OPERATION MANUAL

&
PARTS CATALOGUE
FOR
100T HTU.
MARK-IIIC

JAYPEE ENGG. & HYDRAULIC. EQUIPMENT CO. LTD.

(ISO 9001:2008)
REGD. OFFICE:24 Strand Road.Kolkata- 700 001.
Ph.No.- 2220 4093/2230 5810.
OFFICE & WORKS : Chandannagar (Memonpour)
JEHEL
Budge Budge Trunk Road.
Maheshtala. Kolkata-700 139
Tel :00-90-033-2490 1414/5332
2490 5333. 3293 2291
Fax: 00-91-033-2490 1313
E - Mail - jehel @ dataone-in
Website: www. jehel.com

WONDER WALLCARE PVT LTD.

JAYPEE ENGINEERING & HYDRAULIC EQUIPMENT PVT. LTD.

MODEL: 100 T. HTU – MARK-IIIC

SERIAL NO.: JP100/21-22/883

YEAR OF MANUFACTURING: 21-22

CUSTOMERS’S ORDER NO.: WWPL/PUR/Truck Tippler/2021-22/11 Dtd. 05. 07.2021
 H.T.U. 100 T MARK – III C

TABLE OF CONTENTS:-

PART ‘A’:- GENERAL PAGE – A1 TO A4

PART ‘B’:- OPERATOR’S MANUAL PAGE – B1 TO B15

PART ‘C’:- PARTS CATALOG PAGE – C1 TO C34

Note:
 The Purchaser must specify Model and Serial Number of the Equipment while ordering
Spare Parts.
 Correct Part Number must be clearly indicated enquiries / Orders for Spare Parts.
 The information set out in this Catalogue is subject to change without notice.
 Catalog reference number should be indicated in communications related to this Catalog.
 PART – ‘A’
GENERAL
Contents
Sl. No. Description Page

1. General Arrangement A2

2. Foundation & Load Data A3

3. 2 Yrs. Recommended Spares List A4

Page- A 1
Page - A 2
Page - A 3
 2-YRS. RECOMMENDED SPARES FOR
HYDRAULIC TRUCK UNLOADER 100 MT M-IIIC
Sl. No. Description Part No Reqd. Qty.
1 Bush 103-209-116-03 4

2 Rubber Buffer 103-243-151-00 20

3 Wear Pad 103-243-154-00 8

4 Wear Pad 103-243-153-00 4

5 Rubber Pad LH Top 103-243-160-00 1

6 Rubber Pad RH Top 103-243-161-00 1

7 Rubber Pad LH Bottom 103-243-162-00 1

8 Rubber Pad RH Bottom 103-243-163-00 1

9 Wear Pad 103-243-157-00 2

10 Wear Pad 103-243-158-00 2

11 Wear Pad 103-243-156-00 2

12 Wear Pad 103-243-155-00 2

13 Filler Cum Breather 103-902-025-00 1

14 Filter Cartridge 103-907-250-00 1

15 Seal Kit for Lift Cylinder 103-604-205-00/01 1 Set

16 Seal Kit for Retract Cylinder 103-602-204-00/01 2 Sets

17 Seal Kit for Hooking Cylinder 103-602-204-00/01 1 Set

18 Hose Assembly 103-904-060-58 4

19 Hose Assembly 103-904-080-58 2

20 Hose Assembly 103-904-060-12 12

21 Hose Assembly 103-904-065-58 1

22 Suction Hose Assembly 103-904-080-35 1

23 Spider 103-955-150-00 1

24 ‘O’- Ring 103-914-013-20 20

25 ‘O’- Ring 103-914-017-24 15

26 ‘O’- Ring 103-914-020-25 2

Page- A 4
 PART – ‘B’
OPERATOR’S MANUAL

Contents

Sl. No. Description Page No.

1. Introduction B2

2. Description B3

3. Hydraulic Circuit B4-B5

4. Commissioning of Unloaders B6-B7

5. Working of Unloaders B8

6. Hydraulic Oil B9

7. Instruction / Information on change of Oil B10

8. Operator's Maintenance Schedule B11-B12

9. List of Tools B13

10. Accident Preventions/Safety Precautions B14

11. Do's and Don’ts B15

Page - B 1
 Introduction
‘JEHEL’ Hydraulic Truck Unloader is a compact and economical material handling equipment
incorporating a high degree of simplified mobility, control and profitability in unloading the
Materials from trucks. This tippler possesses full advantageous utility while positioned in line
with a feeder/hopper/conveyor.

Trucks carrying bulk materials such as Dolomite, Gypsum, Lime Stone, Coal, Fertilizers,
Chemicals, Salts, Food grains, Baggasse's of Slender materials such as Bamboo, Sugar cane or
most of other free flowing materials can directly be driven over this tippler and tilted till all the
materials are disposed off on the receiver.

All motions of the tippler and hydraulic fluid, drive and pressurizing system, are independent of
the equipment and can be positioned at a convenient location Normally, controls are located
within the Power Pack, but can be repositioned wherever such necessity warrants.

We have incorporated an Electro-hydraulic interlocking system to ensure complete safety during

operation (Mark – I & Mark – II).

This equipment can be utilized for unloading from almost all two or three axles’ vehicles or
trailers that are being utilized for transportation.

Page - B 2
 Description
Hydraulic Truck Unloader consists of three basic parts, are as follows:-
a) Base Frame
b) Top Frame
c) Power Pack & Hydraulics

a. Bottom Hinge Frame

The Bottom Hinge Frame of fabricated plate structure of high strength with facility for anchoring
into the foundation. The Top Frame & Cylinder mounted on bracket and pivots the Top Frame
and two Hyd. Cylinder which operate the tilting.

b. Top Frame
The top frame is also a fabricated structure from rolled I section to take care of the torsion and
flexibility requirements of holding the trucks while being tilted. The top frame is provided with
skid-free chequered plates on its entire length. A back stop is fitted at the rear for holding the
truck in tilted condition. For additional safety, locking arrangements have been provided to suit
various wheel bases of trucks. The back stops are provided with solid replaceable Rubber Blocks
to protect the tyres from any damage during tilting motion. Back stops are hydraulically operated
for Mark-I & Mark-II.

c. Power Pack and Hydraulics

The Power Pack consists generally of a 415 Volt electric motor for operating the Hydraulic
pump. The pump can also be driven by other means such as diesel engine as and when required.
The delivery of pump is routed through a solenoid control block to regulate the desired functions
of the equipment with the help of a control panel.

Oil tank of 200 liters capacity and 600 liters capacity are used for 40 T/50 T/60T (Mk-I/II) and
100 T Mk-I/II/III respectively over the power pack and is provided with return line filter,
breather. A clog indicator is also provided on the tank to measure the clogging of the hydraulic
oil.

The power pack and the controls can be selectively positioned, but preferably within 5 M. from
the centre line of the hinge point of the equipment.

Page - B 3
 Hydraulic Circuit
 Contents
1. Oil Tank consisting of: - Filter-cum-Air Breather, Filter with Clogging Indicator & Drain
Plug.
2. Free Flow Valve
3. Pump
4. Pressure Relief Valve (for Mk-III) / Unloading Relief Valve for Mk-I & II.
5. Solenoid Control Valve
6. Shut off Valve
7. Flow Control Valve
8. Limit Switch
9. Hose Fail Protector Valve

Page - B 4
 Hydraulic Pump
Hydraulic Pump – single for 40 / 50 / 60 T ( Mk-I & II ) and for Mk-III of all capacity or
Tandem Hydraulic Pump for 70 / 80 / 100 T – Mk-I / II is of positive displacement in nature
and maintains sufficient delivery of oil based on the end requirements, the motor can be
selective. The direction of the pump rotation is indicated by an arrow.

Note:
The pump is not reversible and should receive rotation only in the direction indicated

PERFORMANCE OF THE PUMP IS MUCH DEPENDENT ON THE CONDITIONS AND CHARACTERISTICS

OF HYDRAULIC MEDIA USED AND NECESSARY PRECAUTIONS TOWARDS FILTRATION. TOPPING
UP AND TOTAL CHANGE SHOULD BE SYSTEMATICALLY FOLLOWED AS PER RECOMMENDATIONS.

 Cylinders
The cylinders cushioned during lowering operations are incorporated with patented seals and
synthetic wear rings to slide on honed surfaces. The piston rods are hard chrome plated to
withstand the rigor of working on open areas laden with dust and other abrasive materials. The
special quality seals can withstand even pressure up to 250 bars. The cylinder eyes are provided
with large bearing surfaces to minimize wear.

 Hose Fail Protector Valve

Hose fail protector valves are provided at the main tilting cylinders to prevent dangerous failures
of the truck/unloader due to rupture/burst of related pipes/hoses in the circuit. These are screwed
in directly in the inlet connections of the cylinders. The safety action is provided by means of a
disc, which lifts off from its seat and maintains the desired flow area under normal operating
conditions due to open outlets in the event of any pipe/hose failure, the flow rate gets increased
which, coupled with driving force, extends the controlling force of the valve disc to terminate the
flow through this valve. (Optional)

 Hydraulic Hoses
For top safety, extra high pressure two diagonal high tensile steel wire braided flexible hoses to
DIN 20022 have been used in these unloaders. The hose consists of oil resistant synthetic rubber
(Buna N) inner tube and oil, weather and abrasion resistant synthetic rubber outer cover.
Relief Valve
The Relief Valve remains closed against oil pressure within the stipulated range by spring loaded
ball seat in the direction of operation. Once the set pressure is exceeded, the valve open out and
divert the fluid flow towards the oil tank and arrest further motion in the undesired direction.

Page - B 5
 Commissioning of Unloaders
‘JEHEL’ Hydraulic Truck Unloaders are normally supplied as a whole unit but at times supplied
in sub-assemblies due to limitation in transporting as an assembled unit ensures that the
foundation is built based on the overall general layout with proper care to maintain centre
distance of anchor bolts.

Note:
Ensure that sufficient setting time is given prior to erection of Unloader

Place base frame (for Mark-I) and Bottom Hinge Frame (for Mark-II & Mark-III) on the
foundation and secure with nuts and spring washers. Position the Power Pack on its foundation
and tighten with appropriate nuts and spring washers.

Check oil level of the hydraulic tank, in case topping up is necessary, remove top cover of the
filter, ensure that the filtering element is in position and, pour the required quantity of
recommended hydraulic oil.

Note:
Follow hydraulic oil recommendations

Ensure that the free flow valve between the pump and oil tank is open before switching over the
starter. (Open position denotes the arrow head)

Lift the top frame by about 30 degree and prop in a secured manner for Mk-I only

Connect the power supply for the power pack.

Note:
Ensure that direction of rotation of motor is in conformity to the requirement of the pump.

Check the fittings connection between cylinders & power pack.

Switch on the power pack and push the button up and down for few seconds till sufficient fluid is
filled on either end of the cylinders.

Operate the cylinders to its full stroke no load condition on the equipment.

Extend/ retract the hydraulic cylinders by operating the power pack and connect the piston end
with the push buttons.

Bring down the top frame till it reaches the lower most position and operate for upward motion
approximately to an angle of 30 degree for few times to check for all free motions.

Operate similarly up to 40 degree inclination for few times and repeat the same for 55 degree.

Page - B 6
Fix chequered plate and tack weld on the support brackets wherever chequered plates are
supplied loose.

Check all pins are properly secured with locking arrangement.

Next operation is to test for leaks. Operate the cylinders up to its stop and retain for few seconds
under pressure. Check for leaks; tighten loose connections/ joints, if any.

Note:
Always use two spanners while tightening to ensure that no undue force is exerted on valve
bodies, nipples etc.

If leaks are found on unions connecting aluminum valve bodies, a mild jerk will ensure proper
sealing. Over tightening will result in harmful damages.

Clean with dry cloth all joints thoroughly prior to tightening to achieve leak proof connections.

All pipe connections and joints have been provided with a special 'O' ring which makes the
system leak proof. If any joint/connection is found leaking even after tightening the 'O' ring from
the particular joint/connection should be replaced with a new one.

ALWAYS ENSURE THAT THE SYSTEM IS FILLED WITH OIL AND THE FREE FLOW
VALVE BETWEEN THE PUMP AND OIL TANK IS OPEN BEFORE OPERATING THE
UNLOADERS.

Page - B 7
 Working of Unloaders
The operator must make himself fully familiar with all the functions of the Unloader and must also
understand the following instructions to avoid accidents and damages to the Unloader, carrier and goods.

1. Position the truck centrally in line within the guide rails.

2. Drive the truck backwards towards the back stops till its tyres just touch the back stops.
3. Using hooks lock the front axle with the chains provided at the front end of the unloader
and lock the cylinders in proper position.
4. Ensure that the truck driver and other personnel are away from the platform.
5. In case the truck is provided with tail board, the same has to be opened/unhooked and
lowered.
6. Actuate the control push button for inclining the platform and watch for safety unloading.
7. Once the complete materials are unloaded, push the lowering push button and bring the
platform back to level.
8. Re-fit the tail board back in position and drive the vehicle away.

Page - B 8
 Hydraulic Oil
When buying oil, remember that no other single factor is more important to the life, smooth
working and economic operation of the Unloaders than the quality of oil used and the proper care
of it while being used.

Protect the oil from losing from its properties by rigidly following the schedules of inspection,
service of filters and periodic inspection of oil samples, which forecasts the condition of the oil.

The unloaders are not designed for low grade oils. The Finely machined cylinders and valve
components cannot be expected to withstand abuse due to improper care of the hydraulic system.

The most economical operation of the hydraulic system results from the use of a premium
quality oil and conscientious preventive maintenance.

It is recommended to use hydraulic oil 'Gulf-Harmony 54 AW' marketed by Messrs, Petrosil Oil
Company Ltd., India, for these unloaders. However, the following alternates can also be utilized
in view of their recognized quality and availability:

> Messrs. Indian Oil Corporation Ltd - Grade 68

The above oils are recommended for satisfactory year round operation in most of the
applications. Consult the factory for sustained operation during extremely high or low ambient
temperatures.

The use of cheap oil or mixing up of different brands of oil in a new hydraulic system just invites
trouble.

Page - B 9
 Instruction/Information on change of oil
Every new equipment will be experiencing certain amount of wear during the initial stage of
operation till all components get “self seated” and during this period, enormous heat is generated
which aids “breaking up” of hydraulic oil. Continuous usage of burnt oil forms sludge and
varnish forming materials in the pumps, valves, cylinders, which accelerates the rate of wear on
the components.

The first 100 hours of operation is normally considered as “wearing in” period of standard
hydraulic equipment's of this nature. It is necessary that the hydraulic oil tank is thoroughly
drained after the initial 100 hours of operation and fresh oil filled up for continuity of operations
( it can be construed that Unloaders that are subjected to 8 hours of operation in a day require
refilling of hydraulic oil immediately after a fortnight of Commissioning). It is also necessary to
clean the filter for every 12 hours during this period.

The second oil fill will sustain for about 800 hours of operation, but may need periodical topping
up. In tropical countries like ours, the possibility of condensation is quite common. The
condensed fluid will gradually settle while the Unloaders are at rest and the settling normally
takes about 60 minutes. After this period, the drain plug should be unscrewed and the last five
liters of oil should be removed and allowed to settle in another container. The tank should be
topped up with five liters of oil for continuance of operation. This exercise is to be repeated for
every 100 hours of operations.

Note
Check periodically whether hydraulic oil is contaminated. The simplest way of determining the
condition of oil without going in for laboratory test, etc., is to obtain sample oil from the system
and place it in the clean glass container. If is smells clean and is clear, the oil is in good
condition. If it has rancid smell or is cloudy dark in color, then the oil is to be changed. If water
appears in the bottom of glass after it has stood awhile, the oil needs further draining and topping
up.

Different producers introduce different ingredients during the process of manufacturing

hydraulic oil and by intermixing such products; the resultant chemical combinations may not
possess the required characteristics of any of the original fluids. Refills are to be effected only
with the oil of same brand. In case changeover of brands is required brand of oil before such
changeover is affected.

The filters and other elements are provided to ensure that access to the foreign particles is fully
eliminated. Under any circumstances, the restricting magnet, filtering elements Etc., should not
be removed to accelerate the process of oil filling.

Oil filling should be done only in atmosphere free of dusty winds

Page - B 10
 Operator's Maintenance Schedule
The purpose of this Maintenance Schedule is to keep the equipment in readiness during in-
service' and 'standby' conditions and to detect signs of malfunction during normal operations and
scheduled maintenance checks.

It is vital for the operators to be thoroughly familiar with and understand the information
applicable to operations and light maintenance in order to perform their task. Light maintenance
attended at appropriate time eliminates to a great extent major shutdown period and helps in
trouble-free and safe service of the equipment.

Since motive power for operation of the hydraulic pump of the Hydraulic Truck Unloader is
obtained from external sources, maintenance requirements of such sources should equally be
taken care of to achieve optimum efficiency of the equipment.

Maintenance schedule/ requirements for external motive power/ prime movers are governed by
respective manufacturer’s recommendation. Typical critical points on the maintenance schedules
of the prime movers, which may seriously affect the Unloader performance / operator safety, are
as under.

Electric Motor

 Starter setting, insulation and earthling of connecting cables.

 Ensure electrical wiring of all plug points to be utilized for connecting the motor results
in stipulated direction of rotation of motor.

Equipment Maintenance
Daily
 Visually inspect the equipment for any loose objects and signs of hydraulic leakages.
 Visually inspect whether any external damages to structural positioning have occurred
during the previous periods.
 Wipe off excess lubricants and dirt collections and remove any obstructing materials for
the movements of prime mover/ equipment.
 Check oil level in hydraulic tank

Note:
Retract all cylinders for checking oil level of the equipment.

Page - B 11
Weekly
 Observe daily lubrication and maintenance schedule and complete with weekly schedule.
 Check whether mounting studs connecting the equipment to the foundation have become
loose.
 Check slackness of pump mounting bolts.
 Check hydraulic oil as per instructions
 Check filter element and wipe off metal particles from the magnet. Clogged filter tends to
increase the return pressure of oil and is injurious to pump life.

Monthly
 Check all hydraulic hoses for chafing, bulging, leaking and other damages.
 Check function of limit switch and solenoid valves.
 Check whether any spool sticks- mostly due to control levers/ linkages being out of
adjustment.
 Remove pump and check whether any damages are developing on key drive/spider.
Timely change of key/spider saves replacement of pump.
 Check surfaces of cylinder piston rods for built up edges due to sharp external blows.
Round off by smooth oil stone to save seal life-major damages need total replacement.
 Drain hydraulic oil tank and allow settling. Check up and remove any foreign particles
present in the tank. Condensed water should be separated.

Page - B 12
 List of Tools
The following are the recommended list of tools to be arranged by the customers for proper
maintenance of the equipment's.

Sl. No. Description Quantity Remarks

1. D-Spanner – 10/11, 16/17, 20/22, 24/27, 1 No. each

30/32, 36/41, 46/50

2. Adjustable Wrench 1 No. each

3. Ball Point Hammer 1 No. each

4. Slogging Ring Spanner 36 mm 1 No. each

5. Screw Driver 1 No. each

Page - B 13
 Accident Prevention / Safety Precautions
All personal assigned to operate or to work on the equipment should be thoroughly conversant
with the operating instructions and must be familiar with the controls and their relative effects in
the movements of the equipment. They should be familiar with the following special precautions
in addition to the conventional safety procedures

 Ensure that the maintenance schedule is followed.

 Ensure that the only authorized persons are allowed to handle the equipment.
 Avoid standing on slippery surface while operating the equipment.
 Ensure that the front hooking cylinders are properly secured with the truck chassis
 Ensure that the retractable stoppers are extended before tilting operation is commenced.
 Ensure that both the hooking cylinders and stopper cylinders induce the pre-setting
pressure on the front hook and backstop before the tilting operation is carried out.
 Ensure that all detachable pins are properly held in position with the locking
arrangements provided.
 Do not stand under lifted loads/ unnecessarily wander in the working range of the
equipment.
 Do not disturb the hydraulic valve settings.
 Do not hold the control button in 'lowering position' for longer period after completion of
lowering operation.
 While materials are being unloaded, do not place hands on control button, lest inadvertent
lowering/ lifting takes place.
 Ensure that the truck is centrally located on the platform.
 Ensure that the rear flap of the truck body is opened before commencing the operation.
 Develop the habit of looking into and following the direction of movements of loads
during operations.
 Ensure that obstructions like live power lines are not present near movements of the
equipment.
 Never allow hot objects to be near the hoses.
 Destroy all defective components, lest someone uses it.

If any safety problems are encountered at site, which are left uncovered in the above instructions,
consult manufacturer for appropriate advice/recommendations.

Page - B 14
 DO’s and Don’ts
Do’s
1. Top up Hydraulic Oil, keeping all cylinders in closed position.
2. Always use two spanners while tightening/loosening pipe/hose connectors
3. Ensure correct direction of rotation of the pump as indicated by arrow.
4. Check all pin lock bolts for tightness.
5. Clean the oil filter cartridges weekly.
6. Clear all loose materials deposited between rear hinge of the platform and hopper.
7. Ensure that the front axle of the truck/trailer is properly secured with hook chain.
8. Keep the hook chain in loose condition while lifting the platform
9. Locate the vehicle in the centre of the platform
10. Ensure that the rear flap of the truck is open before lifting the platform
11. Clear all obstructions around the equipment before operation.
12. All truck tires should be on unloading platform at the time of unloading.
Don’ts
1. Do not temper with any valve settings.
2. Do not open any pipe/hose connection while the pump is in operation.
3. Never remove Hydraulic Cylinders hoses without mechanically locking the concerned
parts.
4. Do not stand under the lifted load.
5. Do not operate the equipment without checking the interlocking system.
6. Do not try to open the electric panel door when the equipment is connected to main
power supply.
7. Do not ever jerk the unloading platform. This may lead to damage truck & Equipment.

Page - B 15
 PART – ‘C’
PARTS CATALOG
Contents

Sl. No. Description Figure No. Page No.

1 Frame Assembly 1 C2-C3

2 Front Hooking Mechanism 2 C4-C5

3 Retractable Stopper Arm Assembly 3 C6-C7

4 Oil Tank 4 C8-C9

5 Lifting Cylinder 5 C10-C13

6 Retract Cylinder 6 C14-C15

7 Hooking Cylinder 7 C16-C17

8 Hydraulic Line Arrangement of Lift Cylinder 8 C18-C19

9 Hydraulic Line Arrangement of Retract Cylinder 9 C20-C21

10 Hydraulic Line Arrangement of Hooking Cylinder 10 C22-C23

11 Hydraulic Power Pack 11 C24-C25

12 Drive Arrangement 12 C26-C27

13 Hydraulic Circuit 13 C28-C29

14 Control Panel & Electrical Circuit 14 C30-C32

Page - C 1
Page - C 2
Frame Assembly Ref: Fig. No. - 1

Sl. No. Part No. Description Qty.

1 103-442-197-00 Top Frame S/Assy. 1
2 103-434-131-00 Bottom Hinge Bracket S/Assy. 2
3 103-410-246-00 Pin S/Assy. (Main Hinge) 2
4 103-749-030-16 Hex. Head Bolt 8
5 103-716-000-16 Spring washer 8
6 103-209-116-00 Bush 4
7 103-245-307-00 Spacer 2
8 103-407-441-00 Cylinder Bottom Bracket S/Assy. 2
9 103-410-238-00 Pin S/Assy. (Cylinder Rod Eye) 2
10 103-209-433-00 Bush (Cylinder Trunion Hinge) 4
11 103-749-070-20 Hex. Head Bolt 76
12 103-716-000-20 Spring Washer 76
13 103-780-000-20 Hex. Nut 76
14 103-781-020-12 Lock Nut 76
15 103-243-163-00 Rubber Pad R.H. Bottom 1
16 103-243-162-00 Rubber Pad L.H. Bottom 1
17 103-243-161-00 Rubber Pad R.H. Top 1
18 103-243-160-00 Rubber Pad L.H. Top 1
19 103-746-045- 12 Allen Bolt 48
20 103-716-000-12 Spring Washer 96
21 103-780-000-12 Hex Nut 48
22 103-243-151-00 Buffer Pad 20
23 103-746-035-10 Allen Bolt 60

Page - C 3
Page - C 4
Front Hooking Mechanism Ref: Fig. No. - 2

Sl. No. Part No. Description Qty.

1 103-446-167-00 Hooking Block 4
2 103-243-154-00 Wear Pad 16
3 103-243-153-00 Wear Pad 8
4 103-760-020-10 C.S.K. Screw 40
5 103-133-192-00 Hooking Cylinder S/Assy. 4
6 103-226-632-00 Pin 8
7 103-783-050-05 Split Pin 16
8 103-408-010-14 Chain Hook Assembly 4
9 103-746-025-10 Allen Bolt 64

Page - C 5
Page - C 6
Retractable Stopper Arm Assembly Ref: Fig. No. - 3

Sl. No. Part No. Description Qty.

1 103-446-191-00 Retractable Boom S/Assy. 2
2 103-410-316-00 Pin S/Assy. 1
3 103-749-035-12 Hex. Head Screw 2
4 103-716-000-12 Spring Washer 2
5 103-410-315-00 Pin S/Assy. 1
6 103-602-204-00 Retract Cylinder 1
7 103-243-160-00 Rubber Pad L.H. Top 1
8 103-243-161-00 Rubber Pad R.H. Top 1
9 103-746-045-12 Allen Bolt 24
10 103-716-000-12 Spring Washer 24
11 103-711-000-12 Plain Washer 24
12 103-780-000-12 Hex. Nut 24
13 103-243-157-00 Wear Pad 1
14 103-760-045-10 C.S.K Screw 4
15 103-243-158-00 Wear Pad 1
16 103-760-030-10 C.S.K Screw 4
17 103-243-156-00 Wear Pad 1
18 103-775-045-10 Hex. Head Screw 4
19 103-716-000-10 Spring Washer 8
20 103-243-155-00 Wear Pad 1
21 103-775-045-10 Hex. Head Screw 4
22 103-243-162-00 Rubber Pad L.H. Bottom 1
23 103-243-163-00 Rubber Pad R.H. Bottom 1

Page - C 7
Page - C 8
Oil Tank Ref: Fig. No. - 4

Sl No. Part No. Description Qty.

1 103-435-131-00 Oil Tank S/Assy 1

2 103-205-006-05 Level Gauge 1
3 103-902-025-00 Filler Cum Breather 1
4 103-254-003-00 Plug 1
5 103-921-033-00 Copper washer 1
6 103-905-250-00 Filler unit 1
7 103-907-250-00 Filler cartridge 1
8 103-746-020-08 Allen bolt 4
9 103-716-000-08 Spring washer 4
10 103-746-010-06 Allen bolt 6

Page – C 9
Page - C 10
Lift Cylinder Ref: Fig. No. - 5

Sl. No. Part No. Description Qty.

1 103-604-102-04 Lift Cylinder S/Assy. 2
2 103-418-221-02 Cylinder Shell S/Assy. 1
3 103-224-101-05 Clamp Gland (1st Stage) 1
4 103-221-204-04 Gland (1st Stage) 1
5 103-916-180-15 U-Cup Seal 1
6 103-915-180-08 Rod Seal 1
7 103-918-180-20 Bearing Ring 2
8 103-910-180-18 Wiper Seal 1
9 103-914-190-57 ‘O’-Ring 1
10 103-728-015-10 Grub Screw 3
11 103-218-207-01 Cylinder Tube (1st Stage) 1
12 103-224-102-02 Clamp Gland (2nd Stage) 1
13 103-221-205-03 Gland (2nd Stage) 1
14 103-916-140-14 U-Cup Seal 1
15 103-915-140-06 Rod Seal 1
16 103-918-140-20 Bearing Ring 3
17 103-910-140-16 Wiper Seal 1
18 103-914-149-57 ‘O’-Ring 2
19 103-220-208-05 Piston (1st Stage) 1
20 103-911-200-08 Piston Seal 1
21 103-918-200-15 Bearing Ring 2
22 103-728-015-12 Grub Screw 6
23 103-218-208-02 Cylinder Tube (2nd Stage) 1
24 103-224-103-02 Clamp Gland (3rd Stage) 1
25 103-221-206-04 Gland (3rd Stage) 1
26 103-916-100-14 U-Cup Seal 1
27 103-915-100-06 Rod Seal 3
28 103-918-100-20 Bearing Ring 1
29 103-910-100-12 Wiper Seal 1
30 103-914-114-57 ‘O’-Ring 2
31 103-220-209-08 Piston (2nd Stage) 1
32 103-911-160-08 Piston Seal 1
33 103-918-160-15 Bearing Ring 2

Page - C 11
Page - C 12
Lift Cylinder Ref: Fig. No. - 5

Sl. No. Part No. Description Qty.

34 103-915-020-04 Rod Seal 2
35 103-918-020-97 Bearing Ring 1
36 103-914-044-53 ‘O’-Ring 1
37 103-220-210-04 Piston (3rd Stage) 1
38 103-911-125-06 Piston Seal 1
39 103-918-125-15 Bearing Ring 2
40 103-915-045-06 Rod Seal 2
41 103-918-045-97 Bearing Ring 2
42 103-245-103-00 Spacer 1
43 103-218-209-02 Cylinder Tube (3rd Stage) 1
44 103-218-210-02 Piston Tube (Fixed) 1
45 103-440-102-00 Rod Eye S/Assy. 1
46 103-914-075-53 ‘O’-Ring 1
47 103-209-207-00 Bush Bearing 2
48 103-831-000-08 Grease Nipple 1
49 103-417-121-01 Connecting Tube S/Assy. 1

Page - C 13
Page - C 14
Retract Cylinder Ref: Fig. No. - 6

Sl. No. Part No. Description Qty.

1 103-602-204-00 Stopper Cylinder Assembly 2
2 103-419-329-00 Piston Rod S/Assy. 1
3 103-245-516-00 Spacer 1
4 103-220-353-00 Piston 2
5 103-911-050-18 Piston Seal 2
6 103-230-121-00 Piston Guide Ring 1
7 103-914-020-30 ‘O’-Ring 2
8 103-222-000-20 Nylock Nut 1
9 103-417-312-00 Cylinder Shell S/Assy. 1
10 103-915-040-24 Rod Seal 1
11 103-230-122-00 Guide Ring 1
12 103-910-040-06 Wiper Seal 1
13 103-912-050-01 Back Up Ring 1
14 103-914-050-30 ‘O’-Ring 1
15 103-429-109-00 Gland S/Assy. 1
16 103-215-244-00 Seal Flange 1
17 103-716-000-08 Spring Washer 6
18 103-760-045-08 Socket Head Screw 6

Page - C 15
Page - C 16
Hooking Cylinder Ref: Fig. No. - 7

Sl. No. Part No. Description Qty.

1 103-602-192-00 Hooking Cylinder Assembly 2

2 103-418-363-00 Cylinder Shell S/Assy. 1
3 103-219-423-00 Piston Rod 1
4 103-220-367-00 Piston 2
5 103-911-050-18 Piston Seal 2
6 103-230-139-00 Piston Guide Ring 1
7 103-914-020-03 O-Ring 2
8 103-222-000-20 Nylock Nut 1
9 103-215-278-00 Flange 1
10 103-915-030-24 Rod Seal 1
11 103-230-140-00 Guide Ring 1
12 103-910-030-06 Wiper Seal 1
13 103-912-050-01 Back Up Ring 1
14 103-914-050-30 ‘O’-Ring 1
15 103-429-117-00 Gland S/Assy. 1
16 103-203-357-00 Piston Rod Eye 1
17 103-760-035-08 Allen Head Screw 6
18 103-716-000-08 Spring Washer 6

Page - C 17
Page - C 18
Hydraulic Line Arrangement of Lift Cylinder Ref: Fig. No. - 8

Sl. No. Part No. Description Qty.

1 103-250-001-36 Straight Union 4
2 103-960-036-00 Adaptor 14
3 103-965-001-00 Valve Housing 2
4 103-260-025-00 Clamp 2
5 103-749-035-10 Hex. Screw 2
6 103-904-060-34 Hose Assembly 4
7 103-904-080-34 Hose Assembly 2
8 103-253-036-00 Tee Union 2

Page - C 19
Page - C 20
Hydraulic Line Arrangement of Retract Cylinder Ref: Fig. No. - 9

Sl. No. Part No. Description Qty.

1 103-250-012-24 Straight Union 4
2 103-253-024-00 Tee Union 2
3 103-260-016-00 Clamp 10
4 103-749-030-10 Hex. Screw 10
5 103-904-060-12 Hose Assembly 6

Page - C 21
Page - C 22
Hydraulic Line Arrangement of Hooking Cylinder Ref: Fig. No. - 10

Sl. No. Part No. Description Qty.

1 103-250-012-24 Straight Union 4
2 103-253-024-00 Tee Union 2
3 103-260-016-00 Clamp 15
4 103-749-030-10 Hex. Screw 15
5 103-904-060-12 Hose Assembly 6

Page - C 23
Page - C 24
Hydraulic Power Pack Ref: Fig. No. - 11

Sl. No. Part No. Description Qty.

1 103-250-114-36 Straight Union 1
2 103-251-000-36 Swivel Nut 21
3 103-914-020-25 ‘O’-Ring 23
4 103-253-036-00 Tee Joint 2
5 103-250-001-36 Straight Union 12
6 103-960-036-00 Weldable Adapter 2
7 103-904-050-56 Pilot "X" Port Hose Assy. 1
8 103-250-014-20 Straight Union 2
9 103-914-010-15 'O'-Ring 4
10 103-251-000-20 Swivel Nut 2
11 103-980-036-00 5-Way Joint 1
12 103-904-085-34 Pump Delivery Hose (Large) 1
13 103-904-065-58 Pump Delivery Hose (Small) 1
14 103-914-017-24 'O'-Ring 2
15 103-904-040-50 Suction Hose (Large) 1
16 103-904-040-35 Section Hose (Small) 4
17 103-962-070-00 Jubilee Clip 4
18 103-962-050-00 Jubilee Clip 4
19 103-250-000-24 Swivel Nut 6
20 103-914-013-20 ‘O’-Ring 6
21 103-250-012-24 Straight Union 6
22 103-250-038-24 Straight Union 4
23 103-250-001-30 Straight Union 1
24 103-251-000-30 Swivel Nut 1

Page - C 25
Page - C 26
Drive Arrangement Ref: Fig. No. - 12

Sl. No. Part No. Description Qty.

1 103-407-411-00 Pump Mounting Bracket 1
2 103-775-030-12 Hex. Bolt 4
3 103-775-035-12 Hex. Bolt 4
4 103-775-075-16 Hex. Bolt 4
5 103-780-000-12 Hex. Nut 8
6 103-716-000-12 Spring Washer 8
7 103-711-000-16 Washer 4
8 103-780-000-16 Hex. Nut 4
9 103-716-000-16 Spring Washer 4
10 103-975-225-02 Coupling Half 1
11 103-955-225-00 Spider 1
12 103-975-225-01 Coupling Half 1
13 103-246-167-00 Spacer 1
14 103-535-000-50 Motor 1

Page - C 27
Page - C 28
Hydraulic Circuit Ref: Fig. No. - 13
Sl. No. Part No. Description Qty.
1 103-963-090-29 Tandem Pump 1
2 103-535-000-50 Electric Motor 1
3 103-920-114-00 Gate Valve. 1
3 103-920-002-00 Gate Valve. 1
4 103-902-025-00 Filler Cum Breather. 1
5 103-945-012-00 Pressure Gauge. 2
6 103-435-131-00 Hydraulic Oil Tank. 1
7 103-925-020-00 Direct Operated P.R.V. 2
8 103-930-422-24 Solenoid Valve. 1
9 103-940-001-00 Ball Valve. 1
10 103-930-406-04 Solenoid Valve. 3
11 103-926-010-01 Pilot Operated P.R.V. 1
12 103-935-020-08 Throttle check valve. 1
13 - - - Lift Cylinder. 2
14 - - - Hooking Cylinder. 4
15 - - - Retract Cylinder. 2
16 103-905-06B-25 Return Line Filter Small. 1
16 103-905-250-00 Return Line Filter Big. 1
17 103-954-001-00 Drain Plug. 1
18 103-205-006-05 Level Guage 1

Page - C 29
 75

700
FRONT VIEW WITHOUT DOOR

TOP VIEW FOUNDATION PLAN

R Y B h3

h1 h2 b2 b4 b6 b8
250
350

b1 b0 b3 b5 b7 b9
bE0

C1S C1D C1M

H 670 660

F3

F1
F2

M1
M2
M3
O/L1 700
T 700
DRW. POCKET AT INSIDE TR1
OF FRONT DOOR
a1

A4 SIZE TB3 TB2 TB1 NOTES :

BILL OF MATERIALS
ITEM DESCRIPTION RATING MAKE SIZE TYPE QTY.
a1 SWITCH DISCONNECTOR FUSE UNIT 100A SIEMENS 3KL821 1 NO.
HRC FUSE LINK FOR ABOVE 80A SIEMENS 3NA78220RC 3 NOS.
R INDICATING LAMP - RED 220V AC SIEMENS 22.5 mm. 1 NO.
Y INDICATING LAMP - YELLOW 220V AC SIEMENS 22.5 mm. 1 NO.
B INDICATING LAMP - BLUE 220V AC SIEMENS 22.5 mm. 1 NO.
M1, M2, M3 DP MCB 6A, 10KA SIEMENS 3 NOS.
F1,F2,F3 FUSE LINK 2A SIEMENS 3 NOS.
CIM, C1D AIR BRAKE CONTACTOR 40A, 220V AC SIEMENS 3RT 2035 2 NOS.
C1S AIR BRAKE CONTACTOR 25A, 220V AC SIEMENS 3RT 2026 1 NO.

Page - C 30
OLR1 BIMETALIC OVERLOAD RELAY 22-32A SIEMENS 3RU2136-4EB0 1 NO. LEGEND
bE0 EMERGENCY STOP PB MUSHROOM HEAD-RED KEY TYPE 220V AC SIEMENS 22.5 mm. 1 NO.
R,Y,B - R PHASE, Y PHASE, B PHASE b2 - RETRACTOR UP
T STAR - DELTA TIMER SIEMENS 3RP15 1 NO.
h1 - MOTOR ON b3 - RETRACTOR DOWN
b0 STOP PB ( RED ) WITH 1 NC CONTACT 220V AC SIEMENS 22.5 mm. 1 NO.
h2 - MOTOR TRIP b4 - PLATFORM UP
b1 START PB ( GREEN ) WITH 1 NO CONTACT 220V AC SIEMENS 22.5 mm. 1 NO.
h3 - PLATFORM UP INDICATION LAMP b5 - PLATFORM DOWN
h1 INDICATING LAMP - RED 220V AC SIEMENS 22.5 mm. 1 NO.
bE0 - EMERGENCY STOP b6 - HOOK - 1 UP
h2 INDICATING LAMP - AMBER 220V AC SIEMENS 22.5 mm. 1 NO.
6 NOS. b0 - MOTOR STOP b7 - HOOK - 1 DOWN
b2,b3,b6 PB (GREEN) WITH 2 NO CONTACTS ELEMENT 220V AC SIEMENS 22.5 mm.
b1 - MOTOR START b8 - HOOK - 2 UP
b7,b8,b9
b9 - HOOK - 2 DOWN
TR1 CONTROL TRANSFORMER 415VAC/220VAC, 500VA GUPTA ENGG. 1 NO.
H ELECTRONIC HOOTER 220V AC POWER GUARD 96 X 96 1 NO.
h3 ALERT INDICATING LAMP - RED 220V AC SIEMENS 22.5 mm 1 NO.
b4,b5 PB (GREEN) WITH 1 NO CONTACTS ELEMENT 220V AC SIEMENS 22.5 mm 2 NOS.
KOLKATA

LS1,LS2,LS3 LIMIT SWITCH 1 NO + 1 NC 220V AC BCH NLLA 3 NOS.

GA DIAGRAM & BOM OF CONTROL DESK
JEHEL

TB3 CONTROL TERMINAL (CAGE CLAMP SCREW TYPE) 2.5 SQ.MM 22 NOS.
FOR 100T M-III - C WITH 40 HP MOTOR

ELMEX/WAGO
TB2 MOTOR TERMINAL , 3 WAY 150 A REPUTED STUD 2 NOS.
CLIENT'S NAME:

TB1 INCOMER TERMINAL, 4 WAY 250 A REPUTED STUD 1 NO.

800-100-HTU-WWPL-392 01
Page - C 31
KOLKATA

CIRCUIT DIAGRAM OF CONTROL DESK

JEHEL
FOR 100T M-III - C WITH 40 HP MOTOR
CLIENT'S NAME:
A3 800-100-HTU-WWPL-392 01
 PLAT
DOWN
LIMIT
(LS3)

b2 b3 b4 b5 b6 b7 b8 b9

RECT.
UP
LIMIT
(LS1)

PLAT
TILT
LIMIT
(LS2)

h3 H

UP DN UP DN UP DN UP DN

Page - C 32
RETRACTOR PLATFORM HOOK-1 HOOK-2

3
6
5
7
9
8
4

22
10
10
11
11
12
13
14
15
16

21A
TB3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 SP SP SP SP

FUTURE PLAT RECT. RECT. PLATFORM HOOK -1 HOOK -2 SPARE

KOLKATA

INTERLOCK DOWN SOV. UP SOV. SOV. SOV.

LIMIT LIMIT
UN / SOL.

(LS1) PLAT
CIRCUIT DIAGRAM OF CONTROL DESK

(LS3)
220V AC (-Ve)

JEHEL

TILT
FOR 100T M-III - C WITH 40 HP MOTOR

LIMIT
(LS2)
CLIENT'S NAME:
A3 800-100-HTU-WWPL-392 01