Basic

Equipment Management
And
Maintenance Concepts

Prepared by: Hunegnaw Ayele (Mech.Eng)

Addis Ababa
June 2013

What this Course Covers

Earth moving machine has changed the way we do work… help get the job done.
 And you can help get the job done too, whenever your service or repair the power train.
Thorough and efficient repair keeps the machine out where it should be…working.

The key to doing your job well is knowledge about your power train, how it works, how
the systems operate under normal conditions. It all comes down to basics.

Mastering the basics is what this course is all about.

BASIC EQUIPMENT MANAGEMENT AND MAINTENANCE CONCEPTS lays the
ground work, preparing you for advanced training on equipment management and
maintenance procedures used on all earth moving machine power train.

Module 1 Introduction
- Who is who?
- Why are you here?
- What is Equipment management & maintenance
- Equipment management
- Maintenance
- Selection
Module 2 Equipment Management
- 7 elements of power train management
- Repair indicators
Module 3 preventive maintenance
- Flitters
- Oil spec
- Grease
- Coolant
- Batteries
Module 4 Ground Engaging Tools/GET/ basics.
- GET selection
- GET Management
- Bucket Selection
Module 5 Undercarriage
- link Assembles
- variable that affect the UC wear
- UC measurement
- inspection
- How to manage the condition of UC
- Special fools for UC measurements.
Module 6 General Maintenance procedure.

1. Introduction
Why are you here?
  Equip yourself with the Equipment management and maintenance skill
 Help you to translate Equipment management and maintenance benefit
 Help you understand how all this logically fits together to meet your job needs

Who is who?

 Name & company

 Current positron
 year of experience
 hobbies /outside interests

2. Equipment management & Maintenance

Equipment Management
Company Information

1. What equipment do you have? Identify your machine flit according to:-
a. Brand
b. Type of machine
c. Machine Model
d. Year of manufacture.
2. How and when equipment is used.
a. Which machine comes first?
b. When?
c. Plan your machine combination.
3. How & when equipment maintenance will be?
4. Manage equipment inventory to maximize productivity.

Repair Identification

- Anticipate and prevent problem

- Mange equipment inventory to maximize productivity

<< Repair before Failure>>

7 Elements of power train system management

1. Preventive maintenance
2. S.O.S fluid analysis
3. Inspection
4. Repair management
5. Training
6. Scheduling
7. Record keeping
Advantage

- Directly related to solution feature

- Address customer task motives
- Answer question about how the solution affects the customer’s business issues.

1. Preventive maintenance

Good Preventive maintenance program closely follows manual recommendation

Advantages

- Prevents small problem from becoming major failures

- Allows scheduling downtime and planning for costs
- Helps maximize equipment life
- Increases resale value
- Keeps equipment on the job longer
- Improves profits
- Saves money

2. S.O.S. fluid Analysis

- Program takes in to account

- Trend analysis
- expert interpretable
- meaning full advice
- maintenance
- operating practice
- component condition
- oil condition & cleanness

3. Inspections
- Visual
- Operational
- Technical
<< Catch small problems before they become major catastrophes>>
4. Repair Management
- Repair Indicators - Planned
- Problem
- Rebuild option -find best value
- Lower owning and operating cost
5. Training
- Meeting and seminars
- Individual or group instruction
- Materials
- Routine maintenance training
 - Operation/maintenance training
- Software instruction
- Experienced instruction

Advantages - lower owning and operating cost

6. Scheduling
- Comprehensive scheduling –maintenance, inspecting & planned repair
- Prevent power train failures.
- Scheduling resource
- Record keeping
- Maintenance control
- Preventive maintenance planner soft ware.

Advantages - increase inventory control and management

- increase productivity
- improve profitability.

7. Record keeping
- component history life & cost information
- Locate potential problem areas
- user record keeping resources

Advantage - Reduce and control costs

- decreases down time
- Increase machine resale value

Repair Indicators

Planned
 S.O.S fluid analysis
 Service meter hours
 fuel consumption
 Service history
 Experience
 Site operations & maintenance advise
 Inspection
-Technical -Repair indictor kit
-Visual

Problem
 Low power complaints
 High operating temperature.
  Leaks or vibration
 unusual noises
 Slippage or hesitation
 Overheating
 Break chatter
 Excessive smoke
 Oil consumption.

1. Filters
2. GET
3. UC
4. Lubricant

3. Preventive Maintenance Products

 Introduction
 Fluids
 Oil, Grasses Coolants
 Filters
 Liquid Filters, Air Filters

Oil - specification
- Engine oil
- Transmission
- Hydraulic
- Final Drive
Oil Recommendation – according to the manual of the machine.
To-4 – Reduce transmission slippage
TDTO –Transmission drive Train oil
- control brake chatter
- increase machine break-out force
HYDO – engine oil that meets
- API CF or superior – according to lubricant specification.
- Have a minimum zinc additive content of 900ppm
- Industrial hydraulic oils should not be used!
Grease; -
Is thickened fluid with additives added to enhance properties?
Application: Machine, Component, Speed
Load: Low, Medium, Severe
Ambient Temperature

Ultra 5 Moly Grease Advance 3 moly grease best product for most application and elements

Coolant
 - Extended life coolant – ELC 60% of premature engine failures can be attributed to
cooling system problems.

Heavy Duty Coolant Basics

 Functions
 Heat Transference
 Stay liquid: don’t freeze / don’t boil
 Protect Against Rust and Corrosion
 Glycol Content Minimum 40%
 Water: Soft and De ionized
 Additives
Drain Interval
Conventional EL
Drain Interval 3,000 hr 6,000 hr
Maintenance Every 250hr >3,000 hr
Specification ELC-1

ELC
Benefits
 Superior engine protection
 Easier to maintain
 Reduce maintenance cost
Filter

1. Liquid filter
Filters – Engine Oil
-Fuel
-Hydraulic & Power train
-Liquid
2. Air – Inner
-Outer

Fuel Filters – Increase injector life

Batteries – Premium high output and general service

- use maintenance free batteries

Benefits of maintenance free batteries

- minimal water loss
- less gassing
Reduce maintenance costs
- never need water
 - sealed – no lost vent caps
- no activation
- no handling /storage of acid
‘Avoid vibration – vibration is enemy of batteries’

4. Ground Engaging Tools/GET/ basics

Two most important function of GET

1. Increase productivity
2. Protect machine structural components

Cost/hour/tone Cutting edge or teeth

Think or thin?

My tips have to last as long as possible.

GET triangle

Penetration

Wear life Strength

 Focus on the right costs

HEX – tip selection Vs Productivity

What changed?

 Maintenance manager felt tip life was too short?

 Last Longer
 Save money
 Cycle time down
 Bucket fill up
 Production up

Metallurgy

 The Alloys
  The steel Forming Methods
 Heat Treatment
DH-2
DH-3

DH- 3
DH -2

GET Management

 Selection
 Operation Techniques
 Maintenance

Wear

 Contact
 Pressure
 Motion (relative motion)

Abrasion- Directly linked to material

 Low: clay
 Medium: limestone
 High: granite/silica
 Very high: quartz

Environmental factors

 Impact linked to matinee size

- Low- Loose ground:
- Stockpile
- No rock inclusion
- Medium- compact ground
-Some rock
-Good blasting
- High - Very compact ground
-Large size rock inclusions
 -Low blasting
 Heat – Linked to the application
-Slag operation
- High speed or high load applications
- Increases with abrasion level
- Heat affects material hardness

Different buckets

 GP – General Purpose
 MH – Material Handling
 Penetrating
 RB – Rocky Bucket
 HS - Heavy deity quarry
 Edge – segment
 adapter bolt & met
 tip retainer Selection
 Cutting edge
 Corner guards

Dozer /TTT/ Motor Grader /MG/

- Cutting edge
- End bit
- Bolt & Nut
- Ripper tip
- Retainer & Pin

5. Undercarriage /UC/

Link Assemblies

I. Track Section
- Link
- Pins
- Bushing
- Seal
 Roller
 Track Shoes
 Idlers
 Sprocket Segments
 Hardware

II. Variables that affect the undercarriage wear

1. Non controllable variable
 - Abrasives
- Impact
- packing
- Moisture
- Temperature
- Chemical
- Terrain condition
2. Partially controllable
- Track tension
- Shoe width
- machine alignment
- maintenance
- application conditions
 Speed
 Direction
 Turning
 slipping track
3. Undercarriage
– Measuring
– measuring the track condition and ready for turning & replace the track.

6. General Maintenance Procedures Provides information on

1. How to gather information about the power train to performing maintenance.

2. How to determine service interval.
3. How to perform filter and fluid changes on the lubrication & cooling system.
4. How to perform filter change on the fuel system.
5. How to perform filter changes in the air system.
6. How to take an S.O.S sample and read an S.O.S Report.

“Maintenance procedures are critical to the life of the machine.

Performing the procedures properly ensures long life of machine for productivity.”