Repairing/ Overhauling of Clutch Assembly, Gearbox Assembly, Hydraulic jack, Exhaust system and PTO pump Air compressor assembly of TATA Hyva LPK-2518 (Reg.No.JH10AH-2348) at Moonidih Coal Washery.

Item Description/ Heading

Drain oil, remove mounts and open clutch, bell housing and gearbox

Separate gearbox from engine and inspect clutch release mechanism

Remove clutch plate, pressure plate and release bearing

Recondition pressure plate and check diaphragm spring tension

Replacement of worn out components

Set clutch finger hight and adjust pedal free play

Clutch plate Assembly (CI Facing plate)

Clutch release bearing

Clutch connecting Ring

Clutch Release lever kit

Dismantle gearbox casing and clean internal components

Replace main shaft bearings, counter shaft bearings and roller bearings

Replace top gear pinion, counter pinion, main shaft pinion and reverse pinion

Install new oil sals and gasket kit , refit gearbox to engine with proper alignment

Fill gearbox oil and check for leaks & Tst gear shifting and clutch engagement under load

Roller bearing

Counter shaft bearings

Main shaft bearings

Top gear pinion

Top gear pinion bearing

Main shaft gear pinion

Counter shaft gear pinion

Counter shaft bearings

Reverse gear pinion

Oil seal & Gasket kit

Remove PTO pump, drain oil and open housing

Dismantle pinion, rotor and bearing assembly

Clean housing and inspect gear wear and clearance

Replace PTO housing, pinion, piston bearing and packing kit

Refit PTO pump and check hydraulic line connectins

PTO pump housing

PTO gear pinion

Pump bearing

Pump piston

Packing

Dismantling of complete brake assembly including brake drum and shoe set

Inspection of brake shoes, linings, cam bushes, return springs and actuating mechanism

Replacement of worn or damaged brake shoes etc

Polishing/ dressing of brake drum surface to remove scoring and uneven wear

Adjustment of brake shoe clearance for uniform braking

Reassembly of brake components with proper alignment and clearance

Brake shoe

Cam bush

Brake drum pokish

Dismantling of hydraulic jack (telescopic/ front-end cylinder) from the tipping body and chassis mounting

Opening of cydraulic cylinder, piston and rod assembly

Through cleaning of cylinder bore, piston and internal components

Replacement of worn-out seal kits, packing, O-rings, bushes anddefective internal parts as per condition

Honing/ polishing of cylinder bore and piston rod, whereever required to restore smooth surfact finish

Reassembly of hydraulic jack with proper clearance and alignment

Piston

Packing

Piston

Dismantling of existing silencer and exhaust piping followed by inspection of silencer body, inlet/ outlet pipes, clamps and mounting brackets for corrosing cracks, leakage and blockage

Cleaning of silencer internals and exhaust passagtes to remove soot, carbon deposits and obstructions

Repairing of silencer body by welding, patching or replacement of damaged portions as required

Realignment of exhaust piping to ensure proper clearance from chassis body and bydraulic components

Reinstallation of silencer assembly with proper tightening and secure mounting

Functional test and run to ensure smooth operation after complete fitting

Total impact of GST for the purpose of CTC