Removing the Feed Extension Cylinder

Standard Operating Procedure

Removing the Feed Extension Cylinder

Removing the Feed Extension Cylinder

Prepare and Position the Machine

  1. 1.
    Align the machine in position.
  2. 2.
    Apply the parking brake.
  3. 3.
    Stop the machine.
  4. 4.
    Attach safety locks and tags to the machine in accordance with the site-specific procedures.
  5. 5.
    Block the wheels with wheel chocks.

    NOTE

    Extra requirements can apply. Refer to the local regulations.

  6. 6.
    Install the articulation lock bar to the pins on the machine frames.
  7. 7.
    Insert the locking clips (Figure 1, item B) to secure the articulation lock bar (item A) with the pins.
    Figure 1

    A

    Articulation lock bar

    B

    Locking clip

  8. 8.

    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.

  9. 9.
    Remove the safety locks and tags from the machine in accordance with the site-specific procedures.
  10. 10.
    Start the machine.
  11. 11.

    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.

    Extend the front jack support legs fully from the jack beam (Figure 2).
    Figure 2
  12. 12.
    Lower the front and rear support legs to lift the machine from the ground (Figures 3A and 3B).
    Figure 3A
    Figure 3B
  13. 13.
    Extend the feed extension cylinder to its stroke-end position.
  14. 14.
    Lower the boom, to a comfortable height to access the feed extension cylinder.
  15. 15.
    Stop the engine and isolate the machine with the battery isolation switch.
  16. 16.
    Attach safety locks and tags to the machine in accordance with the site-specific procedures.
  17. 17.

    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.

    Support the boom, feed beam, and bolting unit with the approved maintenance stands for safety (Figure 4).
    Figure 4
  18. 18.

    WARNING

    High-Pressure System

    Working with pressurized systems can cause personal injury.

    1. Do not do the maintenance work when you operate 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 the applicable gloves.

    Release the stored energy from the hydraulic brake system.

    NOTE

    Make sure that there is no pressure in the system.

  19. 19.
    Release the stored energy from the hydraulic tank and system.

    NOTE

    Make sure that there is no pressure in the system.

  20. 20.
    Release the stored energy from the air tank and system.

    NOTE

    Make sure that there is no pressure in the system.

  21. 21.
    Remove the breather filter (Figure 5, item A) from the hydraulic oil tank.
    Figure 5

    A

    Breather filter

  22. 22.
    Connect a vacuum pump to the breather filter location to prevent the wastage of hydraulic oil when you disconnect the hydraulic hoses.
  23. 23.

    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.
  24. 24.
    Start the vacuum pump.

Isolation of the Component

  1. 1.

    WARNING

    Hot Fluids or Components

    Working with hot fluids or components can cause personal injury.

    1. Fluids must be at a safe working temperature when you disconnect the hoses.

    2. Do not touch hot fluids or components.

    3. Always wear personal protective equipment.

    Clean, label, and disconnect the hydraulic hoses (Figures 6A, 6B, 6C, and 6D, item A) from the feed extension cylinder. Plug the hoses and cap the ports immediately.
    Figure 6A Boltec M
    Figure 6B Cabletec M
    Figure 6C Cabletec E
    Figure 6D Cabletec LC

    A

    Hydraulic hose

  2. 2.
    Stop the vacuum pump.

Lifting and Removal

  1. 1.

    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 and support it (Figures 7A, 7B, 7C, and 7D).
    Figure 7A Boltec M
    Figure 7B Cabletec M
    Figure 7C Cabletec E
    Figure 7D Cabletec LC
  2. 2.

    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 hardware from feed extension cylinder rod-end as follows:
    1. Alternative step
      For Boltec M Machine: Remove the screw (Figure 8A, item A) and lock nut (item D) that secure feed extension cylinder. Discard the hardware.
      Figure 8A

      A

      Screw

      B

      Bushings

      C

      Shaft

      D

      Lock nut

    2. Alternative step
      For Cabletec M Machine: Remove the lock nut (Figure 8B, items A), washers (item B) from the feed holder. Discard the hardware.
      Figure 8B

      A

      Lock nut

      B

      Washer

    3. Alternative step
      For Cabletec E Machine: Remove the screw (Figure 8C, item A) and lock nut (item D) that secure feed extension cylinder. Discard the hardware.
      Figure 8C

      A

      Screw

      B

      Bushings

      C

      Shaft

      D

      Lock nut

    4. Alternative step
      For Cabletec LC Machine: Remove the two screws (Figure 8D, item A), washers (item B), shaft lock (item D), and shaft (item C) from the feed extension cylinder. Discard the hardware.
      Figure 8D

      A

      Screw

      B

      Washer

      C

      Shaft

      D

      Shaft lock

  3. 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: Remove the bushings (item B) from the cylinder rod-end shaft and store them in a safe location.

    NOTE

    Watch out for slight movement of the cylinder and boom when the bushings are loosened.

  4. Optional step
    For Boltec M and Cabletec E Machine: Remove the shaft (item C) from the cylinder rod end and store it in a safe location.
  5. 3.
    Store the shaft in a safe location.
  6. 4.
    Connect a mobile hydraulic power pack to the boom lift cylinder.
  7. 5.
    Start the mobile hydraulic power pack.
  8. 6.
    Retract the feed extension cylinder (Figures 9A, 9B, 9C, and 9D).
    Figure 9A Boltec M
    Figure 9B Cabletec M
    Figure 9C Cabletec E
    Figure 9D Cabletec LC
  9. 7.
    Stop the mobile hydraulic power pack and disconnect it from the boom lift cylinder.
  10. 8.
    Plug the hoses and cap the ports immediately.
  11. 9.

    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.
  12. 10.

    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 hardware from feed extension cylinder barrel-end as follows:
    1. Alternative step
      For Boltec M machine: Remove the two screws (Figure 10A, item A), shaft lock (item B), and shaft (item C) that attach the bracket (item D) to the feed extension cylinder. Discard the hardware.
      Figure 10A

      A

      Screw

      B

      Shaft lock

      C

      Shaft

      D

      Bracket

    2. Alternative step
      For Cabletec M machine: Remove the screws (Figure 10B, items A and B), washers (item C), and bracket (item D) from the extension cylinder. Discard the hardware.
      Figure 10B

      A

      Screw

      B

      Screw

      C

      Washer

      D

      Bracket

    3. Alternative step
      For Cabletec E machine: Remove the screw (Figure 10C, item A) and the lock nut (item E) from the bracket (item D). Discard the hardware.
      Figure 10C

      A

      Screw

      B

      Bushings

      C

      Shaft

      D

      Bracket

      E

      Lock nut

    4. Alternative step
      For Cabletec LC machine: Remove the screw (Figure 10D, item A) and the lock nut (item E) from the bracket (item D). Discard the hardware.
      Figure 10D

      A

      Screw

      B

      Bushings

      C

      Shaft

      D

      Bracket

      E

      Lock nut

  13. 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: Remove the bushings (item B) from the cylinder rod-end shaft and store them in a safe location.

    NOTE

    Watch out for slight movement of the cylinder and boom when the bushings are loosened.

  14. Optional step
    For Cabletec E and Cabletec LC Machine: Remove the shaft (item C) from the cylinder rod end and store it in a safe location.
  15. 11.
    Store the shaft in a safe location.
  16. 12.

    WARNING

    Crushing Hazard

    Unexpected movement of parts can cause personal injury or death.

    1. Do not put any part of your body on the object when lifting, moving, or lowering it.

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

    3. Do not put hands and fingers in the pinch point areas when installing or tightening the parts.

    4. Stay away from moving parts.

    Remove the feed extension cylinder with the attached lifting device.
  17. 13.
    Lift the feed extension cylinder from the machine and put it on the approved surface (Figure 11).
    Figure 11
  18. 14.
    Remove the hydraulic and lubrication fittings from the feed extension cylinder.
  19. 15.
    Cover all of the open ports on the feed extension cylinder to prevent oil leaks.
  20. 16.

    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 from the surface with the attached lifting device and store it in a safe location.
  21. 17.
    Remove the attached lifting device from the feed extension cylinder.
  22. 18.
    Put a tag onto the battery isolation switch stating that feed extension cylinder is removed from the machine.