Slide 1

JCB is named after its founder Joseph Cyrill Bamford,producing yellow&black engineering vehicles,diggers,excavators.Company was founded on october ,1945 in Stanffordshire,England and first product was farm trailer from war surplus material.It has two plants in India one in Haryana & other in Pune.

Different units at JCB(Haryana) are -:Assembly unit .Weld &fabrication unit.Paint shop unit.Transmission unit.Central materials unit.Purchase unit.Marketing&Finance.

Boom Sub-Assembly -:Boom is fitted hydraulic ram which provide movement when it is attached with machine. This is responsible for loader bucket movement.Dipper Sub-Assembly-:It is also same as boom assembly the only difference is that this assembly is responsible for excavators movement.Engine sub assembly mainly consist of 4 parts-:Engine-:A kirloskar 76HP,gross power 56 kw at 2200 rpm engine is installed in backhoes.Torque Converter-:Takes the place of mechanical clutch & able to multiply torque when difference between input &output is substantial.Fly Wheel-:A rotating disc that stores kinetic energy.Gear box-:4 speed fully synchromesh gear box with electrically reversing shuttle.JCB 3DX Backhoe loader-:4 cylinder,76HP,4- speed synchromesh,3300psi hydraulics ,front wheel steering.JCB 3DX Super Backhoe loader-:4 cylinder,90HP,4-speed synchromesh with reversing shuttle,3300p hydraulics, front wheel drive.JCB 4DX Backhoe loader-:4 cylinder,96HP,4-speed synchromesh with reversing shuttle,3300psi hydraulics ,front wheel. Above also varies in gear ratio .

Excavator valve block-:EVB mounting plates provides base on which valve block is fitted then adaptors which provide inlet and outlet for hydraulic oil.EVB is used for controlling excavator bucket.Loader valve block-:Responsible for movement control of loader bucket.Radiator assembly-:cooling unit, hydraulic cooler for cooling of hydraulic oil, seal are components of radiator.King post carriage-:it provides supporting mech. to boom dipper . It is a combination of slew ram , boom lock, bushes, feed pipe & seals.Cab Assembly -:it is operating room of the entire machine.

The aim of our project is to determine the cause of hydraulic leakages that has been occurring in JCB machines .As there are so many joints and hose pipes present in machine so 100% efficient is not possible.This leads to loss in efficiency, wastage of time &extra expenditure.

Actuation of various arms are controlled by fluids that are made to flow by piston mechanism for the movement of arm/pistons.

The basic losses due to leakage are-:Clean up.Make up fluid.Disposal of waste oil.Contamination ingress.Decrease in machine efficiency.Increase in expenditure to machine.123456789101112132422224142222Front axle ramLVB to feed pipeEVB to boom ramEVB to dipper ramEVB to bucket ramEVB to slew ramEVB to leg hoseEVB to return feed pipe Header piston jointsHydraulic pump to LVBFeed pipe to tankLVB to return feed pipeOil tank to hydraulic pump141516171819202122232425262724222241422221hydraulic cooler/radiator plugReturn feed pipe to hydraulic coolerOil tank to hydraulic coolerHose to lift ramFuel tank to fuel pumpHose to loader bucket ramOrbitral unit to front axle ramOrbitral unit hose to LVBOrbitral unit to hose hydraulic pumpEVB hose to legsEVB hose to boom ramEVB hose to dipper ramEVB hose to bucket ramRadiator hose

Front axle ram

EVB to boom, dipper &bucket rams

Hydraulic tank to pump

Gear pump to hydraulic cooler

Hose to lift ram

EVB hose to boom ramStudied all the hydraulic jointsComplete inspection of jointsReduced the no. of machines inspected for 2 daysLeft all the machinesAll leakage duly noticedCompared the hot bay test reportIt is quite inevitable a proper inspection technique as most of the leakages occur due to operators negligence.Method to significantly reduce the number of leakage point during assembly line is introduction of inspection zone.This inspection zone includes the point where the cab is placed to where the loader arm is set on the framework.The introduction of inspection zone has following features-:As most of the hydraulic joints ,that are prone to leakages ,are open in this region,it provides Easy Inspection Vicinity.Maximum number of machines can be inspected. Only four minutes is required on one machine by two operators.

Advantages are -:A lot of time is wasted in the Hot bay & PDI zone to rectify the leakages.Hydraulic oil losses can be minimized ,saving a lot of money.Expenditure related to clean up of leakages ,disposal and contamination can be easily prevented.

Major causes of leakages are-:

Leakage due to improper torquing.Leakage due to manufacturing defects.Leakage due to defect because of man-power.Leakage because of contamination of oil.The methods are-:Hydraulic dye test.Hot bay test.Replacement of metal pipe.Reduction of elbows and T-pieces.