GMI- 244

DIRECTOR GENERAL BORDER ROADS

GENERAL MAINTENANCE INSTRUCTION NO: 244

ON OPERATION AND MAINTENANCE OF

HYDRAULIC EXCAVATOR 20 TON MAKE  MODEL TATA HITACHI

 EX 200 LC (TELCON)  WITH ROCK BRAKER ATTACHMENT

INTRODUCTION:

(a)     The Hydraulic Excavator make Tata Hitachi model EX 200 LC (Telcon) having operating weight 20000 Kgs (approx) and mounted on Crawler fitted Tractor type under carriage powered by Cummins make 6BT 5.9C model, 4 stroke, 6 cylinder, water cooled, Turbo charged,  inline, direct injection diesel engine developing 131 HP at 2000 rpm, with 0.90 cum capacity general purpose bucket and Rock Breaker attachment.

(b)     This GMI gives the technical specification and know how on the operation, maintenance and repair procedure of Hydraulic Excavator Telcon model EX 200 LC to ensure maximum performance and safe/satisfactory operation. Compliance with procedures given in this GMI will enable to get desired maximum service from the equipment.

(c)     Maintenance of Hydraulic Excavator Tata Hitachi model EX 200 LC (Telcon) will lead to long life, trouble free operation and less frequent break downs and also to reduce maintenance cost. The periodic maintenance must be carried out according to the ‘Periodic Maintenance Schedule’ described in this GMI. Daily care, inspection and Periodic Maintenance are essential for preventing troubles and accidents to ensure satisfaction and safe operation for prolonging the operating life of the equipment. All information and instructions given in this GMI is based on the latest Operator’s manual and service booklet provided by the firm.

AIM:     The instructions are issued as guidelines for general, preventive maintenance schedule and lubrication of Hydraulic Excavator Telcon model EX 200 LC manufactured by M/s TELCO Construction Equipment CO. 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)	(i)      To carryout and monitor maintenance schedule and oil changes as per periodical maintenance laid down in the maintenance instructions 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 with filling capacity and periodicity for change.	Appendix ‘D’

                                                                                                (MB Negi)

                                                                                                EE (E&M) SG

                                                                                                Joint Director (Tech)

                                                                                                For Dir Gen Border Roads

                                                                                                           

                                                                                                Appendix ‘A’

OPERATING PROCEDURE

1.      Inspect equipment daily before starting.

2.      Make sure all control levers are in neutral position.

3.      Stop engine immediately, if engine oil pressure indicator  glows ON while operating the eqpt.

4.      Drain water and deposits/sediments from fuel tank.

5.      Always keep attachment pedal locked with pedal lock when attachment pedal for Rock breaker is not in use.

6.      Operate the eqpt with the tracks positioned perpendicular to the eqpt which can more easily excavate if the cliff face collapses.

7.      When digging, avoid hitting tracks with boom cylinders. When digging over the end of the tracks, travel motor should be at the rear to minimize the chain and sprocket loading and to maximize the eqpt stability and lifting capacity.

8.      When digging deeply, avoid hitting bottom of boom or bucket cylinder hoses against the ground.

9.      Use the bucket only for digging.  Do not use bucket as a jack hammer or wrecking ball to avoid accident.

10.     Always lower the attachment or implement to the ground before work on the eqpt.

11.     Continuous operation of the engine with low or high coolant temp can damage the engine.

12.     Check for worn or frayed wires and loose connections.

13.     Check for leaks, kinked hoses and lines or hoses those which rub against each other or other parts.

14.     Check lubrication points on the periodic service chart.

15.     Grease in track adjuster is having more pressure and do not remove grease fitting or valve assy to avoid injury/damage.

16.     Always be familiar and well conversant with safety signs/symbols to avoid accident.

17.     Always park the eqpt on a level surface and lower the bucket to the ground.

18.     Turn Auto Idle switch OFF provided to reduce the fuel consumption, turn engine at slow idle speed without load for three minutes, turn key switch to OFF to stop engine, remove key from switch and pull Pilot control shut off lever to lock position.

19.     Extra care be taken when the cab is swung around so that it is facing the rear/track motor end of the under carriage, the action of the tracking controls, steering and transmission direction will be reversed.

20.     When not traveling, do not place your feet on the travel pedals.

21.     Always stop the eqpt to select a different speed range and do not change the speed mode while traveling.

22.     When you are excavating do not rest your feet on the foot pedals. Even light pressure on the pedals can cause the brakes to be released.

23.     Never excavate directly beneath the machine itself.  Excavating beneath the eqpt can weaken the ground and cause the eqpt to tip over. 

24.     Do not excavate on hard or rocky ground with the boom positioned diagonally across the under carriage.  The resulting rocking motion could cause damage to the track gear box sprockets.

25.     Walking or working under raised boom is hazardous. 

26.     Keep all the controls of the eqpt clean and dry.

27.     An incorrectly parking eqpt can move without an operator.            

28.     When lowering the boom, avoid sudden stop that may cause shock load damage to the equipment.

29.     When operating the arm, avoid lowering the cylinder to prevent the cylinder damage.

30.     When digging at an angle, avoid striking the tracks with bucket teeth.

31.     When the Rock breaker is not used, apply the cover to the pipe opening on the arm top and install the plug in to the hose end of the breaker to prevent the entry of contamination in to the system.

32      Operate the equipment slowly with the Rock breaker attachment as the breaker is heavier than bucket.

33.     Avoid using the Rock breaker for hammering operation.

34.     To prevent the cylinder damage, do not operate the Rock breaker with hydraulic cylinder fully retracted or fully extended.

35.     Stop operation if Rock breaker hydraulic hoses jump up abnormally due to change in accumulator pressure or damaged accumulator.

Do’s
1.		Always use correct grade of Engine oil & other Lubricants.
2.		Always use clean diesel and before filling diesel to tank, filter it with fine cloth.
3.		Check lifting equipments before using.
4.		Always face machine when entering to cabin and descending from cabin.
5.		Secure all moving parts of the machine when not in use.
6.		Always ensure electrics are switched off before leaving machine.
7.		Always drive carefully and avoid any sudden stops and changes of direction including Zig-zag driving.
8.		Always stop the machine and lock cabin and other doors to safe guard equipment before leaving the equipment.
9.		Avoid parking on slopes if it is necessary ensure parking brake is on and wheels are chocked.
10.		Avoid high speed operation.
11.		Before towing the equipment it is advisable to disconnect front and rear propeller shafts to avoid damage to the transmission. Also release parking brakes.
12.		Keep bucket about 200 to 300 mm above the ground when traveling up or down a gradient. If the equipment starts to slip or become unstable, lower the bucket immediately.
13.		Always de-pressurize the system before removing any hoses or pipes.
14.		Always switch OFF Auto Idle switch and reduce the engine rpm to low idle before stopping the eqpt.
15.		Always operate machine and services smoothly.
16.		Operate the control levers when you are correctly seated inside the cab.
17.		Understand the electrical circuit before connecting or disconnecting an electrical component to avoid injury/damage.
18.		Before disconnecting or connecting hydraulic hoses, stop the engine and operate the control levers several times to release pressure trapped in the hoses.
19.		Inspect the hoses regularly for any damage/leakage.
20		Always wear protective glass and protective shoes while working on the equipment.
21.		Avoid idling the engine for more than 10 minutes.
22.		Allow the engine to idle 3-5 minutes before shutting it off after a full load operation.
23.		Monitor the oil pressure and coolant temp gauges frequently. Shut of the engine if oil pressure or coolant temp does not met specification,
Don’ts
1.	Do not open the engine cover while the engine is running and avoid using eqpt with engine cover open.
2.	Do not operate the eqpt beyond its designed limits.
3.	Do not carry passengers as the eqpt is a one man machine.
4.	Do not overload the eqpt which can damage and make the eqpt unstable.
5.	Do not walk or work under raised attachments unless they are safely blocked.
6.	Do not operate controls from outside cab and start the engine only from operator’s seat.
7.	Do not use bare hand to check for any oil leakage.
8.	Do not work under a machine when on soft ground.
9.	Do not drive the eqpt with the door unlatched. It must be correctly closed or secured fully open.
9.	Do not use the machine controls as handholds when entering or leaving the eqpt.
10.	Do not wear loose clothing or fitting while operating Eqpt.
11.	Do not engage the starting motor more than 30 seconds.  Wait 2 minutes between each attempt to start.
12.	Do not bend or strike high pressure lines and never install bend or damaged lines, pipes or hoses.
13.	Do not operate the engine on load when temperature of coolant exceeds 980 C and lub oil pressure is low. (18 psi).
14.	Do not operate the engine at full throttle below peak torque engine speed for extended periods (more than one minute) of time.
15.	Do not add cold coolant to a hot engine to avoid damage to engine castings.
16.	Never mix two different brands of lub oil.
17.	Do not hit track with bucket when digging.
18.	Do not allow contamination enter in to the system when connecting the Rock breaker with the bucket.
19.	Do not operate the Rock breaker to the side of the equipment.
20	Do not use Rock breaker to move objects and for lifting operation.
21.	Do not starts the equipment with Auto Idle switch in ON position, otherwise rpm of engine/equipment cannot be varied through accelerator lever.
22.	Never try to increase the rpm of the engine through accelerator lever when the Auto Idle feature is working. To vary the speed of the engine through accelerator lever, initially the pilot lever is to be operated.
23.	Never lubricate or service the equipment while it is moving.
24.	Do not operate the equipment if cables or wires are loose, kinked etc.
25.	Do not make contact with electric wires and bridges.
26.	Avoid traveling across the face of the gradient.
27.	Avoid tipping the equipment when swinging heavy load and do not swing load to the downhill side.  Reduce swing speed.
28.	Do not pull or push dirt/material with the bucket when traveling.
29.	Never use wide track shoes on rough ground such as rocks, sand or gravel.  Wide track shoes are designed only for soft ground.

Rock Breaker

1.	The only gas permitted for charging the accumulator is Nitrogen N2.
2.	Use only the Hose Nozzle to relieve the pressure.
3.	Be sure to check the surroundings of the machine for safety before starting maintenance.
4.	Never use other than Nitrogen N2  gas  in back head.
5.	Do not approach front of tool, charging in back head with Nitrogen N2 gas.
6.	When back head is charged, breaker tool would be come out.
7.	If the breaker is laid down the wooden square bar more than six months, please check all seals in cylinder and corrosion bolts before operation.

                                                                                                                         Appendix ‘B’

 PERIODIC MAINTENANCE SCHEDULE

Maintenance work	Service intervals in hours								Remarks
	Daily	50	125	250	500	1000	1500	2500
ENGINE
Engine oil level.	*
Engine oil change.		*		*					Initial change at 50 Hrs
Engine oil filter change.		*		*					Initial change at 50 Hrs
GEAR OIL
Swing reduction device.
Gear oil level.		*							Initial change at 50 Hrs
Gear oil change.		*				*			Initial change at 50 Hrs
Travel/Propel reduction device.
Gear oil level.				*
Gear oil change.				*		*			Initial change at 250 Hrs
HYDRAULIC SYSTEM
Hyd oil level and condition.	*
Hyd oil tank draining.				*
Hyd oil change.								*	For Rock breaker at every 500 Hrs
Hyd oil tank breather cleaning.						*
Hyd oil tank breather change.									After every 4000 Hrs
Check Hyd hoses and lines.	*			*
Suction filter.								*	Also whenever replacing Hyd oil
Full Flow Filter.					*				For Rock breaker at every 125 Hrs
Pilot filter.					*
FUEL SYSTEM
Fuel Tank sediment  draining.	*
Fuel filter/water separator.				*
Fuel filter sediment draining .				*
Feed pump inlet filter/strainer cleaning				*	*
Fuel tank strainer cleaning.					*
Check fuel hoses.	*			*
AIR INTAKE
Air intake hoses for inspection.				*
Air cleaner element primary.					*
Vacuum indicator change.							*
COOLING SYSTEM
Coolant level check.	*	*
Fan belt tension.	*			*	*
Coolant change .						*
Radiator core cleaning  out side.				*
Radiator core cleaning  in side.							*
Radiator hoses change.							*
ELECTRICAL SYSTEM
Battery fluid level.		*
Battery specific gravity check.		*
Wire harness check..					*
Key switch function.	*
OTHERS
Bucket teeth loose, wear.	*
Track tension.		*
Bucket linkage clearance.	As and when required
Torque check.		*		*					Initial change at 50 Hrs
Calibrate fuel injection pump.							*
Engine valve clearance adjustment.						*
Track shoe bolts tightness.		*
GREASING
Front joint pins (Boom pivot, boom Cyl, bucket & link pins and other pins.	*
Swing bearing.					*
Swing internal gear.					*

Appendix  ‘C’

TECHNICAL SPECIFICATION

Description	:	Hydraulic Excavator 20 Ton TATA HITACHI EX 200 LC (TELCON)
ENGINE
Model /Type.	:	Cummins 6 BT 5.9C.
Cylinder bore x stroke.	:	102 mm x 120 mm.
Compression ratio.	:	17.5 : 1.
Piston displacement.	:	5.88 Ltrs.
Firing Order.	:	1-5-3-6-2-4.
Direction of rotation.	:	Clock wise from front of engine.
Minimum  Engine oil pressure.	:	Idle – 10 psi and full speed/load -30 psi.
Maximum output
Maximum  Torque
Engine weight.	:	440 Kg (Max).
Minimum oil pressure.	:	Idle- 10 psi, Full speed/Load – 30 psi.
Compression Pressure.
Valve Clearance.	:	Inlet – 0.25 mm and Exhaust 0.51 mm.
ELECTRICAL SYSTEM
Battery.	:	12 V 120 AH Qty – 02 Nos.
STATIC DIMENSIONS OF EQPT
Overall length of Crawler.	:	4350 mm.
Overall width of crawler.	:	2990 mm.
Overall width.	:	2990 mm.
Cabin height.	:	2850 mm.
Rear end swing radius.	:	2760 mm.
Sprocket to idler centre.	:	3550 mm.
Standard shoe width.	:	510 mm/ 600 mm.
Height of engine cover .	:	2610 mm.
Overall width of superstructure.	:	2610 mm.
Ground pressure.	:	0.46 Bar. ( 0.45 kgf/cm2)
Minimum ground clearance.	:	435 mm. (excluding shoe lug)
Swing speed.	:	13.7 rpm.
Travel speed.	:	4.6 Kmph.
Gradeability.	:	70% (350).
WORKING RANGE
Maximum digging radius.	:	9250 mm.
Maximum digging depth.	:	5950 mm.
Maximum cutting height.	:	8990 mm.
Maximum dumping height.	:	6230 mm.
Transport height.	:	3020 mm.
Maximum overall Transport length.	:	9680 mm.
Minimum swing radius.	:	3720 mm.
ROCK BREAKER.
Description of machine.	:	Hydraulic Breaker.
Make & Model.	:	DAEMO DMB 210.
Operating weight. (with top box bracket)	:	1800 Kgs.
Overall length. ( with STD mounting bkt)	:	2826 mm.
Chisel outer dia.	:	135 mm.
Chisel Length.	:	1250 mm.
Setting pressure.	:	210 Kgf/Cm2.
Working pressure.	:	130 to 170 Kgf/Cm2.
Oil Flow.	:	130 to 170 Lpm.
Blow Rate.	:	400 to 600 Bpm.
Black head Nitrogen (N2)  Gas pressure.	:	9 Kgf/ Cm2.
Suitable excavator.	:	18 to 25 Ton.

Appendix ‘D’

RECOMMENDED LUBRICANTS WITH FILLING CAPACITY AND PERIODICITY

S/ No	Item	Grade of Lubricant		Filling Capacity	Periodicity for change.
		IOC	TELCON
a)	Engine. Cummins 6BT 5.9 C	Servo premium CF4 15W40.	Telcon 15 W 40 CH4 Engine Plus.	14.2 Ltrs/ 16.4 Ltrs. (System capacity)	First oil/filter change after 50 Hrs and thereafter every 250 Hrs.
b)	Gear oil Swing reduction device. ( Front idler, swing device)	Servo Gear super 80W90.	Telcon TG90 Gear Oil.	7.5 Ltrs.	First oil change after 50 hrs and thereafter every 1000 Hrs.
c)	Propel/Travel reduction device.		Telcon TG90 Gear Oil.	5.5 Ltrs x 2.	First oil change after 250 hrs and thereafter every 1000 Hrs.
d)	Hyd Oil Hydraulic and steering system.	Servo Hydrex TH 46.	Telcon Super 46 S.	220 Ltrs.	1500 Hrs.
			Supreme 46 P.		2500 Hrs.
			Ultra 46 U.		4000 Hrs.
					First change at 500 Hrs and thereafter every 2500 Hrs.
e)	Coolant.	Servo Kool.	Super Cool.	30 Ltrs.	Once in a year/after every 1000 Hrs.
f)	Grease. (Swing Gear, Swing bearing etc)	Servo Gen RR.	Heavy duty EP2 Grease.	-	After every 500 Hrs.
g)	Fuel System.	-	-	270 Ltrs.
h)	Fuel Filter/Water separator.	-	-	-	Element change after every 250 Hrs.
j)	Air Cleaner (in take) element – primary.	-	-	-	If vacuum indicator shows Red mark, clean/replace air cleaner element after every 500 Hrs.
k)	Air filter – safety. (Secondary)	-	-	-	After cleaning outer element for six times, replace both outer and inner elements.
l)	Vacuum indicator.	-	-	-	After every 1500 Hrs.
m)	Suction filter.	-	-	-	Clean suction filter at every 2500 Hrs and also when ever replacing Hyd oil.
n)	Full flow filter. (Hyd oil filter)	-	-	-	Element change after every 500 Hrs. ( 125 Hrs for Rock breaker)
o)	Pilot filter.	-	-	-	Element change after every 500 Hrs.
p)	Hyd oil tank breather.	-	-	-	After every 4000 Hrs.

Note : Never mix two different brands of oil.

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