maintenance guide · 3. energy and machinery isolation – isolate, lock, tag, release energy and...

MAINTENANCE GUIDE

ULTRAEDGE™ LHD LIP SHROUD SYSTEMINSTALLATION, MAINTENANCE AND REMOVAL INSTRUCTIONS

Additional signal words that are not preceded by the attention symbol are:

SafetyGeneral Safety InformationThe safety practices described in this manual are meant as guidelines for safe operation under most conditions and are meant to supplement any safety rules and/or laws that have been established at your worksite.

Personal Safety

Signal WordsThroughout this manual are statements preceded by a special attention symbol: “ ”. The symbol is used with the following signal words to attract your attention to information regarding safety issues.

IMPORTANT: Indicates information that possesses special significance to the described procedures.

Tip: Indicates information that may simplify the procedures or make your job easier.

WARNING: Indicates a hazardous situation which, if not avoided, could result in serious injury or death.

CAUTION: Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE--DAMAGE ALERT: Indicates information that should be acted upon to avoid significant equipment or machine damage that could result in unplanned downtime or maintenance.

WARNING: Read this entire brochure prior to conducting the procedures described in this manual. Failure to follow these instructions could result in injury or death.

WARNING: When performing the work described in these instructions, use proper personal protection equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection that complies with regional, national and worksite requirements (e.g., OSHA, MSHA) when working with this equipment. To avoid injury to bystanders, keep them a safe distance from the work area.

WARNING: The practices described are meant as guidelines for safe operation under most conditions and are meant to supplement any safety rules and/or laws that may be in force in your area. Your safety and the safety of others results from putting into practice your knowledge of the correct operating procedures. Ensure welds are applied by competent welders using good welding practices. Ensure that operators and bystanders are well clear of the load during lifting operations.

Table of Contents

1. Installation

1.1. Preparing the Machine and Bucket for Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4

1.2. Preparing the Lip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4

1.3. Positioning Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5

1.4. Positioning Shroud on Lip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5

1.5. Aligning Threads with Lip Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6

1.6. Installing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6

1.7. Tightening Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7

1.8. Supplemental Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 8

2. Maintenance

2.1. Preparing the Machine and Bucket for Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9

2.2. Checking and Tightening the Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9

2.3. Checking Shrouds and Bolts for Loosening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9

2.4. Checking Shrouds for Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9

3. Removal

3.1. Preparing the Machine and Bucket for Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10

3.2. Cleaning Out Bolt Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10

3.3. Removing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10

4

1.2 Prepare Lip1. If needed, remove old shrouds.

2. Clean lip top, bottom, front, and counterbores completely of debris with needle scaler and wire brush to bare metal. See Figure 1.2.1 and Figure 1.2.2.

3. Inspect lip and correct for uneven surfaces in the fit contact regions that may prevent the shroud from seating on the lip.

1.1 Component Preparation1. The machine and bucket must be blocked against hazardous motion.

2. The machine and bucket must be positioned and oriented to provide safe access to perform the work described below. Before performing any work, a risk assessment in accordance with worksite requirements must be performed to identify potential hazards, and establish safe procedures for completing the necessary tasks.

3. Energy and machinery isolation – Isolate, lock, tag, release energy and test for dead.

4. Shroud nuts are delivered with top and bottom dust covers. Remove and discard before installing the shroud.

1. Installation

WARNING: Unsecured equipment may move by external impact force or accidental machine position change. When working around the bucket, ensure that the bucket is blocked against motion and the machine is isolated, locked and tagged in accordance with worksite requirements.

Figure 1.2.1 Lip

Bottom

Top

Leading Edge

Figure 1.2.2 Lip

5

1.3 Pre-position Nut to About 45°1. If the optimal rotation of the nuts is known from a previous shroud installation then rotate the nuts to that

orientation; If not, leave the nuts rotated about 45°. See Figure 1.3.1.

WARNING: When inspecting shroud, ensure that the shroud is positioned against motion.

Figure 1.3.1 – Nuts Angled at 45°

1.4 Position Shroud on Lip1. Shroud must have full contact on leading edge. See Figure 1.4.1.

2. Shroud must have contact along bottom surface. See Figure 1.4.1.

Contact

Figure 1.4.1 – Shroud Placement on Lip

6

1.5 Align Threads with Lip Holes1. Adjust nut rotation to align threads with lip hole by rotating the nut with a Hex Bit inserted from the top of the lip.

2. Shroud position may have to be adjusted sideways to achieve proper alignment. See Figure 1.5.1.

Figure 1.5.1 – Aligning Threads with Lip Holes

1.6 Install Bolts1. Lubricate bolts with anti-seize compound.

2. Insert bolt and washer and tighten lightly by hand or with small ratchet and 46mm socket. See Figure 1.6.1.

Contact

Figure 1.6.1 – Installing Bolts

Figure 1.6.2 - Hex Bit Placement

Tip: If the condition of the bolt binds or does not thread easily on the nut, insert a 19mm Hex Bit into the nut from the bottom of the shroud and hold breaker bar firmly during bolt assembly. See Figure 1.6.2.

7

1.7 Tighten Bolt1. Tighten bolts to 1,000 ft/lb. See Figure 1.7.1.

2. Check to ensure that the shroud is in solid contact with the front of the lip. See Figure 1.7.2.

3. Repeat tightening process for the remaining bolts in each shroud. Tighten in the order shown. See Figure 1.7.3.

Tip: Using a brass or copper hammer jolt each bolt head 3 times to help settle the shroud and fasteners then retighten to 1,000 ft/lbs. See Figure 1.7.4

Figure 1.7.1 – Bolt Tightening

Figure 1.7.2 – Shroud and lip contact

Contact

Figure 1.7.3 – Bolts Tightening Patterns

3 4

4 3

1 2

2 1

2 1

1 2

3

3 4

Figure 1.7.4 – Settling shroud

8

Figure 1.8.1 – Hex Bit inserted into nut

Figure 1.8.3 – 1/8th turn to relax bolt

Figure 1.8.4 – Bolt placement

1. With the bolt only hand tight, insert 19 mm Hex Bit into the nut from the bottom of the shroud. See Figure 1.8.1.

2. Rotate the nut with the Hex Bit and breaker bar from the bottom of the shroud clockwise when looking down on the shroud to pull the shroud back firmly to the lip. See Figure 1.8.2.

3. Relax the nut approximately 1/8th turn to eliminate any binding or loading of the bolt on the lip hole. See Figure 1.8.3.

4. Hold Hex Bit firmly to eliminate motion of the nut and tighten bolt until it is firmly seated. See Figure 1.8.4.

Figure 1.8.2 – Hex Bit rotation

1.8 Supplemental StepsIf using an impact wrench to perform the installation or if you encounter conditions where the bolts are not easily threaded you can follow these additional steps.

9

2.1 Prepare the Machine and Bucket for Work1. The machine and bucket must be blocked against hazardous motion.



2.2 After 8 Hours, Check and Tighten Bolts 1. Clean out around bolt head with needle scaler or similar tool.

2. Using a brass hammer jolt each bolt head three times to help settle the shroud, nut and bolt.

3. Tighten all bolts with torque wrench to 1,000 ft/lb.

4. Some bolt rotation is expected since there can be some settling of the system

2.3 Check Shrouds and Bolts for Loosening1. Using a brass hammer, jolt each shroud and check for loosening. Look for movement around the bolts

and shroud to lip interface areas.

2. Visually check each bolt to see if it shows any indications of backing out.

3. If any loosening is detected by visual inspection or by impact, the bolts should be retightened.

2.4 Check Shrouds for Wear1. Look at bottom surface of each shroud to see if wear indicators are visible. The dimples should become visible

when there is approximately 10% wear life remaining as shown in Figure 2.4.1.

2. Maintenance

Figure 2.4.1 – Example of Wear Indicators

10

3.1 Prepare the Machine and Bucket for Work1. The machine and bucket must be blocked against hazardous motion.



3.2 Clean Out Bolt Head 1. Remove fines from around bolt head. See Figure 3.2.1

2. Secure shroud against movement.

3.3 Remove Bolts 1. Remove bolts using a 46mm socket and impact wrench.

See Figure 3.3.1

3. Removal

Figure 3.2.1 – Removing Fines

Figure 3.3.1 - Removing Bolts.

maintenance guide · 3. energy and machinery isolation – isolate, lock, tag, release energy and...

Documents