Inspection HYDRO SM fleet

Machine 0056 (HYDRO No 2) was

inspected thoughly.
No 0046 and 0062 ( HYDRO No 1 and
3)only visual inpection
Rear left bottom rocker
arm
Total play 5,4mm

Bore in the chassis

horizontal 82.6
Vertical 81,6

Should be 80+0,1

Total play 5.4mm minus 2,6mm play in

chassis bore = 2.8mm. This indicates
thar rockerarm is worn as well.
Hardened steel bushing in the
rockerarm was not worn. We assume
bore in the rocker arm is oval.
Pin rear left rocker arm
Pin was worn on the load side

Diameter 79,8mm

Pin reinstalled 180° ofset

Pin worn on load side
Play at rear left rockerarm
Play at rear tracks
The rear left track was off the ground.
The rear tracks had been tight
together with 2 comalongs (chain
blocks).
Measure play of rear + left
track suspension
Rear suspension was spreed apart with
a hydraulic cylinder

The difference between pulling

together and spreading apart was
measured at the position of the
hydraulic ram.

Difference was 40mm

That 40 mm is the sumary of play in

both, right and left suspension.
Check turntable ( for
conveyor slew)
A dial gauge was installed between the
chassis side of the bearing and the
conveyor slew side.
With no load on the conveyor the
counteweight is heavier as the
conveyor.
For evalluating the bearing play the
counterweight was lifted with a
hydraulic jack causing the bearing lift
of the race. That indicates the bearing
play.
Measurement was done at the
following positions:
1. Straight to the rear
2. 45° to the left
3. 45° to the right
4. 90° to the left
5. 00° to the right
Readings had been between 0,6 and
0,55. Play should not exceed 1.2mm
The bearing is good for further use.
Check play of the front
lower rocker arms
For checking the play the machine is
sat on the the drum and raise the
tracks. That causes the height
adjustment cylinders pulling instead of
pushing. Because they are connected
to the rocker arm in and angle the pins
are under load from both sides. This
indicates the play.

The left side play was about 5mm and

the right side 6mm

Soon repair is recommended

For accurate measurement rockerarm

shall not be moved. The machine shall
be liftet off the ground with a jack (
instead of moving the rocker arms
with height adjustment rams)
Check rear left steering
bearing and collumn
The bearing was lifted of the steering
collumn. The collumn and the thrust
bearing had been checked for
dammage and wear.

The collumn was measured with a

micrometer and found in excellent
condition. Good for further use.
Check steering bearing
Thrust bearing in good condition.
It was observed that most wear was
sideways. That indicates load resulting
from missalligned tracks. ( Play of
rocker arms)
Bearings are in good condition. Good
for further use.
It is recomended to swap upper and
bottom thrust bearing and replace the
felt seal.
 Cracks
• All 3 machines show the same cracks.
• All machines have rockerarm play on all 4
positions. Action is required to avoid
consequential damage on the steering bearings
and collums.
• For long lasting repair the high stress points that
have cracks need a relieve like aditional gussets.
• Smooth load distribution from the gussets into
frame is required like radius etc.
 Cracks in rear cross beam
Vetical gusset Horizontal gusset
crack in drum housing left
side
Additional longer ribs

Weld between chassis and drum

housing recomended
Reinforcement on scraper stops
Cracks in left side upper structure
 Recomendations
• Exhaust gas pipes shall not leak.
• Install new flex pipes clamps and isolation
• Repair or exchange rockerarms before steering
bearings are damaged.
• Shorter discharge conveyor by 2m and reduce
counterweight. Easier handling to minimise load
risk of truck catching on the conveyor.
• Avoid backlock of repair.
• Adjust primary conveyor deflector plate to middle
of discharge convyor. Avoid spillage.
Optimise truck
Shorter discharge conveyor allows 90°
loading
Maintain exhaust piping
Successful repair with reinforcement
Fix pin on counterweight
 Repair strategy
Preventive
• More spare part cost
• Better availability
• Highest safety level
• Propper organisation is
possible
• Extended live of the
machine
• Lower in labour cost
(planed repair=quick repair)
Run to faillure
• Cheap in spare part
consumtion
• Unscheduled downtime
• Safety components not
exchanged in time
• High cost for disturbence
down the production line
 Repair modules reduce downtime
• Primary conveyor
• Discharge conveyor
• Set of lower rockerarms
 To Do (Wirtgen)
• Supply sketches for reinforcemnt
• Supply welding procedure
• Change steel on rocker arms to high tensile
strength
• Redesign of high stress areas (further
machines)
• Supply tollerances for rocker arm and chassis
bores for in line boreing.
 summary
• The bauxite in some pits is hard to cut.
• Machines work under high shock load and
vibration.
• Cracks in structure are fatique related
• With propper reinforcement and skilled repair
the machines can work for thousands of hours
at good availibillity.
 Thank you
• For support during our stay
• For open discussions
• For parking the machines for inspection
• For helping disassembly / assembly of
components to be checked
We wish you a marry Christmas!