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General Maintenance Instruction PDF
General Maintenance Instruction PDF
Introduction: - The JCB 3DX Excavator cum loader is powered by Kirloskar 4R 1040
NEUTRAL lapse rated diesel engine developing 65 HP at rated 1500 RPM. The machine is
fitted with torque converter, synero shuttle, fully synchromesh, gear box and 4x4 wheel drive.
The equipment has got separate excavating mechanism and clam shovel loading device fitted on
same chassis.
Aim: - Aim of issuing this GMI to enumerate the details of periodic and preventive maintenance
of JCB 3DX excavator loader machines.
Action by:-
(a) USER UNIT. To carry out periodic inspection, regular servicing and preventive
maintenance tasks as laid down.
(i) To check the record of maintenance and lubrication in the log book of the eqpt
during its inspection and repairs if carried out as per maintenance and lubrication
schedules given in this instructions.
(ii) Advice user units in respect of any discrepancy/short coming noticed.
Details :-
(Hari Prakash)
SE (E&M) FS
Director (Tech)
For Dir Gen Border Roads
This General Maintenance Instruction is required to attention and followed by the operator and
supervisor for ensuring efficient and trouble free operation of the machine, Do not start any Job
until you are sure that you and those around you will be safe.
SAFETY PRECAUTION
1. Obey all laws, worksite and local regulations which affect you and your machine.
2. All the time you are working with or on the machine take care and stay alert.
3. You can wear proper clothing when you are operating the machine.
4. Operate the control levers only when you are seated correctly inside the cab.
5. Do not operate the machine which is defective or has missing parts makes sure the
maintenance procedures are completed before using the machine.
6. Maintenance technicians should understand the hydraulic circuit. They should know how
to release trapped pressure before disconnecting any hose.
7. Do not perform new operations until you are sure you can do them safely.
12. Do not operate the machine until the fault has been corrected.
16. Do not use the machine in closed areas where then is flammable material, vapour or dust.
21. The loader arm must be lowered and backhoe closed whilst traveling.
E:\GMI 224 TO 246\GMI No 238.doc
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22. Operate in first gear on hill sides.
23. Use extreme caution when driving into ramps and trailers.
24. You remove and fit metal pins such as pivot pins wear safety glasses.
25. Before starting the engine make sure the others are clear of the danger areas.
27. Understand the electrical circuit before attempting to connect to disconnect any electrical
components.
29. Keep the electrolyte away from your clothes skin mouth and eyes.
30. Do not check the battery charge by shorting the terminals with metal. Use a hydrometer
or voltmeter.
31. Do not remove the radiator cup when the engine is hot.
34. Do not refuel with the engine running there could be a fire and injury if you do not
follow these precautions.
37. Make sure the radiator/oil cooler matrix is kept clear of dirt.
38. When leaving or parking the machine close all rams if possible to avoid.
41. Do not use trichloroethylene or paint thinners in the presence of a rings and seals.
50 hrs maintenance
The 100 hourly maintenance schedules should be carried out at either 100 hrs of continuous
operation or 1 month which ever is earlier.
1. Carry out maintenance schedule specified for 10 hrs and 50 hrs maintenance.
2. Check for any damage to ram piston rods.
3. Check for correct functioning of pump drive and listen to any abnormal sound coming
from drive. Report workshop if any abnormal sound coming.
4. Check all hydraulic oil carrying pipes for leakage/chaffing/damage. Replace if required
5. Get following check from workshop:-
1000 50 0.3-0.9
2000 50 1.8-2.4
1000 100 0.1-0.3
2000 100 1.3-2.1
MAIN LINE PRESSURE (IN NEUTRAL)
1000 50 0.3-0.9
2000 50 1.8-2.4
1000 100 10.4-12.4
2000 100 11.8-14.3
CLUTCH PRESSURE (IN NEUTRAL) all clutch pressure should be same as main
line pressure with in 0.7 bar 10 Lbs.
PUMP AT 50 oC
1000 50 3.0-4.1
2000 50 6.7-8.8
MRV Pressure
3. Check pivot pins and bushes for damage and grease if required any.
4. Check for parking brakes and adjust suitable.
5. Check engine injector pressure and calibrate suitably.
Tyre Pressure
Size PR Pressure
bar
9.00x16 16 7.2
12.5x18 16 3.5
14.00x25 20 2.8
16.9x28 10 2.8
Industrial