Name Site Document No.

Version / Issue
Standard Operating Procedures Sandvik Mining and Rock Technology HZL/RDM SOP/22 00/00
Job: DD321 Scheduled maintenance Date: 28/01/2019
Created by: Lukhendra Bisen Reviewed by: Approved by:

Special Comments:(This procedure is to be used in conjunction with any operating manuals or training relevant to the task)
Machine System Description of work Remarks
DD321 DD321 AC System DD321 AC Compressor replacement work
References to be
completed
Qualification & KSA requirements Task Specific PPE requirements Task Specific Tools & Equipment Duration: 4 hours
1. Fitter / Mechanical Trade / Competent Person. • All site-specific PPE • Hand tools. No of persons:
2. D.M.E • ½ “Impact wrench and inhex impact sockets 2
• Overhead Crane.
3. Tag and Lock Out Training. • 1 x twin chain lifting chains an assortment of D shackles
4. Maintenance operator’s Authorization and (2 x 2Ton Chain blocks (Optional.)
• Approved safety stands.
5. Fire Fighting Training.
• Hydraulic power pack and an assortment of hydraulic rams.
6. First Aid Certificate. • Oil drain container
• An assortment of caps and plugs to cap hydraulic hosing.
Authorisation: Only trained & authorised personnel to operate compressed air. Repairs to be carried out by qualified personnel. Ensure all parts are in good working condition; Ensure
that you are in good physical condition & mental health; Do not operate when fatigued; take regular breaks;

Pre-Task Preparations: During this task, is there any chances of exposure to below Critical Risks?
1. Ensure position of the feed to reachable height of working person If Yes, Use Critical Risks Controls Check Sheets
2. Ensure positive ventilation and an even / flat surface.
3. Ensure work area is clear of obstructions and sufficient air flow is provided.
4. Turn machine off and Isolate machine at main Isolator Fit out of service tag
5. Fit safety lock and personal danger tag.
Fall from Rock Fall Suspende Vehicle Unintended Electricity
6. Depressurise all the pressurised hose and cylinders
heights d Loads Movements energy Contact
7. Test machine for effective isolation Position access steps / platform

S.N Task and step by step activities

o

E.H.S-10.03.03 Page 1 of 4 Version 00 / Issue 00

01 TASK SEQUENCE STEPS RISK SPECS Critical
Controls
Positioning of machine • Shift the machine at flat surface & Safe tramming (only authorized person)
jack up.
• To ensure surrounding area free from Risk of hitting or falling
any slippery/obstacle things.
02 Changing of AC • Remove the air conditioning Risk of finger injury! Be careful when handling hot oil.
compressor compressor /condenser unit cover.
• Disconnect hydraulic hoses above the Risk of finger injury! & Risk of tools Use proper size & correct tools.
compressor bracket flange (picture 1). slipping!
• Plug the disconnected hydraulic lines. Risk of oil spillage! & Risk of
environmental hazards!
• Remove the end plate and hydraulic Risk of finger injury! Be aware of sharp edge of end plate.
hoses aside (picture 2).
If the hydraulic line is attached to the end
Picture-1 plate side of condenser unit, remove the
end plate as much as possible aside.
• Remove the compressor mounting Risk of tools slipping! Use proper size & correct tools.
bolts (picture 3).

• Pull the compressor away from the Risk of falling from Hight!
clutch and remove the red spacer ring
from the clutch (picture 4).
Picture-2
03 • Switch the yellow spacer ring into the Ensure safe and environmentally
clutch. Set a 50 – 65mm hose binding protective disposal of process
around the clutch (picture 5). materials and exchange parts.
• Set the clutch elements opposite each Risk of tools slipping!
other and mount the compressor back
in the bracket. Do not tighten bolts
yet!
Picture-3 • Tighten the hose binding around the
clutch (picture 6).
• Tighten the compressor mounting
bolts and remove the hose binding.

04 • Measure the clearance between the

clutch elements using a feeler gauge
Picture-4 (picture 7). Measure the clearance

E.H.S-10.03.03 Page 2 of 4 Version 00 / Issue 00

 from the top and bottom.
The clearance should be between 1-2 mm!

Picture-5

Picture-6 Picture-7 Picture-8 Picture-9

If the measured clearance is more than Always use approved safety gloves
2mm or less than 1mm, proceed as when changing the engine oil.
follows:
• Remove the compressor as described Always use approved safety gloves.
Picture-10 above. Move the compressor (hoses
attached) above the condenser unit
(picture 8).
If there is no space above the condenser
unit, move the compressor so that you can
reach the tightening nut of the clutch
element.
• Remove the tightening nut of the Risk of finger injury! Crossing hazard: Injury to hand at
Picture-11 clutch element. Remove the clutch the time of opening & tightening of
element from the compressor shaft. If nut.
necessary, use an extractor (picture
9).
• Remove the locking wedge from the
shaft (picture 10).
• Add (or remove) the shim plates on
the shaft based on the measured
Picture-12 clearance (picture 11).
• Mount back the locking wedge.

• Install the clutch element back on to Risk of finger injury!

the compressor shaft (picture 12).
The torque for the tightening nut is 35Nm.
• Install the compressor back and
measure the clearance between the
clutch elements. If the clearance is
still not within the margins, repeat the
previous steps.
E.H.S-10.03.03 Page 3 of 4 Version 00 / Issue 00
 • When the clearance is right, install the Risk of finger injury! Be aware of sharp edge of condenser
end plate of the condenser unit and unit.
hydraulic hoses back in place.
• Install the cover of the condenser unit Be aware of sharp edge of cover of
and test the operation of the air condenser unit.
conditioning system.

SNo Critical Control Check Sheet activities – Unintended Movement
1 Barricade the area to entry of unauthorised entry
2 2
Complete isolation throughout service
3 All Maintenance and Repair start after reducing the tyre
pressure at safe level
4 4
Prevent Un Authorise Operation
5 Schedule Maintenance using OEM Recommended hoses
6 Check the tyre condition if poor - no work
7 Regular Check-up of Brakes and Door Limit Switch
8 Competent person check the system (Level)
9 Quality check of hydraulics on machine after each
Maintenance
10 Establish process to check KEY Control register
11 Establish process to check system effectiveness
12 Use of Support Stands with flexible height adjustments/ boom
lock pins / Articulation Lock/ Bucket Support Bar
13 Separate Parking area from work area
14 Access to Emergency Services
Y N NA SNo Critical Control Check List activities – Suspended Loads Y N NA
1 Use correctly rated certified lifting accessories
Periodic testing and certification of lifting accessories by
competent person
3
Visual inspection of lifting accessories before start of the lift
Check the physical condition and the certification of the crane
by a competent person (Pre-shift)
5 Overloading limit switch is functional
6 Check and follow SWL lifting capacities
7 Only authorised certified operators can access crane controls
8 Monitor operator competency regularly
9 10 feet rule is followed no one is allowed within 10 feet of the
lifting area

E.H.S-10.03.03 Page 4 of 4 Version 00 / Issue 00