temperature sensor is present to check if the temperature of the coolant
is hot or cold. Once the coolant is hot it passes through the radiator and the radiator
absorbs heat and re circulates the coolant back to the engine with the help of the
centrifugal water pump.

4
Vibratory System
In the vibration of the compactor drum the eccentric weight plays the major role. On
the panel of the operator station the switch which indicate what drum must be
vibrated is present. As the switch is pressed the solenoid of the respective drum
operates which directs the oil pump to drive the front or back motor. As the motor is
rotated the eccentric weight also rotates. As the centrifugal force so produced from
the rotation of the eccentric weight is high the drum starts to vibrate.

Propel System

NEUTRAL

When the propel lever is in neutral the direction control valve doesn’t direct oil to the
servo piston and as a result the swash plate is in zero angle. When the swash plate
is at zero angle the rotating system doesn’t rotate any of the propel motors.

When the parking brakes are engaged the solenoids are energized the brake and
control valves are open to the tank. This causes the brake springs to be undisturbed
and causes the servo piston to remain at the center position.

5
FORWARD

When the lever is at the forward position the direction control valve pushes the servo
piton to the front side and thereby causes the swash plate to move at a certain
angle. Feedback linkage causes the direction control valve to remain back in the
neutral position as a result the servo piston is restricted to rotate the swash plate at a
large angle than what is required.

TRACTION CONTROL
When Traction is turned on then the traction control solenoid is energized. This
allows the flow of oil to the divider valves. When the oil flows through this valve the
amount of oil passing through will be halved. Thus, the oil flow is halved to each of
the motor. As a result the motor will be rotated at a slow rate.

6
2.1.2 Wheel Loader

Wheel loaders are mobile machineries which are used to transfer materials from
stockpiles to trucks. They are mainly used for construction purposes .

Figure 3: A wheel loader

Implements like buckets used in the wheel loaders are mainly operated in the cabin
and are hydraulically functioned.

Implement function

Figure 4: Bucket(Implement)

7
Numerous implements can be fitted onto the machines depending upon the capacity
of the machine. A wheel loader is mainly used for transferring materials so a bucket
is sufficient.
But the teeth type can vary depending on the type of job being done.

A signal resolver network is one of the main parts of the machine if the machine is
equipped with more than one implement. A resolver network compares two different
signal pressures if the operator wants to use two different implements at the same
time. The single highest signal pressure flows to the pump which is an axial
displacement pump.

An axial displacement pump is a pump which has a swashplate with cylinders

mounted on it.
The swashplate is rotated with the help of an input shaft and based on the operator’s
requirement the swashplate changes the angle for upstroking of the pump. If the
requirement of the pump is not required then pump destrokes allowing less amount
of oil to be pumped.

As the oil is pumped it flows to the main control valve. The main control valve is used
to direct the oil to the head-end or the rod-end of the respective cylinders. As one
part of the cylinders gets filled with oil the oil from the other end goes to the tank.
This enables the implements to raise or lower depending on the need of the
operator.

Steering Function

Figure 5: HMU Steering

The steering function of the Wheel loader is HMU (Hand Metering Unit) system. The
steering system comprises of steering wheel (In the cabin) and a metering pump
which is connected to the steering wheel rod. When the steering wheel is not in use
no oil flows into the inlet side of the pump section and directly flows to the tank. But a
fraction of the oil enters the steering unit for quick steering response.

8
As the steering wheel is turned the Inlet port opens up causing the oil to enter the
metering unit. Metering unit has a spool and sleeve which turns as the steering
wheel opening up different ports. These ports allow oil to flow to the rod-end or the
head-end of the steering cylinders, allowing the machine to turn left or right.

In a machine like excavator which has no steering unit travel motors help in steering
left and right. The travel motor is present in either side of the excavator. When the
operator uses the lever to turn right the left travel motor will get more oil supply and
the right travel motor will get less. As a result the machine will turn right.

2.2 Generator Sets

Figure 6: A Generator Set

A generator is a device which converts mechanical energy to electrical energy.

Mechanical energy is given through the engine flywheel and the output ie, electrical
energy is produced with the help of an alternator.

2.2.1 Engine

Engine - Basic Components

 Cylinder Head
 Cylinder Block
 Piston and Connecting Rod
 Crankshaft
 Camshaft
 Timing case and gear
 Flywheel and Flywheel Housing

Cylinder Block and Cylinder Head

9
 Figure 7: Cylinder Block and Cylinder Head

The cylinder head has 6 cylinders which are placed in line.

The cylinder block have 5 main bearing journals and have thrust washers on both
sides of the center main bearing.
A cylinder head gasket is used to have a sealing between the engine block and
cylinder head so that no leakage of gases and fluids occurs.

Pistons, Piston ring and Connecting rod

Figure 8: Piston Rings Figure 9: Piston

The piston has a combustion chamber in the top of the piston in order to provide for
an effective combustion.
Each piston has 3 piston rings. Two are for Compression purpose and the other ring
is for the oil control.
Correct piston height is required for proper working and also to avoid unwanted
damages caused inside an engine.

Crankshaft and Camshaft

Figure 10: Camshaft Figure 11: Crankshaft

10
The Crankshaft is used to convert combustion forces produced in the cylinders to
usable rotating torque from the engine. Crankshaft gears drives the idler gears which
then drives the:-
 Camshaft gear
 Fuel injection pump gear

The engine has a single camshaft. The camshaft gear is driven by the idler gear
which in turn is run by the crankshaft gear. As the Camshaft moves, it in turn moves
the valve system components. Timing of both the Camshaft and the Crankshaft
gears is a must in order to avoid overlapping of valves which can damage the
engine.

Valve Clearance/ Valve Lash

Figure 12: Rocker arm and Lifer rod

Valve clearance refers to the small gap which is present between the rocker arm and
the push rods. A feeler gauge is used to perform this operation. This is crucial
because an excessive clearance can lead to noise production in the engine and too
little clearance can lead improper closing and opening of the valves.

Fuel Injection Pump

Figure 13: Fuel Injection Pump

The fuel injection pump is a pressurized system. The pump sends the correct
amount of fuel under high pressure at the correct time through the fuel injection
11
nozzles to the individual cylinders. The fuel injection pump regulates the amount of
fuel that is delivered to the fuel injection nozzles. This action controls the engine rpm
by the governor setting or the position of the throttle control.

2.2.2 Alternator

Figure 14: Alternator

An alternator comprises of the

 Main Stator
 Main Rotor
 Exciter Stator
 Exciter Rotor
 AVR( Automatic Voltage Regulator)

The working principle of any alternator is Faraday’s Law of electromagnetic induction

which states that when a magnetic field around a coil is changing an EMF is induced.

12
 Figure 15: Various components of the alternator

In an alternator, DC current passes through the main rotor and forms a magnetic
field around it. When the main rotor which is coupled to the flywheel starts rotating
the magnetic field in the main rotor starts cutting the windings of the main stator
(There are three windings in a stators which is connecting in a phase difference of
120). When the magnetic fields are cut an EMF is induced on the stator and current
flows through the 3-Phase buss bars. The buss bars are in turn connected to an AVR
which checks whether the voltage produced from the generator is meeting the
required amounts. If not, the AVR sends AC signals to the exciter stator. When
current passes through the stator a magnetic field is induced onto it. When the
exciter rotor rotates the magnetic field is cut and EMF is induced. The current so
produced is AC which is converted to DC using a Diode assembly. The current is
directed to the main exciter which strengthens its magnetic field produced till the
required output is reached.

Load Bank Test

Figure 16: Load Bank

A load bank test is a preventive maintenance where the engine is connected to an

auxiliary load bank. By testing with the load bank the generator can be tested to
100% of its designed capacity. Running the engine 100% load ensures that all of the
13
generator’s components are tested especially the cooling system which is the
common cause of failure.

Another reason to test the generator using a load bank is to remove the un-burnt fuel
and carbon buildup. If a generator continuously runs at 30% of the load it causes
carbon deposits to deposit on the Injectors, pistons, rings etc. A frequent sign of the
engine having wet stacking is frequent black smoke emitted out from the engine
exhaust system.

CHAPTER 3
Conclusion

Al-Bahar are dealers of CAT Machinery, Heavy equipment and power systems for a
wide variety of applications, including earthmoving, building and construction,
mining, road making, construction, demolition, waste and scrap handling, electric
power generation, marine propulsion etc

This company had given me an insight on how heavy machineries and power
generation units operate. Two different machineries were inspected and various
functions like; Propel system, Vibratory system, Steering system and implement
system were studied using SIS. Engine components were studied including the uses
and functioning of various parts.

In the later sections of the report, generator sets were discussed, regarding its
functioning along with the various tests conducted on it

14
 References

1. Al-Bahar company website

https://www.albahar.com/company/about-us

2. Machinery and generator set information from SIS(Service Information

System)

15