SUMMER TRAINING

REPORT










INTRODUCTION
The company JCB (Joseph Cyril Bamford Excavators limited)s founder is Joseph Cyril Bamford
(1916-2001).
JCB is one of the world's top three manufacturers of construction equipment. IT employ around
11,000 people on four continents and sell ITS products in 150 countries through 2,000 dealer
depot locations.
Throughout their 68 year history, it has always invested heavily in research and development,
keeping JCB at the cutting edge of innovation.
Today, JCB has some of the finest engineering facilities across the globe, produces a range of
over 300 machines and maintains a reputation for unrivalled customer service.

PRODUCTS MADE IN THE
PLANT
1. J CB 3DX
BACKHOE LOADER
It is the machine which comes under the
category of earth movers in which there is a
bucket fitted in the front portion of the machine
& an excavator fitted Backwards which are
used to dig earth or transfer it from one position
to other.
This machine does 3-dimensional movement
during its working thats why ,it is Called 3DX
backhoe loader. Its functioning is totally based
on hydraulics
76 horsepower fuel efficient KOEL engine with
increased size of coolers for better performance
2. J CB 3DX SUPER
Its construction, functioning , working as well as
area of applicability is very much similar to that
of the 3DX backhoe apart from the only
difference that, it is a 4-wheel drive machine
giving it more power & edge over the 3dx backhoe
loader.

3. 4DX BACHOE
LOADER
This machine is also quite similar to
3DX backhoe loader apart from the
difference that its forward bucket
area as well as volume can be
increased or decreased according to
the need of the user thus making it a
4-dimensional working machine as
it called so as 4DX backhoe loader.
4. LIFTALL :

LI FTALL lift and carry mobile crane.
The first model, JCB liftall 1253 is a 12T
capacity mobile crane fitted with a
telescopically extendable 3-part boom and
is very useful for the erection and
construction sites, container, steel and
timber yards. This will be a highly useful
tool for equipment rental companies
because of its versatility.
These are the four products which are
manufactured at the JCB (Balabhgarh)
plant which is worlds largest plant for the
manufacturing of backhoe loaders

HOW J CB MACHINE WORKS
The basic idea of hydraulics :
The basic idea behind any hydraulic system is very simple: force that is applied at one point is
transmitted to another point using an incompressible fluid. The fluid is almost always an oil of
some sort. The force is almost always multiplied in the process. If two pistons fit into two glass
cylinders filled with oil and connected to one another with an oil-filled pipe. If you apply a
downward force to one piston (suppose the left one ), then the force is transmitted to the second
piston through the oil in the pipe. Since oil is incompressible, the efficiency is very good -- almost
all of the applied force appears at the second piston. The great thing about hydraulic systems is that
the pipe connecting the two cylinders can be any length and shape, allowing it to snake through all
sorts of things separating the two pistons. The pipe can also fork, so that one master cylinder can
drive more than one slave cylinder if desired.

HYDRAULIC
MULTIPLICATION
The neat thing about hydraulic systems is that it
is very easy to add force multiplication (or
division) to the system. In a hydraulic system, all
you do is change the size of one piston and
cylinder relative to the other, as shown here:
suppose the piston on the right has a surface area
two times greater than the piston on the left.
When force is applied to the left piston, it will
move two units for every one unit that the right
piston moves, and the force is multiplied by two
on the right-hand piston.

GEAR PUMP
In external gear pump two gears come into and out
of mesh to produce flow. However, it uses two
identical gears rotating against each other one gear
is driven by a motor and it in turn drives the other
gear. Each gear is supported by a shaft with
bearings on both sides of the gear. As the gears
come out of mesh, they create expanding volume
on the inlet side of the pump. Liquid flows into the
cavity and is trapped by the gear teeth as they
rotate. Liquid travels around the interior of the
casing in the pockets between the teeth and the
casing, it does not pass between the gears. Finally,
the meshing of the gears forces liquid through the
outlet port under pressure.

SCHEMATIC DIAGRAM OF BACKHOE LOADER
SPECIFICATION OF BACKHOE 3DX LOADER
Horse power of Engine 76 hp
Max. Torque 310Nm @1110 rpm
Total Wt. 7460 kg
Cubic Capacity of loader Bucket 1.1 m3
Cubic Capacity of excavator Bucket 0.24 m3
Wheel base Length 2.17 m
Total length 5.9 m
Max. Height 5.97 m
Max. Dig Depth 4.77 m
Length of Loader Bucket 1.73 m
Max. Speed 36 kmph
Fuel Tank Capacity 128 litre
Hydraulic Tank Capacity 130 litre
Pump Discharge 110 lpm @ 2200rpm
CIRCULATION OF HYDRAULICS IN BACKHOE
LOADERS
CYCLE OF MANUFACTURING UNIT AT
BALLABHGARH PLANT
CYCLE OF MANUFACTURING UNIT
LOGISTICS TO FABRICATION :
First of all, the machined sheets & pre-build parts (e.g., Gear assy. Parts, rear axle assy. Parts &
engine etc.) are brought in the logistics area. These parts are given by different vendors set by the
company,(e.g., Engine by Kirloshkar etc.)
Then, according to the requirements :
Metal sheets from which main frames, rear frames, boomers/dippers are to be welded are moved
to fabrication shop.
Engines are moved to skid sub-assembly line and the gears & rear axle parts are moved to
transmission line.

FABRICATION
SHOP
In fabrication shop, welding of different parts of (3DX
backhoe loader),the product which is made are done and
then after their machining, finishing, surface smoothening
etc. are done. After machining, the machine parts are
moved to paint shop.
FABRICATION SHOP IS DIVIDED IN FOLLOWING
ZONE:
1.BOOM CELL
2.REAR FRAME CELL
3.LOADER TOWER ROBOTIC CELL
4.LOADER TOWER BORING CELL
5.PRESS SHOP
6. MAIN FRAME WELDING PROCESS
7.BOOM/DIPPER ROBOTIC WELDING



PAINT SHOP
In paint shop, after washing
phosphate coating (Fixodiene) is
done. After washing again it passes
Through dry off section where
heating is done up to 62 degree
celsius 1Atm pressure. Finally last
coating is done after masking of
holes by primer booth blower then
components are moved in baking
zone where components are baked at
temperature range of 90-95 degree
Celsius .
MAIN FRAME
ASSEMBLY LINE
(M-LINE) :
The machine parts from paint shop
are brought to the main assembly
line with the help of EMS (electric
monorail system) & cranes.
This line has 10 zones ,for each
zone certain workload is divided. In
this line all the assembling of the
main frame is done. Then, this
assembled main frame is moved to
the backhoe assembly line with the
help of cranes & EMS system.

BACKHOE ASSEMBLY LINE (A-LINE)
At the backhoe assembly line, skid is dropped from the skid sub assembly line.
Skid sub-assembly line : Assembled gear box & rear axle from transmission line are moved to
skid sub-assy. Line. Here, the engine is connected to the gear box & rear axle. Thus (skid=engine +
rear axle + gear box).
The main frame is then dropped on this skid and, then after the process asseble backhoe starts.
The main assembly line (a-line) has 22 zones for each zone certain workload is divided , just
likewise in the main frame assy. Line.
The assembled backhoe is then moved over to twin-slat line.

TWIN-SLAT LINE
At twin-slat line firstly the booms & dippers come from the boom/dipper sub-assy. Line is
attached to the machine and then the different oil filling process in the machine is done.

TESTING ZONE :
The backhoe after being assembled in previous zones is moved to the testing zone in which the
full range of machine functioning (i.e., Working of all the parts of the machine; missing of any part,
bolts or nuts; mismatching or defects in part of the machine ) is checked.
Then after, the machine is greased, washed & again goes on for the 45 minutes trial run.
After that, all the machines parts are checked and if any part is missing or defected, then the list of
those parts are made. Then after, the machine goes on for the U.V. Test by which the lower portion
of the machine is checked ,whether any leakage or defect in the hose and feed pipes are not.
After making the list of all the defects and deformities ,the machine moves in the reworking zone
where all these remedies are solved.
And then after final washing paint touch-ups ,the machine is green signaled for dispatch.