DIRECTOR GENERAL
BORDER ROADS
GENERAL MAINTENANCE
INSTRUCTION NO: 240
ON OPERATION AND MAIN TENANCE OF
VIBRATORY SOIL COMPACTOR L&T
1107 D
INTRODUCTION:
(a) L & T Case make and 1107 D model
Vibratory Soil Compactor having hydrostatic drive on both front drum and rear
drive axle, with high strength main frame/chassis, with dual amplitude setting
and having dual frequency of 30 and 33 Hz in the front drum, hydraulic steering
mechanism, hydrostatic service brake, powered by Kirloskar HA 694 air cooled 6
cylinder diesel engine developing 112 HP @ 2500 rpm and with 12 V starting
system.
(b) This GMI gives the technical specification
and know how on the operation, maintenance and repair procedure of Vibratory
Soil Compactor L&T 1107 D to ensure maximum performance and
safe/satisfactory operation. Compliance with procedures given in this GMI will
enable to desire the maximum service from the equipment.
(c) To prolong the life of Vibratory Soil
Compactor L&T 1107 D, to prevent frequent break downs and to reduce maintenance
cost, the periodic maintenance must be carried out according to the ‘Periodic
Maintenance Schedule’ described in this GMI. Periodic Maintenance is
essential for preventing troubles and accidents to ensure satisfaction and
safety. Daily care and inspection is also essential for prolonging the
operating life of the equipment and for safe operation. All information and
instruction given in this GMI is based on the latest owner’s manual and service
booklet provided by the firm.
AIM: The instructions are issued as guidelines
for general, preventive maintenance schedule and lubrication of Vibratory Soil
Compactor L&T 1107 D manufactured by M/s Larsen & Toubro Case Equipment
Pvt Ltd for regular attention to keep the equipment in good mechanical condition
which must be strictly followed.
ACTION
BY:
|
a)
|
User unit: To carryout periodic inspection and
monitor regular/periodical maintenance as laid down in this instruction and
record the tasks done in log book.
|
|
|
b)
|
Field Workshop :
|
|
|
|
i)
|
To carryout and
monitor maintenance schedule and oil changes as per periodical maintenance
laid down in the maintenance instruction and to check the record of
maintenance including lubrication.
|
|
|
ii)
|
To advise the user
unit in respect of any lapse noticed.
|
|
c)
|
Mobile Maintenance
Team: To ensure that proper maintenance is
carried out and submit report accordingly to Task Force Commander and OC Wksp
for their necessary action.
|
|
DETAILS:
This instruction includes the following
aspects:-
|
a)
|
Operating
Procedure
|
Appendix
‘A’
|
|
b)
|
Periodic
Maintenance schedule
|
Appendix
‘B’
|
|
c)
|
Technical
Specification
|
Appendix
‘C’
|
|
d)
|
Recommended
Lubricants/Filling Capacities
|
Appendix
‘D’
|
(V N Singh)
SE
(E&M) FS
Director
(Tech)
For
Dir Gen Border Roads
Appendix
‘A’
OPERATING PROCEDURE
Daily Pre Operation Checks before
starting the engine:
1. Check fuel level in the fuel tank and top
up if required.
2. Fill in diesel fuel in time so as to avoid
unnecessary bleeding of the fuel system.
3. Do not spill diesel fuel on the engines.
4. If the fuel tank has been run empty it is
necessary to bleed the fuel system.
5. Check hydraulic oil level in the tank and
top up, if required.
6. Check engine lub. Oil and top up if
required.
7. Visually check for leakages and damages to
electrical components and connections.
8. Visually inspect and ensure that all the
doors and covers are closed and locked. No tools like spanners, screw drivers
should be left on the machine.
Starting
the engine:
1. Check whether the Articulation joint
arrester is removed.
2. Ensure that all the miniature circuit
breakers (MCBs) are switched ON at the MCB Box below Operators Platform (RH).
3. The drive lever and the exciter switch
must be in their neutral positions.
4. Push the accelerator lever back to the low
idling position.
5. Switch OFF the parking brake switch if it
is in ON position.
6. Insert the ignition key into the ignition
switch and turn clockwise by 45 degrees and check all indicators.
7. Low lub. Oil pressure indicator and
Battery non-charging indicator will glow.
8. Turn and depress the ignition key to start
the engine.
9. Do not actuate the ignition switch for
more than 5 seconds. While attempting to start the engine, wait for one minute
before trying again.
10. After the Engine has picked up and warning
lights like Low lub. Oil pressure indicator and battery non-charging indicator
have gone off, the engine should be run on idling speed for 2-3 minutes.
Thereafter rotate the throttle lever to increase the rpm of the engine. At the
maximum position the engine will be operating in full speed.
11. Machine must be operated (Travel & Vibration)
in high engine rpm only.
Operating
the machine (Travel) :
1. Drive the machine with the drive lever
(FNR) into the desired driving direction (forward/back word from neutral). The
speed will increase, the more the lever is moved forward or backward.
2. For braking, move the drive lever out of
the respective forward or reverse driving position to the neutral position.
3. During parking in slope, put on parking
brake switch (P).
4. Parking brake is to be operated only when
machine is in neutral. Electrical system is designed in such a way that parking
brake will be engaged only when FNR lever is in neutral. And when parking brake
switch is ON engine can’t be started.
Setting the exciter
into operation :
1. Start the engine according to the
procedure given above.
2. Start traveling (Moving forward or reverse
direction) the M/C in working speed (Put OFF high speed switch).
3. Turn vibration frequency selector rotary
switch to left to select low frequency & high amplitude or to right to
select high frequency & low amplitude.
Setting the other
features available in the machine:
1. Switch ON/ OFF front head lamps, Rear
working lamps, side indicators, parking lamps, if necessary.
Setting Machine out
of operation :
1. Rotate frequency selector switch to
neutral (at centre) to stop vibration.
2. Then bring FNR lever to neutral to stop
traveling.
3. Put on parking brake toggle switch during
parking the M/C on slope to prevent the M/C roll back.
4. Bring Throttle lever to low idle position.
5. Pull the stop cable knob until Engine
stops. Low lub oil pressure indicator & battery non charging indicator
should glow.
6. Turn ignition key anticlockwise. All indicators
should go off.
7. Switch off all the MCBs.
8. Secure the machine by means of wheel
chocks and/or stone/rocks if necessary.
9. Do not stop the Engine suddenly from full
load, but allow it to run sometime with no load.
Safety Features:
1. Electrical circuit protected by MCBs
2. Machine cannot be started when
Forward-Reverse lever is not in neutral
3. Machine cannot be started when parking
brake switch is on.
4. Parking brake automatically disengage when
m/c is not in neutral
5. No vibration in high speed (Transport)
mode of travel.
6. Automatic engine cut off in case of Engine
belt failure
7. Neutral indicator
8. 2 speed indicator
9. Battery Non-charging indicator
10. Low lub oil pressure indicator
11. Air filter clog indicator (Mech.)
12. Hydraulic oil filter clog indicator
13. Parking brake indicator
14. Fan belt failure indicator
15. Engine lub oil Pressure & Temperature
gauge
16. Service hour meter
17. Rigid Rear Axle with inboard planetary
drives
Precautionary
measures:
1. Uphill driving is impermissible, if the
gradient exceeds the permissible gradient of the machine during operation.
2. The machine is equipped with infinitely
variable hydrostatic propulsion so that a jerky take off or a jerky reversal in
the opposite direction should be avoided.
3. Before starting to drive uphill, check at
the beginning of the gradient in the driving direction envisaged, whether the
wheels and drum have a sufficient frictional engagement and ground contact with
the track way.
4. While taking off the machine and while
reversing the travel direction, take care of a smooth and uniform acceleration
and deceleration so as to avoid unevenness of the layer placed.
5. For compacting, select the drive range and
move into the loose material using forward and reverse gears.
Appendix
‘B’
PERIODIC MAINTENANCE
SCHEDULE
|
Maintenance
work
|
Maintenance
Instants
|
||||||||
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After first 50 hours
|
Daily
|
Regularly every
(Hours)
|
In case of need
|
||||||
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10
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50
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100
|
200
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500
|
1000
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CHECKING
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MACHINE
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Visual
inspection for damage
|
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*
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*
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Visual
inspection for leakages
|
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*
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*
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Visual
indicator for contamination (Hydraulic filter choke indicator)
|
|
*
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*
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Air
intake system
|
|
*
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*
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Air
cleaner chock indicator
|
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*
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*
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Exhaust
pipe
|
*
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*
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*
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Engine
mounting (AVMs/bolts)
|
*
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|
|
|
*
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|
*
|
|
Roller
mounting (AVMs/Screws)
|
*
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|
*
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*
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|
Scrapper
|
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*
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*
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V-belt
tension
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*
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*
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Battery
charge (Red/White/green in “Magic Eye”
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*
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*
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FUNCTIONS
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Engine
oil temperature gauge
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*
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*
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Engine
oil pressure gauge
|
|
*
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*
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Low
engine oil pressure indicator
|
|
*
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*
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|
Parking
brake ( In m/c neutral)
|
|
*
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*
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Electrical
system
|
|
*
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*
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Vibration
with low & high frequency
|
|
*
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*
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Steering
|
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*
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*
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Tyre
pressure (adjust if required)
|
*
|
*
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*
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CLEANING
|
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Clean
machine
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*
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*
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Air
intake system
|
|
*
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*
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Hydraulic
oil cooler
|
|
*
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|
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*
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|
Water
separator
|
|
*
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*
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|
Fuel
tank (Drain water)
|
|
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*
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*
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|
Fuel
tank
|
|
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*
|
*
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|
LUBRICATION
|
|
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Oil
level in the engine
(top up if required)
|
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*
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*
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|
Oil
level in hydraulic Tank
(
top up required)
|
|
*
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|
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|
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*
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|
Greasing
at Steering Cylinder rod &head end
|
|
*
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*
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|
Greasing
at articulation joint pins
|
|
*
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*
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Greasing
at travel bearing
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*
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Battery
electrolyte level
|
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*
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*
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|
Clean
& apply petroleum jelly at battery terminals
|
|
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*
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*
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TORQUING
|
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Roller
mounting
|
*
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*
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*
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Articulation
joints
|
*
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*
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*
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Roller
|
*
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*
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*
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Engine
|
*
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*
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|
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*
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Axle
mounting bolts
|
*
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*
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*
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Wheel
nuts
|
*
|
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*
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|
*
|
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REPLACE
|
|
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Hydraulic
oil filter element
|
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*
|
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*
|
|
Hydraulic
Oil
|
|
|
|
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|
*
|
*
|
|
Exciter
Oil
|
|
|
|
|
|
|
|
*
|
*
|
|
Axle
oil
|
|
|
|
|
|
|
|
*
|
*
|
|
Reduction
Gear Housing Oil
|
|
|
|
|
|
|
|
*
|
*
|
|
Auxiliary
Drum oil
|
|
|
|
|
|
|
|
*
|
*
|
|
ENGINE
|
|
|
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|
|
|
|
|
|
|
Engine
oil change
|
After
every 250 hrs run.
|
||||||||
|
Engine
oil filter change
|
After
every 250 hrs run.
|
||||||||
|
Fuel
filter insert (Pre filter)
|
After
every 500 hrs run.
|
||||||||
|
Fuel
filter insert (Micro filter)
|
After
every 750 hrs run.
|
||||||||
|
Fuel
strainer (Bottom filter at feed pump inlet)
|
Clean
after every 125 hrs run.
|
||||||||
Appendix ‘C’
TECHNICAL
SPECIFICATION
|
Description
|
:
|
Soil
Compactor L&T 1107 D.
|
|
Vibration
|
:
|
Dual
Mode.
|
|
Propulsion
|
:
|
Front
drum drive and Rear Axle drive.
|
|
Steering
|
:
|
Hydraulic
Steering with Articulation.
|
|
Brake
|
:
|
Service
Brake (Hydrostatic) and Parking brake.
|
|
Operating
weight
|
:
|
11,
300 kg.
|
|
Axle
Loads
|
:
|
Front
: 6450 kg.
Rear : 4850 kg.
|
|
Static
linear load (front)
|
:
|
30
kg/cm.
|
|
Vibration
frequency
|
:
|
Stage
1 : 30 Hz.
Stage
2 : 33 Hz.
|
|
Nominal
Amplitude
|
:
|
Stage
1 : 1.8 mm.
Stage
2 : 0.8 mm.
|
|
Centrifugal
Force
|
:
|
Stage
1 : 25, 530 kg.
Stage
2 : 13, 820 kg.
|
|
Travel
speed
|
:
|
Work
Mode : 0 – 6 Kmph.
Travel
Mode : 0 – 14 Kmph.
|
|
Gradeability
|
|
|
|
Continuous
|
:
|
Degrees
: 19.8
Percent
: 36
|
|
Intermittent
|
:
|
Degrees
: 21.8
Percent
: 40
|
|
Internal
Turning Radius
|
:
|
3.45
m.
|
|
Drum
Oscillation Angle
|
:
|
15
degrees.
|
|
ENGINE
|
|
|
|
Make
|
:
|
Kirloskar
Oil Engines Ltd, Pune.
|
|
Type
|
:
|
4
Stroke, 6 Cylinder, inline, Direct Injection Air Cooled .Engine.
|
|
Model
|
:
|
HA
694.
|
|
Nature
of Aspiration
|
:
|
Naturally
Aspirated.
|
|
Power
rating
|
:
|
112
HP @ 2500 rpm as per std DIN 6271 IFN.
|
|
Bore
|
:
|
100
mm.
|
|
Stroke
|
:
|
120
mm.
|
|
Displacement
|
:
|
5652
cc.
|
|
Direction
of rotation
|
:
|
Anticlockwise
when viewed from flywheel end.
|
|
Type
of fuel pump
|
:
|
In
line.
|
|
Type
of Air Filter
|
:
|
Dry
type with dual element.
|
|
Type
of governing
|
:
|
Mechanical.
|
|
Starting
system
|
:
|
Electrical
12 V.
|
|
Lubrication
system
|
:
|
Forced
feed.
|
|
Dry
weight of the engine
|
:
|
530
Kgs.
|
|
PROPULSION
(TRAVEL):
|
|
|
|
Type
|
:
|
Hydrostatic
system acting on front drum and rear wheel.
|
|
Travel
Pump
|
:
|
Variable
displacement pump with manual displacement control.
|
|
Drum
drive Motor
|
:
|
Low
speed, High torque (G3/G4 type) Radial piston Motor with brake.
|
|
Wheel
drive Motor
|
:
|
High
speed, Low torque motor mounted on Rear axle input shaft.
|
|
EXCITER
DRIVE:
|
|
|
|
Type
|
:
|
Hydrostatic
system acting on the front and rear exciter. shafts
|
|
Kind
of Exciter
|
:
|
Single
shaft with two floating masses for dual amplitude.
|
|
Vibration
Motor
|
:
|
Fixed
displacement axial piston motor.
|
|
EXCITER
CONTROL:
|
|
|
|
Stage
1 (30 Hz)
|
:
|
High
Exciter force, Low frequency, High Amplitude.
|
|
Stage
21 (33 Hz)
|
:
|
Low
Exciter force, High frequency, Low Amplitude.
|
|
STEERING
SYSTEM:
|
|
|
|
Type
|
:
|
Hydrostatic
system acting via the steering wheel, steering unit and steering cylinder on
the articulated joint.
|
|
Steering
Pump
|
:
|
Gear
type.
|
|
ELECTRICAL
SYSTEM:
|
|
|
|
Battery
|
:
|
12
V, 120 AH.
|
|
Alternator
|
:
|
12
V, 35 Amph.
|
|
HYDRAULIC
|
|
|
|
Type
|
:
|
Paper
Element.
|
|
Filter
Rating
|
:
|
10
Micron. (Nominal)
|
|
Number
of Filters
|
:
|
1
|
|
BRAKES:
|
|
|
|
Service
Brake
|
:
|
Hydrostatic.
|
|
Parking
Brake
|
:
|
Spring
applied, hydraulic release.
|
|
RELIEF
VALVE SETTINGS:
|
|
|
|
Travel
circuit
|
:
|
430
bar.
|
|
Vibration
Circuit
|
:
|
320
bar. (Rexrath Pump), 350 bar (SD Pump)
|
|
TRANSPORT
DIMENSIONS:
|
|
|
|
Length
of the machine
|
:
|
5344
mm.
|
|
Width
of the machine
|
:
|
2300
mm.
|
|
Height
of the machine up to Optr cabin top
|
:
|
3150
mm.
|
|
Height
of the machine up to Silencer top
|
:
|
2410
mm.
|
|
Wheel
base
|
:
|
3000
mm.
|
|
Ground
Clearance
|
:
|
395
mm.
|
|
Diameter
of Rear wheel
|
:
|
1528
mm.
|
|
Diameter
of front wheel
|
:
|
1500
mm.
|
Appendix ‘D’
RECOMMENDED
LUBRICANTS
|
S/No
|
Item
|
Brand
Name
|
Manufacturer
|
|
a)
|
Engine
oil *
(SAE
40)
|
CRD
40
SERVO
SUPER 30/40
Hylube
Milcy 30/40
BHARAT
ACTUMA SUPER
HYLUBE
HDX 40
VEEDOL
HDB 40
|
Castrol
India Ltd
IOCL
HPCL
BPCL
HPCL
TIDE
WATER
|
|
b)
|
Hydraulic
Oil (Tropical)
|
HYSPIN
68
HYSPIN
–AWH 100TP
SERVO
HYDREX 100 HP
Power
Fluid LTP 100
BHARAT
HYDROL P 100
|
Castrol
India Ltd
Indrol
Lubricants & Specialties Ltd.
IOCL
HPCL
BPCL
|
|
c)
|
Exciter
Oil
|
Hypoi
EP 90
|
CASTROL
INDIA
|
|
d)
|
Grease
( For greasing drum, steering cyl, displaceable steering part)
|
SERVOGEM
EP-2
|
IOCL
|
|
e)
|
Rear
Axle and Reduction Gear Housing
|
M2C-134-D
AGRI
TFD
NAS9
|
CASTROL
INDIA
|
|
f)
|
Auxiliary
Drum
|
HYSPIN
68
|
CASTROL
INDIA
|
* Recommended
Eng oil for atmospheric temp above 250 C and for below 250
C, please refer engine side operator’s manual supplied by M/s KOEL.
FILLING
CAPACITIES
|
Engine
Oil
|
14
Ltrs.
|
|
Rear
Axle oil
|
27
Ltrs.
|
|
Rear
Axle Reduction Gear Housing Oil
|
0.5
ltrs.
|
|
Exciter
Chamber
|
19.5
Lltrs.
|
|
Auxiliary
Drum (for
|
4
Ltrs.
|
|
Hydraulic
oil tank
|
70
Ltrs.
|
_____________
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