Cblm-backhoe-loader-unit-2-lo2.docx

LEARNING OUTCOME NO. 2 PERFORM BASIC PREVENTIVE MAINTENANCE SERVICING (PMS) Contents: 1. Fluids and Lubricants used in Backhoe Loader Preventive Maintenance Servicing (PMS) 2. Basic Preventive Maintenance Servicing (PMS) in Backhoe Loader Assessment Criteria 1.

Fluids and lubricants are used based on manufacturer’s manual

2.

Basic preventive maintenance servicing (PMS) is carried out in accordance with manufacturer’s and/or site conditions/requirements

Conditions The students/trainees must be provided with the following: 1.WORK PLACE LOCATION 2.EQUIPMENT -

Computer/Laptop LCD

3.TOOLS, ACCCESSORIES AND SUPPLIES -

Whiteboard CD Tapes Equipment Tools (e.g. Hand Tools: Wrenches, Pliers, Screw Driver, etc.)

4.TRAINING MATERIALS -

Learning Packages Ball pens Whiteboard Markers Manuals / Handouts Daily Preventive Maintenance Checklist Report Sheet / Log Sheet for Equipment

Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation

Date Developed:

Document No.:

November 2019 Developed by: Erris S. Sanciangco

BLO0001 Issued by:

Page 1 of 25

Assessment Method: Written and/or oral questionings Direct observation/Practical demonstration Work record and document

Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation

Date Developed:

Document No.:

November 2019 Developed by: Erris S. Sanciangco

BLO0001 Issued by:

Page 2 of 25

Learning Experiences Learning Outcome 2 PERFORM BASIC PREVENTIVE MAINTENANCE SERVICING (PMS) Learning Activities

Special Instructions

1. Read Information Sheet 2.2-1 – Different Fluids and Lubricants used in Backhoe Loader

Read and understand the information sheet 2.1-1 on “Different Fluids and Lubricants used in Backhoe Loader”

You must answer all the questions correctly before proceeding to the 2. Answer Self-Check 2.2-1 next activity. You can ask the Compare answers to Answer Key assistance of your trainer for further explanation regarding the 2.2-1 topic that you may not understand. 3. View the Power Point on Different Fluids and Lubricants used in Backhoe Loader Answer the trainer’s question

4. Read Information Sheet 2.2-2 – Basic Preventive Maintenance Servicing (PMS)

Listen and understand the power lecture or point presentation on “Different Fluids and Lubricants used in Backhoe Loader”

Read and understand the information sheet 2.1-2 on “Basic Preventive Maintenance Servicing (PMS)”

You must answer all the questions correctly before proceeding to the 5. Answer Self-Check 2.2-2 next activity. You can ask the Compare answers to Answer Key assistance of your trainer for further explanation regarding the 2.2-2 topic that you may not understand. 6. View the Power Point on Basic Preventive Maintenance Servicing Answer the trainer’s question

Listen and understand the power lecture or point presentation on “Basic Preventive Maintenance Servicing”

Information Sheet 2.2-1 Fluids and Lubricants Used in Backhoe Loader Learning Objectives: After reading this INFORMATION SHEET, YOU MUST be able to: 1. Identify the different fluids and lubricants used in Backhoe Loader In Module Performing Pre- and Post-Operation Procedures for Backhoe Loader Operation you learned to perform visual check of equipment. You learned to perform “BLOWAF” and perform operation and post-operation procedures. In this module you will learn LO2 of Performing Basic Preventive Maintenance Servicing of Backhoe Loader this includes the Fluids and Lubricants Used in Backhoe Loader. Heavy equipment like Backhoe Loader utilizes the same system like those in light equipment like cars but in a larger scale. Additional fluid to oil and lube, heavy equipment requires hydraulic fluids which circulates in the hydraulic system. The following are the Fluids and Lubricants in the system of the Backhoe Loader. Engine Oil. An engine’s oil system is a circular flow designed to ensure that clean oil is delivered where it is needed on the engine’s moving parts at a designated temperature, pressure, and flow rate. Its starts with oil stored in the engine’s oil sump located in a pan below the engine body. The oil pan often encloses the entire lower portion of the engine block in order to ensure complete capture of the used oil.

The oil is drawn from the sump through tubing by means of an oil pump. As the oil is discharged from the pump it is forced through an oil filter. The heart of the system, the oil pump, is quite intricate in design and rugged in operation. Usually a gear type pump, the driving force is provided by a pair of meshing gears. Oil fills the spaces between the aligned teeth of the opposing gears as they turn. The spinning of the gears continues to expel the oil to the discharge hose that caries the oil under pressure into the oil filter. The filter traps impurities that could actually harm the engine allowing only clean smooth oil to be used, retaining dirt particles from the passing oil. Oil filters are removed and replaced as part of an engine’s regular maintenance cycle depending the number of hours of operation. It is especially critical that oil is cleaned prior to coming into contact with the engine bearings. Discharge tubes from the pump and the filter carry oil to the engine’s main bearings and drilled holes through the engine block. This is referred to as the oil gallery. At some point along these tubes, an oil pressure gauge is installed to monitor the oils operating pressure. A minimum pressure is required to force the pump through the filter and around engine fittings and linkages. From the main bearings, the oil is forced through drilled feedholes into the crankshaft, connecting the pistons as well as the bearings of the connecting rod. In order to increase the amount oil in contact with their surfaces, some rods are designed with grooves and holes that can retain more oil. In doing so, the oil lubricates the bearings of the piston pin and the walls of the piston cylinder get a coating of oil to lubricated the motion of the enclosed piston. Each individual piston is fed oil via a branch line from the main engine pipeline. Other branch pipelines deliver oil to gears, timing chain, and drive of the camshaft. Excess oil then drains back into the sump. By this time, the oil is very hot, having passed through an operating engine. The oil sump is not just of storing oil for use in later feed cycles, it also acts as a cooler. This is designed to prevent overheating of the oil. Cooling is achieved by the flow of engine coolant adjacent to the tubes carrying the hot

oil. From there, the coolant transports the excess heat to the engine’s radiator. Additional heat can be expelled directly through the walls of the sump. While in the sump, the excess heat of the incoming oil is transferred to the walls of the sump. During its time in storage, its excess heat is radiated to the surrounding air, cooling the oil back down to a useable temperature. Time of storage in the sump depends on usage requirements, pump rates, the number feed cycles per minute, and the capacity of the oil sump. Figure 1 shows a simplified engine oil system. Why does an engine need an oil circulating system? It is not just to allow surfaces to slide past each other more efficiently by minimizing the contact surface friction coefficient. It minimizes wear and tear to both contact surfaces by sealing the clearances between the various moving parts (piston cam and cylinder wall, ball bearing and rotating shaft, etc.). Maintaining a proper thickness of oil over all contact surfaces prevents physical contact. Oil also absorbs heat from the engine and its moving parts. The oil transfers this heat to the oil pan during its use cycles, thus helping to prevent the engine from overheating. Oil also acts as a cushion against the sudden application of heavier loads or increased torque. Oil seals off open spaces at it fills and covers, preventing gas blow out from the pistons. Once filtered and cleaned, the oil can then prevent the impingement of dirt and dust particles which could foul moving parts over time. Rock, dust, dirt, sand, and water working their way into engine components will form an abrasive that will significantly reduce bearing life. Recycling the oil through the filter removes these impurities with each use cycle. In effect, oil cleans the engine. What could go wrong with lack of proper maintenance? Crankshafts can get worn, reducing the engine pressure and causing the oil to be thrown all over the engine’s inside. The oil splash won’t be contained by the piston rings and the engine will actually burn the excess oil. This creates a negative feedback loops where the quantity of oil is reduced by the burning which in turn leads to greater wear and tear on the engine which then leads to more wasting of oil, and so on. Keeping a good seal in turn prevents leakage of the fuel air mixture normally combusted in the piston cylinder. This, in turn, comes back to properly maintaining the piston’s oil controlling ring so that it keeps the minimally required thickness of oily film on the inside to the cylinder walls. Even with the best maintenance, oil degrades over time, and so oil will always need to be changed at regular intervals.

Lube Oil/Grease Oil. Greases are used where lubrication may be infrequent and/or where the lubricant is required to remain in place over a significant length of time. Note that oil change and lube job are two different things. Though oil lubricates the engine, a true lube job involves oiling the suspension system, drivelines, and the vehicle chassis. None of these vehicle parts shares oil with the engine oil system. The goal is to insure free movement of the equipment undercarriage while minimizing wear and tear. In the past, wheel bearings would also be part of a lube job, but most wheel bearing housings are sealed and rarely go bad unless there has been physical damage to the housing resulting in a leak of its lubricant. One method to ensure proper oil and lubrication is the automatic lubrication system. Manual lubrication takes at least 30 minutes, to an hour each workday. This can be delayed by bad weather, and in any case reduces overall productivity by taking equipment out of service. Performing oil changes manually in the field presents certain safety issues and depends on the logistical availability of the lube truck. Heavy equipment lubrication can be more complicated with every pin on a bucket or arm needing lubrication in multiple positions. Manual oil change and lubrication requires trained personnel in an industry that is already facing a shortage of skilled workers. Significant labor savings can be achieved by the use of automat lubrication systems for daily and weekly lubrication points using manual lubrication only for small equipment, points that cannot be reached by machine, and bearing that require lubrication only at extended intervals. By maximizing automatic lubrication systems, almost an hour of additional productivity can be achieved each workday. Machines can deliver the exact amount of grease needed and in controlled even applications, minimizing waste. Machine lubrication does not pose the same safety problems, nor is it affected by weather conditions. A typical automatic lubrication system includes an electric pump with flow meters and control valves, supply hoses and feedlines, lubricant storage reservoir, and malfunction reporting systems. Divider valves control grease flow, directing it to where it is needed and in the proper quantities required by each pin or bearing location. Proximity switches indicate a successful lube application and signal the pump to shut off. Grease is a thickened oil, not a thicker oil. The thickener within a grease acts as a sponge, holding the base oil and the additives together. Hydraulic Oil. Hydraulic oil is a non-compressible fluid that is used to transfer power within hydraulic machinery and equipment. Otherwise known as hydraulic fluid, hydraulic oil can be synthetic- or mineral-based. Hydraulic systems are force multipliers. They transmit force along hoses and lines to where it is needed to operate the business end of the heavy

equipment whether it be dozer blade or excavator bucket. By utilizing an incompressible fluid (such as oil), pressure applied at one end is transmitted without loss. Due to the laws of hydraulics, the pressure stays constant throughout the fluid, which can result in increased force at the receiving end. For example, 100 pounds of force applied on a fluid in a pipeline 1 square inch in cross section area is subject to a pressure of 100 psi. Should the receiving end of this fluid have a cross-sectional or contact area of 10 square inches, the resultant applied force is actually 1,000 pounds (100 psi x 10 square inches) . However, the distance that the surface is raised or move the equipment is moved at the receiving end is reduce to 1/10. So, if the applied load in this example moves 10 feet, the receiving load moves only 1 foot. The hydraulic oil used as a working fluid to transmit force throughout the system is under extremely high pressure and the smallest leak can result in significant loss of fluid. Nearly as bad, leaks can allow air to enter the system leading to entrained air bubbles that short circuit the transmission of force down the lines. When subject to pressure, the air bubbles become compressed, resulting is loss of applied force at the slave cylinder. As a consequence, hydraulic lines can feel “mushy”—a particularly dangerous condition for vehicle brake systems. To prevent leaks, the fittings and appurtenances must be durable and strong, capable of resisting pressures as high as 50,000 psi. To achieve the necessary level of resistance and strength, hydraulic systems utilize materials such as titanium, steel and stainless steel alloys, bras, woven wire, and synthetics. The force is generated by the pumps that circulate the fluid through the hydraulic system. There are several types of oils utilized as hydraulic working fluid: mineral oil polyalphaolefin or organophosphate ester. Being incompressible, the fluid carries the force directly to the actuators that physically move the arms, buckets, blades, and load beds of heavy earth moving equipment. As with engine lubricant oil, the hydraulic fluid is recycled through the system passing through a filter that removes impurities. The need for removing impurities is less about overheating and wear and tear so much as it is about maintaining the required levels of force. The number of actuators varies for each type of machine. The more complicated the movement, the more actuators required. For example, crawler excavators require a minimum of six actuators: boom, lift arm,

bucket, swing, travel left, and travel right. The excavator’s tracks also hydraulically controlled. The tracks are not only driven by hydraulic motors located at one end (to provide driving force) but by a free spinning toothed wheel at the other (to maintain alignment and tension). Skid loaders, on the other hand, require three pairs of actuators to work their front-loading buckets (one pair to raises and lowers the bucket, another pair that vertically tilts and rotates the bucket to allow loading and dumping, and a last pair that can split the bucket to allow it to grab objects). Dump truck have an even simpler system with only one or two actuators to raise and lower its truck bed. The system must be sophisticated enough to allow for all of these actuators to operate simultaneously with differing degrees of movement. This requires actuators of differing size hose connections with varying flow rates, with high-flow volumes required for fast movements. Efficiency is another important operating characteristic. Ideally, the hydraulic drive system should be able to convert 100% of the engine’s or pump’s energy into movement. These requires optimized flows and efficient control valves. To reduce costs, the number of pumps are minimized in favour of a more complicated system of hoses and connections. Control valves allow for the operation of this complicated network directing hydraulic fluid to where it is needed, when it is needed. Control valves can be further augmented by control software and sensor technology. The newest equipment utilizes artificial intelligence systems to assist the operator. Coolant. Due to the laws of thermodynamics, all engines are less than 100% efficient and produce waste heat. This unavoidable fact requires the services of an engine coolant system to remove and radiate the waste heat in an efficient and safe manner. In many ways, modern engines are victims of their own success. Modern environmental pollution control systems minimize exhaust but generate additional heat. To meet these challenges, a coolant system must provide efficient heat transfer away from the engine block to prevent engine overheat and temperature strain on the engine’s metal components. In addition to protecting the engine, a coolant system protects the liquids used in engine operation, preventing both freezing and boil over. Figure 3 shows a simplified engine coolant system. Figure 3. Engine coolant system (Source: “Properly Maintaining Your Heavy-Duty Engine Cooling System,” Prestone, October 2014.)

Like the engine oil system, the coolant system relies upon a pump. In this case it is a water pump that circulates water mixed with coolant around the engine block and its combustion chambers in an open space called the water jacket. As the cool water/coolant mixture comes into contact with the hot engine, it draws off heat raising its own temperature. It then travels through a hose to a radiator located at the front of the engine. The radiator is designed with vanes that increase its surface area without increasing its overall volume. Water travelling through theses vanes sheds its excess heat with the help of a large fan or the actual movement of air through the front grill work. Heat is passed into this air flow stream and carried away from the engine. Coolants (which protect against freezing as well as overheating) come in a variety of inorganic and organic chemical formulations. These include Inorganic Additive Technology (IAT), Organic Acid Technology (OAT) formulas, and Hybrid Organic Acid Technology (HOAT). The American Trucking Associations’ Technology & Maintenance Council has established industry standards for coolant maintenance. Its recommended (“RP-365 Coolant Maintenance”) standards for each type of coolant are as shown in Table 1.

Indirectly, the coolant system must also protect itself against corrosion of all its metallic components. Since glycol and water mixtures are corrosive, inorganic and organic salts and chemicals, (corrosion inhibitors) are added to the coolant in order to prevent long-term corrosion of the cooling system components. The wrong amount or type of coolant can also cause hose cracking, breakage, and leaks. With the coolant under pressure, this can result in rapid, high-volume loss of coolant loss. Not tending to this situation immediately and responding with a quick engine shut down can result in overheating and engine breakdown. In the long term, it can cause oil breakdown and even engine deformation. Maintaining the appropriate level of coolant is essential to continued fleet operations.

Transmission Oil. Transmission refers simply to the gearbox that uses gear and gear trains to provide speed and torque conversions from a rotating power source (engine) to another device (wheels). Transmission fluid is used to lubricate the components of an equipment’s transmission for optimum performance. Manual transmissions (most of them) use a variety of oils that have the API specification GL-4. To ensure that you are using the correct fluid for your car’s transmission, please consult your owner's manual. Why you need transmission fluid? It's very important that the fluid in your transmission is at the proper level, or your transmission will experience significant wear. The synchro rings and sliders depend on a slick surface to match speeds when shifting. If your transmission is low on oil, the wear on these components will accelerate significantly and shifting the car will be more difficult. If your car is having problems shifting, check the level of the transmission oil. While the primary function of transmission fluids is to lubricate the various parts of the transmission, it can serve other functions as well:    

Clean and protect metal surfaces from wear Condition gaskets Enhance cooling function and reduce high operating temperatures Increase rotational speed and temperature range

Transmissions are designed to operate at high temperatures, but consistent overheating can break down the fluid. Therefore, contrary to popular belief, transmission fluids are not “filled-for-life” and need to be replaced. To find out about the recommended change intervals, as always, consult your owner’s manual or check our oil advisor tool. Differential/Gear Oil. Differential oil, sometimes referred to as gear oil, is found in the axle housing. It’s thicker than engine oil and is designed to perform under high pressure (gears mashing together, hydraulic nature of clutch packs) rather than high temperatures like engine oil. As you cruise down the road, the gear oil splashes about lubricating gears, bearings and clutch packs. The differential oil lubricates the ring and pinion gears that transfer power from the driveshaft to the wheel axles. If your car is fitted with a limitedslip differential, it also keeps all the moving parts in that assembly healthy.

The purpose of the differential fluid is to cool and lubricate your differential. Without the oil your differential would overheat due to the metal-to-metal contact and burn itself out. Changing this oil is just as important as changing your engine’s oil, and for the same reason. Metal-to-metal contact wears down surfaces and creates heat from friction, which inevitably weakens the gears and leads to failure. To keep your differential in optimum condition and to avoid costly repairs, it is best to follow the manufacturer’s recommendation on when to change the differential oil. Brake Oil. Brake fluid is a type of hydraulic fluid used in hydraulic brake and hydraulic clutch applications in vehicles. It is responsible for transferring force into pressure, and to amplify braking force. Simply stated, when you apply your foot to the brake pedal, brake fluid transfers this force into pressure to the front and rear brakes and stops the vehicle. It works because liquids are incompressible.

Example of Manufacturer’s Guide for the Type of Fluids and Lubricants to be used in a Backhoe Loader

Lubrication Diagram

Self- Check 2.2-1 I. MULTIPLE CHOICE: Direction: Choose the letter of the best answer. Encircle the letter of your choice.

1.

2.

3.

4.

5.

6.

7.

8.

9.

A thickened oil which acts as a sponge, holding the base oil and the additives together a. Coolant b. Grease c. Engine Oil d. Brake Oil Used for lubrication of internal combustion engine. The main function is to reduce friction and wear on moving parts and to clean the engine from sludge. a. Coolant b. Grease c. Engine Oil d. Brake Oil Is found in the axle housing. It’s thicker than engine oil and is designed to perform under high pressure (gears mashing together, hydraulic nature of clutch packs) rather than high temperatures like engine oil. a. Hydraulic Oil b. Brake Fluid c. Coolant d. Gear Oil Is a non-compressible fluid that is used to transfer power within hydraulic machinery and equipment. a. Hydraulic Oil b. Brake Fluid c. Coolant d. Engine Oil Is a type of hydraulic fluid used in hydraulic brake and hydraulic clutch applications in vehicle. It is responsible for transferring force into pressure, and to amplify braking force. a. Hydraulic Oil b. Brake Fluid c. Gear Oil d. Engine Oil What pressurized fluid is used in the hydraulic system? a. SAE 10 b. SAE 20 c. SAE 30 d. SAE 40 Is used to lubricate the components of an equipment’s transmission for optimum performance. a. Transmission Oil b. Brake Fluid c. Gear Oil d. Engine Oil Also called as antifreeze, is a bright yellow or green liquid that mixes with the water to keep the radiators from freezing or overheating. a. Coolant b. Grease c. Engine Oil d. Brake Oil The figure in the right indicates.

10.

a. Engine Oil b. Transmission Oil c. Brake Oil d. Hydraulic Oil The figure in the right indicates. a. Engine Oil b. Transmission Oil c. Brake Oil d. Hydraulic Oil

II. TRUE OR FALSE: Direction: Tell whether the given statements are correct. Write T if the statement is true and F if the statement is false.

_________1. The cooling system unlike the engine system does not rely on a pump to circulate the coolant. _________2. If engine oil is not replaced it will not cause harm on the crankshaft and will not cause is to wear. _________3. Oil change and lube job are similar. _________4. Grease are applied on the nipples _________5. The hydraulic oil used as a working fluid to transmit force throughout the system is under extremely high pressure and the smallest leak can result in significant loss of fluid. _________6. Even with the best maintenance, oil degrades over time, and so oil will always need to be changed at regular intervals. _________7. Leaks in the hydraulic system is not a critical matter and will not cause problem if air enter the system _________8. Maintaining the appropriate level of coolant is essential to continued fleet operations. _________9. It is not important to maintain the fluid level in your transmission. _________10. Transmission fluid is a type of hydraulic fluid used in hydraulic brake and hydraulic clutch applications in vehicles. It is responsible for transferring force into pressure, and to amplify braking force.

ANSWER KEY 2.1-1 I. Multiple Choice 1. B 2. C 3. D 4. A 5. B 6. C 7. A 8. A 9. C 10. D II. True or False 1. F 2. F 3. F 4. T 5. T 6. T 7. F 8. T 9. F 10. F

Information Sheet 2.2-2 Basic Preventive Maintenance Servicing (PMS) Learning Objectives: After reading this INFORMATION SHEET, YOU MUST be able to: 1. Identify the Basic Preventive Maintenance Servicing (PMS) of Backhoe Loader Below are the guides to consider in performing the Basic Preventive Maintenance Servicing (PMS) of Backhoe Loader BASIC PREVENTIVE MAINTENANCE FOR BACKHOE LOADER Backhoe Loaders (BHLs) are necessary at every construction site because they are highly versatile and multi-purpose equipment. Since they are costly, it is necessary to maintain the BHLs properly so as to increase their productivity and jobsite safety. This makes preventive maintenance necessary and can help the BHLs to run at the peak power and efficiency. Also, preventive maintenance helps in cutting down the operating costs over the period of time by helping in avoiding expensive repairs and this can increase the life of the equipment. Often, it is the operator’s responsibility to carry out the basic daily or weekly preventive maintenance for the BHLs. So, if you are a BHL operator or owner, here are the tips on basic preventive maintenance of BHLs to keep them productive and efficient over a longer period of time. 1. Refer to the BHLs operators’ manual to get familiar with all the manufacturer-recommended maintenance procedures and intervals. You also need to read the warning labels, stickers and specification charts and other important information posted around the machine. 2. Walk around the equipment and visually inspect the whole machine before and after the operation so as to inspect any leak, damage or other signs of problem. 3. You also need to carefully check controls, engine, compartment, cooling system, gear boxes, hydraulic parts and other parts. 4. Ensure that you check around the backhoe and loader arms as the equipment is heavily stressed here. If you observe a crack in the paint, it could mean structural crack and this need to be inspected further before using the equipment again.

5. It is necessary to check the tire pressure and condition before and after using the BHL. Debris such as loose gravel or mud may get stuck in the tire and impact it’s working. You also need to check that each of the tire has the right pressure as this can help in lessening tire wear, improve stability and reduce the fatigue of the operator. Also, you need to check for any cuts and replace the tires when needed. 6. Checking of hoses, belts and auxiliary connections before and after the use of equipment is also very important. 7. Generally, the hydraulic hoses get ripped upon due to operators messing up the hose routing. In addition, if the hoses are leaky or damaged, then the operating expenses can get doubled. Hence, house routing should be made accurate. Typically, hoses should be tied correctly, then secured near the stick and boom and not just strung simultaneously and hanging unfastened. 8. Backhoe Loaders are fitted with special seals and filters designed to keep dirt and grime out of sensitive areas. Hence, broken seals must be repaired immediately, breathers must be kept clean and all filters should be inspected regularly and changed when they become dirty or clogged. 9. Air filter should be checked and cleaned regularly. 10. The boom and stick of the Backhoe Loader should also be checked for any leaks and wear. 11. The cutting edge of the bucket should be checked for any signs of wear. If there is any, then it needs to replaced. Also, it should be seen that all the bolts are intact and tight. 12.

Ensure that the bucket teeth are all there with retainer pins.

13. You need to check all the attachments of the BHL before and after work. 14. You also need to make it a point to check the fuel levels and document the periodic refills. Also, the hydraulic fluid level before and after using the equipment should be checked.

15. Use fuel which is prescribed by the manufacturer and avoid adulterated fuel which can reduce the life and productivity of the equipment. 16. Without fail, look out for any clear signs of oil leakage. There are many protocols and ways to carry out this inspection. If you are smart enough to pay attention to the leaky valves, you can carry out repairs much faster, thereby, preventing the machine from further damage. 17. Properly grease and lubricate all moving parts of the equipment in order to save them from failing to work and creating excess friction leading to severe wear and tear of the machinery, frequent breakdowns and shorter life span. If you hear noise coming from any part of the equipment like around pins, bushings, pivot points and bearing joints, you need to grease those parts properly. For greasing, refer to your operation and maintenance manual to learn about the specifications of the manufacturer. 18. All the electric wires in the Backhoe Loader should be protected from exposure to harmful external elements. This can be done by covering critical wires properly or sheltering the whole equipment under a covering. 19. BHLs are often employed in rough terrains and this may lead to misalignment of the equipment in certain situations. Although, BHLs are made in such a way that they can withstand adverse conditions, however, assuring proper alignment of the equipment remains a crucial task. 20. It is necessary to confirm that all safety features of machine are working aptly. 21. The equipment should be stored in cool and dry place, protected from all the contamination. 22.

Always avoid engine idling as much as possible.

23. Create and follow a maintenance schedule. Include notations on how often each part of the machinery should be inspected for problems, repairs and general maintenance. 24. BHL operators should be trained well regarding Backhoe Loader operation and preventive maintenance measures. Without

proper operator training, operators can damage the machinery or even injure themselves or others. Overall, by following these simple preventive maintenance safety tips, BHL’s lifespan can be increased considerably. These small but important tips can help to increase productivity as well as efficiency of the equipment to a very large extent.

PREVENTIVE MAINTENANCE ACTIVITIES (Maintenance Plan is based from Komatsu Backhoe Loader WB93S-5)

SERVICE TO BE PERFORMED BEFORE OPERATION/ENGINE START

ACTIVITY/CHECKPOINTS

ACTIVITY/CHECKPOINTS

SERVICE TO BE PERFORMED

EVERY 250 HOURS

1. Walk Around Inspection

Check for damages-loose parts & missing items

8. Differential System

Change front and rear axle oil

2. Leakages

Check for oil, fuel or coolant leakages

9. Transmission

Change hydraulic transmission oil and filter

Check the condition of the rims and the condition of the tires, unusual wear, deformation or cracks

10. Hydraulic System

Change oil filter

3. Tires/Wheels

11. Fan-Aircon

Belt tension adjust to correct play

12. Batteries

Check electrolyte level

13. Tires/Wheels

Check wheel nut driving torque

4. Lights and Instrument

Make sure that instruments, lights, worklights and direction indicators work correctly

5. Safety and Housekeeping

Check the soundness of the safety belt Check the soundness and legibility of the warning plates Make sure that the laders and handles used to reach the driver's seat and the inside of the cab are clean

EVERY 500 HOURS

EVERY 10 HOURS 1. Lube points

Lubricant the joints

EVERY 50 HOURS Check Oil Level - top up - Check hoses connection. Replace hydraulic system oil filter

2. Hydraulic System

Check Coolant Level - top up, if necessary Check Oil Level - top up, if necessary

3. Cooling System 4. Brake System 5. Differential System

Lubricate the propeller shafts, front axle joints and central coupling and the rear axle joints

6. Tires/Wheels

Check pressure-rectify-see for condition

7. Fuel System

Water from tank and filter. Draining the water separator

EVERY 3000 HOURS Check engine components and adjust valve clearance

23. Engine

EVERY 4000 HOURS 24. Engine

Change thermostatic valve

14. Hydraulic System

Change hydraulic oil. Clean intake filter

15. Engine

Change oil and filter

16. Fuel System

Change fuel filter

17. Cooling System

Clean outside of radiator

18. Aircon

Clean outside of condenser

EVERY 2000 HOURS

 

19. Cooling System

Change coolant

20. Brake System

Change brake fluid

21. Starter Motor

Replace (component parts exchange)

22. Alternator/ Generator

Replace (component parts exchange)

Note: Every 50 hours , includes check points 1-7 Every 250 hours , includes check points 1-13 Every 500 hours , includes check points 1-18 Every 2000 hours , includes check points 1-22 Every 3000 hours , includes check points 1-23 Every 4000 hours , includes check points 1-24

Resources: Operations & Maintenance Backhoe Loader, Komatsu

Manual,

WEAM007504,

WB93S-5,

Self- Check 2.2-2 I. TRUE OR FALSE: Direction: Tell whether the given statements about the “Basic Preventive Maintenance Servicing of Backhoe Loader” are correct. Write T if the statement is true and F if the statement is false.

_________1. Checking of hoses, belts and auxiliary connections before and after the use of equipment is also very important. _________2. It is not necessary to check the recommended maintenance plan in performing maintenance. _________3. It is necessary to confirm that all safety features of machine are working aptly. _________4. You also need to make it a point to check the fuel levels and document the periodic refills. _________5. The hydraulic fluid level before and after using the equipment should be checked. _________6. Loose bolts will not cause harm and is necessary for a better operation output. _________7. The equipment should be stored in cool and dry place, protected from all the contamination _________8. It is not necessary to check and clan air filter. _________9. You need to check all the attachments of the BHL before and after work. _________10. BHL operators should be trained well regarding Backhoe Loader operation and preventive maintenance measures.

II. Enumeration: 1.

Enumerate activity/checkpoints operation/engine starts

to

ANSWER KEY 2.1-2 I. True or False 1. T 2. F 3. T 4. T 5. T 6. F 7. T 8. F 9. T 10. T II. Identification 1. Walk around inspection 2. Check for leakages 3. Check Tires/Wheels 4. Check light and instruments 5. Check safety and housekeeping

be

consider

before