BEML APPRENTICE TRAINING REPORT
1.1 BEML INTRODUCTION
Bharat earth movers limited is a multi- technology and multi-location mini ratna category-1
company under the ministry of defence, offering high quality products for diverse sectors of
economy such as coal, mining, steel, limestone, power, irrigation, construction, road building,
aviation, defence, metro and railways. It has emerged as the forerunner of heavy engineering
industry with a track record of growth and revenues for over five decades
The company operates under three major business verticals - viz. mining &
construction, defence and rail & metro. Each of the above business is headed by a director who
acts as CEO of the business and reports to the chairman & managing director of the company.
BEML manufactures and supplies defence ground support equipment such as TATRA based
high mobility trucks, recovery vehicles, bridge systems, vehicles for missile projects, tank
transportation trailers, milrail wagons, mine ploughs, crash fire tenders, snow cutters, aircraft
towing tractors, aircraft weapon loading trolley. The company also plans to take up overhaul
and up gradation of battle tanks with a view to assemble and roll out the products. under
mining and construction business, the company manufactures and supplies mining &
construction equipment like bull dozers, excavators, dumpers, shovels, loaders and motor
graders to various user segments and under rail & metro business, manufactures and supplies
rail coaches, metro cars, ac emus, ohe cars, steel and aluminium wagons to the rail sector.
The company has a dedicated R&D infrastructure and team in line with consistent
policy of the company to meet the technological demands through in-house R&D and strategic
technical tie-ups with global players.
1.2 BEML HISTORY
 1964 - Incorporation of our company has a private limited company with the registered
office at Bangalore.
 1968 - Establishment of the heavy earth moving equipment division at kolar gold fields
(KGF).
 1979 -They entered into a collaboration agreement with komatsu limited, Japan for
technical know-how in a wide range of mining and construction equipment such as
bulldozers.
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BEML APPRENTICE TRAINING REPORT
 1985 – The company established the dump truck division at Mysore also vignyan industries
ltd became a subsidiary of the company during the year, by transfer of shares constituting
over 75% from the government of Karnataka.
 1986 - Received national import substitution award from ministry of science technology,
government of India.
 1987 - The company set up an exclusive hydraulics and power line division and a fullfledged R&D centre in the kolar gold field (kgf) facility.
 1990 - Received corporate excellence award for an outstanding performance from the
department of public enterprises government of India.
 1991 - Engine division set up at Mysore for manufacturing heavy duty diesel engines.
 1992 - The government of India divested the equity shares in the company and the company
was converted into a public limited company also the company was recognized as an export
house with star exporter status during the year.
 1994 - The company shares were listed at the stock exchanges at Bangalore, Mumbai,
Kolkata, Delhi and Chennai also the company launched the mammoth equipment 'walking
dragline'.
 1996 - The company entered into a major counter trade agreement with Syria executed
against import of rock phosphate.
 1997 - Recipient of award for best employers of the physically handicapped from ministry
of welfare, government of India.
 1998 - Bags orders against World Bank traders valued at Rs 70,000 lac for equipment
supply to cil projects.
 1999 - Integrated hi-tech applications program implemented in division covering
manufacturing, operation and communications.
 2001 - Awarded the best exporter by the department of industry and commerce government
of Karnataka.
 2002 - Regional award for highest exports awarded by engineer export promotion council,
southern region.
 2003 - The company entered the metro railway business with the manufacture and supply of
hi-tech stainless steel metro coaches to the Delhi metro rail corporation.
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BEML APPRENTICE TRAINING REPORT
 2004 - They acquired over 1,100 acres of land and 2 workshops on lease basis from the
now-defunct public sector undertaking Bharath gold mines ltd in kolar gold fields for
supporting their expanding production activities in the defence and railway sectors. Also
they formally launched 7 t class excavator - BE71 and backhoe loader - BL 9h.
 2004 - Our company's equity shares got voluntarily delisted from DSE and MSE,
application made for voluntary delisting of our equity share to CSE.
 2005 - The company introduced the R&D innovative product, load haul dumper (LHD) BL15 and exhibited in the IMME - Kolkata. Four-cylinder indigenous engine B4D105 was
successfully built, tested, evaluated and fitted on one of the earthmoving equipment for user
trials. Also the in-house developed 20T class excavator BE200 has successfully completed
user trials and released for production.
 2005 - BEML thrives with Rs 3680mn orders and BEML signs MOU with HMT to draw
financial assistant provided by government of India for metro infrastructure. Also BEML
signs MOU with ROTEM for aerobridges. BEML joins hand with Korean co Rotem to
build aerobridges.
 2006 - Defence production inaugurates BEML technology division. BEML join hand with
us firm Terex corp.
 2006 – April 1, The Company undergoes organizational restructuring to improve their
competitiveness in the global market. Consequent to this, the company operations was
divided into three business groups, namely mining & construction, defence and railway &
metro business.
 2006 - April 12, The Company diversified into new business areas by opening two new
divisions, namely technology division and trading division.
 2006 - August 29, the company was conferred 'Mini Ratna - category 1' status by the
ministry of defence.
 2006 - September, the company signed an MOU with CCC (compagnie comercio
constructors) and established a joint venture company for manufacturing and supplying of
rail wagons & bogies, mining & construction equipment and spares.
 2006 - December, the company entered into an agreement with us based Terex mining to
manufacture, sell and service and to provide support for certain mining haul trucks of Terex
design.
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BEML APPRENTICE TRAINING REPORT
 2007 - February, Taneja aerospace & aviation ltd signed a mou with the company at aero
India in order to explore the aeronautical offset opportunities in the defence and civilian
sectors and also the development opportunities in the domestic market.
 2007 - The credit rating of our company has been done by ICRA limited and it has assigned
"IRAAA"(pronounced as issuer rating triple) to our company. This rating indicates the
highest credit quality ratings assigned by ICRA limited which means, our company caries
the lowest credit risks and BEML ltd has set up a subsidiary in Brazil for sourcing and
assembling of mining and construction equipment to cater to the growing Latin American
market.
 2007 - The company's R&D centre developed pipe layer BP70X with unique features like
modular planetary winches mounted on one side for improved visibility, rugged boom, and
pilot operated hydraulic system. Also the company launched the R&D centre developed
equipments, namely hydraulic excavator BE700 and transmission for BH35-2.
 2007 - April 18, the company formed a joint venture company namely BEML Midwest
Hyderabad. The joint venture is a professionally well knit company with the company
having 45% share, Midwest granite Pvt ltd and p t sumber mitra jaya of Indonesia as
partners with 55% share.
 2007 - October, the company launched marketing office cum warehouse at Malaysia in the
name of BEML (Malaysia) SDN BHD (787108-a) at Johor bharu. also, they secured an
order from Delhi metro rail corporation (DMRC) for manufacture and supply of 156
numbers state of the art standard gauge stainless steel metro cars towards second phase of
operation worth Rs 1144 crore. During the year 2008-09, the company's R&D developed
BE300 with Rexroth hydraulics, BL200 re-engineered version, WS70 high capacity water
sprinkler, BA28 air craft towing tractor, transmission and torque converter for BH35-2.
 2008 – May, the company entered into a mou with steel authority of India ltd in which sail
will purchase a total number of 261mining equipment over a period of next three years.
Also, the company signed a long term agreement for 12 years with coal India ltd for joint
production of off the road (OTR) to meet the requirement for production by the company
and after sale requirement by coal India ltd.
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BEML APPRENTICE TRAINING REPORT
1.3 BEML Major Customers
 Coal India Limited
 Neyveli Lignite Corporation
 Associated Cement Company
 Steel Authority of India Limited
 The National Hydro Electric Thermal Power Corporation
1.4 BEML Operating Fields
 Mining & Construction
 Defence & Aerospace
 Rail & Metro
1.5 BEML Has Four Manufacturing Units
Kolar Gold Fields (KGF) Complex (around 100 kms from Bangalore)
 Earth Moving Division
 Rail Coach Unit II
 Heavy Fabrication Unit
 Hydraulic & Power line Division
Mysore Complex (around 130 kms from Bangalore)
 Truck Division
 Engine Division
 Aerospace Manufacturing Division
Bangalore Complex
 Rail & Metro Division
Palakkad Complex Kerala State - Defense Products Manufacturing
 BEML - Tatra Trucks 12x12, 10x10,8x8, 6x6, 4x4 & Variants
 Pontoon Bridge System
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BEML APPRENTICE TRAINING REPORT
 Ground Support Vehicles for Guided Missile Programme
 Heavy, Medium and Light Recovery Vehicles
 50T Trailer for Tank Transportation
 Mil Rail Coaches and Mil Wagons
1.6 BEML Quality Objectives
 Manufacture and supply equipments to meet customer’s needs and guarantee satisfactory
performance of products.
 Bring about the quality awareness in customer’s personnel in operation and maintenance of
products to maximize utilization.
 Achieve operational excellence through waste elimination and value engineering efforts.
 Ensure reliability and offer prompt customer service to achieve high equipment availability.
 Strive continuously to achieve cost reduction and higher profitability.
 Strive continuously for better product quality through technological improvements and
products up-gradation to cater to ever changing customers’ needs.
 Have an effective and documented system to ensure that every input to the product is
designed, procured, manufactured, and ever-changing customer needs.
 Upgrade design capability and self reliant in technology development.
 Accord prime importance to safety aspect in all activities.
 Train and motivate personnel at levels continuously so as to inculcate quality consciousness
and foster teamwork.
1.7 BEML Quality Policy
 To offer products and services to the satisfaction of customers.
 Strive to upgrade quality and operational efficiency continuously.
 To ensure high availability of products by constantly endeavouring to provide high quality
after sales with least possible delay to the customer.
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BEML APPRENTICE TRAINING REPORT
2.1 BEML Standards and systems
Some of the standards and systems adopted by the BEML are:
ISO 9000 and ISO 14000
ISO 9000 is a quality management standard that presents guidelines intended to increase
business efficiency and customer satisfaction. The goal of ISO 9000 is to embed a quality
management system within an organization, increasing productivity, reducing unnecessary
costs, and ensuring quality of processes and products.
ISO 9000 Principles
 A Customer Focus
 Good Leadership
 Involvement of people
 Process approach to quality management
 Management system approach
 Continual Improvement
 Factual approach to decision making
 Supplier relationships
ISO 14000 is a series of environmental management standards developed and published by the
International Organization for Standardization (ISO) for organizations. The ISO 14000
standards provide a guideline or framework for organizations that need to systematize and
improve their environmental management efforts.
ISO 14000 Principles
 To result in better environmental management
 To encompass environmental management systems and the aspects of products
 To be applicable in all countries
 To promote the broader interests of the public as well as users of these standards
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BEML APPRENTICE TRAINING REPORT
 To be cost-effective, non-prescriptive and flexible so they are able to meet the differing
needs of organizations of any type or size, worldwide
2.2 5S
5S is short for: Sort, Set in Order, Shine, Standardize and Sustain
5S represents 5 disciplines for maintaining a visual workplace
5S is one of the activities that will help ensure our company’s survival
 Sort - All unneeded tools, parts and supplies are removed from the area
 Set in Order - A place for everything and everything is in its place
 Shine - The area is cleaned as the work is performed
 Standardize - Cleaning and identification methods are consistently applied
 Sustain - 5S is a habit and is continually improved
Also Work areas are safe and free of hazardous or dangerous conditions
2.3 KAIZEN
KAI

Changes
ZEN

Become Good
Kaizen signifies small improvements as a result of coordinated continuous efforts by all
employees
Five key elements of kaizen:
 Team work
 Self-discipline
 Improved morale
 Quality circles
 Suggestion for improvement
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BEML APPRENTICE TRAINING REPORT
2.4 Directorate General of Mines Safety (DGMS)
Directorate General of Mines Safety, DGMS in short, is the Indian Government Regulatory
agency for safety in mines and oil-fields.
The mission of the DGMS is to continually improve safety and health standards, practices and
performance in the mining industry and upstream petroleum industry by implementing:
 Pro-active safety and health strategies.
 Continuous improvement of processes.
 Effective use of resources.
 Commitment and professional behaviour in its personnel.
2.5 Occupational Health & Safety Assessment Series (OHSAS)
OHSAS 18000 is an international occupational health and safety management system
specification. It comprises two parts, 18001 and 18002 and embraces BS8800 and a number of
other publications.
OHSAS helps in a variety of respects, it helps in minimise risk to employees, improve an
existing OH&S management system, demonstrate diligence, gain assurance etc. The benefits
can be substantial. Its supporters claim that an occupational health and safety management
system (OHSMS) promotes a safe and healthy working environment by providing a framework
that helps organizations to:
 Identify and control health and safety risks
 Reduce the potential for accidents
 Aid legal compliance
 Improve overall performance
2.6 National Accreditation Board for Testing and Calibration Laboratories
(NABL)
National Accreditation Board for Testing and Calibration Laboratories (NABL) is an
autonomous body under the aegis of Department of Science & Technology, Government of
India, and is registered under the Societies Act 1860. NABL has been established with the
objective to provide Government, Industry Associations and Industry in general with a scheme
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BEML APPRENTICE TRAINING REPORT
for third-party assessment of the quality and technical competence of testing and calibration
laboratories. Government of India has authorised NABL as the accreditation body for Testing
and Calibration Laboratories. In order to achieve this objective, NABL provides laboratory
accreditation services to laboratories that are performing tests calibrations in accordance with
ISO/IEC 17025:2005 and ISO 15189:2007 for medical laboratories. These services are offered
in a non-discriminatory manner and are accessible to all testing and calibration laboratories in
India and abroad, regardless of their ownership, legal status, size and degree of independence.
2.7 Society of Automotive Engineers (SAE) Grades
The Society of Automotive Engineers (SAE) has established a numerical code system
for grading motor oils according to their viscosity characteristics. SAE viscosity grading
includes the following, from low to high viscosity: 0, 5, 10, 15, 20, 25, 30, 40, 50 or 60. The
numbers 0, 5, 10, 15 and 25 are suffixed with the letter W, designating they are "winter" (not
"weight") or cold-start viscosity, at lower temperature. The number 20 comes with or without a
W, depending on whether it is being used to denote a cold or hot viscosity grade. The document
SAE J300 defines the viscometrics related to these grades. Kinematic viscosity is graded by
measuring the time it takes for a standard amount of oil to flow through a standard orifice, at
standard temperatures. The longer it takes, the higher the viscosity and thus higher SAE c
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BEML APPRENTICE TRAINING REPORT
3.1 LIGHT ASSEMBLY
In Light assembly they will do earth moving equipments like, different capacities of dumpers,
water sprinklers and motor graders. Dumpers are used for ore moving purpose and carrying
loose materials, Water sprinklers are used for sprinkling purpose and Motor graders are earth
moving equipments which used grade the soil. In dumpers there are two different kinds in
colours that can be helpful in identifying coal body or sand body.
Light Assembly involves in the assembly of following Equipments:
 BH35-2
 BH60
 BWS28-2
 BG405ABG605(I/A)
 BG825
Model Abbreviation:

B
- Bharat

H
- Haulpak

WS
- Water Sprinkler

G
-Grader

BH60 M - 60Ton Capacity And M-Mechanically Driven

Bh35-2

Bws28-2 - Modification Of Ws28

BG 405A & 605(I/A) - 40 & 60-Machine Size In Ascending Order, 5-Power Shift Drive,
- Modification Of Bh35
I - Integrated & A - Have Articulating Cylinders

BG825
- 82-Machine Size In Ascending Order, 5-Power Shift Drive
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BEML APPRENTICE TRAINING REPORT
3.2 DRIVE SYSTEM OF BG825, BG605 (I/A) & BG405A:
The major functions of a motor grader are to level road surfaces and dig ditches of fixed shape.
In terms of function, a grader can be likened to a gigantic carpenter's plane. The motive force
from engine passes through the flywheel and is transmitted to the output shaft. The twisting
vibration is
Absorbed by the output shaft and the motive force passes through drive shaft and is transmitted
to torque converter. The motive force transmitted to the torque converter has its torque
converted by the oil inside torque converter, and is then transmitted to hydro shift transmission.
In hydro shift Transmission, the clutch is selected according to the load, travel speed, and
direction of travel of the machine and the motive force is transmitted to tandem axle through
drive shaft. In tandem axle, the rotation is reduced by the bevel pinion and bevel gear, and the
motive force is transmitted to the final drive. In final drive, the speed is further reduced by a
planetary gear system, and the motive force is transmitted to the tyres.
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BEML APPRENTICE TRAINING REPORT
Hydro shift transmission:
For vehicles with an Internal Combustion Engine (ICE) as the primary energy source,
the engine power needs to be transformed into rotational mechanical power at the wheels of the
vehicle. For construction machines, a sleeplessly variable speed ratio is often required with a
wide torque/speed conversion range. For this reason, energy converters, such as hydraulic
displacement machines (hydraulic pumps/motors), can be used that allow power transformation
to be made sleeplessly in another physical domain. An HST with two hydraulic displacement
machines is consequently a Continuously Variable Transmission (CVT) with an intermediate
hydraulic power transformation. Modern hydraulic axial piston machines often have the ability
to be controlled to zero displacement, which makes the HST an Infinitely Variable
Transmission (IVT) that has the ability to transform the input shaft speed into zero output shaft
speed.
HMTs are transmissions that transfer power both hydraulically and mechanically, either
in series, like an HST with mechanical gear steps, or in parallel. The parallel power-split
architecture divides the power into a mechanical branch and a hydrostatic branch, which allows
for a wide conversion range and high efficiency. Hydro mechanical architectures can be divided
into single-mode transmissions and multiple-mode transmissions. The single-mode
transmissions are the basic hydro mechanical configurations, either of power-split or
hydrostatic type. Single-mode transmissions have no clutches, whereas multiple-mode
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BEML APPRENTICE TRAINING REPORT
3.3 WORK EQUIPMENT:
Scarifier:
The Scarifier is mounted behind the front wheels and is hydraulically operated from
inside the cab. The Scarifier is equipped with up to eleven teeth that are adjustable and
replaceable. Use the Scarifier to break up surfaces that are too hard to cut with the mould board.
For especially hard surfaces, reduce the number of teeth. This has the following, Scarified
cylinder, scarified body, Scarified tooth, Bolt, Wedge & Pin
Ripper:
The ripper is very useful for breaking up asphalt pavement, large rocks and tree stumps.
The ripper can be equipped with seven ripper teeth.
Blade and circles:
Mould boards are normally mounted to the grader in circle-mounted configuration. The
mould board is attached under the grader’s frame with a ring that can be swivelled vertically to
adjust the casting angle of the blade. By adjusting this way, the grader is able to work sideways,
enabling it to do jobs such as pulling itches and sloping banks. The motor grader’s front wheels
can be tilted up to some degree so as to balance the machine horizontally when the mould board
is working at vertical angle.
Drawbar
Type: A-shaped, U-section press-formed and welded construction for maximum
strength.
Circle: Internal gear type hydraulically controlled with six guide shoes for 3600 smooth
rotation.
Mould Board
Type: Box-section construction with wear resistant steel, hydraulic blade side shift and
tip control, Reversible overlay end bits, side edges are attached.
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BEML APPRENTICE TRAINING REPORT
3.4 ASSEMBLY:
Sub Assembly
 Engine and hydro shift transmission
 Frame and tandem axle
 Pipes assembly of hydraulic and air system
 Steering wheel mounting to sub frame
 Wheel assembly with brake section
 Axle assembly
Main Assembly
 Engine & hydro shaft is mounted on to sub assembly of frame and tandem axle

Steering wheel sub assembly is mounted on to main frame
 Steering cylinder installation
 Flow control valve installation
 Tandem pump installation
 Sub assembled pipe lines of hydraulic and air system are mounted on to frame
 Operator seat mounting
 Draw Blade and circle
 Lifter is assembly to frame
 Blade lift cylinder (LH & RH)
 Draw bar shift cylinder
 Leaning cylinder to front axle
 Articulating cylinders
 Scarifier cylinder
 Brake valve
 Tyres mounting to axle
 Front Axle assembly with knuckle arm and king pin
FINAL TESTING ASSEMBLY:
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BEML APPRENTICE TRAINING REPORT
Welding Works:
 Emergency steering connections
 Reverse alarm
 Auto lube
 Auto fire protection system (AFPS)
 AC welding
Final Works
 Cabin mounting
 Blades of moving parts
 AC installation
 Lubrication (grease)
 Preparation for start
 Start & check
 After test check
 Decal fixing etc
3.5 MOTOR GRADER - BG605I
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BEML APPRENTICE TRAINING REPORT
Salient features:
Product: BEML Motor grader BG605I has been fitted with Bharat stage III CEV compliant
BEML engine.
Performance: With its high engine horse power and operating weight BG605I is ideal for
heavy duty road constructional and maintenance jobs at mining and demanding job site.
Productivity: High power engine, coupled with high performance blade equipment ensure high
productivity. The finger tip control of smooth transmission shifting provides high
manoeuvrability.
Comfort: Rear frame mounted operator’s compartment enables ease of viewing the machines
travelling directions. Operators comfort is enhanced by adjustable oil, suspension seat and
rubber pad mounted on operator compartment.
Standard parts:
Engine:
Make:
BEML
Model: BSAA6D125-BS III CEV
Type:
Diesel, 4 strokes, turbocharged overhead valve, direct injection, mechanical speed
governor
Gross power: 112 KW (152 hp) @ 1800 rpm
Maximum torque: 721 Nm (73.5 kg-m) @ 1200 rpm
Bore * Stroke: 125 * 150 mm
Electricals:
Alternator: 24 V, 45 A
Starting motor: 24 V, 7.5 kW
Battery: 2 * 12 V, 200Ah
Transmission:
Make: BEML, Hydro shift transmission
Travelling Speed: Forward - 43.6 Kmph & backward – 30.9 kmph
Tandem:
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BEML APPRENTICE TRAINING REPORT
Tandem case swing up to 13 degree assuring high machine stability and positive traction during
operation.
Blade Equipment:
Draw bar: A shaped, U section press formed and welded and constructed for maximum
strength.
Circle: Internally gear type hydraulically controlled with 6 guide shoes for 360 degree smooth
rotation.
Cutting Edge: Tungsten carbide tipped cutting edges. No. of cutting edges is 4.
3.6 Air System & Hydraulic System:
Air System Basics:
 Quick release valve: To rapidly exhaust the air pressure from the break actuators.
 Limiting and Quick release Valve (LQRV): To regulate the input & output pressure in a
specific ratio. E.g. Dry & slippery condition.
 Graduated control Valve: To change and exhaust the air from spring break actuators for
applying the parking brake in truck.
 Spring Break Actuators: To produce braking force at the wheel or transmission for the
secondary or parking brake.
 Double Check valve: To change a control line in a selected manner from two independent
sources.
 Pressure reducer Valve: To maintain a predetermined reduced pressure at its delivery port.
 Retarder Hand Break Valve: Gradually change and exhaust the service brake line for
applying breaks during downhill travel of the vehicle.
 Quadruple system protection valve: vital part in DBS. It changes a single line from
compressor to 4 lines and prevents back flow of compressed air from any line. Also in the
event of failure of any line it will keep the other lines intact. E.g. BG605

Condensing unit & Auto drain Valve: To filter, cool and to remove the moisture and oil
from air before it enters the reservoir and pipe lines. The condensed moisture and oil are
automatically ejected.
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BEML APPRENTICE TRAINING REPORT
 Unloaded Valve with Tyres Inflator: To control the system pressure and also to inflate the
tyre when required.
 Low Pressure Indicator Switch: Warning lamp & Buzzer.
 Stop light switch: To switch on when brake is applied.
 Relay Valve: To apply and release air pressure from the brake actuators. Also it shortens the
response time and build up time in brake system.
 Relay emergency Valve: To control the trailer brakes in twin line break system.
 Evolution of Braking: Air brake system introduction in 1920 in railways and 1930 for
automobiles. Earlier vacuum was used for power assistance. Basic braking of bicycle to
advanced system of braking heavy commercial vehicles principle of operation remains same
but the means of actuation has varied with vehicle’s in load, speed and service conditions.
 Dual Brake System: A split system of breaks actuating the front & rare breaks separately
both in full air system as well as air assisted hydraulic system. Advantage-Partial braking
for vehicle in event of failure of either front or rare brakes. E.g. Dumpers BH35, BH352,BH60 & BH100
 Compressor: To generate the compressed air needed for the operation.
 Reservoir: To generate the compressed air provided with auto drain valve/manual drain
valve.
 Dual Brake Valve: to gradually change and exhaust the brake actuators and also to control
the trailer brake systems through trailer control valve in a dual brake system.
HYDRAULIC SYSTEM
The hydraulic systems consists a number of parts for its proper functioning. These include
storage tank, filter, hydraulic pump, pressure regulator, control valve, hydraulic cylinder, piston
and leak proof fluid flow pipelines. The schematic of a simple hydraulic system is shown in
figure. It consists of:
 A movable piston connected to the output shaft in an enclosed cylinder
 Storage tank
 Filter
 Electric pump
 Pressure regulator
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BEML APPRENTICE TRAINING REPORT
 Control valve
 Leak proof closed loop piping
The output shaft transfers the motion or force however all other parts help to control the system.
The storage/fluid tank is a reservoir for the liquid used as a transmission media. The liquid used
is generally high density incompressible oil. It is filtered to remove dust or any other unwanted
Particles and then pumped by the hydraulic pump. The capacity of pump depends on the
hydraulic system design. These pumps generally deliver constant volume in each revolution of
the pump shaft. Therefore, the fluid pressure can increase indefinitely at the dead end of the
piston until the system fails. The pressure regulator is used to avoid such circumstances which
redirect the excess fluid back to the storage tank. The movement of piston is controlled by
changing liquid flow from port A and port B. The cylinder movement is controlled by using
control valve which directs the fluid flow. The fluid pressure line is connected to the port B to
raise the piston and it is connected to port A to lower down the piston. The valve can also stop
the fluid flow in any of the port. The leak proof piping is also important due to safety,
environmental hazards and economical aspects. Some accessories such as flow control system,
travel limit control, electric motor starter and overload protection may also be used in the
hydraulic systems which are not shown in figure.
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BEML APPRENTICE TRAINING REPORT
3.6 PARAMETERS OF MOTOR GRADER:
Model
BG405A
BG605(I/A)
BG825
Make
Mahindra heavy engines
Pvt. Ltd.
BEML
BEML
Power shift
Hydro shift
Hydro shift
Type
Diesel, 4-stroke, direct
injection, water cooled,
Mechanical all speed
governor.
Diesel, 4-stroke,
turbocharged overhead
valve, water cooled, direct
injection, and Mechanical
variable speed governor.
Diesel, 4-stroke,
turbocharged overhead
valve, water cooled,
direct injection, and
Mechanical variable
speed governor.
power
101kw (135 hp)
@ 2200 r/min
112kw (152 hp)
@ 1800 r/min
209kw (280 hp)
@ 2100 r/min
605 N-m (61.7 kg-m)
@ 1200 r/min
721 N-m (73.5 kg-m)
@ 1200 r/min
1661 N-m (170 kg-m)
@ 1200 r/min
Starting
motor
24V, 45A
24V, 45A
24V, 45A
Battery
24V, 7.5kw
24V, 7.5kw
24V, 7.5kw
2 x 12V, 100Ah, 1100
CCA
2 x 12V, 200Ah
Transmission
Max torque
Alternator
2 x 12V, 200Ah
Oscillation angle
(to each sides)
150
150
150
Front wheel lean
angle
(to each sides)
220
230
230
Cutting angle of
blade
(Max-min)
820-380
Std-450
710-240
Std-360
840-25.50
Std-490
12.75Mpa
175kg/cm2
210kg/cm2
Working
equipment pressure
21
BEML APPRENTICE TRAINING REPORT
Steering relief
pressure
13.73Mpa
140kg/cm2
175kg/cm2
Scarifies, Front
dozer blades,
Rare mounting
rippers and
ROPS cabs
Scarifies, Front dozer
blades, Rare mounting
rippers and ROPS cabs
Rare mounting rippers
and ROPS cabs
Fuel tank capacity
(L)
180
250
500
Hydraulic tank
capacity (L)
41
58
105
Tungsten
carbide tipped
cutting edges
Tungsten carbide tipped
cutting edges
Curved type cutting
edges meet SAE standard
Optional
attachments
Cutting edges type
22
BEML APPRENTICE TRAINING REPORT
3.7 DRIVE SYSTEM OF BH35-2 & BH60M
The motive force from engine (1) passes through the flywheel and is transmitted to the output
shaft (2). The twisting vibration is absorbed by the output shaft (2) and the motive force passes
through drive shaft (3) and is transmitted to torque converter (4). The motive force transmitted
to the torque converter (4) has its torque converted by the oil inside torque converter (4), and is
then transmitted to transmission (5). In transmission (5), the clutch is selected according to the
load, travel speed, and direction of travel of the machine and the motive force is transmitted to
differential (7) through drive shaft (6). In differential (7), the rotation is reduced by the bevel
pinion and bevel gear, and the motive force is transmitted to the final drive (8). In final drive
(8), the speed is further reduced by a planetary gear system, and the motive force is transmitted
to the tires (9).
23
BEML APPRENTICE TRAINING REPORT
Light Assembly BH35-2 & BH60 Stage wise work:
Sub Assembly:
 Hydraulic tank sub assembly
 Fuel tank sub assembly
 Front axle sub assembly
 Transmission sub assembly & Installation
 Engine sub assembly & Installation
 Radiator sub assembly
 Front Axle sub assembly (LH)
 Front Axle sub assembly (RH)
 Lever Assembly LH
 Lever Assembly RH
24
BEML APPRENTICE TRAINING REPORT
Ist Step:
 Rear Axle & Rear Suspension Installation
 A-Frame & Front Axle Installation
 Steering Cylinder & Tie Rod Installation
 Guard Installation
 Installation Of Fire Protective System
 Press three bore bkt bushes: press bushes
 Arbitral valve mounting bkt setup & weld: orbit
 Lock plate setup & weld: all lock
 Final drive random torque checking to IM
IInd & IIIrd Step:
 Converter cooler mounting & piping
 Hydraulic tank installation
 Scu-delling (tank-pump, pump-d.valve)
 Transmission oil filter mounting piping
 Hoist cylinder mounting & piping
 Brake oil cool mounting & piping
 Steering piping
 Priority valve, filter installation & piping
 Emergency steering pump mounting & piping
 Fuel tank mount & piping
 Auto greasing installation
 Steering gear box mounting & piping
 Mounting of fuel filter & water separator
 Auto greasing bosses setup & weld
IVth, Vth & VIth Step:
 Front & rear supp mounting
25
BEML APPRENTICE TRAINING REPORT
 Radiator s/a & installation
 Radiator piping installation
 Floor installation RH
 Cabin installation
 Air intake piping installation
 Ladder installation
 Installation hoods & guards, stays, etc
 Assy of throttle linkages speedometer
 Engine belly pan bkt
 Set up pads of hoods latches
 Addl air cleaner mounting bkt installation
 Hand rail pads located & weld: locate set
VIIth, VIIIth & IXth Step:
 Additional brake reserve tank installation.
 Tyre installation
 Air system (modified)
 Body installation
 Split spacer setup & grinding
 Mounting of air drier
 Air cleaner mounting channel setup & weld
 Air system piping bosses weld
Electrical Work:
 Electrical installation like indicators required
 Electrical connections
 Air pressure switch & fog lamps
 Battery cable preparation
 ST offer electrical introduced
26
BEML APPRENTICE TRAINING REPORT
 AC Electrical installation
Procedure final testing Works:
 Preparation (like transmission, engine, differential and Hydraulic oil, Bearing check, Grease
check, Filters changing, Turbocharger blades check etc).
 Two stages of ST offers will be done by quality department on final testing to ensure the
quality of equipment.
 After the1st ST of equipment is over the equipment will be driven by operator for some
time.
 If any leakages or other problem occurs when driving that will be noted and it is attended by
final testing team.
 And equipment will be sent for painting.
 After painting 2ndST offer of equipments begins with remaining snags attending and final
drive test of equipment.
They will give final touch up for equipment with additional parts required for costumer when
equipments released from assembly some of them are,
 Lubrication (grease)
 Preparation for start
 Start & check
 After test check-1
 Decal fixing
 Drive shaft & spider greasing
 Bearing rotation & rub bead
 Running test
 After test check-2
 Grease charging
 Final check up
 Mounting of front drive shaft guard
 Mount of splash guard
27
BEML APPRENTICE TRAINING REPORT
 Decal fix on front & rear suspension
 ST offer mechanical introduced
 Transmission magnetic filter cleaning amended
 Wrap exhaust cloth
 Magnetic filter cleaning: clean magnetic
 Toe in adjustment
 Steering inter lock
Welding Work:
 Weld fire protective system
 Welding of mirror stand
 Weld and gas cut spacer pads
 Welding of air drier
 Welding of grease pr switch
 Welding of filter & water separator
 Weld front drive shaft guard
 Welding of splash guard
 Weld of pads in place of latch
 Weld of air clean piping pads
 Weld of flywheel housing guard
 AC welding
Electrical Work:
 Auto lube electrical
 Auto fire protection system (AFPS)
 Payload monitoring system (PLMS)
 Air pressure switch & fog lamps
 Emergency steering connections
 Proximity sensor (body up)
28
BEML APPRENTICE TRAINING REPORT
 Body cut off switch
 Radar indication sensor
 Camera
 Reverse alarm
Oil Work:
 Oil charging
 Suspension charging
 Oil & fuel filling & suspension charge
Grill Work:
 Slack adjust mounting
 Cabin sub assembly with blower & wiper
 Exhaust box mounting & piping
 Operator seat, buddy seat & fire extension
 Battery box & bat mounting assembly
 Turbo charger inspection clearance (twice)
 Mounting of checker plates in cabin
 Mounting of exhaust box top cover
 Mounting of mirror stand
 AC hoses crimping
 AC kit installation
 Cabin heater installation
 Brake line pads setup & weld: setup and weld
Lath Work:
 Bench work (tubes) 7 items
 Assy & flare (tubes) 7 items
 Bend (tubes) 7 items
 Weld (tubes) 7 items
29
BEML APPRENTICE TRAINING REPORT
 Leak test (tubes) 7 items
 Purging of hydraulic piping
 Fuel tank purging
Standard Equipment Has:
General: ROPS cabin, Electric Diagnostic system, Vandalism protection cap (Fuel tank), Head
and tail lights, Air horn, Turn signal lights, Alternator, Electric starter, Key-switch, Wiper
motor, Manual emergency steering, Windshield washer, Dump brake, Right & left Hand mirror,
portable fire extinguisher, tool kit, parking brake valves, Tiltable steering wheel and column,
Exhaust heated body, Central warning lamp & buzzer, Battery relay, Backup Alarm with
flasher, catwalk, Mud flaps, Body lock pins, Rock ejectors, Cabin floor mat, Safety seat belt,
Co-operator seat, air dryer, Front brake cut-off switch, Emergency Brake, Engine shut-off
switch, Twin fresh air fans, Fog lights, Dial on fuel tank, Auto retarder, Blind spot mirror &
steering locking, reflective stickers on all sides.
Gauges: Ammeter, Voltmeter, Air pressure, Engine oil pressure, Water temperature,
Transmission oil temperature & pressure, Brake oil temperature, Air cleaner restriction,
Speedometer, Tocho-meter, Electrical hour meter, Fuel level.
Indicators: Hi-beam, Reverse, Turn signal, Body-up, Lube oil pressure, Water temperature,
Parking brake and emergency steering “ON”, Alternator warning, Transmission oil temperature
and pressure, Fuel level, Transmission filter clogging, Air pressure and hydraulic oil
temperature.
Alarms: Air pressure, Water temperature, transmission oil temperature & pressure, Lube oil
pressure, Hydraulic oil temperature, Transmission filter clogging, Body-up and parking brake
“ON”, Low fuel level.
Optional Accessories:
Tyre inflation kit, Suspension charging kit, Auto emergency steering, air conditioner and Heater
unit, exhaust muffler (Non exhaust heated body), Fast fill system for fuel, Automatic
centralized lubrication system, Parking brake interlock, Radial tyres, Auto fire suppression
system, Body wear bars, Coal body.
30
BEML APPRENTICE TRAINING REPORT
3.8 TYPES OF BRAKES USED IN BH35-2 & BH60:
BH35-2
 Service Brakes
Front - Air-over-hydraulic, dry calliper disc.
Rare - Air-over-hydraulic, wet multiple disc.
 Emergency Air-over-hydraulic, automatic application through relay emergency valves
Parking brake spring actuated, air released, dry calliper disc on axle input flange.
 Retarder brakes Rear brake serves as retarder brake meets ISO 3450 performance
Steering system
 Type Orbitrol, full time power steering.
 Cylinder type double acting piston type.
BH60
 Front Hydraulically actuated Rockwell calliper disc Braking Surface: 2.632 cm2.
 Rear Oil-cooled hydraulically actuated multiple disc brakes provide both service and
dynamic retarding. Brakes are sealed for protection from environment contaminants,
Braking surface: 58193 cm2.
 Automatic emergency braking system Unique designed brake control module constantly
monitors brake pressure in dual brake accumulators and will active an audio – visual alaram
if pressure on either accumulator drops below a toleradle level. If pressure should continue
to drop, service brakres will automatically apply.
 Manual emergency braking system In the event of failure of the brake pedal, the service
brakes can be manually applied by an operator switch located on the inatrument panel.
 Praking brake Dry calliper disc-types mounted on axle input flange. Spring applied
hydraulically released, the parking brake will automatically apply if hydraulic pressure is
lost.
 Dynamic retarder Constant sped retarder is provided by a separate foot pedal for the
retaeder function, allowing the operator to apply the retarder without removing his hands
from the steering wheel. The foot operated valve controls the hydraulically actuated oilcooled wet disc brakes on the rear axle.
 Wheel brake lock Controlled by switch on control panel activites and locks brakes while
loading and dumping.
31
BEML APPRENTICE TRAINING REPORT
Steering system:
Orbitrol as power steering control with pressure compensating steering pump and two doubleacting steering cylinders Front hydrair suspensions serve as steering kingpins to provide
excellent manoeuvrability. Automatic supplemental, accumulator steering is standard.
3.9 PARAMETERS OF DUMPERS:
Model
BH35-2
Make
Cummins
BEML
Transmission
AVTEC(India
AVTEC(India)
Type
IC-Diesel, 4-stroke, turbocharged,
direct injection, after cooled, water
cooled
Flywheel
power
280Kw (375 hp)
@ 2100 rpm
280Kw (375 hp)
@ 2100 rpm
Max torque
1627 N-m (166 kg-m)
@ 1400 rpm
1627 N-m (166 kg-m)
@ 1400 rpm
IC-Diesel, 4-stroke, turbocharged,
direct injection, water cooled
Starting
motor
Battery
24V DC,7.5kw
24V DC, 7.5kw
2 x 12V, 200Ah
2 x 12V, 200Ah
Alternator
24V ,30A
24 V, 30A
32
BEML APPRENTICE TRAINING REPORT
Model
BH60
Make
Transmission
Cummins
AVTEC(India
BEML
AVTEC(India)
Diesel, 4-stroke, twin turbocharged,
direct injection, after cooled, water
cooled
Type
Diesel, 4-stroke,2 stage
turbocharged, direct injection, after
cooled, water cooled / Diesel, 4stroke, turbocharged, Charged air
cooled, Electronic Engine & water
cooled
Engine
model
KTTA 19-C/ QSK 19-C
BSA6D170A-1
Flywheel
power
485kw (650 hp)
@2100 rpm
485kw (650 hp)
@2100 rpm
Max torque
2863Nm (292kg-m)
@1400 rpm
2863Nm (292kg-m)
@1400 rpm
Starting
motor
Battery
24V,9kw
7.5kw x 2nos
2 x 12V, 200Ah
2 x 12V, 200Ah
Alternator
24V,75A
24V,100A
Model
BH35-2/WS28-2
BH60
Hoist
pressure
17.2Mpa (175kg/cm2)
18.96Mpa (192.5kg/cm2)
Emergency
steering
pressure
Depends on battery voltage
2750psi
Hoist
cylinder
type
Twin, 3-stage, double acting, Twin, 2-stage, double acting, telescopic
telescopic type
type
33
BEML APPRENTICE TRAINING REPORT
Body
time
hoist
Charging
suspension
pressure
16
1.5sec
Front
2.8Mp
a,
28.12k
g/cm2
Rare
1.9Mpa,
19.5kg/cm2
Load/Deflect
482kg/
ion rate
cm,
408kg/cm,
Empty/loade
1132kg 5504kg/cm
d
/cm
13
2sec
Front
2.9Mpa,
29.12kg/
cm2
637kg/c
m2 ,
2401kg/
cm2
Rare
2Mpa,
20.05kg/cm2
435kg/cm2,
24385kg/cm2
Steering
relief
pressure
12.4Mpa (126kg/cm2)
17.5Mpa (179kg/cm2)
Fuel tank
Capacity
(L)
540
770
Hydraulic
tank
capacity (L)
225
360
Engine oil
SAE 15W-40
SAE 15W-40
Transmissio
n oil
SAE 30
SAE 30
Hydraulic
oil
SAE 10
SAE 10
Multi
purposes
gear oil
SAE 90
SAE 90
Suspension
Hydro
pneumatic
rebound control
integral Variable rate independent oil pneumatic
suspension
34
BEML APPRENTICE TRAINING REPORT
4. RESEARCH AND DEVELOPMENT
R&D means Research and Development. Its main role is to discover and create new
knowledge about scientific and technological aspects and Developing new products, process
and services. It is also responsible for using efficient method of production. It designs new
equipment and making any alternation to it. They use Computer Aided Designing software
like, CATIA, PRO-E, AUTO CAD and Computer Aided Engineering software like ANSYS
for designing the products. This year BEML manufacturing dumper of 205-ton capacity
The R&D lab facilities includes CAD Centre, Power line Laboratories, Structural
Engineering Laboratories, Fluid power Laboratories, Material Science Laboratories,
Electronics and Instrumentation Laboratories and Prototype Shops.
R&D centre at KGF was established in 1984, which is the biggest development centre
in India. It is recognized by Dept. of Science. This centre is included a vital contribution
towards strengthening the Earth Mover and related Industries in the country. Comprehensive
facilities in highly specialized area are available at the centre. Extensive computerization has
led to highly advanced technology development in various areas of activities in BEML R&D
division like CAD Centre, Fluid power, Power line testing & Structural Engineering.
Behind the success of R&D division is undoubtedly the brainpower of its highly
competent engineers, who are specialized in advanced field of mechanical design, engine
technology, structural engineering, material science, fluid power and electronics. In view of
the challenge of diversification plans in the field of mining, Railways, Defence, Robotics and
Industrial Atomization, the company plans to augment the strength of R&D professionally by
reducing by recruiting skilled man power.
Vision
BEML will build the future business around its core competent in high tech engineering
product for defence and chosen area by developing people competencies, upgrading
technologies, innovating and adding value to the with in-house R&D and HRD efforts and
aiming towards self-reliance.
Mission:
BEML will strive to maintain a balanced growth with profitability in all its activities
and strive for domestic market and global presence by developing a strong brand name.
35
BEML APPRENTICE TRAINING REPORT
R&D Focus:
 To design and develop state of the art products to meet the demands of core sector viz.
Defence Mining, Railways and infrastructure.
 Build total self-reliance in Earth Moving and related technology
 Update current products for higher performance, reliability and be a leader in the field.
 Create test facilities for evaluating equipment and aggregates performance and reliability.
CAD Centre Objectives:
 Establish state-of-the-art facility in CAD /CAE for design and development of Earth
moving Equipment and Aggregates to meet international standards
 Developed software for simulations/ application to suit in-house requirements.
 Provide consultancy and training to various departments in the area of computers.
 Achieve total computerization of R&D activities incorporating Emerging Information
Technology.
R&D Activities:
 Steady and evaluation of technological innovation
 Up gradation of existing products
 developments of new products
 Introduction of new products through technology transfer
 In house development of critical Hi-tech aggregates
 Joint development with industries and academic institution
 Representing BEML in various technology forums
 patenting and intellectual property rights (IPR) activities
 Collaborative R&D with DSIR laboratories
 Collaborative product development with funding agencies like TIFAC
 Company standardization activities.
36
BEML APPRENTICE TRAINING REPORT
FLOW CHART FOR NEW PRODUCT DEVELOPMENT:
MARKETING
NEW
PRODUCT
DESIGN
NO
FEASIBLE
NO
FEEDBACK
TO
MARKETING
STOP
START OF
PRODUCT
DEVELOPMENT
R&D
YES
APPROVAL
FROM
MANAGEMENT
RELEASE
RELEASE
OF
OF
DRAWINGS
DRAWINGS
YES
IOM
3D
MODELLING
CAD ACTIVITIES , ANALYSIS
& DRAFTING
UPDATING
DATABASE
ERP
ENGINEERING CHANGE NOTICE (ECN):
RELEASE
DRAWINGS
SHOP, FIELD FAILURE
REPORT PROBLEM
ISSUE ECN
ANALYSE
PROBLEM
CREATE
ECN
R&D
CREATE
ECR
IMPACT
ANALYSIS
INCORPORATE
DESIGN CHANGES
37
BEML APPRENTICE TRAINING REPORT
Awards of R&D Excellence

DSIR Award-outstanding R&D achievments:1990-91

CII Award-Excellence in Technology:1986-87

SEI Award-company standardization 1990, 1992 & 1995

Accredited for calibration of Pressure and Flow
Software Used In R&D Department
 PRO-ENGINEERING (Pro-E)
 AUTOCAD
 UNIGRAPHICS
PRO-ENGINEERING :( Pro-E Wildfire-3 and wildfire-5)
38
BEML APPRENTICE TRAINING REPORT
AUTO CAD-2007:
UNIGRAPHICS: (NX 7.5)
39
BEML APPRENTICE TRAINING REPORT
5 CONCLUSION:
In this one-year apprenticeship training period, I learnt many technical things which
I have studied during my academic and also learnt about industrial standards, working
principles, safety precautions. I have improved my technical skills as well as personal skills. I
hope this training will help to get a job in good company and also it may help in future to
achieve my goal.
40