DIRECTOR GENERAL
BORDER ROADS
GENERAL MAINTENANCE
INSTRUCTION NO: 238
ON OPERATION AND MAIN TENANCE OF
JCB 3DX SUPER EXCA VATOR CUM LOADER
Introduction: - The JCB 3DX
Excavator cum loader is powered by Kirloskar 4R 1040 NEUTRAL lapse rated diesel
engine developing 65 HP at rated 1500 RPM .
The machine is fitted with torque converter, synero shuttle, fully synchromesh,
gear box and 4x4 wheel drive. The equipment has got separate excavating mechanism
and clam shovel loading device fitted on same chassis.
Aim: - Aim of issuing this
GMI to enumerate the details of periodic and preventive maintenance of JCB 3DX
excavator loader machines.
Action by:-
a)
|
User unit. To carry out
periodic inspection, regular servicing and preventive maintenance tasks as laid down. USER UNIT. To carry out
periodic inspection, regular servicing and preventive maintenance tasks as laid down.
|
|
b)
|
Field workshop (GREF)
|
|
i)
|
To check the record
of maintenance and lubrication in the log book of the eqpt during its
inspection and repairs if carried out as per maintenance and lubrication schedules
given in this instructions.
|
|
ii)
|
Advice user units
in respect of any discrepancy/short coming noticed.
|
|
c)
|
Mobile Maintenance
Team – To ensure and lubrication maintenance is carried out and report accordingly to OC filed workshop for
necessary action.
|
|
Details :-
This
instruction covers the following:-
a)
|
Periodic
maintenance tasks
|
Appx-‘A’
|
b)
|
Oil and lubrication
capacity, periodicity and check card
|
Appx-‘B’
|
c)
|
Coolant capacity,
antifreeze ratio/ Tyre pressure
|
Appx-‘C’
|
d)
|
Technical data
|
Appx-‘D’
|
(Hari Prakash)
SE (E&M) FS
Director
(Tech)
For Dir
Gen Border Roads
GENERAL
This
General Maintenance Instruction is required to attention and followed by the
operator and supervisor for ensuring efficient and trouble free operation of
the machine, Do not start any Job until you are sure that you and those around
you will be safe.
SAFETY
PRECAUTION
1. Obey all laws, worksite and local
regulations which affect you and your machine.
2. All the time you are working with or on
the machine take care and stay alert.
3. You can wear proper clothing when you are
operating the machine.
4. Operate the control levers only when you
are seated correctly inside the cab.
5. Do not operate the machine which is
defective or has missing parts makes sure the maintenance procedures are
completed before using the machine.
6. Maintenance technicians should understand
the hydraulic circuit. They should know how to release trapped pressure before
disconnecting any hose.
7. Do not perform new operations until you
are sure you can do them safely.
8. Do not try to upgrade the machine
performance by unapproved modifications.
9. Do not operate the machine with the bonnet
open.
10. Never try to dismount from a moving machine.
11. Do not use the controls as handholds.
12. Do not operate the machine until the fault
has been corrected.
13. Do not reveres in third or forth gear with
full throttle.
14. Always drive at safe speed to suit the
conditions.
15. Do not rely on spoken commands.
16. Do not use the machine in closed areas where
then is flammable material, vapour or dust.
17. Do not operate the machine in closed spaces.
18. Know the weight of the load before lifting
it.
19. Never lift a load with one fork.
20. An incorrectly parked machine can move
without an operator.
21. The loader arm must be lowered and backhoe
closed whilst traveling.
22. Operate in first gear on hill sides.
23. Use extreme caution when driving into ramps
and trailers.
24. You remove and fit metal pins such as pivot
pins wear safety glasses.
25. Before starting the engine make sure the
others are clear of the danger areas.
26. Get the work done by a specialist.
27. Understand the electrical circuit before
attempting to connect to disconnect any electrical components.
28. Do not weld cast iron parts.
29. Keep the electrolyte away from your clothes
skin mouth and eyes.
30. Do not check the battery charge by shorting
the terminals with metal. Use a hydrometer or voltmeter.
31. Do not remove the radiator cup when the
engine is hot.
32. Never work under a machine on soft ground.
33. Do not weld or out wheel rims.
34. Do not refuel with the engine running there
could be a fire and injury if you do not follow these precautions.
35. Do not use petrol in this machine.
36. Do not use your fingers to check for small
leaks.
37. Make sure the radiator/oil cooler matrix is
kept clear of dirt.
38. When leaving or parking the machine close
all rams if possible to avoid.
39. Do not handle used engine oil move than
necessary.
40. Check the hoses regularly.
41. Do not use trichloroethylene or paint
thinners in the presence of a rings and seals.
Appx
‘A’
Calendar
equivalents
10
Hrs
|
-
|
Daily/10
Hrs or daily which is earlier
|
50
Hrs
|
-
|
Weekly -do-
|
500
Hrs
|
-
|
Three
months -do-
|
1000
Hrs
|
-
|
Six
months -do-
|
2000
Hrs
|
-
|
One
year -do-
|
Periodic Maintenance Schedule.
Every
10 hrs or daily maintenance task
1. Check the eng/ hyd fluid level and
replenish it up to level if required.
2. Check hyd system for any hyd oil leakage
and rectify.
3. Check the operation of all hyd systems/sub
system for correct functioning.
4. Check the water/antifreeze coolant level
in radiator and replenish if required.
5. Check leaks in radiator and rectified if
required.
6. Observe the engine smoke emitting from
exhaust pipe and report workshop if excessive smoke coming from engine exhaust.
7. Check for normal working of all
electrical/electronic devices, report to workshop in respect of defective
devices.
8. Check for correct working of all
instruments panel meters if defective, report workshop for repair/replacement.
9. Check for correct working of transmission
system and listen to any abnormal sound. Report workshop if found leaking or
abnormal sound coming from components.
10. Check torque converter oil level and
replenish if required.
11. Check correct working of steering system.
12. Clean air filter pre cleaner if fitted on
eqpt.
13. Check the brake fluid level and replenish if
required.
14. Check wheel nuts for tightness if found
loose tighten them.
15. Check for correct functioning of parking
brake and foot brake operation.
16. Following parts should be greased:-
i)
|
steer axle yoke
pivot.
|
ii)
|
King pins and
bushes.
|
iii)
|
Hubs (2WD only)
|
iv)
|
Track rod ends.
|
v)
|
Universal joints
(4WD only)
|
vi)
|
Steer ram grease
nipple.
|
vii)
|
All pivot pins.
|
viii)
|
Propeller shaft
4WD.
|
ix)
|
King post and
carriage.
|
50 hrs maintenance
1. Carry out complete maintenance schedule
specified for 10 hrs maintenance.
2. Check fan belt tension pressed sagging should
not increase 8-10mm. If incorrect tighten or replace fan belt.
3. Check radiator hoses and their condition
if found perished or leaking replace.
4. Check oil level in the following:-
i)
|
Oil
cooler transmission.
|
ii)
|
Oil
cooler hydraulic.
|
5. Check axle oil level and replenish if
required with correct grade of lubricant oil rectify any leakage found.
6. Check slewing actuator oil and replenish
if required.
7. Check for fuel sediments trapped and drain
them out.
8. Drain fuel filter.
9. Grease propeller shaft from gear box to
rear axle.
10. Grease propeller shaft of 4 wheel drive.
11. Grease extending dipper.
100
hrs maintenance
The 100
hourly maintenance schedules should be carried out at either 100 hrs of
continuous operation or 1 month which ever is earlier.
1. Carry out maintenance schedule specified for
10 hrs and 50 Hrs maintenance.
2. Check for any damage to ram piston rods.
3. Check for correct functioning of pump
drive and listen to any abnormal sound coming from drive. Report workshop if
any abnormal sound coming.
4. Check all hydraulic oil carrying pipes for
leakage/chaffing/damage. Replace if required
5. Get following check from workshop:-
i)
|
Engine
cylinder head torque setting.
|
||
ii)
|
Idling
speed, it should be 550-600 rpm if required adjust.
|
||
iii)
|
Max
speed it should be 2200 rpm it required adjust.
|
||
iv)
|
Pulled
down speed it should be 1200 rpm.
|
||
v)
|
Valve
clearance it should be as under when engine is cold.
|
||
a)
|
Inlet
valve
|
.30mm
|
|
b)
|
Exhaust
valve
|
.25mm
|
|
6. Check fuel system for leakage and rectify.
7. Check mounting bolts for tightness if
loose tighten.
8. Check electrical wiring for chafing
insulate/replace if required.
9. Check for screen washer bottle and change
water.
10. Check clutch oil pressure and torque
converter main line pressure following is the limit, if less notify wksp.
Convector Pressure (in NEUTRAL position)
Temperature in o
C
|
Pressure Kg/ Cm2
|
|
IN PRESSURE
|
||
1000 IN
|
50
|
1.5 - 2.5
|
2000
|
50
|
5.4 - 6.8
|
1000 IN
|
100
|
0.5 - 1.3
|
1000 OUT
|
50
|
0.8 - 1.6
|
2000
|
50
|
3.1 - 4.1
|
1000 OUT
|
100
|
0.3 - 0.6
|
2000
|
2.1 - 3.0
|
|
LUBRICATION
PRESSURE (IN NEUTRAL)
|
||
1000
|
50
|
0.3 - 0.9
|
2000
|
50
|
1.8 - 2.4
|
1000
|
100
|
0.1 - 0.3
|
2000
|
100
|
1.3 - 2.1
|
1000
|
50
|
0.3 - 0.9
|
2000
|
50
|
1.8 - 2.4
|
1000
|
100
|
10.4 - 12.4
|
2000
|
100
|
11.8 - 14.3
|
CLUTCH PRESSURE (IN
NEUTRAL) all
clutch pressure should be same as main line pressure with in 0.7 bar 10 Lbs.
|
||
1000 Cooler
|
50
|
2.0 - 2.9
|
2000
|
50
|
3.6 - 5.3
|
1000
|
100
|
1.1 - 2.2
|
2000
|
100
|
3.8 - 4.6
|
PUMP AT 50 o C
|
||
1000
|
50
|
3.0 - 4.1
|
2000
|
50
|
6.7 - 8.8
|
11. Grease wheel hub bearing and king pin
bushes.
12. Grease pump drive shaft and all linkages.
13. Clean battery terminal. Wash corroded
material with ammonia solution consisting 115 gm. Of baking soda added to 1
liter of water.
14. Clean fuel lift pump.
200 hrs maintenance
schedule
1. Carry out 10, 50 & 100 hrs maintenance
schedule checks.
400 hrs maintenance
tasks:-
1. Carryout 100 & 200 hrs maintenance
schedule checks.
2. Check following pressure.
MRV Pressure
i)
|
MRV Pressure (Excavator)
|
-
|
210 kg/cm2
|
ii)
|
MRV pressure (Loader)
|
-
|
183 kg/cm2
|
ARV Pressure Loader
i)
|
Shovel ram head side
|
-
|
176 kg/cm2
|
ii)
|
Shovel ram rod side
|
-
|
245 kg/cm2
|
iii)
|
Shovel ram rod side
|
-
|
316 kg/cm2
|
ARV Pressure Excavator
i)
|
Bucket ram head side
|
-
|
245 kg/cm2
|
ii)
|
Dipper ram head side
|
-
|
245 kg/cm2
|
iii)
|
Dipper ram rod side
|
-
|
245 kg/cm2
|
iv)
|
Boom ram dead side
|
-
|
245 kg/cm2
|
3. Check pivot pins and bushes for damage and
grease if required any.
4. Check for parking brakes and adjust
suitable.
5. Check engine injector pressure and
calibrate suitably.
800 hrs maintenance
task
1. Carry out 400 hrs maintenance task.
1600 hrs maintenance
task
2. Carry out 800 hrs maintenance task.
Note: If working conditions are extremely
dusty & quality of fuel/lubricants is poor, please change filter earlier than specified period.
(*) Whichever is earlier.
Appx-
‘C’
Recommended
Coolants
| ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
Castrol
heavy duty coolant
Use
ethylene glycol antifreeze diluted with coolant blend as mentioned below in the
following proportion in (radiator) cooling system.
Ambient
Temp.
|
Ratio
by volume of antifreeze to cooling water-blend.
|
Deg
C
+50o to -5 o
-6 o to -15 o
-16 o to -25 o
Below
- 25 o
|
20
: 80
33
: 67
40
: 60
50
: 50 (Max . permissible ratio)
|
Tyre
Pressure
Size
|
PR
|
Pressure
|
Bar
|
||
9.00x16
|
16
|
7.2
|
12.5x18
|
16
|
3.5
|
14.00x25
|
20
|
2.8
|
16.9x28
Industrial
|
10
|
2.8
|
Appx-‘D’
ENGINE
SPECIFICATION FOR R1040 SERIES
1.
|
Bore
x Stroke (mm x mm)
|
:
|
105
x 120
|
2.
|
Firing
Order
|
:
|
1-3-4-2
|
3.
|
Displacement
|
:
|
4160
|
4.
|
Direction
of Rotation
|
:
|
ACWR
|
5.
|
Aspiration
|
:
|
Naturally
Aspirated
|
6.
|
Compression
Ratio
|
:
|
19
: 1
|
7.
|
Starting
Arrangement
|
:
|
Electric
Start
|
8.
|
Governor
type
|
:
|
Mechanical
|
9.
|
Lub
Oil Consumption
|
:
|
.3%
of fuel consumption
|
10.
|
Specific
Fuel Consumption
|
:
|
165
gm/hp-hr
|
11.
|
Lub
Oil Sump Capacity
|
:
|
11.5
Liters
|
12.
|
:
|
65.01
HP
|
|
13.
|
Power
consumed by Radiator
|
:
|
3.0
HP
|
14.
|
Rate
|
:
|
1500
|
15.
|
Dry
Engine weight
With Radiator without Bell Housing
With flywheel and SAE3 Flywheel Housing and Radiator
|
:
:
|
494
kg
522
kg
|
16.
|
Radiator
Capacity
|
:
|
15+8
= 23 Ltrs
|
_________
No comments:
Post a Comment