Leak Free Analysis of JCB

Backhoe Loaders

Introduction to company
1.

2.

3.

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.

Products manufactured by
JCB

Different units at JCB plant

Different units at JCB(Haryana) are -:
1. Assembly unit .
2. Weld &fabrication unit.
3. Paint shop unit.
4. Transmission unit.
5. Central materials unit.
6. Purchase unit.
7. Marketing&Finance.

Assembly Line Layout

MAIN FRAME

BOOM & DIPPER

FITMENT

INNER LEG
FITMENT

TYRE MOUNTING

FRONT
AXLE
FITMENT

BRAKE
BLEADING

STONE
GUARD
FITMENT

CAB FITMENT

LIFT RAM &

LOADER ARM
FITMENT

LVB & EVB

CONNECTION

FRONT END

FUEL TANK &

HYDRAULIC
TANK
FITMENT

COOLING
SYSTEM

KPC FITMENT

ELECTRICAL
CONNECTIONS

SKID & MAIN

FRAME
DROPPING

Boom-Dipper Assembly
1.

2.

Boom Sub-Assembly -:Boom is fittted

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 differnce is that this
assembly is responsible for excavators
movement.

Engine Sub - Assembly

Engine sub assembly mainly consist of 4 parts-:
1. Engine-:A kirloskar 76HP,gross power 56 kw at
2200 rpm engine is installed in backhoes.
2. Torque Converter-:Takes the place of
mechanical clutch&able to multiply torque when
difference between input &output is substantial.
3. Fly Wheel-:A rotating disc that stores kinetic
energy.
4. Gear box-:4 speed fully syncromesh gear box
with electrically reversing shuttle.

Specification of products
manufactured by JCB(HRY)
JCB 3DX Backhoe loader-:4 cylinder,76HP,4speed synchromesh,3300psi hydraulics ,front
wheel steering.
2. JCB 3DX Super Backhoe loader-:4
cylinder,90HP,4-speed synchromesh with
reversing shuttle,3300p hydraulics, front wheel
drive.
3. JCB 4DX Backhoe loader-:4 cylinder,96HP,4speed synchromesh with reversing
shuttle,3300psi hyadraulics ,front wheel.
1.

Valve Blocks
1.

2.

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.

Other Sub -Assemblies

Radiator assembly-:cooling unit, hydraulic
cooler for cooling of hydraulic oil, seal are
components of radiator.
2. King post carriage-:it provides supporting
mech. to boom dipper . It is a combination of
slew ram , boom lock, bushes, feed pipe &
seals.
3. Cab Assembly -:it is operating room of the
entire machine.
1.

Leakage Analysis
1.

2.

3.

The aim of our project is to determine the cause

of hydraulic leakages that has been occuring 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.

Mechanism involved in the

hydraulic movements

Actuation of various arms are controlled by fluids

that are made to flow by piston mechanism for
the movement of arm/pistons.

Losses due to leakages

The basic losses due to leakage are-:
1. Clean up.
2. Make up fluid.
3. Disposal of waste oil.
4. Contamination ingress.
5. Decrease in machine efficiency.
6. Increase in expenditure to machine.

Major joints of leakage

1

Front axle ram

14

hydraulic cooler/radiator plug

LVB to feed pipe

15

Return feed pipe to hydraulic cooler

EVB to boom ram

16

Oil tank to hydraulic cooler

EVB to dipper ram

17

Hose to lift ram

EVB to bucket ram

18

Fuel tank to fuel pump

EVB to slew ram

19

Hose to loader bucket ram

EVB to leg hose

20

Orbitral unit to front axle ram

EVB to return feed pipe

21

Orbitral unit hose to LVB

Header piston joints

22

Orbitral unit to hose hydraulic pump

10

Hydraulic pump to LVB

23

EVB hose to legs

11

Feed pipe to tank

24

EVB hose to boom ram

12

LVB to return feed pipe

25

EVB hose to dipper ram

13

Oil tank to hydraulic pump

26

EVB hose to bucket ram

27

Radiator hose

Some of important joints

Front axle ram

Gear pump to
hydraulic cooler

EVB to boom,
dipper &bucket
rams

Hydraulic tank to
pump

Hose to lift ram

EVB hose to
boom ram

Methodology of Analysis
Studied all the
hydraulic joints

Complete
inspection of
joints

All leakage
duly
noticed

Reduced the
no. of
machines
inspected for 2
days

Left all the

machines

Compared the
hot bay test
report

Inspection zone
1.

2.

3.

It 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.

Features of inspection zone

The introduction of inspection zone has following
features-:
1. As most of the hydraulic joints ,that are prone to
leakages ,are open in this region,it provides

Easy Inspection Vicinity.

2.

Maximum number of machines can be

inspected. Only four minutes is required on
one machine by two operators.

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

Major causes of leakage

Major causes of leakages are-:
1.
2.
3.
4.

Leakage due to improper torquing.

Leakage due to manufacturing defects.
Leakage due to defect because of man-power.
Leakage because of contamination of oil.

Other ways to tackle

leakages
The methods are-:
1. Hydraulic dye test.
2. Hot bay test.
3. Replacement of metal pipe.
4. Reduction of elbows and T-pieces.

THANK
YOU

&

HAVE A
NICE DAY