To make a detail report on all the manufacturing & Assembly departments

& Hydraulic leakage analysis of backhoe machine

A PROJECT REPORT
Submitted in partial fulfilment of the
Requirement for the award of the
degree of
BACHELOR OF TECHNOLOGY (B.Tech)

By

ABHISHEK SAMRIWAL (169109012)

UNDER THE GUIDANCE OF
MR. KAPIL SHARMA
(SENIOR MANAGER)

DEPARTMENT OF MECHANICAL ENGINEERING

(SAMM)
MANIPAL UNIVERSITY JAIPUR
DEHMI KALAN JAIPUR - 303007
(2019 - 2020)
 DEPARTMENT OF MECHANICAL ENGINEERING
MANIPAL UNIVERSITY JAIPUR, JAIPUR – 303 007 (RAJASTHAN), INDIA

Date

CERTIFICATE

This is to certify that the project titled detail report on all the manufacturing &
Assembly departments in the company & Hydraulic leakage analysis of
the backhoe machine is a record of the bonafide work done by ABHISHEK
SAMRIWAL (169109012) submitted in partial fulfilment of the requirements for the
award of the Degree of Bachelor of Technology (B.Tech) in (Discipline) of
Manipal University Jaipur, during the academic year 2019-20.

Dr Sasanka Sekhar Ghosh

Project Guide, Dept of MECHANICAL ENGINEERING
Manipal University Jaipur

HOD Name Anshul Goyal

HOD, Dept of MECHANICAL ENGINEERING
Manipal University Jaipur
 CERTIFICATE

This is to certify that the project entitled report on all the manufacturing &

Assembly departments in the company & Hydraulic leakage analysis of

backhoe machine was carried out by ABHISHEK SAMRIWAL (169109012) at

JCB, FARIDABAD under my guidance during JANUARY, 2020 to JUNE 2020.

KAPIL SHARMA
Senior manager,
JCB, Faridabad
 ACKNOWLEDGEMENT

Its a great pleasure to present this report of summer training in JCB at

Ballabhgarh in partial fulfillment of B.Tech Program under Manipal
University Jaipur, JAIPUR

At the outset, I would like to express my immense gratitude to my training

guide Mr. Kapil Sharma who guided me right from the inception till the
successful completion of the training.

I am falling short of words for expressing my feelings of gratitude towards

him for extending his valuable guidance about all the aspects of
manufacturing from technical level to administrative level and support for
literature, critical reviews of project and the report and above all the moral
support he had provided me throughout all stages of this training.

I would also like to thank my friends and all my group members for
their help and cooperation throughout the training.

Trainer Mr. Kapil Sharma

JCB INDIA LTD.

 ABSTRACT

During my internship, I was asked by my mentor Kapil Sharma Sir (senior

manager) to make a detail report step by step on all the different department
of the manufacturing of backhoe machine in the plant for my midterm
evaluation project. While going through every department I observe each and
every process very carefully and time require from one station to another.
Then I made a standard operating procedure (SOP) for all the departments
then I prepared standard work flow chart to better understand the process
and different step involved. Then I gathered information from workers and
production engineering about each station step by step .After acquiring every
information on each station and taking photos of all the stations I discussed
with my mentor and made the necessary changes and then made a formal
presentation of my project.
In this project an attempt has been made to carefully study all the steps and
time required for the manufacturing of backhoe machine

After this I was assigned a project of hydraulic leakage analysis The aim of
our project is to determine the causes of hydraulic leakage that is been
causing in the JCB Backhoe machine. As there are so many hose pipes and
joints in the machine 100 % leak proof is not possible. This leads to loss in
efficiency , high maintenance cost and wastage of time
 CONTENTS
Chapter No. TITLE Page No.

1. List of abbreviations
2. List of tables

1 INTRODUCTION
1. Introduction / Heritage
2. Product made by the company
3. Operation & Dimension specifications
4. Machine specifications
5. Flow chart

2 WORKING OF THE MACHINE

1. HOW JCB MACHINE WORKS
2. Hydraulic & Transmission specifications

3 CYCLES OF MANUFACTURING UNIT

1. LOGISTICS
2. FABRICATION SHOP
3. BOOM & DIPPER SUB ASSEMBLY
4. RAM PAINT SHOP
5. ENGINE MACHINING & ASSEMBLY
6. TRANSMISSION ASSEMBLY
7. MAIN FRAME ASSEMBLY LINE(M-LINE)
8. SKID SUB ASSEMBLY
9. BACKHOE ASSEMBLY(ENGINE+ FRAME)
10. MAIN ASSEMBLY(ENGINE+FRAME+HYDRAULICS)
11. PDI & TESTING ZONE
4 AXLE, TRANSMISSION & GEAR BOX ASSEMBLY
5 FRONT AXLE SUB ASSEMBLY

6 MAIN ASSEMBLY
1. MAIN FRAME ASSEMBLY (M LINE)
2. MAIN ASSEMBLY LINE (A LINE)
3. TWIN SLAT LINE

7 PDI AND HOT BAY TEST ZONE

8 PROJECT REPORT (HYDRAULIC LEAKAGE ANALYSIS)
9 MOTIVATION/LITERATURE REVIEW/OBJECTIVE/TARGET
10 CONCLUSION/TOOL REQUIRED/TECHANICAL REFRENCE
11 FUTURE SCOPE OF WORK
 LIST OF ABBREVIATIONS

 ASSY - ASSEMBLY
 LTM – LEAK TESTING MACHINE
 OP – OPERATING PROCEDURE
 PDI – PRE DELIVERY INSPECTION
 FIP – PUEL INJECTION PUMP
 M/F – MAIN FRAME
 B/D - BODY
 EMS – ELECTRIFIED MONORAIL SYSTEM
 LVB FITMENT – LOADER VALVE BLOCK
 EVB FITMENT – EXCAVATOR VALVE BLOCK
 KPC FITMENT – KING POST CARRAGE
 WBC – WHEEL BEARING CUP
 PHC - PLATING HALF CARRIER
 BPH – BREAK PISTION HOUSING
 DIFF. – DIFFERENTIAL
 HYD. – HYDRAULICS
 HP- HORSE POWER
 LIST OF FIGURES

 CYCLE FLOW CHART

 ENGINE HEAD MACHINING CHART
 AXLE ASSEMBLY
 GEAR BOX ASSEMBLY
 EXCAVATOR VALVE BUCKET
 LOADER VALVE BUCKET
 METHOLOGY OF ANALYSIS
 INTRODUCTION

J.C. Bamford Excavators Ltd., universally known as JCB, is a

British multinational corporation, with headquarters
in Rochester, Staffordshire, and manufacturing equipment for construction,
agriculture, waste handling and demolition.
JCB was founded in 1945 by Joseph Cyril Bamford, after whom it is named;
it continues to be owned by the Bamford family.
Who always followed the motto?
“ you know my motto from my initials J.C – Jamal’s Content – that’s very very
much me. I am never content.”

JCB Heritage

What begin in a garage of 12 feet by 15 feet back in 1945, today

manufacturers
Over 220 models of construction & agricultural equipment on four different
Continents with bases in U.K., the U.S., India & South America.
JCB world headquarters is one of the finest engineering factories in Europe
and
Sells a full range of equipment in over 150 countries.
Today, JCB is one of the world’s largest construction equipment
manufacturer.

It follows policy of E=MC2

Where,
E = Energy to infuse “sense of urgency”
M = Motivation to win
C = Challenge
C = Care & Commitment
 PRODUCTS MADE BY THE COMPANY

1. JCB 3DX BACKHOE LOADER :

 It is the machine which comes under the category of earth movers
 Is a bucket fitted in the front portion of the machine & an excavator fitted
 Backwards which are used to dig earth or transfer it from one position to other.
 This machine does 3-dimensional movement during its working that’s why ,it is
 Called 3DX Backhoe Loader. Its functioning is totally based on hydraulics.

Features:

 Engine

 76 horsepower fuel efficient KOEL engine with increased size of coolers

 For better performance in hot and dusty working conditions.
 New transmission designed to provide high traction forces and long life
 For continuous loading duties.
 Low Fuel Consumption.
 76 horsepower fuel efficient KOEL engine with increased size of coolers
 For better performance in hot and dusty working conditions.
 New transmission designed to provide high traction forces and long life
 For continuous loading duties.
 Low Fuel Consumption.

 Performance

 Increased shovel capacity of I.I co. with high breakout forces give
Extraordinary loader productivity.
 Improved performance. Increased diesel tank capacity, protection on
Excavator, hoses and improved excavator valve block feature, ensure
Even better excavation economics.
 Highest Productivity in Class.
 Increased shovel capacity of I.I co. with high breakout forces give
Extraordinary loader productivity.
 Improved performance. Increased diesel tank capacity, protection on
Excavator, hoses and improved excavator valve block feature, ensure
Even better excavation economics.
 Highest Productivity in Class.

 Design

 D section loader arm and chassis design gives lifelong structural durability
 Pannier design diesel and hydraulic tank s greatly add to the operator
 High Versatility.
 Strong Excavator End.
 D section loader arm and chassis design gives lifelong structural
 Durability.
 Pannier design diesel and hydraulic tank s greatly add to the operator
 High Versatility.

3DX Backhoe Loader

2. JCB 3DX Super :

 Its construction,functioning,working as well as area of applicability is very

 Much similar to that of the 3DX Backhoe apart from the only difference
 That, it is a 4-wheel drive machine giving it more power & edge over the 3DX
 It has a more powerful engine 90 hp 4 speed synchromesh with reversing shuttle,
3300psi hydraulic front wheel drive

 Features :

• Strong excavator ends

• 4 wheel Drive machine
• Two did depth option
• Bigger coolers to work in hot and dusty conditions.
• 90hp powerful engine

JCB 3DX SUPER MAX

 3. 4DX Backhoe Loader :

This machine is also quite similar to 3DX Backhoe Loader apart from the difference that
it’s forward bucket area as well l as volume can be increased or decreased according to
the need of the user thus making it a 4-dimensional working machine as it called so as
4DX Backhoe Loader.
It is the most powerful excavator that the company manufactures it is a 96 hp , 4 speed
synchromesh with reversing shuttle, 3300 psi, front wheel drive

Features:

• Strong excavator ends

• 4 wheel Drive machine
• Two did depth option
• Bigger coolers to work in hot and dusty conditions.
• 96hp powerful engine

4DX Backhoe loader

 4. Lift all :
LIFTALL – Lift and Carry Mobile Crane.

The first model, JCB Lift all – 1253 is a 12T capacity mobile crane fitted with a
Telescopically extendable 3-part boom and is very useful for the erection and
Construction sites, container, steel and timber yards. This will be a highly useful
Tool for equipment rental companies because of its versatility.
This is the only machine in its class presently in India with European standard (IP-
69) Electrics, making the piece of equipment very reliable. It also has many
Exclusive and superior features, best in class, like height of lift 12.5m under hook;
Travel speed – 30 mph; a very sturdy transmission for more reliability;
Unrestricted visibility on full height and wider why eel track, altogether making it a
Safe and highly useful machine for erection and container jobs.
Like all JCB products, the Lift all offers unparalleled operator comfort, with its
Insulated ceiling, fan, long helper seat (adequate for overnight sleep on distant
Sites) and large tool box. All controls are ergonomically designed for better
Operation.

Liftall

These are the four products which are manufactured at the JCB (Balabhgarh)
Plant which is world’s largest plant for the manufacturing of backhoe loaders.
Here, at JCB 75 Backhoe Loaders are produced daily with its 5 working days in a
Week out of which generally four days are of production & 1 day in a week is NPD
(Non-Production day).On NPD ,there is no production but t the reworking of the
produced goods are done as well as plant’s inspection takes place.
 OPERATIONAL & DIMENSIONAL SPECTFICATION
Operational
Operating Weight
Max Weight
Fuel Capacity
Fluid Capacity (Oil System)
Fluid Capacity (Cooling System)
Front Axle Fluid Capacity
Rear Axle Fluid Capacity
Turning Radius
Front Tire Size
Rear Tire Size
Operating Voltage
Alternator Supplied Amperage
Dimensions
A: Load Height
B: Reach From Swivel
C: Dig Depth (Backhoe)
D: Reach (Load Height)
E: Clearance (Max Dump Height)
F: Reach (Max Dump Height)
G: Dig Depth (Loader)
H: Length
I: Width
J: Height
K: Wheelbase
M: Ground Clearance
N: Height (Top of Cab)
17515 lb (7944.7 kg)
18701 lb (8482.6 kg)
42.3 gal (160 L)
4 gal (15 L)
6.1 gal (23 L)
4.2 gal (16 L)
4.2 gal (16 L)
13.8 ft in (4200 mm)
(2WD / 4WD)14-17.5 FWD 10 ply
(2WD / 4WD)19.5L-24 R4 10 ply
12 V
95 amps
13 ft in (3960 mm)
20.9 ft in (6380 mm)
17.6 ft in (5360 mm)
7.2 ft in (2180 mm)
8.8 ft in (2690 mm)
2.7 ft in (810 mm)
2 in (50 mm)
24.6 ft in (7490 mm)
8 ft in (2440 mm)
13.6 ft in (4140 mm )
7.4 ft in (2260 mm)
1.1 ft in (330 mm)
9.4 ft in (2870 mm)
 MACHINE SPECTIFICATIONS
Backhoe
Dig Depth (Standard)
Dig Depth (Extend)
Reach From Swivel (Standard)
Reach From Swivel (Extend)
Bucket Dig Force (Standard)
Bucket Dig Force (Extend)
Load at Max Lift (Standard)
Load at Max Lift (Extend)
Load Height (Standard)
Load Height (Extend)
Reach at Load Height (Standard)
Reach at Load Height (Extend)
Loader
Bucket Capacity
Bucket Width
Bucket Breakout Force
Lift Capacity (Full Height)
Clearance (Max Dump Height)
Reach (Max Dump Height)
Dig Depth
17.6 ft in (5360 mm)
21.5 ft in (6550 mm)
20.9 ft in (6380 mm)
24.7 ft in (7520 mm)
12202.6 lb (5535 kg)
12202.6 lb (5535 kg)
5121.3 lb (2323 kg)
3240.8 lb (1470 kg)
13 ft in (3960 mm)
14.7 ft in (4470 mm)
7.2 ft in (2180 mm)
10.8 ft in (3300 mm)
1.6 yd3 (1.2 m3)
96 in (2438.4 mm)
14560 lb (64.8 kN)
9046 lb (4103.2 kg)
8.8 ft in (2690 mm)
2.7 ft in (810 mm)
2 in (50 mm)
 HOW JCB MACHINE WORKS
The Basic Idea of hydraulics:
The basic idea behind any hydraulic system is very simple: Force that is applied at one point is
transmitted to another point using an incompressible fluid. The fluid is almost always an oil of
some sort. The force is almost always multiplied in the process.

If two pistons fit into two glass cylinders filled with oil and connected to one another with an oil-
filled pipe. If you apply a downward force to one piston (suppose the left one ), then the force is
transmitted to the second piston through the oil in the pipe. Since oil is incompressible, the
efficiency is very good – almost all of the applied force appears at the second piston. The great
thing about hydraulic systems is that the pipe connecting the two cylinders can be any length and
shape, allowing it to snake through all sorts of things separating the two pistons. The pipe can also
fork, so that one master cylinder can drive more than one slave cylinder if desired.

The neat thing about hydraulic systems is that it is very easy to add force multiplication (or
division) to the system. In a hydraulic system, all you do is change the size of one piston and
cylinder relative to the other, as shown here:

Hydraulic multiplication:
Suppose the piston on the right has a surface area nine times greater than the piston on the left.
When force is applied to the left piston, it will move nine units for every one unit that the right
piston moves, and the force is multiplied by nine on the right-hand piston.
To determine the multiplication factor, start by looking at the size of the pistons. Assume that the
piston on the left is 2 inches in diameter (1-inch radius), while the piston on the right is 6 inches in
diameter (3-inch radius).
The area of the two pistons is Pi * r2. The area of the left piston is therefore 3.14, while the area
of the piston on the right is 28.26.
The piston on the right is 9 times larger than the piston on the left. What that means is that any
force applied to the left-hand piston will appear 9 times greater on the right-hand piston. So if you
apply a 100-pound downward force to the left piston, a 900-pound upward force will appear on the
right.
The only catch is that you will have to depress the left piston 9 inches to raise the right piston 1
inch.

Air in the System

It is important that a hydraulic system contains no air bubbles. We may have heard about the need
to "bleed the air out of the brake lines" of our car.
If there is an air bubble in the system, then the force applied to the first piston gets used
compressing the air in the bubble rather than moving the second piston, which has
a big effect on the efficiency of the system.
The brakes in our car are a good example of a basic piston-driven hydraulic system.
When we depress the brake pedal in our car, it is pushing on the piston in
the brake's master cylinder.Four slave pistons, one at each wheel, actuate to press
the brake pads against the brake rotor to stop the car. (Actually, in almost all cars
on the road today two master cylinders are driving two slave cylinders each.
That way if one of the master cylinders has a problem or springs a leak, we can still
stop the car.)
In most other hydraulic systems, hydraulic cylinders and pistons are connected
through valves to a pump supplying high-pressure oil.
 HYDRAULICS & TRANSMISSION SPECTIFICATIONS

Transmission
TypeJCB Autoshift
Forward Gears 4
Reverse Gears 4
Max Speed (Forward) 22.5 mph (36.2 km/h)
Max Speed (Reverse) 22.5 mph (36.2 km/h)
Fluid Capacity (Transmission) 4.2 gal (16 L)

Hydraulics
Pump Type
Relief Valve Pressure
Pump Flow Capacity
Fluid Capacity (Hydraulic System)
dual gear pumps
3300 psi (22752.7 kPa)
40.9 gal/min (155 L/min)
33.5 gal (127 L)
FLOW CHART
 CYCLES OF MANUFACTURING UNITS

Logistics to fabrication :

• First of all, the machined sheets & pre-build parts (e.g., gear assy. Parts, rear axle
assy. Parts & engine etc.) are brought in the logistics area. These parts are given
by different vendors set by the company,(e.g., Engine by Kirloshkar etc.)
Then, according to the requirements :
• Metal sheets from which main frames, rear frames, Boomers/Dippers are to be
Welded are moved to fabrication shop.
• Engines parts are to be machined and moved to skid sub-assembly line and the gears
& rear –axle parts are moved to transmission line.

Fabrication Shop :

• In fabrication shop, welding of different parts of (3DX Backhoe loader),the product

which is made are done and then after their machining, finishing, surface smoothening
etc. are done. After machining, the machine parts are moved to paint shop.

Paint Shop :

• In paint shop, all the components parts are moved and painted, then the
Painted parts are moved to main frame assembly line.

Main Frame Assembly Line (M-Line) :

The machine parts from paint shop are brought to the main assembly line with the help of
EMS (Electric Monorail System) & cranes.
• This line has 10 zones ,for each zone certain workload is divided. In this line all
the assembling of the main frame is done.Then,this assembled main frame is
moved to the backhoe assembly line with the help of cranes & EMS system.

Backhoe Assembly Line (A-Line) :

• At the backhoe assembly line, skid is dropped from the skid sub assembly line.
Skid Sub-Assembly Line: Assembled gear box & rear axle from transmission
Line are moved to skid sub-assembly line. Here, the engine is connected to the gear
Box & rear axle. Thus (skid=Engine + Rear axle + gear box).
• The main frame is then dropped on this skid and then assembly of backhoe starts.
• The main assembly line (A-Line) has 22 zones for each zone certain workload is divided,
just likewise in the main frame assembly line.
• The assembled Backhoe is then moved over to twin-slat line.
Twin-Slat Line :

• At twin-slat line firstly the booms & dippers coming from the Boom/Dipper Sub assembly.
Line is attached to the machine and then the different oil filling process in
the machine is done.

PDI AND TESTING ZONE :

• The backhoe after being assembled in previous zones is moved to the PDI and testing
zone in which the full range of machine functioning (i.e., working of all the parts of the
machine; missing of any part, bolts or nuts;dismatching or defects in part of the machine
is checked).
• Then after, the machine is greased, washed & again goes on for the 45 minutes trial run.
• After that, all the machines parts are checked and if any part is missing or defected, then
the list of those parts are made. Then after, the machine goes on for the U.V.test by which
the lower portion of the machine is checked, whether any Leakage or defect in the hose
and feed pipes are not.
• After making the list of all the defects and deformities, the machine moves in the
reworking zone where all these remedies are solved.
• And, then after final washing, decal pastings & paint touch-ups ,the machine is green
signaled for dispatch.
 FABRICATION SHOP

1.Boom Cell :

3DX Boom is assembled and welded in this zone. In this zone manual welding is
Done with the process used is gas welding.

 Boom Sub Assembly – Boom is fitted with hydraulic arm which provide movement
when it is attach to the machine
 This is responsible for loder bucket movement
 Dipper sub assembly – it is alos same as the boom assembly the only difference is that
is is responsible for excavator movements

2.Rear Frame Cell :

Rear frame parts are assembled, welded and machined to give smoothness & Finishing.

3.Loader Arm Assembly

The parts of the loader tower are brought, assembled, tacked & then welded in
this zone with the help of robotic welding. After which manual welding &
machining of those parts are done which can’t be done with the help of robot welding.
6. Main Frame Welding Process :
 Different parts of the main frame are assembled or arranged by tacking them in
main frame tacking fixture cell.
 Then, it is pre-welded in pre-welding zone where simple welding spots are done on
the main fame.
 Then, the main frame is moved to Manual welding shop where those parts are
welded which can’t be welded in Robotic cell.
 Then, the main frame fixture is moved to Robotic cell where there are two stations.
 Station 1 for robotic welding to take place. Thus, the final main frame fixture is
obtained.

7.Boom/Dipper Robotic Welding :

In this zone,robotic welding of boom/dipper is done in which those parts are

welded which was left after manual welding.
After this ,boom/dipper are moved in boom/dipper machining area where they
are machined and then collected in the storage area.
Each & every component after fabrication are stored in fabrication business
unit(Fixture storage) after which all components with main frame,boom/dipper is
moved in the paint shop where they are painted and then moved to main frame
 RAM PAINT SHOP

 It is the shop in which hydraulic rams as well as certain other components of the
Machinery parts are painted. These components are :
KPC, LEG, SHAVAL, LIFT, BOOM, DIPPER, CROWD, ST-RAM

 The raw material is fed into the loading zone where they are moved over EMS
System which after then follows the cycle.

 The material which is pre-greased & oiled (to prevent corrosion) is passed.
Through WATER RINSE-1, where it is bathed with a mixture of water mixed with
Chemical.
 Chemical name: Deoxy lite 54NC

 Then, the components are passed through activation zone and after that in the
Phosphating zone where phosphate coating is done on the surface of the
Components.
 The coating chemical is Fixodiene 30-L

 Then, the components are moved in the reason water rinsing section-2

 Then, the component is moved to air blow-off zone in which the components are air
blown so that no water molecules should stick on the surface

 The component is moved to dry-off zone where it is heated in the oven, heating
temperature maintained at 62 degree Celsius and 1 atm. Pressure. In this zone
the components are fully dried.

 The component is moved to masking zone where masking of holes are done to
prevent the inflow of paint in the bores.

 Then, the component is moved to primer booth blower where the component is
coated with the primer.

 The components are then moved to top-coat booth blower where final coating
of the paint is done and then the components are moved in the baking zone
where the components are baked in the oven having temperature in the range of
(90-95) degree Celsius.

 Here, the paint on the components surfaces are baked.

 The components are then unloaded in the unloading zone and then prepared to
move to different sections of the manufacturing lines.
 ENGINE SPECIFICATION

Make JCB

Model 444
Net Power 97.6 hp (72.8 kw)
Gross Power 100 hp (74.6 kw)
Measured at 2200 rpm
Displacement 268.5 cu in (4.4 L)
Torque Measured at 1300 rpm
Engine Cylinders 4
Aspiration Turbocharged
 ENGINE ASSEMBLY

Engine Head and Block Machining

Engine block machining:-

 The engine block and engine head are bought in the logistics area from different
venders set by the company.
 These parts are semi finished so they are moved in the machining areas where
they are machined using CNC & DNC machines
 First the engine block is placed on the infeed conveyor where it is transported to
bed plate tightening machine where all the bolt at the bottom of the block is tight up
to a particular point
 After that the block is transported to the CNC machine where the particular
program is been already fitted in the machine and different operations like milling
boring tapping reaming are performed
 Honing operation is performed on the block to improve the geometric form of the
surface and may also improve the surface texture it is done inside the cylinder
block area
 After performing all the operations the finished block is wash to remove extra
material and dirt from it
 Then CCV Valve and Cup Plug are inserted in the block, CCV valve remove
unwanted gases from the crank case and cup plug is used to reduce oil leaking
 Then the engine head is mark to verify the which parts are added in the particular
engine during further assembly
 At the end block are marked according to their dimensions and are send to the
SKID Assembly area
 Engine Head Machining

 In engine head machining the head is placed on the conveyor belt where it is
transferred to the cylinder head CNC Machine
 The inlet and outlet head of the block is machined to high accuracy
 The same process is repeated on the other side of the head
 Then the engine head is transferred to the washing area where all the unwanted
dirt and scrap metal is removed from it

ENGINE ASSEMBLY

Crank shaft assembly:-

 Step 1- manual plate and engine block after machining are placed on the assembly
conveyor

 Step 2-Cup plug + saddle jet + bearing cell + oil galley

 Step 3- thrust washer + o ring + bearing cell + crank shaft

Bed plate placement :-

 Step 4 – sealent is addend on the cylinder block and manual plate is placed on top
of it,

 Step 5 – FIP is attached to gear cast via sealent and then assembled to engine
block
FLYWHEEL AND GEAR ASSEMBLY:-
 Step 6 – on the opposite side of gear cast CAM gear + crank gear +oil pump +oil
pickup seam + FIP gear

 Step 7 – on the top of the gear cast flywheel housing is attach to the block via
sealent

PISTON ASSEMBLY & HOUSING:-

 Step 8- CIR clip + piston + connecting rod+ gudgeon pin piston rings(top
,intermediate, oil rings) + bearing
  Step 9 - piston is assembled in the piston housing

GASKET &PISTON PROTRUSION ASSEMBLY:-

 Step 10- OIL gasket is assembled on top of the engine via sealent below the
engine block

 Step 11 - the assembled engine is transferred to the piston protrusion system

where timings and placement of the piston is set
ROCKER ARM ASSEMBLY:-

 Step 12 – cylinder head + water inlet +lift pump + rocker arm + elephant foot

OIL COOLER ASSEMBLY:-

 Step 13- OIL cooler +filter( fuel filter, air filter)+ dip stick+ water/oil temperature
switch + cam/core plug

INJECTOR ASSEMBLY:-

 Step 14- injector +air vent +cover+ booster pipe+ auto tensioner
MAINFOLD ASSEMBLY:-

 Step 15 – front/rear seal+ intake gasket

 Step 16 – fan + hub + exhaust manifold

 Step 17 - leak off rail + low pressure pile + high pressure pipe

FLWHEEL ASSEMBLY:-

 Step 18 - fan pulley (radiator)+ flywheel + crank pulley + cross tube+ flywheel
sensor(CIDI Sensor) + ducter plate

 Step 19 - crank pulley tightening

 ENGINE TESTING

 It is the final stage for engine assembly in this test the engine is attached to the
dynamo via ducter plate
 Coolant and other oil is added in the engine and the engine is ready for testing
 The dynamo is turned on and a sensor in the dynamo machine transmitted data to
the software from where necessary information is calculated
 Power test, low ide test , high idle test , free flow test and all pressure test such
data is displayed on the screen
 It the engine is passed in these test the engine is then transferred to other machine
where it is run for some time to calculate if there is any variation in the power
output and to calculate its endurance
 After the endurance test the engine leakage test is performed in the engine where
engine is kept in a dark room and then UV light is passed through it to check if
there are any leaks in the engine or not
 After clearing all there test a final manual inspection is carried out on the engine
and then it is transferred to SKID assembly line where other important component
such as gear box, axle and transmission shaft is installed with the engine
 TRANSMISSION,AXLE & GEAR BOX ASSEMBLY

AXLE ASSEMBLY:-

WBC ASSEMBLY
 Axle arm + dust plate + cup press + bearing press + sealent + stud
 Annulus ring + bolt

DC TOOL 320 NM
 Bearing press + drovel press + bolt tightening (320 nm) force

PHC SUB ASSEMBLY

 PSC + 2D gear + plug +thrust plate + drive shaft
BPH SUB ASSEMBLY
 Spring + base plate + black rubber ring + white rubber ring+ seal
+BPH press + millets

DRIVE HEAD ASSEMBLY

 Drive head + cone + sim + spacer setting gauge
 Hear space between the pinion is check so that during gear
changing it won’t damage the gear box
 Gap between the gear must be between 1.2 to 4.2

PINION ASSEMBLY
 Pinion + spark plate + drive head
DIFFERENTIAL CASE ASSEMBLY
 Bearing + bolt + crown plate +rear axle + spherical valve

DRIVE HEAD SUB BPH ASSEMBLY

 Break piston hub and differential assembly is fitted in the drive head
 Sealent is applied on the two side of the drive head assembly where
the two axle arm will be fitted
AXLE REWORK
 Axle arms are lifted via machine and are placed in the two sides of
the drive plate
 Then these axle arms are tightened via bolts
 GEAR BOX ASSEMBLY

FRONT CASE LOADING

 Spool + bleed screw + spring + adapter + bounded washer+
plug relief valve+ male test coupling +gasket +dowel
 All there components are fitted and tightened in the front
case

Reversal assembly
 Bearing + spacer gauge test (reading must be 3 to 4 ) + flexible
washer + gear + reversal press
REAR CASE ASSEMBLY
 Cup + cone + redilube + stack nut +coring yoke + seal press tool

SYNCHRONISER ASSEMBLY (LAY MAIN SHAFT ASSEMBLY)

 Spacer + oil seal+ pilot bearing + needle roller bearing + cone
+hub sleeve+ inner race bearing + lay bush +lay top cone + main
top cone

FRONT CASE REVERSAL SUB ASSEMBLY

 Reversal is fitted in the front case and tightened with screw
 Lay shaft + main shaft + ideal gear + transfer gear + float are fitted
in the front case
  The rear case is fitted on the top of the assembly and sealent is
applied and then tightened with bolts

FLYWHEEL ASSEMBLY
 Torque meter + triple lip seal + yoke +bolts +turret bolts+ lay cover
+ o ring +flywheel + turret +charge pump
 FRONT AXLE SUB ASSEMBLY

DRIVE HEAD ASSEMBLY

STEP 1 – (manipulator) - Drive head + pinion(SD55) + Coupling
STEP 2 – (backlash fixture) – casting differential case + bearing cone + press

PHC ASSEMBLY
STEP 1 – PHC Thrust cap + PHC( 5 HOLES , 10 HOLES) + SEAL + Gear 1 + Gear
2 + PHC Circlip

PRESSING OPERATIONS
STEP 1 – axle arm(center case) + drive shaft + drive head + sealent
STEP 2 - force exerted 300kg/cm2
FRONT AXLE FIXTURE
STEP 1 – PHC + Hubswivle + magnetic plug +dowty washer + wheel stud(80 mm)
STEP 2 - gear OIL Filling (axle casing 7.59 psi , PHC + HUBSWIVEL CASING 1.9psi)
 MAIN ASSEMBLY LINE

Main Frame Assembly Line (M-Line ) :-

ZONE M1 :- Main Frame Drop

• Pick main frame
• Drop main frame on M-line
• Pick adjuster plugs from bins & Place on main frame
• Pick pads & legs from bins & place it on main frame
• Pick pneumatic gun & fix adjuster plug
• Pick rivet gun from stand & fasten rivets with rivet guns of M8 &M10 size

ZONE M2 : Leg Fitment Zone

• Pick leg ram from trolley & place it on outer leg.
• Pick pivot pin from trolley
• Place in aligned hole in outer leg & inner leg
• Pick leg ram from trolley & place it on rear frame
• Pick pivot pins from trolley & fix leg in place with pivot pins

ZONE M3 : FRONT AXLE FITMENT

• Pick front axle from trolley & place it on main frame
• Pick pivot pins & shims from trolley
• Align hole of front axle & axle yoke, insert pivot pin in the hole
• Pick bolt & nut from the inlock pivot pin in place with bolt & lock nut.
• Pick battery gun, socket & nut runner. Tighten the bolt
• Pick cover plate from bin,Pick screws, battery gun & socket. Tighten the screws
• axle yoke transfer power from drive shaft to pinion of the axle

ZONE 4 : STONE GUARD FITMENT

• Pick left & right hand stone guards from trolley. Place it on main frame
• Pick bolts,nuts & washers from bins. Pick battery gun, socket & nut runner
• Fasten stone guards in place with the help of bolts & nuts

ZONE 5 : VALVE BLOCKS

Loader hoses fitment :
• Pick hoses from trolley. Place it on main frame
• Pick hoses clamp from bin.Place it on main frame
• Pick battery gun, socket, nut runner. Tighten hoses in place using battery gun
• hoses provide flexibility, they connect to loader arm

LVB FITMENT :
• Pick resilient mount(sound isolators clip) from bin .Place it on main frame
• Pick LVB from trolley. Place on resilient mounts
• Pick lock nuts from bins. Pick battery gun socket. Tighten the LVB with lock nuts using
battery gun
• Pick torque wrench. Join hoses of LVB to loader feed hoses.
EVB FITMENT :
• Pick EVB from trolley. Place it on main frame
• Pick bolts,nuts & washers from bins. Place it on EVB
• Pick battery gun, socket & nut runner. Tighten the EVB using battery gun
• EVB mounting plate provide base on which valve blocks are fitted
• Adapters are fitted which provide inlet and outlet for hydraulic oil
• EVB is use to control excavators bucket

ZONE 6 : HOSES/PIPES
• Pick hoses from trolley. Place it on main frame
• Fasten two hoses on EVB to pipe rear return
• Fasten hose from LVB to EVB .Fasten hose to leg ram on both sides
• Fasten 4 hoses to EVB .Place it in retainer via right house guide
• Fasten 5 hoses to LVB .Place it in retainer via right house guide
• Place both retainers. Fasten hoses from front axle to orbital standing ram
• Fasten hose from EVB to tank. Place cab mountings on main frame.

ZONE 7 : FUEL TANK FITMENT

• Pick fuel tank from trolley. Place it on main frame
• Pick screws, washers from bins. Place on fuel tank. Pick pneumatic gun, socket
• Tighten the tank into place
ZONE 8 : HYDRAULIC TANK FITMENT
• Pick hydraulic tank from trolley. Place it on main frame
• Pick screws ,washers from bins. Place it on the hydraulic tank
• Pick pneumatic gun ,socket & tighten the tank into place

ZONE 9 : KPC FITMENT

• Lift KPC sub assy.Place it on main frame
• Pick upper & lower lock washers from bins. Tighten the locks to KPC
• Align one hose from EVB to right hand hydraulic clamp T-joint
• Pick torque wrench. Tighten hose using wrench
• Fasten hose from EVB to right hand upper hydra clamp adaptor
• Fasten hose from right hand upper hydra clamp to left hand lower hydra clamp
• KPC provide supporting mechanism to boom dipper, it is the combination of slew ram,
boom, lock brushes, feed pipe & seal

ZONE 10 :
• Main frame loading to move it on main assembly line through EMS & cranes.
 MAIN ASSEMBLY LINE (A-Line )

ZONE 1 & 2 : SKID DROP

• Pick skid from fixture & place it on conveyor
• Pick parking brakes from trolley
• Pick pneumatic gun,nuts,bolts & shuns from bin.
• Fix parking brake to rear axle.

ZONE 3 & 4 : MAIN FRAME DROP

• Unload main frame from hoist & place it on conveyor.
• Pick bolts,nuts & washers from bins. Place it on main frame.
• Pick yoke plate from trolley. Place on gear box.
• Pick bolts,nuts, washers from bins. Pick pneumatic gun nut runner.
• Fasten yoke plate to gear box using the bolts,nuts.
• Pick bolts,nuts & washers from bin.Fasten yoke plate to m/f using bolts,nuts.

ZONE 5 : DRESS UP
• Pick hose from trolley and torque wrench.
• Attach one end of hose to return feed pipe and another to hydraulic cooler using wrench
• Connect return hose from EVB to hyd. Tank already placed on m/f using torque wrench.
• Fasten the hose from transmission to cooler. Pick hydraulic section hose from trolley.
• Attach one end of hose to hyd. Tank and other to pump using the clips Connect pressure
sensor.

ZONE 6 : AFTER DROPPING ELECTRICAL FITMENT

• Fasten hoses from m/f to transmission.
• Fasten hoses from hydraulic tank to check valve
• Lift hose to connect loader valve back to hydraulic pump
• Place cable tie from yoke late to conveyor to engine
• Connect harness with starter & alternator
• Pick battery gun & socket. Connect +ve cable with starter on one side and the other end
on the battery side. Tighten the –ve harness.
• Connect m/f harness with alternator connector, oil pressure switch connector
• Connect m/f harness with transmission switches for reverse & forward & connect with
transmission switch and one with speedometer switch.

ZONE 6 & 7 : ELECTRICAL FITMENT & RADIATOR/T. COOLER

• Pick horns from bins. Pick on main frame & Fix horns using washers
• Pick battery gun & socket. Tighten the lever using the gun
• Pick hose from trolley. Assemble with clip on water temperature switch connector
• Tighten one end. Pick jubilee clip, battery gun. Fasten the hose using clip & gun
• Mount rubber grommet & dipstick assembly on gearbox. Assemble dipstick on
transmission using clamp & bolt.
• Pick mounting bracket. Fasten the bracket on the engine
• Pick air cleaner. Fasten the air –cleaner on engine using bolts.
ZONE 7:- COOLING PACKAGE 1 & 2
• Pick mud filter & sediment from trolley. Place it on main frame.
• Pick bolts from bins. Attach both filters using bolts.
• Pick torque wrench. Fasten the hose from engine to filter using the wrench.
• Fasten the hose from sediment filter to mud filter using the wrench.
• Fasten the hose from mud filter to diesel tank using the wrench.
• Lift cooling package assy. Place it on main frame.
• Pick bolts, washers & lock nuts from bin. Pick battery gun, socket & spanner. Fasten the
assembly using bolts & nuts.
• Pick jubilee clip. Fasten the hose bend to radiator using the clip & the gun.
• Pick bolts, washers & nuts from bin. Pick battery, socket & spanner.
• Fasten the transmission & hydraulic cooler using the bolts & nuts.

ZONE 9: FRONT END

• Pick battery & mat from material feed conveyor. Place it on main frame.
• Join all the knob cable with harness connectors. Pick brake fluid reservoir.
• Pick bracket & place it on reservoir. Pick bolts, washers & nuts from bins.
• Pick assembly from tray & place it on main frame. Pick bolts, nuts & washers from bin.
Pick battery gun, socket & nut runner. Mount the reservoir using bolts, nuts.
• Pick bumper from mat conveyor. Place it on main frame.
• Pick hack screws from bin. Pick battery gun, extension socket.
• Pick bolts, nuts & washers from bin. Pick battery gun, socket.
ZONE 10: LIFT RAM FITMENT
• Pick lift ram from trolley. Place it on loader tower
• Pick retaining collars, nuts & bolts from bin. Place on pivot pin
• Fix in place using nut & bolt. Pick torque wrench.
• Connect the hoses from lift ram to m/f using the wrench.
• Assemble the silencer on manifold one side & other side on fuel sedimentation filter
bracket.
• Tighten silencer on engine with engine manifold by tightening 2 bolts first & then top 2
bolts using battery gun.

ZONE 11-12: LEVEL LINK FITMENT & CHASIS NUMBER

• Pick level link from trolley. Mount on pivot pin already placed on trolley.
• Pick safety strut & T-bolt.
• Mount the strut on the link using the T-bolt.
• Pick collar & bolt from the bin.Place the collar on the pivot pin using bolt, lock nut.
• Bring punching machine to the main frame.
• Fix it & engrave the chassis no. on it

ZONE 13: LOADER ARM

• Bring down loader arm from EMS loop. Allign its rear end with loader tower upper hole.
• Pick pins & shims from bin. Fasten the loader arm to loader tower using the pivot pin,
shim
• Insert collar & bolt in pin. Pick bolts & nuts from bin. Fix pin in place using nuts & bolts.
Align hole of level link & loader arm.
• Down the crane & remove the tackle for ram rod end both sides
• Insert lift ram b/w links of loader arm on both sides by using special rods for alignment.
• Pick bolts & nuts from bins. Pick pivot pin from bin.
• Place pins in the aligned hole. Fix pin in place using the nuts & bolts.
• Tighten all the nuts & bolts with battery gannet runner.
• Release the tackle & front side after making loader arm fully down and send for
EMS loop.
ZONE 13: BONNET FITMENT
• Pick bonnet from material feed conveyor. Place it on table.
• Pick bonnet hinge, washers, bolts & nuts from bins. Place on table.
• Assemble all the parts to the bonnet .Pick battery gun, nut runner.
• Tighten the nuts, bolts using the gun. Lift the bonnet.
• Place it over shroud on one side & grill housing on the other.
• Pick bolts, washers & nuts from bin. Assemble the bonnet in place using the bolts, nuts.

ZONE 14 & 15: CAB FITMENT

• Lift cab from mat feed conveyor .Place it on main frame.
• Pick nuts, bolts & washers from bin. Fix them in their aligned holes.
• Pick side panels from trolley. Place it on main frame.
• Pick bolts, nuts & washers from bin.Pick battery gun, nut runner. Fix panels in place
using battery gun & nut runner.
• Pick up gun to tighten the hoses. Push button to start cycle
• Remove gun after completion of the cycle. Place gun bolt on the machine.
ZONE 16 & 17: CAB INTERNAL
• Pick floor mat from trolley. Place on L/H & R/H side on the cab.
• Check electrical in the cab .Check lights from head lamp, indicators.
• Pick cab side cover from trolley. Pick battery gun socket.
• Pick bolts, washers from bin. Pick panels in place using bolts, nut & washers.
• Fix the panels in place using bolts & washers.
• Put the battery cable on the battery. Pick battery cover from trolley.
• Pick bolts, washers & flynet from bin. Place the cover on the battery using the fly nuts

ZONE 18: BRAKE BLEEDING

• Break bleeding is the procedure to evaluate air bubble present in the break lines and
hose lines of hydraulic breaking system.
• As break fluid is incompressible liquid and air is compressible so it reduces the hydraulic
pressure build up in the breaks lines reducing the break efficiency
ZONE 19 & 20: TYRE FITMENT

• Pick rear tire sub –assy. Place them on rear axle.

• Pick front tire sub-assy. Place them on rear axle.
• Pick nuts from bin.Place on rear & front axle. Fasten tires to both the axles using nuts
& bolts & pneumatic gun.
 TWIN-SLAT LINE

•Pick trolley having boom & dipper. Place the boom & dipper on dedicated stand.
Join hoses of boom & dipper.
•Pick bolts, collars, shims & pivot pin from stand & bin.
• Connect boom & dipper using the pins. Fix them using a hammer. Join ram of boom
using to dipper using the pivot pin.
• Connect the remaining hoses to KPC assembly.
• Fill the oil in five respective oil tanks
DIESEL, ENGINE, COOLANT, TRANSMISSION, HYDRAULICS.
 PDI AND HOT TEST ZONE :

BAY – 1 :

BUCKET FITMENT ZONE

Loader buckets as well as excavators buckets are brought in this zone to be attached to
the 3DX backhoe loader.
Excavator buckets :
These are first attached to rear portion through pivot pins.
Loader buckets :
These are attached to the front portion through pivot pins.
Then, the working of the buckets are tasted in this zone. The nuts of the king post carriage
are adjusted in such a way that the KPC arrangement could easily slide along the line of
the machine.

PRE-RECTIFICATION ZONE :
 In this zone, all the fastenings of the machines are checked whether some
fastenings are missing, tightly fitted or loosely fitted, then all the errors are rectified.
 If in any tank ,the oil is less then the required oil is filled according to the need.
 Then the machine goes in the greasing zone where different portion are greased
using CASTROL grease.
 Hydraulic dye is filled in the hydraulic tank to inspect any leakage in the tank.

WASHING BAY :
 Washing chemical : HENKEL-P3T768
 With the help of this chemical the washing of the hole machine is done. After that,
the machine goes for a 45 minutes trial run in which it is used harshly to check all
the functioning of the machine.
BAY – 2 :

DYNAMIC AND HUMP TEST ZONE :

 Locate the machine on roller testing bench. Move the hydraulic platform (b/w
the rollers ) downwards by pressing PB on electrical panel.
 Operate the machine in first gear & then in second & so on. Observe any abnormal
noises.
 Apply sudden brakes & observe the status on electrical panel.
 TOTAL CYCLE TIME OF THE PROCESS : 10 MINUTES

BAY – 3 :

INSPECTION ZONE :
 Quality inspection is done according to the parameters set up by the company or
quality control department.
 UV testing as well done here in this zone.

INSPECTION ZONE :
Reworking of machine of all the faults detected by the inspection zone at BAY – 3.is done
here in this zone.

FINAL TOUCH-UP :
 After reworking the machine goes in for the final touch in different sections :
 Washing BAY
 PDI BAY – 1
 DECAL PASTING
 PAINT TOUCH UP BAY – 1
 Major Rework BAY
 PROJECT REPORT

LEAKAGE ANALYSIS

 The aim of our project is to determine the causes of hydraulic leakage that is been
causing in the JCB Backhoe machine
 As there are so many hose pipes and joints in the machine 100 % leak proof is not
possible
 This leads to loss in efficiency , high maintenance cost and wastage of time

1. Motivation
 In the present stage of my project I have done the first part of my project which is to
perform a hydraulic leakage analysis and the second part will be completed once
the work resumes in the company.
 The project was important because it focuses on the hydraulic leakages in the
machine which is a very common problem face by the many companies making
such products. Hydraulic leakages is a very serious problem as it causes loss of
efficacy and increase the maintenance cost of the machine
 In order to compete this problem I first did the careful analysis of the machine
identifying the critical hotspots were leakage contamination is very common and
after that I studied the process involve in the inspection zone where each machine
has to go through a dynamic and dry hump test

2. Literature Review

The project is divided into two parts in the first part the main objective is to determine the
areas prone to hydraulic leakages and methods and test performed to prevent them. In
the second part of the project is to find the root cause and eliminate the problem of
contamination and rust in the hydraulic feed pipes

Brief background

•The quality of the hydraulic system design and manufacturing plays a key role in the
entire machinery system. No leakage is one of the critical quality features that will ensure
the hydraulic system quality. Absolute leakage for any hydraulic and pneumatic system is
always present. Depending on intended application, a good or faulty system is defined by
the certain amount of leakage rate in a period of time.

•Hydraulic systems are composed of hydraulic components, including pump, valve,

cylinder, tube, hydraulic oil, seal parts, control system and related accessories. Contrary
to so many advantages mentioned earlier, there are also some disadvantages. The
hydraulic system has higher requirements for maintenance compared with ordinary 5
mechanical systems, such that the hydraulic oil cleanliness must be maintained at a
certain level; the working environment temperature must be in certain range; and the cost
for components are relatively high. Comparing with common mechanical systems, the
complexity, cost, precision and accuracy requirements of manufacturing processes for
hydraulic components are higher.
•The quality of the components directly influences the functionality of the hydraulic
system. From the quality engineering aspect, the hydraulic leakage is one of the main
problems in hydraulic systems. It is estimated that contaminated lubricants cause 80% of
machine and equipment stoppages and component failures; many times these
contaminated fluids are a direct cause of fluid leaks from hydraulic machinery The leakage
will cause unnecessary energy consumption, reduce equipment performance, decrease
reliability and increase fluid costs. The direct impact is that the system loses pressure,
which results in insufficient power to do the intended work.

Literature Survey

The hydraulic leakage generally includes two kinds of status: the external leakage and
internal leakage.
The external leakage often happens on the connection and seal position, such as the
connecting position between cylinder and tube, or the valve and tube. Faulty installation
and poor maintenance are the primary causes of external leakage. The excessive
pressures or contamination can cause seals to blow or be damaged. The leakage could
be caused by a gash, rust or other corrosion hole, a very tiny pinhole leak, crack or micro
crack, or inadequate sealing between components or parts joined together. For example,
the seal issue or the tiny pinholes can cause the leakage coming from hydraulic cylinder
and hydraulic rod. External leakage can be hazardous, expensive, and unsightly
The internal leakage often happens on hydraulic system interior. It can occur in the pump,
valves, and other moving parts such as the leakage between valve spool and valve
housing, leakage between two gears in gear pump, leakage between cylinder rod and
sleeve. Internal leakage almost can’t be avoided and it is more difficult to detect and
isolate. Partial internal leakage can act as a self-lubricate function, but too much internal
leakage will slow down actuators. The power loss is accompanied by the heat generated
at a leakage path. The clearance between two components is the key factor causing 15
internal leakage. It includes the fitting clearance and assembly clearance. The fitting
clearance indicates the manufacturing precision of single parts. The assembly clearance
indicates the process stability of assembly process. The minimum fitting and assembly
clearances are key parameters to ensure the internal leakage

1. Objective of the work

The main objective to undertake this project work is to understand whole plant process
layout and quality management of hydraulic component.

2. Target Specifications
At the end of this project I am optimistic that I will have a better knowledge of the project
that I am undertaking hear at the industry. This will not only help me in my 8 semester
internship but in the long term when I pursue my career in mechanical field . The project
will help me to gain better insights on how a leakage analysis is being done.
MECHANISM INVOLVE IN HYDRAULIC

 The hydraulic cylinder consists of a cylinder barrel, in which a piston connected to

a piston rod moves back and forth. The piston has sliding rings and seals.
 The piston divides the inside of the cylinder into two chambers, the bottom chamber (cap
end) and the piston rod side chamber
 Actuation of various arms are controlled by fluid that are made to flow by piston
mechanism for the movement of arm and piston

METHOLOGY OF ANALYSIS

LOSSES DUE TO LEAKAGE

 Make up fluid
 Disposal of waste oil
 Contamination ingress
 Decrease in machine efficiency
 Increase of expenditure of the machine
Valve block
 Excavator valve block - Evb mounting plates provides base on which valve block is fitted
then adapters which provide inlet and outlet for hydraulic oil . EVB is use for controlling
excavators buckets
When you move the joystick in a certain direction, it presses down on a particular piston. This
piston pushes oil through a hose to move the spool valve controlling a particular hydraulic ram. By
moving different spools, you extend or retract different hydraulic pistons

 Loader Valve buckets - responsible for movement control of loader bucket, A

backhoe loader uses something called a spool valve to direct oil to either side of a ram.
... In other backhoes, the joysticks operate hydraulic pistons that control the movement
of the spool valves. When you move the joystick in a certain direction, it presses down
on a particular piston

Excavator valve block

 When we move the lever this will lead to an upward and downward motion of the spool
resulting in the matching of the oil galleries and the flow of oil to hydraulic circuit
resulting in the motion of the hydraulic arm
 When the spool is in neutral position the higher diameter of the spool is placed between the
upward gally 1 which will block the flow of oil and force it to flow through the neutral
gally and the because of the circular structure of the valve block the oil will pass through
the gally to the tank
 When we move the lever the spool of smaller diameter will come in contact with the
upward gally resulting in some clearance causing hydraulic oil to move to gally1 to the
hydraulic arm and then the return pipe will lead the oil to the lower gally to the return
hydraulic tank.
Loader valve bucket
 Purpose – when we perform a certain loading application with the front loader arm .
There are two stages to raise the bucket arm in stage 1 the front loader arm lifts up and in
stage 2 the bucket lifts up so during the transition from stage 1 to stage 2 there is a certain
delay of 2 to 3 sec in the hydraulic pump to supply necessary pressure which cause a
sudden downward motion of the bucket and can cause accidents so in order to avoid such
accident loader valve is used
 working – during stage 1 the pump feed oil which passes through the loader valve the
metallic ball move upwards causing the oil flow to the hydraulic arm. During the
transitions period when the bucket tends to move down there is a reverse flow of oil to
the pump which is stopped by the loader valve. The valve disconnects the pump to the
hydraulic arm until necessary pressure is created by the pump to lift the bucket
Major joints of leakages

Some of the joints prone to leakages

Front axle arm EVB to boom dipper bucket arm hydraulic tank to pump

Gear pump to hydraulic cooler hose to lift ram EVB hose to boom ram
Major causes of leakages
 Leakages due to improper torqueing
 Leakages due to manufacturing defects
 Leakages due to defects because of man power
 Leakages due to contamination of oil

INSPECTION ZONE
 It is quite inevitable a proper inspection technique as most of the leakage occur due to
operator negligence
 Method to significantly reduce the number of leakage points during assembly line is
introduction of inspection zone
 This inspection zone include the point where the cab is placed to where the loader arm is
set in the framework
 In this zone, all the fastenings of the machines are checked whether some bolts are
missing, then all the errors are rectified.
 If in any tank ,the oil is less than the required oil is filled according to the need.
 Then the machine goes in the greasing zone where different portion are greased using
CASTROL grease.

 WASHING BAY :
 Washing chemical : HENKEL-P3T768
 With the help of this chemical the washing of the hole machine is done. After that, the
machine goes for a 45 minutes trial run in which it is used harshly to check all the
functioning of the machine.

Features of inspection zone

 As most of the hydraulic joints that are prone to leakages are open it provides Easy
inspection Vicinity
 Maximum number of machines can be inspected. Only 4 minutes are required on one
machine by two operators

Advantages of inspection zone

 A lot of time is wasted in the hot bay and PDI zone to rectify the leakages
 Hydraulic oil losses can be minimized, saving a lot of money
 Expenditure related to clean up the leakages, disposal and contamination can be easily
prevented
Other ways to tackle leakages

 FLOROCENT DYE TEST

Ultraviolet dyes are an effective tool for identifying individual leaks within a hydraulic system.
They help to pinpoint active leaks in the presence of other oil and fluid films.
To properly use an ultraviolet dye test, follow these five steps:

1. Add ultraviolet dye to the hydraulic reservoir as recommended by the dye supplier.
2. Operate the machine normally to allow the dye to disperse throughout the system. It may
be necessary to run several cycles at the end with metalworking coolants or other process
fluids, which tend to wash the dyed oil away.
3. Inspect the machine using a high-powered ultraviolet light for signs of the dye. Start in
areas where leaked oil accumulates such as in drip trays, coolant systems, or basements.
Once an accumulation is found, look for signs of oil flowing or dripping into the
accumulation. The ultraviolet dye will illuminate oil along a path or stream. Trace this
path back to its source.
4. System consumption may be the result of one or many leaks. Quantify the rate of each
find and compare the total against system consumption. Rates may vary with pressure,
so observe the leak throughout the machine cycle if safely possible. Search until the
number of leaks found accounts for the system consumption rate.

DYNAMIC AND HUMP TEST

 Locate the machine on roller testing bench.

 Operate the machine in first gear & then in second & so on. Observe any abnormal
noises.
 Apply sudden brakes & observe the status on electrical panel.

 TOTAL CYCLE TIME OF THE PROCESS : 10 MINUTES

 CONCLUSION

During my 6 month final internship in JOSEPH CRYLIC BAMFORD (JCB) Put Ltd .My
work was to study all the different manufacturing units for the production of
backhoe machine in the company. After the completion of the project I will have
gained the basic knowledge of each process involved in manufacturing of an
backhoe machine. I learned about important parameters that need to be checked
before delivering the vehicle. It is great opportunity to understand the practical
application of our technical knowledge. This Industrial training also helped me to
experience the working atmosphere and functioning of an industry.
Not only did I learn about the working of a professional company and gained
great insights into the manufacturing process but I also learnt how to maintain
composure in a professional working environment and work independently.
Also, I learnt that in a company, one is not only responsible for his work profile
but his work also influences all other members in the team. A great performance
can really lift up the team. One’s work also serves as input data for other
employees so it has to be very accurate. Working in a company is about working
in tandem to produce desired results. So I realized the indispensible value of
teamwork.

I am grateful to the Manipal University Jaipur and JCB India Limited for giving me
this wonderful opportunity to me.

Tools required
Microsoft excel, word and PowerPoint were used to record all the data in tabular form
and to formulate a detail report

Technical References
 JCB OPERATING STANDARDS
 JCB guide book
 Web
 www.jcb.com
FUTURE SCOPE OF WORK

Coming to the further scope in the company it is a great opportunity to be part of

the company and have an insight to how India’s largest construction manufacturer
works. But the work here is more of learning about the existing systems and
solving line issues. There are no innovative projects which are undertaken by the
employees in all departments. Only the engineering department does that which is
not very encouraging to others..

At last I would like to conclude with the fact that I learnt how the industry runs and
what skill set is needed to be a part of it which I am sure will definitely help me in
doing things in the right way in future. Also I would like to convey my sincere
thanks to my project guides and my faculty coordinator for such an enriching
experience.