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