Cost Effective Gasket and Paint Cleaning Processes

1.0 Introduction Efficient parts cleaning processes are critical to several facets of CRC operations. Parts cleaning may be considered a non-value adding step, but it represents a substantial portion of labor and expenses in the rebuilding process. The cleaning step is an important segment in the critical path, since the last parts disassembled are the first parts needed in assembly. All other parts must wait in staging until those critical few...

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3500 Engine Cylinder Head Bolt Torque Fixture

1.0 Introduction This Best Practice is a dealer-fabricated fixture to improve the process to set 3500 engine cylinder head bolt torque. The fixture allows the use of a pneumatic torque wrench with proper alignment and engagement of the sockets on the head bolts and support of the torque wrench and reaction arm. The fixture reduces the time required to torque all the cylinder head bolts by 20% or more, reduces technician fatigue, and improves the...

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3500 Engine Exhaust Manifold Salvage

1.0 Introduction Significant cost savings can be achieved by salvaging the ends of certain 3500 engine exhaust manifolds. 2.0 Best Practice Description The ends of the manifolds can be machined down, a fabricated repair sleeve can be installed, and the manifold can be returned to service. 3.0 Implementation Steps CAUTION: SAFETY PROCEDURES FOR THE SHOP EQUIPMENT INVOLVED MUST BE FOLLOWED. Clean the exhaust manifold using a shot-peen or sandblast...

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In Ground Silo Rebuild Station for OHT Wheel Groups

1.0 Introduction The size of large Off Highway Truck Wheel Groups makes rebuild difficult. Wheel group rebuild procedure requires the wheel group to be positioned vertically for disassembly and assembly. Technicians work with ladders and work platforms to rebuild the larger model Wheel Groups. A new wheel group rebuild work station concept consists of an in ground silo, a rotating platform to hold the wheel group and rotate the spindle for wheel...

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Managing Fluid Cleanliness through Effective Measurement & Recordkeeping

1.0 Introduction Maximizing component life and minimizing component cost-per-hour requires that fluid cleanliness be maintained at very high levels. This requires a new approach to measuring and managing fluid cleanliness. Effective fluid management requires a process to: - Identify when fluids are dirty - Identify when fluids are clean - Maintain records to show how the fluids are behaving over history This site has created a process to measure...

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Desiccant Breathers Prevent Bulk Fluids Moisture from Damaging Machine Components

1.0 Introduction A desiccant breather on a bulk oil tank The best way to reduce machine powertrain cost per hour is to maximize component life and utilize all of the value built into the component. Avoiding premature component failure is essential to maximizing component life. There are many variables that contribute to premature component failure. One of those variables is corrosion damage of highly loaded precision components, such as bearings...

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Off-Board Fluid Filtration

1.0 Introduction The performance expectations for components and systems on modern mining machines have grown rapidly in the past two decades. This has driven the design of hydraulic systems to operate at much higher pressures, and dramatically increased the load factor on drivetrain components. The increased performance demands also increase the rate of abrasive wear and failure of components compared to older designs, which operated at lower load factors. 2.0 Best Practice Description 2.1 Debris In order to increase durability, it is necessary...

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Measuring Oil Cleanliness

1.0 Introduction Maximizing component life requires maintaining high levels of fluid cleanliness. The ability to effectively and consistently measure debris in fluids is a key element in catching failures before they occur. Laser particle counters are used to measure the amount of debris in oil. These units may be permanent installations in an oil analysis lab or portable units for field use. Lab units are more repeatable and have less variability, but transportation to a lab and processing could take up to two days. Portable units provide real-time...

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