Earthmover scrappers are heavy machinery and require constant maintenance to ensure that they deliver to their functions. For many years, the manufacture of many heavy machines has happened. Their demand has always increased and therefore the demand of proper maintenance plan has always been needed. Organizations in industries such as construction have invested highly on these heavy machines. Proper maintenance is a compulsory requirement of these machines considering the type of work they do. Although it is the responsibility of the owner companies of the machinery to make plans on the machine maintenance plans, manufacturing companies such as Caterpillar do provide preventive and predictive maintenance plans of the heavy machines they produce (Caterpillar Inc., United States., & United States, 1943). In addition to the manufacturers maintenance plans, the users plays critical roles in the achieving the better state of the machines. This paper will be able to present a key preventive and predictive maintenance plans for the Caterpillar 631C. This heavy machine was introduced in 1969 and became one of the best selling earthmover scrapper.
The main aim of this report is to present a better preventative and predictive maintenance plans for the Caterpillar 631C. This report will be designed to help users, technicians and other stakeholders to get a better proactive maintenance plans. Waiting for the failure to occur in order to rectify it may be both costly in terms of money as well as time consuming. Having a clear predictive plan to look at the different parts and replacing them when necessary is key to have a better working machine (Caterpillar Inc, 2012). In addition, having a report which offers the plans to rectify the problems and prolonging the working time is a key area which the other stakeholders may focus to add their investment in the use of the machinery. Moreover, this plan will be able to address crucial preventative and predictive maintenance schedules of the CAT 631C. This plan will be able to focus on enhancing that the CAT 631C stays in better working condition (Stratton, 2007). Nevertheless, the report does not contain all the maintenance tasks needed to keep the machine on best shape.
The CAT 631C is useful in different instances such as operations in construction of airfields by the soldiers, roads, landing zones, military constructions and also in cut and fill situations. Moreover, this is a self-mobile tractor, which is well balanced such that the scrapper can be detached and replaced with other parts such as water distributor. In addition, the earthmover has a capacity to move large quantities over long distances (Schmauss, 2007). Figure 1 shows the CAT 631C under operation and in construction industry under use. This presents a view of the situation which this machine is used under and the need to proper maintenance plans to keep it executing the duties.
Figure 1: CAT 631C in Action
Source (Caterpillar Inc, 2012).
Caterpillar J619 (619C) and J621 are the key predecessors of the heavy machines which were developed before the CAT 631C. Nevertheless, the CAT 631C was able to retain more advantageous factors than the previous designs. For instance, the CAT 631C had an increased capacity to handle larger loads while under use (Caterpillar Inc, 2003). Under the design, the 631 model had an increased reliability due to the upgraded two-speed elevator enhancing its operation under different soils. According to the design, the CAT 631C had two different parts, that is the tractor and the scraper part. The following figure shows the different parts of the CAT 631C.
Figure 2: Parts of a CAT 631C 2
Source (Hartley, Macro & Taylor, 2007)
Bowl – this helps to carry the loaded materials. In the construction industry, when the bowl is low, the cutting edge enters the ground and loads the materials. Additionally, the auger in front of the bowl is responsible for lifting the materials off the cutting edge. In addition, the auger is responsible for distributing the loads evenly after the bowl is raised up. When dumping the material, the bowl is lowered and therefore opens letting the materials out.
Apron – this part is in front of the bowl and it retains the loaded materials (Moore, Michael Hoff Productions., & National Geographic Society (U.S.),(2014). As the scrapper loads the material, the apron moves the materials to create a new space for the incoming material. Moreover, the apron closes upon hauling in order to prevent spillage.
Injector – the injector is used to remove the materials in the rear wall of the bowl. The injector moves the materials forward and therefore forcing for them to be discharged from the bowl.
LeTourneau is considered a key figure in the history of earthmovers scrappers. Between 1920s and 1930s, he completed many earthmoving projects which led to set up of many earthmoving machines we have today (Hartley, Macro & Taylor, 2007). During his career, after completing the first earthmover scrapper in 1922 dedicated in enhancing the designs and coming up with new designs to fill the market gaps. At the time, LeTourneau achieved great to even developing the self-propelled scrapper. With these initial stages, great earthmover scrappers were developed.
Figure 3: Display of some initial earthmovers scrappers designed by Le Tourneau
Source (Caterpillar Inc., 1989)
On the use of the CAT 631, Heavyequipment.org summarises al the activities of the scrapper when they state that “A scraper is a compromise between a machines designed exclusively for either loading or hauling” (Heavyequipment.org, 2015). CAT 631C is used in road construction and mostly by the military men in their function. Due to its speed and high capacity, it is used for loading and hauling over different distances. Moreover, the angled ejector top plate aids the scrapper’s capability in retaining loadings for maximum productivity and minimum spillage while hauling. This makes the CAT 631C most suitable applied in construction industries and preference for the military loadings and hauling.
In addition, CAT 631C is also applied on clean up works due to the increased capacity to carry more loads. Additionally, it is usually preferred on the fill situations due to the high capacity which enhance the productivity and high performance.
Due to the working conditions in the construction industry, CAT 631C is faced with different challenges which require constant look out such as lubrication and greasing of different parts. Under the dusty conditions, the greasy and lubricated parts are susceptible to contamination and therefore need constant monitoring (Caterpillar Inc., 2008). In addition, contaminated air may be trapped in the machine and therefore contaminating it. Due to the two parts of CAT 631 C, that is the tractor and scrapper, the component of contamination is doubled.
Overview And Plan
According to Wireman, preventive maintenance is defined as “… a fundamental, planned maintenance activity which is designed to improve equipment life and avoid any unplanned maintenance activity” (p. 1). The preventative maintenance is aligned in different timelines such as the maintenance activities which are taken daily, weekly month and yearly. The preventative will be used to ensure that the machine failure does not happen (Caterpillar Inc., 2008). In addition, the manufacturers also have the option and instructions of the technicians to perform the regular checks on the machines. Directives are issued on whether to replace the parts or perform proactive measures on the machines.
Before operations
Under this category, the operators have to fill a checklist on the status of the machine before they operate them (Dawson, 2012). Visual inspections are also performed at this stage. The following are some of the key areas which these activities can be performed;
Draining of air tank moisture and sediments – the air tank can be contaminated with air and sediments. Each day, it’s advisable drain the air tank and ensures that the tank is able to accommodate enough air.
Air tanks are both on the tractor and the scrapper. There are a number of valves in the tractor, indicated with (1). Turning the valves counterclockwise opens the valves and allows the draining of the contaminations. After that the valves has to be turned clockwise after draining the tanks. The same has to be done on the tanks on the tanks on scrapper.
Weekly maintenance plan
Lubrication of Hitch, all fittings need to be greased frequently or at least 50 hours in a week. The draft frame has fittings which need lubrication.
Monthly maintenance plan
This involves look of long lasting components such as the battery check. On this, the operator has to switch off the engine before cleaning the battery. Inspection and cleaning of the terminals has to be done and then cover them with jelly.
Quarterly plan
This involves about 500 hour’s service within the quarter of a year. It involves different aspects such as change of pump filter, inspection of the drain filter for the piston and motor case drain filter.
Yearly plan
This involves look and inspection and replacing of parts such as the brake shoes and drums. This has to be done by a qualified technician.
Predictive maintenance focuses on improving productivity, enhancing the product quality as well as improving the overall effectiveness of the manufacturing and production plants. Moreover, the predictive maintenance is condition driven and ensures that the machine is kept at correct state (Brand, 2003). CAT has over 3,000 distribution centers which are used for the predictive measures which help to provide the predictive maintenance measures of such machines. Lubrication and greasing of the parts are some of the key predictive parts which help to prolong the lives of the parts through reduced wear and tear. Moreover, the environment of operation plays a key role on the lubrication schedule of the machines.
Conclusion
The main aim of the maintenance of the machines is to enhance their operational timeline. Through the plans, operational costs are saved as well as the time used to operating the machine is added. Preventive and predictive maintenance plans are used by manufacturers and owners of the machines to ensure that the machine operation is enhanced. To eliminate these unwanted situations, preventive maintenance provides a good maintenance practice by constantly inspecting and replacing components based on manufacture specifications. Moreover, predictive maintenance is somewhat higher level of preventative maintenance. It offers a condition driven preventative maintenance by scheduling maintenance tasks based on actual statistics from the equipment. By applying predictive maintenance, the owner also maximizes equipment lifetime, therefore saving money from costly equipment replacement.
References
Brand, J. (2003). The caterpillar. Orlando. Fla: Harcourt.
Caterpillar (2010). 631C Wheel tractor scraper Before operation. Retrieved from https://safety.cat.com/cda/layout?m=388580&x=7
Caterpillar (2010). 631C Wheel tractorscraper Maintenance intervals. Retrieved from https://safety.cat.com/cda/layout?m=388580&x=7
Caterpillar Inc. (1989). Caterpillar custom track service handbook. Peoria? Ill.: Caterpillar.
Caterpillar Inc. (2003). Trucks and diggers one to ten: Counting. San Francisco, Calif: Chronicle Books.
Caterpillar Inc. (2008). Caterpillar performance handbook. Peoria, Ill: Caterpillar In
Caterpillar Inc. (2012). C is for construction: Big trucks and diggers from A to Z. San Francisco: Chronicle Books.
Caterpillar Inc., United States., & United States. (1943). Ordnance engine model RD-1820 (Caterpillar). Washington, D.C: War Dept.
Dawson, C. (2012, August 5). Caterpillar 631C scraper [Photograph]. Retrieved from https://www.finning.ca
Hartley, K., Macro, C., & Taylor, P. (2007). Caterpillar. Oxford: Heinemann Library. https://flic.kr/p/cKV6vY
Moore, K., Michael Hoff Productions., & National Geographic Society (U.S.). (2014). Caterpillar.
Schmauss, J. K. (2007). Caterpillar. Fitzgerald Books.
Stratton, T. (2007). A new extraction approach. Tracks and Treads . Retrieved from
Wireman, T. (2008). Preventive maintenance. New York, NY: Industrial Press.
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