GMI - 224

DIRECTOR GENERAL BORDER ROADS

GENERAL MAINTENANCE INSTRUCTION NO 224

OF

HYD ROCK & CONC SPLITTER 

INTRODUCTION: - Hydraulic Concrete Rock Splitter of Shri Krishna make and S-240 Model shall be powered by Greaves make and 1510 model air cooled engine fitted with cold starting device developing 8.3 HP at 3000 rpm as per IS specification. The eqpt model as per manufacture’s design of latest technology should be of internationally accepted/ proven in the Trade market and should be capable for using/maximum five number splitter assemblies. The eqpt should be complete in all respect including wheel mounted tubular chassis, adequate capacity hyd oil and fuel tanks, power pack, filter, splitter assemblies, wedge sets, low and high pressure hoses, and shall be generally as per the specification given by manufacture.

           Regular pre-check and periodic maintenance are essential to prolong the life of the eqpt. Also it should be ensured that preventative maintenance tasks are carried out timely. repair to asset defects from developing into major ones are done expeditiously and that the eqpt is operated efficiently at all times there by minimising breakdown and down time and production losses.

AIM:- To enumerate the details of periodic preventive maintenance of Hyd Conc Rock & Splitter and power pack.

ACTION BY

USER UNIT: - To carryout maintenance schedule and oil changes as per periodic lay down by the instruction and also follow safety precaution for optimum utilisation. To enter the all task/record in concern log book.

FIELD WORKSHOP 

           

a)	To check maint against & lubrication task on actually carried out by the user unit as per Log book record.
b)	Advise user unit in respect of any discrepancies/short coming noticed

DETAILS :-

i)	Safety instruction and Maintenance	:	Appendix ‘A’
ii)	Do’s and Don’ts	:	Appendix ‘B’
iii)	Trouble shooting	:	Appendix ‘C’
iv)	Technical data	:	Appendix ‘D’
v)	Recommended lubricants	:	Appendix ‘E’
				(Hari Prakash)
				SE (E&M) FS
				Dir (Tech)
	Distribution			for Dir Gen Border Roads
	Normal

                                                                                                                         Appx ‘A’

SAFETY INSTRUCTION      

1.      Before operating the machine the operators is required to read the operating instruction.

2.      Sri Krishna Hydraulic Power Unit type SK7DE may only be used in conjunction with Sri Krishna rock splitters. Other form of use is strictly prohibited.

3.      Follow all safety measures, use protective clothing, Helmet and safety glasses, while on the excavation job.

4.      External forces coming into play, or a failure to observe regulations, may result and serious injury or death.

5.      Certain parts of eqpt operate under high pressure when installing dual hose sets, do not interchange the low pressure and high pressure hoses. Hoses must not be kinked. Inspect hoses for damage before use. Damage hoses must not be used, otherwise they may split giving injury by Hyd fluid Escaping under high pressure and the Whiplash movement of hose line it self.

6.      Do not release or remove the center wedges during operation, otherwise a risk of damaging of the splitter beyond repair.

7.      To avoid damaging the splitter (Wedge fracture). The depth of the drilled holes must under no circumstances be less than the specified depth. It must also be drilled straight.

8.      If the splitter leans to the either side by more than 10 degree when is use, the risk arises that the counter wedges and the center wedges may deform or may fracture. So grease the wedges as per instruction.

9.      If the wedges set is not fully inserted into the drilled hole or the equipment is overloaded,  lubrication is inadequate or an unsuitable lubricating compound is used, the wedge set may fracture, causing the splitting cylinder to jolt or hose line to whip about, leading in turn to crushing or internal injuries or death. Insert the wedges set into the drilled hole to atleast 3/4 of its length. Maintain a safe distance of one arm’s length. Use only recommended oil/lubricants.

10.    Due to severe stress on splitter wedges the contact faces of wedges must be greased after every 3 splits. Failure of this may lead to permanent damage of the wedges.

11.    If the splitter is not to be used for a prolonged period the control lever must be set to neutral position.

12.    If two or more splitters are connected to a single hyd power and none of the control levers on the splitters must be left in the neutral position, otherwise it will be impossible for the necessary pressure to buildup.

13.    The control levers on those splitters not in use should be set into return.

14.    After asserting all splitters into the holes all splitter control lever be informed or reverse condition simultaneously.

15.    If one of the connected splitter to be used then rest all splitter control lever must be in reverse position to build splitting pressure in system.

16.    When splitter is working keep on arms length away from cylinder due to possible sudden movement when break occurs.

17.    When splitter is used off the ground or overhead the cylinder should be supported so it does not fall after break is made.

18.    Do not use splitter as lever or Crow Bar.

19.    Do not stand on any part or section that could move or fall after splitting.

20.    Check Engine Oil level and top up if necessary.

21.    Clean air cleaner assy.

22.    Check battery electrolyte top up if necessary.

23.    Clean fuel filter if found dirty are checked.

Appx- ‘B’

           

SPLITTER DO’S AND DONT’S

DO’S

1.    Lubricate every second or third split.

2.    Use only specified lubricant for counter wedges and centre wedge.

3.    Keep hose connection clean.

4.    Check oil level periodically (Daily).

5.    Follow standard safety procedures.

6.    Drill hole to the proper depth and diameter.

7.    When splitter is used off the ground or overhead, splitter should be supported or tied up by rope so it does not fall after break is made.

Don’ts

1.    Do not use splitter as lever or bar.

2.    Do not operate splitter with defective or damage center wedge or counter wedge.

3.    Do not drill short holes.

4.    Do not leave splitter with center wedge extended.

5.    Do not drill bend holes/radial hole this will bend the whole wedge set while splitting and result in breakage of whole wedge set.

                                                                                                                      Appx - ‘C’

TROUBLE SHOOTING

Leakage problems

1.    Leakage between cylinder and head around center wedge & counter wedge when stuffing box ‘O’ ring and seal warn. Replace seals & ‘O’ rings.

2.    Leakage around Oil Tank due to oil Tank Plate screws loose ‘O’ Ring adapter warn out, tighten all screw replace ‘O’ ring.

3.    Leakage around distribution block due to fitting loose. Tighten or reinstall with Toflon Tape.

4.    Leakage around valve block due to ‘O’ ring and cap nut too tight or not tight. Replace ‘O’ Ring. Tighten Cap nuts, Tighten hose connections or apply Teflon Tape.

Centre wedge & Counter wedge problems

1.    Center wedge broken or bend at bottom or lower half when hole length too small or hole not straight. Drill hole of the correct size and straight.

2.    Excessive wear in center wedge and counter wedge due to not enough lubrication, Wrong lubrication lubricant contain with rock chips, Lubricant for every 2-3 split, use specified lubricant and keep lubricant covered when not in use.

3.    Center wedge broken at top due to lack of improper lubrication, Use specified lubricant and lubricate when required.

4.    Center wedge ‘Chatter’ during splitting due to improper lubrication. Lubricate every split in tough work.

5.    Broken counter wedge shoulders due to insufficient lubrication, lubricate every split in tough work.

6.    Counter wedge loose. Due to lock pin broken, bent, lock sleeve broken or bent, counter wedge head warn and spring tension reduces. Replace all defective parts.

Pressure Problem

1.    Center wedge moves forward wont reverse pressure too high or pressure too low due to faulty adjustment of pressure relief valve, adjust relief valve.

2.    Pressure OK center wedge not moves forward or reverse reason as faulty connection of high pressure hose & low pressure hose. Replace connection.

3.    Engine runs fine; no pressure due to broken coupling and drive key missing. Replace both parts.

4.    Over heating of splitter and high pressure hose breakage due to operate fails to pause in neutral position the valve. Maintain value in neutral position when not in use.

				Appx - ‘D’
	TECHNICAL DATA
1.	Engine	:	Greaves engine model 1510 air cooled engine 01
2.	Hydraulic Power Unit-5A7DE	:	01
3.	Prime Mover	:	01
4.	Hydraulic Pump	:	01
5.	Pressure relief valve	:	01
6.	Hyd Oil Tank	:	01
7.	Battery for engine start	:	01
8.	Tubular Steel Frame	:	01

           Appx- ‘E’

RECOMMENDED LUBRICANT

LUBRICANTS

Hydraulic Oil -           32 Nos. Hyd oil Make HP ESSO or equivalent.

Engine Oil     -           20W-40

GREASE FOR WEDGES

AP3               -           Castrol or equivalent

Caution:-

       Due to severe stress on the wedges set, the contact faces of center wedge and the counter wedges must be greased after 3 splits. Failure to do this may lead to the splitter being damaged beyond repair.

Advantage of Lubricants:-

1.      Best result obtained

2.      Considerably reduces the friction.

3.      Facilities maximum splitting force.

4.      Little maintenance required, resulting in cost reduction.

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