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leak free analysis
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Leak Free Analysis of JCB Backhoe Loaders
1. JCB is named after its founder Joseph Cyrill Bamford,producing yellow&black engineering vehicles,diggers,excavators.
2. Company was founded on october ,1945 in Stanffordshire,England and first product was farm trailer from war surplus material.
3. It has two plants in India one in Haryana & other in Pune.
Introduction to company
Products manufactured by JCB
Different units at JCB(Haryana) are -:1. Assembly unit .2. Weld &fabrication unit.3. Paint shop unit.4. Transmission unit.5. Central materials unit.6. Purchase unit.7. Marketing&Finance.
Different units at JCB plant
Assembly Line Layout
MAIN FRAME INNER LEG FITMENT
FRONT AXLE
FITMENT
STONE GUARD FITMEN
T
LVB & EVB CONNECTIO
N
FUEL TANK & HYDRAULIC
TANK FITMENT
KPC FITMENT
GANG WAYS
SKID & MAIN FRAME DROPPING
ELECTRICAL CONNECTIONSCOOLING SYSTEMFRONT END LIFT RAM & LOADER
ARM FITMENTCAB FITMENTBRAKE BLEADINGTYRE MOUNTINGBOOM & DIPPER FITMENT
Oil filling Machine testing
1. Boom Sub-Assembly -:Boom is fittted hydraulic ram which provide movement when it is attached with machine.This is responsible for loader bucket movement.
2. Dipper Sub-Assembly-:It is also same as boom assembly the only differnce is that this assembly is responsible for excavator’s movement.
Boom-Dipper Assembly
Engine sub –assembly mainly consist of 4 parts-:1. Engine-:A kirloskar 76HP,gross power 56 kw
at 2200 rpm engine is installed in backhoes.2. Torque Converter-:Takes the place of
mechanical clutch&able to multiply torque when difference between input &output is substantial.
3. Fly Wheel-:A rotating disc that stores kinetic energy.
4. Gear box-:4 speed fully syncromesh gear box with electrically reversing shuttle.
Engine Sub - Assembly
1. JCB 3DX Backhoe loader-:4 cylinder,76HP,4- speed synchromesh,3300psi hydraulics ,front wheel steering.
2. JCB 3DX Super Backhoe loader-:4 cylinder,90HP,4-speed synchromesh with reversing shuttle,3300p hydraulics, front wheel drive.
3. JCB 4DX Backhoe loader-:4 cylinder,96HP,4-speed synchromesh with reversing shuttle,3300psi hyadraulics ,front wheel.
Above also varies in gear ratio .
Specification of products manufactured by JCB(HRY)
1. Excavator valve block-:EVB mounting plates provides base on which valve block is fitted then adaptors which provide inlet and outlet for hydraulic oil.EVB is used for controlling excavator bucket.
2. Loader valve block-:Responsible for movement control of loader bucket.
Valve Blocks
1. Radiator assembly-:cooling unit, hydraulic cooler for cooling of hydraulic oil, seal are components of radiator.
2. King post carriage-:it provides supporting mech. to boom dipper . It is a combination of slew ram , boom lock, bushes, feed pipe & seals.
3. Cab Assembly -:it is operating room of the entire machine.
Other Sub -Assemblies
1. The aim of our project is to determine the cause of hydraulic leakages that has been occuring in JCB machines .
2. As there are so many joints and hose pipes present in machine so 100% efficient is not possible.
3. This leads to loss in efficiency, wastage of time &extra expenditure.
Leakage Analysis
Actuation of various arms are controlled by fluids that are made to flow by piston mechanism for the movement of arm/pistons.
Mechanism involved in the hydraulic movements
The basic losses due to leakage are-:1. Clean up.2. Make up fluid.3. Disposal of waste oil.4. Contamination ingress.5. Decrease in machine efficiency.6. Increase in expenditure to machine.
Losses due to leakages
Major joints of leakage
1
2
3
4
5
6
7
8
9
10
11
12
13
2
4
2
2
2
2
4
1
4
2
2
2
2
Front axle ram
LVB to feed pipe
EVB to boom ram
EVB to dipper ram
EVB to bucket ram
EVB to slew ram
EVB to leg hose
EVB to return feed pipe
Header piston joints
Hydraulic pump to LVB
Feed pipe to tank
LVB to return feed pipe
Oil tank to hydraulic pump
14
15
16
17
18
19
20
21
22
23
24
25
26
27
2
4
2
2
2
2
4
1
4
2
2
2
2
1
hydraulic cooler/radiator plug
Return feed pipe to hydraulic cooler
Oil tank to hydraulic cooler
Hose to lift ram
Fuel tank to fuel pump
Hose to loader bucket ram
Orbitral unit to front axle ram
Orbitral unit hose to LVB
Orbitral unit to hose hydraulic pump
EVB hose to legs
EVB hose to boom ram
EVB hose to dipper ram
EVB hose to bucket ram
Radiator hose
Some of important joints
Front axle ram EVB to boom, dipper &bucket
rams
Hydraulic tank to pump
Gear pump to hydraulic cooler
Hose to lift ram EVB hose to boom ram
Methodology of Analysis
Studied all the hydraulic joints
Complete inspection of
joints
Reduced the no. of
machines inspected for 2
days
Left all the machines
All leakage duly
noticed
Compared the hot bay test
report
1. It is quite inevitable a proper inspection technique as most of the leakages occur due to operators negligence.
2. Method to significantly reduce the number of leakage point during assembly line is introduction of inspection zone.
3. This inspection zone includes the point where the cab is placed to where the loader arm is set on the framework.
Inspection zone
The introduction of inspection zone has following features-:
1. As most of the hydraulic joints ,that are prone to leakages ,are open in this region,it provides Easy Inspection Vicinity.
2. Maximum number of machines can be inspected. Only four minutes is required on one machine by two operators.
Features of inspection zone
Advantages are -:1. A lot of time is wasted in the Hot bay &
PDI zone to rectify the leakages.2. Hydraulic oil losses can be
minimized ,saving a lot of money.3. Expenditure related to clean up of
leakages ,disposal and contamination can be easily prevented.
Advantages of inspection zone
Major causes of leakages are-:
1. Leakage due to improper torquing.2. Leakage due to manufacturing defects.3. Leakage due to defect because of man-
power.4. Leakage because of contamination of oil.
Major causes of leakage
The methods are-:1. Hydraulic dye test.2. Hot bay test.3. Replacement of metal pipe.4. Reduction of elbows and T-pieces.
Other ways to tackle leakages
THANK YOU &
HAVE A NICE DAY
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