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DIRECTOR GENERAL BORDER ROADS

GENERAL MAINTENANCE INSTRUCTION NO. 240

ON OPERATION AND MAINTENANCE OF

VIBRATORY SOIL COMPACTOR L&T 1107 D

INTRODUCTION:

(a) L & T Case make and 1107 D model Vibratory Soil Compactor having
hydrostatic drive on both front drum and rear drive axle, with high strength main
frame/chassis, with dual amplitude setting and having dual frequency of 30 and 33 Hz
in the front drum, hydraulic steering mechanism, hydrostatic service brake, powered by
Kirloskar HA 694 air cooled 6 cylinder diesel engine developing 112 HP @ 2500 rpm
and with 12 V starting system.

(b) This GMI gives the technical specification and know how on the operation,
maintenance and repair procedure of Vibratory Soil Compactor L&T 1107 D to ensure
maximum performance and safe/satisfactory operation. Compliance with procedures
given in this GMI will enable to desire the maximum service from the equipment.

(c) To prolong the life of Vibratory Soil Compactor L&T 1107 D, to prevent frequent
brake downs and to reduce maintenance cost, the periodic maintenance must be
carried out according to the ‘Periodic Maintenance Schedule’ described in this GMI.
Periodic Maintenance is essential for preventing troubles and accidents to ensure
satisfaction and safety. Daily care and inspection is also essential for prolonging the
operating life of the equipment and for safe operation. All information and instruction
given in this GMI is based on the latest owner‟s manual and service booklet provided by
the firm.

AIM:

The instructions are issued as guidelines for general, preventive maintenance

schedule and lubrication of Vibratory Soil Compactor L&T 1107 D manufactured by M/s
Larsen & Toubro Case Equipment Pvt Ltd for regular attention to keep the equipment in
good mechanical condition which must be strictly followed.

ACTION BY:

(a) User unit: To carryout periodic inspection and monitor

regular/periodical maintenance as laid down in this instruction and record
the tasks done in log book.

(b) Field Workshop :

(i) To carryout and monitor maintenance schedule and oil

changes as per periodical maintenance laid down in the
maintenance instruction and to check the record of maintenance
including lubrication.

(ii) To advise the user unit in respect of any lapse noticed.

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(c) Mobile Maintenance Team: To ensure that proper maintenance is

carried out and submit report accordingly to Task Force Commander and
OC Wksp for their necessary action.

DETAILS:

This instruction includes the following aspects:-

a) Operating Procedure - Appendix „A‟

b) Periodic Maintenance schedule - Appendix „B‟
c) Technical Specification - Appendix „C‟
d) Recommended Lubricants/Filling Capacities - Appendix „D‟

(V N Singh)
SE (E&M) FS
Director (Tech)
For Dir Gen Border Roads

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Appendix ‘A’
OPERATING PROCEDURE

Daily Pre Operation Checks before starting the engine:

1. Check fuel level in the fuel tank and top up if required.

2. Fill in diesel fuel in time so as to avoid unnecessary bleeding of the fuel system.

3. Do not spill diesel fuel on the engines.

4. If the fuel tank has been run empty it is necessary to bleed the fuel system.

5. Check hydraulic oil level in the tank and top up, if required.

6. Check engine lub. Oil and top up if required.

7. Visually check for leakages and damages to electrical components and

connections.

8. Visually inspect and ensure that all the doors and covers are closed and locked.
No tools like spanners, screw drivers should be left on the machine.

Starting the engine :

1. Check whether the Articulation joint arrester is removed.

2. Ensure that all the miniature circuit breakers (MCBs) are switched ON at the
MCB Box below Operators Platform (RH).

3. The drive lever and the exciter switch must be in their neutral positions.

4. Push the accelerator lever back to the low idling position.

5. Switch OFF the parking brake switch if it is in ON position.

6. Insert the ignition key into the ignition switch and turn clockwise by 45 degrees
and check all indicators.

7. Low lub. Oil pressure indicator and Battery non-charging indicator will glow.

8. Turn and depress the ignition key to start the engine.

9. Do not actuate the ignition switch for more than 5 seconds. While attempting to
start the engine, wait for one minute before trying again.

10. After the Engine has picked up and warning lights like Low lub. Oil pressure
indicator and battery non-charging indicator have gone off, the engine should be
run on idling speed for 2-3 minutes. Thereafter rotate the throttle lever to
increase the rpm of the engine. At the maximum position the engine will be
operating in full speed.

11. Machine must be operated (Travel & Vibration) in high engine rpm only.
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Operating the machine (Travel) :
1. Drive the machine with the drive lever (FNR) into the desired driving direction
(forward/back word from neutral). The speed will increase, the more the lever is
moved forward or backward.

2. For braking, move the drive lever out of the respective forward or reverse driving
position to the neutral position.

3. During parking in slope, put on parking brake switch (P)

4. Parking brake is to be operated only when machine is in neutral. Electrical

system is designed in such a way that parking brake will be engaged only when
FNR lever is in neutral. And when parking brake switch is ON engine can‟t be
started.

Setting the exciter into operation :

1. Start the engine according to the procedure given above.

2. Start traveling (Moving forward or reverse direction) the M/C iin working speed
(Put OFF high speed switch).

3. Turn vibration frequency selector rotary switch to left to select low frequency &
high amplitude or to right to select high frequency & low amplitude.

Setting the other features available in the machine:

1. Switch ON/OFF front head lamps, Rear working lamps, side indicators, parking
lamps, if necessary.

Setting Machine out of operation :

1. Rotate frequency selector switch to neutral (at centre) to stop vibration.

2. Then bring FNR lever to neutral to stop traveling.

3. Put on parking brake toggle switch during parking the M/C on slope to prevent
the M/C roll back.

4. Bring Throttle lever to low idle position.

5. Pull the stop cable knob until Engine stops. Low lub. Oil pressure indicator &
battery non charging indicator should glow.

6. Turn ignition key anticlockwise. All indicators should go off.

7. Switch off all the MCBs.

8. Secure the machine by means of wheel chocks and/or stone/rocks if necessary.

9. Do not stop the Engine suddenly from full load, but allow it to run sometime with
no load.

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Safety Features:

1. Electrical circuit protected by MCBs

2. Machine cannot be started when Forward-Reverse lever is not in neutral
3. Machine cannot be started when parking brake switch is on.
4. Parking brake automatically disengage when m/c is not in neutral
5. No vibration in high speed (Transport) mode of travel.
6. Automatic engine cut off in case of Engine belt failure
7. Neutral indicator
8. 2 speed indicator
9. Battery Non-charging indicator
10. Low lub oil pressure indicator
11. Air filter clog indicator (Mech.)
12. Hydraulic oil filter clog indicator
13. Parking brake indicator
14. Fan belt failure indicator
15. Engine lub oil Pressure & Temperature gauge
16. Service hour meter
17. Rigid Rear Axle with inboard planetary drives

Precautionary measures:

1. Uphill driving is impermissible, if the gradient exceeds the permissible gradient of

the machine during operation.

2. The machine is equipped with an infinitely variable hydrostatic propulsion so that

a jerky take off or a jerky reversal in the opposite direction should be avoided.

3. Before starting to drive uphill, check at the beginning of the gradient in the
driving direction envisaged, whether the wheels and drum have a sufficient frictional
engagement and ground contact with the track way.

4. While taking off the machine and while reversing the travel direction, take care of
a smooth and uniform acceleration and deceleration so as to avoid unevenness of the
layer placed.

5. For compacting, select the drive range and move into the loose material using
forward and reverse gears.

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Appendix ‘B’

PERIODIC MAINTENANCE SCHEDULE

Maintenance work Maintenance Instants

After Daily In case
first 50 Regularly every (Hours) of need
hours 10 50 100 200 500 1000
CHECKING
MACHINE
Visual inspection for * *
damage
Visual inspection for * *
leakages
Visual indicator for * *
contamination
(Hydraulic filter choke
indicator)
Air intake system * *
Air cleaner chock * *
indicator
Exhaust pipe * * *
Engine mounting * * *
(AVMs/bolts)
Roller mounting * * *
(AVMs/Screws)
Scrapper * *
V-belt tension * *
Battery charge * *
(Red/White/green in
“Magic Eye”
FUNCTIONS
Engine oil temperature * *
gauge
Engine oil pressure * *
gauge
Low engine oil pressure * *
indicator
Parking brake ( In m/c * *
neutral)
Electrical system * *
Vibration with low & high * *
frequency
Steering * *
Tyre pressure ( adjust if * * *
required)
CLEANING
Clean machine * *
Air intake system * *
Hydraulic oil cooler * *
Water separator * *
Fuel tank (Drain water) * *
Fuel tank * *
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Maintenance work Maintenance Instants

After Daily Regularly every (Hours) In
first 50 10 50 100 200 500 1000 case
hours of
need
LUBRICATION
Oil level in the engine ( top * *
up if required)
Oil level in hydraulic Tank * *
( top up required)
Greasing at Steering * *
Cylinder rod &head end
Greasing at articulation * *
joint pins
Greasing at travel bearing *
Battery electrolyte level * *
Clean & apply petroleum * *
jelly at battery terminals
TORQUING
Roller mounting * * *
Articulation joints * * *
Roller AVM mounting * * *
screws
Engine AVM mounting * * *
Screws
Axle mounting bolts * * *
Wheel nuts * * *
REPLACE
Hydraulic oil filter element * *
Hydraulic Oil * *
Exciter Oil * *
Axle oil * *
Reduction Gear Housing * *
Oil
Auxiliary Drum oil * *

ENGINE
Engine oil change After every 250 hrs run

Engine oil filter change After every 250 hrs run

Fuel filter insert (Pre filter) After every 500 hrs run
Fuel filter insert (Micro After every 750 hrs run
filter)

Fuel strainer (Bottom filter Clean after every 125 hrs run
at feed pump inlet)

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Appendix ‘C’

TECHNICAL SPECIFICATION

Description Soil Compactor L&T 1107 D

Vibration Dual Mode

Propulsion Front drum drive and Rear Axle drive

Steering Hydraulic Steering with Articulation

Brake Service Brake (Hydrostatic) and Parking

brake

Operating weight 11, 300 kg

Axle Loads Front : 6450 kg

Rear : 4850 kg

Static linear load (front) 30 kg/cm

Vibration frequency Stage 1 : 30 Hz

Stage 2 : 33 Hz

Nominal Amplitude Stage 1 : 1.8 mm

Stage 2 : 0.8 mm

Centrifugal Force Stage 1 : 25, 530 kg

Stage 2 : 13, 820 kg

Travel speed Work Mode : 0 – 6 Kmph

Travel Mode : 0 – 14 Kmph

Gradeability
Continuous Degrees : 19.8
Percent : 36

Intermittent Degrees : 21.8

Percent : 40

Internal Turning Radius 3.45 m

Drum Oscillation Angle 15 degrees

ENGINE
Make Kirloskar Oil Engines Ltd, Pune
Type 4 Stroke, 6 Cylinder, Iinline, Direct
Injection Air Cooled Engine

Model HA 694
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Nature of Aspiration Naturally Aspirated
Power rating 112 HP @ 2500 rpm as per std DIN 6271
IFN
Bore 100 mm
Stroke 120 mm
Displacement 5652 cc
Direction of rotation Anticlockwise when viewd from flywheel
end
Type of fuel pump In line
Type of Air Filter Dry type with dual element

Type of governing Mechanical

Starting system Electrical 12 V
Lubrication system Forced feed
Dry weight of the engine 530 Kgs

PROPULSION (TRAVEL):

Type Hydrostatic system acting on front drum

and rear wheel

Travel Pump Variable displacement pump with manual

displacement control
Drum drive Motor Low speed, High torque (G3/G4 type)
Radial piston Motor with brake
Wheel drive Motor High speed, Low torque motor mounted
on Rear axle input shaft

EXCITER DRIVE:

Type Hydrostatic system acting on the front and

rear exciter shafts

Kind of Exciter Single shaft with two floating masses for

dual amplitude
Vibration Motor Fixed displacement axial piston motor

EXCITER CONTROL:

Stage 1 (30 Hz) High Exciter force, Low frequency, High

Amplitude

Stage 21 (33 Hz) Low Exciter force, High frequency, Low

Amplitude

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STEERING SYSTEM:

Type Hydrostatic system acting via the steering

wheel, steering unit and steering cylinder
on the articulated joint
Steering Pump Gear type

ELECTRICAL SYSTEM:
Battery 12 V, 120 AH
Alternator 12 V, 35 Amphs

HYDRAULIC OIL FILTER:

Type Paper Element

Filter Rating 10 Micron (Nominal)
Number of Filters 1

BRAKES:

Service Brake Hydrostatic

Parking Brake Spring applied, hydraulic release

RELIEF VALVE SETTINGS:

Travel circuit 430 bar

Vibration Circuit 320 bar (Rexrath Pump), 350 bar (SD
Pump)
TRANSPORT DIMENSIONS:

Length of the machine 5344 mm

Width of the machine 2300 mm

Height of the machine up to Optr cabin top 3150 mm

Height of the machine up to Silencer top 2410 mm

Wheel base 3000 mm

Ground Clearance 395 mm

Diameter of Rear wheel 1528 mm

Diameter of front wheel 1500 mm

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Appendix ‘D’

RECOMMENDED LUBRICANTS

S/No Item Brand Name Manufacturer

a) Engine oil * CRD 40 Castrol India Ltd
(SAE 40) SERVO SUPER 30/40 IOCL
Hylube Milcy 30/40 HPCL
BHARAT ACTUMA SUPER BPCL
OIL 40
HYLUBE HDX 40 HPCL
VEEDOL HDB 40 TIDE WATER OIL CO.

b) Hydraulic Oil (Tropical) HYSPIN 68 Castrol India Ltd

HYSPIN –AWH 100TP Indrol Lubricants &
Specialities Ltd
SERVO HYDREX 100 HP IOCL
Power Fluid LTP 100 HPCL
BHARAT HYDROL P 100 BPCL

c) Exciter Oil Hypoi EP 90 CASTROL INDIA LTD

d) Grease ( For greasing SERVOGEM EP-2 IOCL

drum, steering cyl,
displaceable steering
part)
e) Rear Axle and M2C-134-D CASTROL INDIA LTD
Reduction Gear AGRI TFD
Housing NAS9

f) Auxiliary Drum HYSPIN 68 CASTROL INDIA LTD

* Recommended Eng oil for atmospheric temp above 250 C and for below 250 C,
please refer engine side operator‟s manual supplied by M/s KOEL.

FILLING CAPACITIES

Engine Oil 14 Ltrs

Rear Axle oil 27 Ltrs

Rear Axle Reduction Gear Housing Oil 0.5 ltrs

Exciter Chamber 19.5 Lltrs

Auxiliary Drum (for STD model) 4 Ltrs

Hydraulic oil tank 70 Ltrs

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