Installing the Feed Extension Cylinder

Standard Operating Procedure

Installing the Feed Extension Cylinder

Installing the Feed Extension Cylinder

Prepare and Position the Machine

  1. 1.
    Make sure that the machine is isolated and, if necessary, isolate the machine with the battery isolation switch.

Lifting and Installation

  1. 1.
    Install the hydraulic and the lubrication fittings to the feed extension cylinder.

    NOTE

    Make sure that the hydraulic connections are orientated in the correct way.

  2. 2.

    WARNING

    Crushing Hazard

    Can cause personal injury.

    1. Lifting equipment must be adequately sized, have the correct lifting capacity, and be in good condition.

    2. Be careful when you lift heavy components.

    Attach an approved lifting device to the feed extension cylinder (Figure 12).
    Figure 12
  3. 3.

    WARNING

    Crushing Hazard

    Unexpected movement of parts can cause personal injury or death.

    1. Do not put your hand or any other body parts on the object when lifting, moving, or lowering it.

    2. Do not go in, reside, or put body parts below the unsecured, moveable, or lifted parts.

    3. Do not put any part of your body in the path of the pinch point area when you remove or install the parts.

    4. Stay away from the moving parts.

    Lift the feed extension cylinder and the bracket into the feed beam.
  4. 4.
    Align the cylinder barrel-end to the cylinder bracket on the feed beam.
  5. 5.
    Lubricate the shaft.
  6. Optional step

    WARNING

    Pinch Points

    Can cause serious injury.

    1. Keep hands and fingers away from the moving parts during removal and installation of the component.

    2. Put on the applicable Personal Protective Equipment (PPE).

    WARNING

    Accidental Movements of the Cylinder

    Accidental movements when installing the shaft engaging the cylinder can cause personal injury.

    1. Examine the unwanted cylinder movement with a spotter while installing the shaft.

    2. Make sure that the cylinder is secured and does not move before installing the bushings, nut, and screw.

    For Cabletec E and Cabletec LC Machine: Insert the shaft (Figures 13A and 13B, item C) to secure the cylinder barrel end with the bracket (item D).
    Figure 13A Cabletec E
    Figure 13B Cabletec LC

    A

    Screw

    B

    Bushings

    C

    Shaft

    D

    Bracket

    E

    Lock nut

  7. Optional step

    WARNING

    Pinch Points

    Can cause serious injury.

    1. Keep hands and fingers away from the moving parts during removal and installation of the component.

    2. Put on the applicable Personal Protective Equipment (PPE).

    For Cabletec E and Cabletec LC Machine: Install the bushings (item B) to both the sides of the shaft (item D).
  8. 6.

    WARNING

    Pinch Points

    Can cause serious injury.

    1. Keep hands and fingers away from the moving parts during removal and installation of the component.

    2. Put on the applicable Personal Protective Equipment (PPE).

    WARNING

    Heavy Components

    Lifting the heavy components by hand can cause body or muscle strains.

    1. Position the body accordingly to support the weight of the component.

    Install the hardware to feed extension cylinder barrel-end as follows:
    1. Alternative step
      For Boltec M Machine: Install the new two screws (Figure 14B, item A), shaft lock (item B), and shaft (item C) that attach bracket (item D) the feed extension cylinder.
      Figure 14A

      A

      Screw

      B

      Shaft lock

      C

      Shaft

      D

      Bracket

    2. Alternative step
      For Cabletec M machine: Install the new screws (Figure 14B, items A and B), washers (item C), and bracket (item D) to the feed extension cylinder.
      Figure 14B

      A

      Screw

      B

      Screw

      C

      Washer

      D

      Bracket

    3. Alternative step
      For Cabletec E Machine: Install the new screw (Figure 13A, item B) and the lock nut (item E) to the bracket (item D).
    4. Alternative step
      For Cabletec LC Machine: Install the new screw (Figure 13B, item B) and the lock nut (item E) to the bracket (item D).
  9. 7.
    Torque the cylinder barrel-end screws as follows:
    1. Alternative step
      For Boltec M Machine: Torque the screw to 20 Newton meters (15 foot-pounds) dry.
    2. Alternative step
      For Cabletec M Machine: Torque all the screw to 69 Newton meters (51 foot-pounds) dry.
    3. Alternative step
      For Cabletec E and Cabletec LC Machine: Torque the screw to 171 Newton meters (126 foot-pounds) dry.
  10. 8.

    WARNING

    Slipping Hazard

    Fluid leaks or spills can cause personal injury.

    1. Cover all of the open ports.

    2. Wipe off any spilled fluid immediately.

    Put the container or oil absorbent materials below the feed extension cylinder to collect the spilled oil.
  11. 9.
    Connect the mobile hydraulic power pack to the feed extension cylinder.
  12. 10.
    Start the mobile hydraulic power pack.
  13. 11.

    NOTICE

    Component Damage

    Unexpected movements of the cylinder could cause damage to machine components and cylinder.

    1. Use an approved tool to operate the cylinder manually.

    2. Make sure that only authorized personnel operate the crane.

    3. Use a spotter to observe the cylinder movements when you handle it.

    Extend and retract the feed extension cylinder rod few times to release air from the cylinder.

    NOTE

    Make sure that the feed extension cylinder functions smoothly.

  14. 12.
    Extend the cylinder rod-end and align it with the rear link set (Figures 15A, 15B, 15C, and 15D).
    Figure 15A Boltec M
    Figure 15B Cabletec M
    Figure 15C Cabletec E
    Figure 15D Cabletec LC
  15. 13.
    Stop the mobile hydraulic power pack.
  16. 14.
    Lubricate the shaft.
  17. Optional step

    WARNING

    Pinch Points

    Can cause serious injury.

    1. Keep hands and fingers away from the moving parts during removal and installation of the component.

    2. Put on the applicable Personal Protective Equipment (PPE).

    WARNING

    Accidental Movements of the Cylinder

    Accidental movements when installing the shaft engaging the cylinder can cause personal injury.

    1. Examine the unwanted cylinder movement with a spotter while installing the shaft.

    2. Make sure that the cylinder is secured and does not move before installing the bushings, nut, and screw.

    For Boltec M and Cabletec E Machine: Insert the shaft (Figures 16A and 16B, item C) to secure the cylinder barrel end.
    Figure 16A Boltec M
    Figure 16B Cabletec E

    A

    Screw

    B

    Bushing

    C

    Shaft

    D

    Lock nut

  18. Optional step

    WARNING

    Pinch Points

    Can cause serious injury.

    1. Keep hands and fingers away from the moving parts during removal and installation of the component.

    2. Put on the applicable Personal Protective Equipment (PPE).

    For Boltec M and Cabletec E Machine: Install the bushings (item B) to both the sides of the shaft (item C).
  19. 15.

    WARNING

    Heavy Components

    Lifting the heavy components by hand can cause body or muscle strains.

    1. Position the body accordingly to support the weight of the component.

    Install the hardware to feed extension cylinder rod-end as follows:
    1. Alternative step
      For Boltec M Machine: Install the new screw (Figure 16A, item A) and lock nut (item D) that secure feed extension cylinder.
    2. Alternative step
      For Cabletec M Machine: Install the new lock nut (Figure 17A, items A), washers (item B) to the feed extension cylinder.
      Figure 17A

      A

      Lock nut

      B

      Washer

    3. Alternative step
      For Cabletec E Machine: Install the new screw (Figure 16B, item A) and lock nut (item D) that secure feed extension cylinder.
    4. Alternative step
      For Cabletec LC Machine: Install shaft (Figure 17B, item C), shaft lock (item D), washers (item B), and two screws (item A) to the feed extension cylinder.
      Figure 17B

      A

      Screw

      B

      Washer

      C

      Shaft

      D

      Shaft lock

  20. 16.
    Torque the cylinder rod-end screws as follows:
    1. Alternative step
      For Boltec M Machine: Torque the screw to 20 Newton meters (15 foot-pounds) dry.
    2. Alternative step
      For Cabletec M Machine: Torque all the screw to 573 Newton meters (423 foot-pounds) dry.
    3. Alternative step
      For Cabletec E Machine: Torque the screw to 171 Newton meters (126 foot-pounds) dry.
    4. Alternative step
      For Cabletec LC Machine: Torque the screw to 40 Newton meters (30 foot-pounds) dry.
  21. 17.
    Remove the attached lifting device from the feed extension cylinder.
  22. 18.
    Disconnect the mobile hydraulic power pack from the feed extension cylinder. Plug the hoses and cap the ports immediately.

Preparation of the Component

  1. 1.
    Connect the lubrication hoses to the feed extension cylinder.
  2. 2.
    Start the vacuum pump.
  3. 3.
    Connect the hydraulic hoses (Figure 18A, 18B, 18C, and 18D, item A) to the feed extension cylinder.
    Figure 18A Boltec M
    Figure 18B Cabletec M
    Figure 18CCabletec E
    Figure 18D Cabletec LC

    A

    Hydraulic hose

  4. 4.
    Stop the vacuum pump.
  5. 5.

    CAUTION

    Environmental Contaminant

    Oil is an environmental contaminant and must be discarded correctly.

    1. Do not let the used oil drain onto the ground.

    2. Discard the used oil in accordance with local environmental regulations.

    Remove the container or oil absorbent materials from below the feed extension cylinder.
  6. 6.

    WARNING

    High-Pressure System

    Working with pressurized systems can cause personal injury.

    1. Do not do the maintenance work when operating the machine.

    2. Make sure that the hydraulic, water, and air systems are depressurized before you start to work on these systems.

    3. Put on applicable gloves.

    Install the breather filter (Figure 19, item A).
    Figure 19

    A

    Breather filter

  7. 7.

    WARNING

    Heavy Components

    Lifting the heavy components by hand can cause body or muscle strains.

    1. Position the body accordingly to support the weight of the component.

    Remove the maintenance stands from below the boom, feed beam, and bolting unit.
  8. 8.
    Store the maintenance stands in a safe location.
  9. 9.

    WARNING

    Energized Machine

    Can cause serious injury.

    1. The machine must be fully energized and the engine must be switched on to complete this procedure.

    2. Be careful around moving parts and pinch points.

    Inform the supervisor, lead hand, and all other persons who are concerned of the intent to restart the machine.

    NOTE

    Make sure that all personnel and bystanders are clear of the machine before start-up.

  10. 10.
    Remove the safety locks and tags from the machine in accordance with the site-specific procedures.
  11. 11.
    Start the machine.
  12. 12.

    WARNING

    Accidental Movements

    Can cause serious injury or death.

    1. Make sure that no one is at danger or hazard zone before you start or operate the machine.

    Retract the front and rear support legs to lower the machine onto the ground (Figures 20A and 20B).
    Figure 20A
    Figure 20B
  13. 13.
    Retract the front jack support legs fully into the jack beam (Figure 21).
    Figure 21
  14. 14.
    Stop the engine and isolate the machine with the battery isolation switch.
  15. 15.
    Attach safety locks and tags to the machine in accordance with the site-specific procedures.
  16. 16.
    Put a tag onto the battery isolation switch stating that the feed extension cylinder is replaced.