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
FITMENT
LVB & EVB
CONNECTION
FUEL TANK &
HYDRAULIC
TANK
FITMENT
KPC FITMENT
SKID & MAIN
FRAME
DROPPING
ELECTRICAL
CONNECTIONS
COOLING
SYSTEM
FRONT END
LIFT RAM &
LOADER ARM
FITMENT
CAB FITMENT
BRAKE
BLEADING
TYRE MOUNTING
BOOM & DIPPER
FITMENT

1. Boom Sub-Assembly -:Boom is fitted
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 difference 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 synchromesh 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 hydraulics ,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 occurring 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 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