INDEX

Cover
Dedication
Index
Introduction 5

CHAPTER I: HISTORICAL BACKGROUND AND CLASSIFICATION OF THE

MACHINERY

1. History of construction machinery and equipment 6

2. Machinery classification 7
2.1. Heavy machinery 7
2.2. Semi-heavy machinery 7
2.3. Light equipment 7
2.4. Heavy vehicles 7
2.5. Semi-heavy vehicles 8
2.6. Lightweight vehicles 8
2.7. Vehicles according to the number of axles
8
2.8. Depending on the energy source
9
2.9. According to the translation system
9
2.10. According to the operations carried out 9
3. Excavators 10
3.1. Definition 10
3.2. Operations 10
3.3. Scheme 10
3.4. Applications 10
3.5. Guys 10
3.6. Transport 13
3.7. Maintenance 13
3.8. Industrial Security 14
4. Backhoe 14
4.1. Definition 14
4.2. Operations 15
4.3. Scheme 15
4.4. Applications 15
4.5. Guys 16
4.6. Transport 17
4.7. Maintenance 17
4.8. Industrial Security 18
5. Dredges and Draglines 18
 5.1. Definition 18
5.2. Operations 18
5.3. Scheme 18
5.4. Applications 20
5.5. Guys 20
5.6. Transport 20
5.7. Maintenance 20
5.8. Industrial Security 20
6. Dozer tractors 21
6.1. Definition 21
6.2. Operations 21
6.3. Scheme 22
6.4. Applications 22
6.5. Guys 22
6.6. Transport 23
6.7. Maintenance 23
7. Trailers and Scrapers 25
7.1. Definition 25
7.2. Operations 25
7.3. Scheme 26
7.4. Applications 26
7.5. Transport 26
7.6. Maintenance 27
8. Front loaders 27
8.1. Definition 27
8.2. Operations 28
8.3. Scheme 28
8.4. Applications 29
8.5. Guys 29
8.6. Transport 29
8.7. Maintenance 29
8.8. Industrial Security 30
9. Hauling or transport units 30
9.1. Definition 30
9.2. Operations 31
9.3. Scheme 31
9.4. Applications 31
9.5. Guys 31
9.6. Transport 33
9.7. Maintenance 33
9.8. Industrial Security 34
10. Compaction equipment 34
10.1. Definition 34
10.2. Operations 36
10.3. Scheme 36

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 10.4. Applications 36
10.5. Guy 37
10.6. Transport 37
10.7. Maintenance 37
10.8. Industrial Security 37
11. Motor Graders 38
11.1. Definition 38
11.2. Operations 39
11.3. Scheme 39
11.4. Applications 39
11.5. Guys 40
11.6. Transport 40
11.7. Maintenance 40
11.8. Industrial Security 40
12. Other equipment 41
12.1. Milling machine
41
12.2. tunnel boring machine
41
12.3. Asphalt or Agglomerate Paver 41
12.4. Paver 42
12.5. Rock work machine 43
12.6. Trenchers 43

CHAPTER II: TYPES OF MAINTENANCE

1. Types of maintenance 44
1.1. Maintenance 44
2. Machinery Maintenance Plan 48
2.1. Conservation recommendations 46
2.2. Filling capacities 49
2.3. Lubricant viscosities 49
2.4. Break-in of machinery 52
3. Service periods 55
3.1. When necessary 55
3.2. Daily or every 10 hours 56
3.3. Machinery maintenance control sheet 57

CONCLUSIONS 65
RECOMMENDATIONS 66
BIBLIOGRAPHY 67

3
 INTRODUCTION

For maintenance work to be efficient, control, work planning and correct

distribution of human force are necessary, thus reducing costs, downtime of work
teams, etc.

The heavy machinery workshop department of road zone 11 of roads, in the

department of Izabal does not currently have these 3 maintenance points.

This need is the main reason for the existence of this work in which the
solutions to it are proposed.

To execute the above, a division is made into three major types of

maintenance on which the implementation of a good maintenance program
depends.
maintenance:

a) Predictive maintenance: predicts failures based on observations that

indicate trends.
b) Corrective maintenance: carried out to predict failures based on design
parameters and assumed working conditions.
c) Corrective maintenance: carried out when failures have occurred:

Another important factor in a maintenance program and which will also be

emphasized is lubrication since it plays a vitally important role in proper operation.
Control is carried out through time periods, either in hours or days of work. The
lubricating oils that should be used must also be taken into account, since these
must be appropriate for the extreme climate and environment conditions in which
they work.

4
 CHAPTER I
HISTORICAL BACKGROUND AND CLASSIFICATION OF MACHINERY

1.- HISTORY OF CONSTRUCTION MACHINERY AND EQUIPMENT

The United States was the first to develop labor-saving innovations, first in
agriculture, then in construction, both fitting into a vigorous tradition of
mechanization. The UK and Europe were significantly behind in both sectors,
probably due to an abundance of labor and the smaller scale of works to be
carried out, which led to a dilution of the impetus towards greater productivity.
North American equipment manufacturers, pioneers in planned obsolescence,
contrary to the European principle of durable construction, also fueled the process
of change, in addition to the fact that the ties between manufacturers and users
were always close, thus allowing operational lessons to be learned. incorporated
into the design process.
The history of improvement in machine design, which occurred primarily in
the United States, gives us a fascinating illustration of the principle of how form
follows function. The specialization of earth moving equipment, essentially as a
function of hauling distance, gave rise to the grader, scraper, bulldozer,
compactor, loader and the ubiquitous agricultural tractor. This process occurred
more or less around the 1880s until the end of the First World War. By this time
everyone had acquired their familiar silhouette. The elegant and utilitarian design
of the farm tractor has changed little in the last ninety years. The first graders,
scrapers and compactors were animal-powered, but the necessary traction effort
required equipment of excessive size (teams of up to sixteen mules were
mentioned), so quickly the tractor, and then the track settler, were adapted to be
able to pull them Then they were motorized. The addition of the bulldozer bucket
to the skidder, a key innovation for moving dirt over short distances, came a little
later. To the extent that steam traction did not dominate as was the case in the
UK, where indestructibility (Victorian steam engines remained in service for half a
century and more) was undoubtedly a brake on the development of relatively light
and agile machinery , the internal combustion engine was quickly adopted.
Without a doubt, the fact that it was so compact and practical stimulated the
design a lot. Although it was a non-trivial task to start an oil engine in freezing
temperatures at the turn of the century, the procedures for starting a steam engine
occupied the first hours of each day.
After rapid development in the thirty years before the First World War, the
design was consolidated in the 1920s and 1930s. The size and power of engines
increased, diesel engines became quite universal, as did hydraulic systems. On

5
the threshold of the Second World War, construction machinery had roughly
reached its current form.

2.- CLASSIFICATION OF MACHINERY

The machinery according to the weight/volume ratio, that is, according to its
capacity, is classified as follows:

2.1 Heavy machinery

Machinery of large geometric proportions compared to
light vehicles, have weight and volume considered; requires a
trained operator because the operation varies depending on
the machinery; It is used in earthworks in large civil
engineering works and in open pit mining works. Examples
Cranes, excavators, tractor, etc.

2.2 Semi-heavy machinery

They are medium-sized machinery generally used in
construction, for example: dump truck, tanker or water truck,
ladder truck. The weight and volume of these units is medium.

2.3 Lightweight Equipment

They can be small machines or specialized equipment; such
as: compressors, water pump, mud pump, vibrators, winches, steel
cutters, pavement breakers, forklifts, etc.

2.4 Heavy vehicles

These vehicles include the stake truck or truck with a body.

2.5 Semi-heavy vehicles

Among the semi-heavy vehicles there are those for public
use such as: buses, minibuses, etc.

2.6 Lightweight vehicles

Low in weight and volume, self-transportable, for example:
car, vans, jeep, van, minibus, etc.

2.7 Vehicles according to the number of axles:

6
 The classification of vehicles presented by the National Road Service
through axle counting in Bolivia is as follows:

7
2.8 Depending on the energy source
The type of engine of the machine is taken as a reference, defining the
engine as: “Material system that transforms a certain type of energy (hydraulic,
chemical, electrical, etc.) into mechanical energy and produces movement.

2.9 According to the translation system

They are classified based on the method of transportation, dimensions and
weight of the machinery.

2.10 According to the operations carried out

They are classified according to the common operations performed by
machines.

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3.- EXCAVATORS
3.1 Definition
Self-propelled machine on wheels or chains with a superstructure capable
of 360º rotation, which excavates, loads, lifts, rotates and unloads materials by the
action of a bucket fixed to a boom and dipper assembly, without the chassis or
structure bearing is displaced.
The previous definition specifies that if the machine described is not
capable of rotating its superstructure a complete turn (360º), it is not considered an
excavator. The precision of the working organs, such as boom, stick, supporting
structure, etc.; fixes and unifies the classifying criteria.

3.2 Operations
 Dig
 Load
 Rotate
 Move
 Mobilize and demobilize

3.3 Scheme

3.4 Applications
 Trenching
 Excavation of large trenches
 Combing slopes above the machine's support plane.
 Excavation for structures.
 Excavation in loan banks or excavation of materials.

3.5 Guys

9
 Excavators are classified as follows:
According to its drive:
 Cable or mechanical excavators.
 Hydraulic Excavators.
According to the translation system:
 Excavators mounted on chains (tracks)
 Excavators mounted on wheels or tires.
 Rail mounted excavators.
 Excavators mounted on ships.
Depending on the Type of operation:
 Normal or standard excavators
 Jaw excavators.
 Tamber excavators
 Rosario excavator

3.5.1 Normal Bucket Excavator

To unload, the bucket rotates around a vertical axis and is lowered until it is
positioned at a pouring point; discharges onto the bottom.
Turnover corresponds to unproductive time and this must be reduced to a
minimum; Therefore, the trucks to load the excavated material must be located as
close as possible to the front of the attack. When the operator is expert, he
performs both movements, turning and putting it in the unloading position,
simultaneously, thus reducing to a minimum the time necessary for the machine's
operating cycle. It is not advisable to turn when the bucket is being loaded, as the
boom is subjected to a torque that can cause damage.
A more modern type of normal excavator is equipped with a conveyor belt;
Its way of working is analogous, with the great advantage of reducing the time
necessary for turning, unloading the bucket and repositioning it at the front of the
attack. This conveyor belt cannot transport the material at inclinations greater than
15% or 20%.

3.5.2 Excavator or wheel loader

The excavator or loader model in the image is a machine with a large load
capacity and power, ideal for extraction and earth moving tasks.
In the image we can see the machine working in a
stockpile of aggregates existing in gravel pits, agglomerate
and gravel production plants, etc. Its design with wheels
makes it suitable and ideal for uniform terrain. The lack of

10
teeth on the loader indicates in this case that it works in soft areas with already
moved earth.

3.5.3 Jaw Excavator

This type of excavator has the particularity
of using an accessory that works under its own
weight, with mechanisms that allow digging in
stacked material. The bucket has jaws that open
and close. This type of equipment has very little
application in earth moving, but it is applied in
building construction, since it transports loose material.
The capacity of this equipment is given by the jaw bucket whose capacity
varies from 0.3 to 2 m3 loose. The weights of this type of excavators range
between 10 and 30 tons and their travel speed ranges from 1 to 4 KPH. The spoon
weighs about a ton.
There are several designs of jaw spoons.

3.5.4 Rosario Excavators

This type of equipment is used for excavating large trenches. The
excavation system is a kind of endless belt with numerous excavation buckets.
This equipment is widely used in Europe, mainly in Germany.

3.5.5 Normal drum excavator

3.5.6 Large mining excavator

This machine is specially designed for the extraction of aggregates in open
pit mining excavations, although it can also be used in large earthworks during the
construction of large civil works such as reservoirs, etc... It is a machine that,
although it is equipped with chains, does not usually make continuous movements
during its activity and its excavator shovel is designed with special steel alloys and
is even equipped with diamond teeth for the extraction of very hard rock and

11
aggregates. The volume and capacity of both the machine and the shovel are
capable of loading large dumpers in just a few movements.

3.5.7 Small Excavators

There are small machines that are ideal for excavating land in small places
where it is impossible for large machines to maneuver. These machines perform
functions such as making trenches for foundations on small plots or in works in
which the complexity of the foundation framework makes the possibility of
mechanical excavation almost impossible.

3.6 Transport
The excavator can be transported by the Loy Boy if it cannot be transported
alone, if it is on wheels and the work is nearby it may not need transportation.

3.7 Maintenance

PREVENTIVE:
 Checking lubricants and greases before leaving.
 Review the preventive maintenance sheet.
 Existence of filters in warehouses.
 Type of lubricant in machine and existence in warehouses.
 Check grease points.
 Oil increases and changes.

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PREDICTIVE:
 Taking a sample of the oil change.
 Verification of mechanical recommendations on the machine.
 If the equipment is wheeled, check the air pressure of the tires.
 Locate the laboratory where the analysis will be done.

CORRECTIVE:
 Plan to change nails or claws.
 Spoon conditioning.
 Change of parts.
 Control panel.
 List of spare parts that are most used in the machine with estimated costs and
suppliers.
 Installations in workshop or post.
 Lubricator truck.
 Master truck.

3.8 Industrial Security

Clothing should be relatively tight, loose jackets, shirt sleeves, rings and
any other type of jewelry should be avoided, as there is a danger of getting them
caught in moving parts. The required clothing is:
 Resistant helmets,
 Safety glasses,
 Reflective dress,
 Safety shoes
 Ear protection helmets

4.- BACKHOE
4.1 Definition
The backhoe is a machine in which the boom goes down and up in each
operation; The bucket, attached to it, excavates by pulling towards the cart, that is,
backwards as seen in the figure, instead of pushing forward, as the normal
excavator does.
It is essential that transportation is organized in such a way that the
excavator does not wait for the means of transportation; The capacity of these
must be a multiple of the bucket, to avoid that a load has to be emptied into
different elements; A good system, whenever practically possible, consists of

13
placing the trucks alternately on one side and the other of the excavator and as
close as possible to the front of the attack.

4.2 Operations
 Dig
 It is the best machine for excavating vertical slopes below the machine's
support plane.
 Carry
 Making turns along its vertical axis towards the dump truck behind it.
 Spin
 Displace
 Mobilize and demobilize

4.3 Scheme

4.4 Applications
 Excavation of trenches with vertical slopes; previously disintegrated hard rock.
The excavation is carried out below the support level of the excavator
regardless of the water table.
 Foundation excavations
 Canal excavation
 Cleaning and leveling
 Dismantling, loading and unloading of materials
 Filling foundations and trenches
 Scarifying (process of removing the structure of an existing pavement, and
tearing, removing rocky terrain (Ripper).

4.5 Guys
According to its drive:

14
 Cable or mechanical backhoes.
 Hydraulic backhoes.

According to the translation system:

 Rail backhoes
 Chain-mounted backhoes (tracks)

The chassis is supported by two parallel chains. Likewise, the control devices, as
in the tire control system, are located in the driver's cabin.
Backhoes mounted on wheels or tires.
The running gear is made up of rubber wheels, the travel, steering and brake
control members are in the cabin. Stability is ensured with independent wheel
stabilizers.

4.5.1 Mixed Backhoe

This type of machine is very practical given that on the one hand it has a
wide shovel capable of moving considerable volumes of earth and on the other
hand it has a shovel with an articulated arm that is very practical for carrying out
ditches, working on slopes, rubble, etc. Its use is very common in clearing or
clearing debris from lots and land to start new buildings, cleaning the land and
excavating ditches and wells for their foundations.

4.5.2 Retro chandelier

It is a rotating backhoe, equipped with two wheels and two legs, with
variable geometry and capable of working and moving on slopes greater than
100%. Its characteristics allow it great versatility of movement, being able to
minimize the impact caused by its movement. while optimizing work performance

Applications

15
 In Agriculture for the construction and maintenance of drainage or irrigation
channels.
 In Mining for exploration, exploitation in rivers and others.
 In the Construction of High Voltage Lines, Funiculars, Alpine Hostels.

4.6 Transport
The Backhoe can be transported by the Loy Boy if it cannot be transported
alone, if it is on wheels and the work is nearby it may not need transportation.

4.7 Maintenance
The engine must be stopped to perform maintenance, if ignition is required
to make adjustments, the operator must be in the cabin to prevent access to the
controls by strangers.

Preventive
 Power-on protocol
 Fuel tank capacity
 Plan for possible locations of sewer or gas pipes.
 If welding is to be performed on the unit, disconnect the alternator and batteries.
 Batteries during charging or discharging produce hydrogen and oxygen, a very
explosive mixture, a spark can cause their detonation.

Predictive
 Board Tilters
 Visual inspection around the machine.

Corrective
 Replacing dirty grease with new one
 Fuel change
 Visual inspection around the machine.
 Use the oil recommended by the manufacturer.
 In the case of wheeled excavators, when inflating the tires, use a long hose that
can be placed parallel to the wheel and out of reach of possible bursts.

4.8 Industrial Security

Dress

16
Clothing should be relatively tight, loose jackets, rings and any other type of
jewelry should be avoided. The required clothing is:
 Resistant helmets,
 Safety glasses,
 Safety shoes
 Ear protection helmets

5.- DRAGES AND DRAGALINES

5.1 Definition
Dredgers are machines specially designed to carry out aquatic excavations
and extract waste from these works. Various designs are available on the market,
dredgers can be classified according to their function or operation, according to
their function there are dredgers for lagoons, hazardous waste, pumping viscous
flows and marine constructions and depending on the mode of operation there are
electric, diesel, remote-controlled, manned or automatic propulsion dredgers.

5.2 Operations
A dredging operation involves excavating earthen material covered by
water. Often, the material is suspended in water to transport it to the deposit site.
Such works may have as their objective the general underwater excavation of a
bay, a beach, a river or a lake. In those cases, if the area to be excavated has a
considerable width, as well as length, the dredge is positioned so that it exerts a
continuous and extensive travel action on the water surface, around a center of
rotation. In other jobs, the dredge will need to excavate a channel or trench, and
will need to move along a line as the excavation progresses.
Excavate.- By dragging material.
Load .- Loading of loose material

5.3 Scheme
Parts that constitute the dredging equipment:

DRAGA.- It is a vessel that supports the system of pumps and winches.

DREDGING MODULE.- It is the device attached to a supporting castle on the bow
of the dredge by means of a cable that, when released by a winch, allows the
module to reach the sediment to disintegrate it, mix it with water and absorb it.
PIPE.- It constitutes the third part and allows the mixture to be transported above
the water level of the reservoir and deposited at the foot of the dam where the

17
surpluses that come out through the spillway and bottom drain and the tributaries
drag the sediment downstream of the river. .

DRAGLINE.- They are equipment that is made up of a cabin, a translation system,

a long boom, in the order of 60 meters.

5.4 Applications
 Cleaning the bottom of ports and coasts.
 Increase in draft depth necessary for the transit of certain vessels.
 Dredging of rivers and dams
 Excavation of aggregates from the bottom of river beds.
 Increase in draft depth necessary for the transit of certain vessels.
 Material transfer technique
 Removal of overburden to reveal coal seams
 Demolition
 Pipeline construction
 Dredging of rivers and dams

18
5.5 Guys
Dredging equipment can be classified into two large groups: MECHANICAL
EXCAVATOR DREDGES OR DRAGGINGLINES and HYDRAULIC SUCTION
DREDGES, based on the capture of bed material using suction pipes and
pumping equipment.

5.6 Transport
The Dredger is transported by means of the Low Boy if it cannot be
transported alone, if it is on wheels and the work is nearby it can be transported
alone.

5.7 Maintenance
To perform maintenance the engine must be stopped.
 Visual inspection
 Idle (progressive engine warm-up)
 Grease required parts
 Fuel change
 In the case of wheeled dredgers, inflate them with a long hose out of the reach
of possible bursts.

5.8 Industrial Security

 To work, it is necessary to achieve a horizontal settlement plane for the
machinery.
 The hauling units must be located as close to these machines as possible.
 Do not make turns with the loaded bucket, to avoid torsional stress on the boom.
 Way of approaching work: operators must be aware and responsible for safety;
be physically, mentally and emotionally in good condition.
 Power on.- Inspect the machinery
 Off.- Once the work is finished, lower all the implements to the ground or place
them on a support strong enough to support their weight.
 Work.- During work, do not exceed the lifting capacity and remain within the
lifting limits set forth in the manufacturer's table.

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6.- TRACTORS WITH THRUST BLADE

6.1 Definition
Earth moving machine with great power and
robustness in its structure, specially designed for cutting
work (digging) and at the same time pushing with the
blade (transport). Various equipment is mounted on this
machine to be able to carry out its work. Additionally, due
to its great power, it has the possibility of pushing or
supporting other machines when they need it (e.g. a
scraper).

6.2 Operations
 Excavate (large open pit).
 Large-scale hauling.

6.3 Scheme

6.4 Applications
 Large open pit excavations
 Excavation in loan bank
 Cleaning and clearing
 Opening of roads

6.5 Types

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6.5.1 By the translation system
6.5.1.1 Tracked
 Their fuel is mostly diesel, they are higher power equipment.
 Rigid chassis.
 Maximum speeds between 7 and 15 km/h.
 Powers between 140 and 770 HP.
 Mechanical transmissions.
 Weights in service between 13.5 and 68 t.
 Ability to climb slopes of up to 45º.

6.5.1.2 Wheeled
 They produce less compaction in the soil, they are
used more in agronomy.
 Articulated chassis with angles of 40º to 45º.
 Four wheel drive.
 Maximum travel speeds between 16 and 60 km/h.
 Powers between 170 and 820 HP.
 Mechanical or electrical transmissions.
 Weights in service between 18.5 and 96 t.

6.5.2 By the way you move your blade

Dozer blades can perform the following movements:
 Lateral inclination.
 Variation of the angle of attack of the blade.
 Variation of the angle of the blade with respect to the direction of travel.
 Lifting and lowering of the blade.

6.5.3 Another classification according to caterpillar

 Straight blade
 Universal sheet
 Semi-universal blade
 Semi-universal variable radius blade
 Cushioned blade

6.5.4 Additional Accessories

21
It can also have a scarifier on its back. This accessory allows you to excavate
hard soils that cannot be removed with the blade, such as asphalt, old pavement
and frozen surfaces.

6.6 Transport
The Bulldozer is transported by means of the Low Boy if it cannot be
transported alone, if it is on wheels and the work is nearby it can be transported
alone. The assembly of a Bult dozer is presented.

6.7 Maintenance
Maintenance in the work area:
 Place the machine on level ground. Block the wheels or chains.
 Place the spoon resting on the ground. If the bucket must be kept raised, it will
be adequately immobilized.
 Disconnect the battery to prevent a sudden start of the machine.
 Do not stay between the wheels or on the chains, under the bucket or arm.
 Never place a metal piece on top of the battery terminals.
 Use a charge meter to check the battery.
 Never use a lighter or matches to see inside the engine.
 Learn to use fire extinguishers.
 Keep the machine in a good state of cleanliness.

Workshop maintenance
 Before starting repairs, it is advisable to clean the area to be repaired.
 Never clean the parts with gasoline. Work in a ventilated room.
 NO SMOKING.
 Before starting repairs, remove the ignition key, lock the machine and post
signs indicating that the mechanisms should not be tampered with.
 If several mechanics work on the same machine, their jobs must be coordinated
and known to each other.
 Let the engine cool before removing the radiator cap.
 Lower the pressure in the hydraulic circuit before removing the drain plug, and
when draining the oil, make sure it is not burning.
 If the arm and bucket have to be left elevated, they will be immobilized before
starting work.
 Evacuate the gases from the exhaust pipe directly to the outside of the
premises.
 When the tension of the engine belts is fixed, the engine will be stopped.

22
 Before starting the engine, check that no tools have been left on it.
 Use gloves and safety shoes.

Machine examination
 Before starting any work, the machine must be examined in all its parts.
 The exams must be renewed as many times as necessary and fundamentally
when there has been a failure in the material, the machine, the facilities or the
safety devices, whether or not an accident has occurred.
 All these examinations will be carried out by the person in charge or competent
personnel designated by him. The name and position of this person will be
recorded in a security log book, which will be kept by the person in charge.

6.8 Industrial Safety

Before starting any work, it is necessary to know the rules and recommendations
advised by the construction contractor. Likewise, the special recommendations
made by the person in charge of the work must be followed.
Tips for the driver
 Do not drink alcoholic beverages before and during work.
 Do not take medications without a prescription, especially tranquilizers.
 Do not race or joke with other drivers.
 Be only attentive to work.
 Do not transport anyone in the spoon.
 When someone must guide the driver, he will never lose sight of him.
 Never let this assistant touch the controls.
 Turn on your headlights at the end of the day to see and be seen.

7.- Scrapers and motor scrapers

7.1 Definition
The Trailla consists, in principle, of a frame or chassis that carries a
transport box or container and must be towed.
A scraper must have the power, traction and speed for continuous high
production with a wide range of materials, conditions and applications. Some of
the Scraper options include single motor with open box, tandem motor with open
box, tandem push and pull motor, elevators and auger configurations. Scrapers
cut and load quickly, have high travel speeds, extend in operation and eventually
compact by own weight during operation.

23
7.2 Operations
 Ground cutting
 Load of removed material
 Transportation of material
 Emptying or unloading and its joint compaction

24
7.3 Scheme

FIGURE 7-1: Scraper Parts

7.4 Applications
 Complete earthworks cycle
 Loan Bank Carry
 Platform viewing
 Excavation in large borrow banks and unloading or spreading for embankments
or large fills.
 It is applied in road construction where the quality of the land is relatively
homogeneous.
 Earth movements

Scraper operation is used to carry out excavations in layers, loading and

transporting excavated land, and placing material in layers. Due to these
characteristics, they are used in excavations with transfer and placement of
material, ditches, pits, dams, embankments, knight canals, uncovering in quarries
and loans, grading, land leveling, cuts can be made with slopes less than 1:3.5.
dependent.

There are three types of scrapers: trailer, semi-trailer and motorcycle scrapers.

7.6 Transport
The Scraper is transported by means of the Low Boy if it cannot be
transported alone, it is generally transported alone if the work is located nearby.

25
7.7 Maintenance
You must take into account carrying out maintenance in the case of trailers
with trailers, also maintaining the pusher tractor.
This equipment requires preventive maintenance (lubricants and greases
periodically), it also includes laboratory analysis of the machine's used oil. Another
type of maintenance is Corrective maintenance, which consists of changing the
spare parts that the machinery needs.
Check the hooking devices, the penetration blade and the blade
incorporated into the blade.

7.8 Industrial Security

 Know and comply with your company's security program.
 Wear safety clothing relevant to the work assigned to you.
 You must know the capabilities of your machine, as well as its limitations.
 Familiarize yourself with the controls, gauges and instruments.
 You must know in advance the status of the work areas.
 You must know the traffic signs, the signals made with the hands and who are
in charge of the signs.
 Make sure you are aware of the direction of travel and any other internal farm
rules that may differ significantly from normal procedures.
 Employee safety programs should require the presence of a man in each
workplace who takes responsibility and authority when it comes to safety.
 Always wear the required protective accessories, such as hard hats, safety
glasses, reflective clothing, safety shoes, and hearing protection helmets.
 Your clothing should be relatively tight-fitting.

8.- FRONT LOADERS

8.1 Definition
The front loader is a tractor, mounted on tracks or wheels, that has a large
bucket at its front end.
Loaders are equipment for loading, hauling and eventually excavating. In
the case of hauling, it is only recommended to do so over short distances.
The use of loaders provides modern solutions to a problem of hauling and
loading materials, with the aim of reducing costs and increasing production. In the
case of excavations with explosives, its good mobility allows it to move out of the
blasting area quickly and safely; and before the dust from the explosion clears, the

26
loader may be collecting the scattered rock and preparing for delivery of the
material.
Front loader buckets range in size from 0.19 m3 to over 19.1 m3 capacity,
heaped. The bucket size is strictly related to the machine size.

8.2 Operations
 Dig
 Load
 Download

Carry or transport
Loaders are equipment for loading, hauling and eventually excavating. In the case
of hauling, it is only recommended to do so over short distances.
The use of loaders provides modern solutions to a problem of hauling and loading
materials, with the aim of reducing costs and increasing production.

In the case of excavations with explosives, its good mobility allows it to move out
of the blasting area quickly and safely; and before the dust from the explosion
clears, the loader may be collecting the scattered rock and preparing for delivery
of the material.

8.3 Scheme

8.4 Applications
It is applied in constructions where there is ample space to maneuver, it is
used in any work that requires cutting, loading, hauling and unloading medium
volumes of earth Loading of materials
 Mix of materials
 Excavation of loose or soft ground
27
 Stacking of material and loading of loose material
 Deposit the loose material, either in a plant (crusher, concrete, asphalt, recycler,
etc.) or in a disposal site.

8.5 Guys
According to the way of downloading:
 Front discharge
 Lateral discharge
 Rear discharge

According to the bearing shape:

 Tires (rigid or articulated frame)
 Tracked

8.6 Transport
The Front Loader is transported by means of the Low Boy if it cannot be
transported alone, if it is on wheels and the work is nearby it can be transported
alone.

8.7 Maintenance
 Power-on protocol
 Grease connection point
 Fuel tank capacity
 Preventive maintenance plan (oil change)
 Replacing dirty grease with new one
 Visual inspection around the equipment
 Make sure there are no fallen mirrors, broken lenses, cuts in the tires, bucket in
good condition, shattered windows, wipers in poor condition, engine oil levels,
hydraulic oil levels, transmission oil levels, water level in the engine coolant,
batteries and their terminal, current cut-off, fire extinguishers expiration dates,
discharge of air accumulators if applicable, tank covers, tires and their
respective pressures recommended by the tire manufacturer.

28
8.8 Industrial Security
Dangerous Circumstances
 Maneuver the machine interruptedly
Precautionary measures
 Know the possibilities and limits of the machine and particularly the space
necessary to maneuver.
 When the maneuvering space is very small or limited by obstacles, the area of
its evolution must be marked.
 Monitor the position, function, and direction of operation of each of the controls
of the signaling devices and safety devices.

Know the work area

Dangerous Circumstances
 Failure to properly examine the work area
Precautionary measures
 Know the work circulation plan and be informed every day of the work carried
out that may constitute a risk: Open trenches, cable laying.
 Know the height of the machine when circulating and working, as well as areas
of limited or narrow height.
 With the rubber wheel running gear, drive with caution or at slow speed in areas
of dust, mud or frozen ground.
 Carry out good maintenance of circulation areas.

9.- HAULING OR TRANSPORT UNITS

9.1 Definition
These machines are designed for the transportation of material and its
respective unloading. It has a hopper whose capacity can be flush or full, the
weight to be loaded into said hopper depends on the type of material. The load
volume must also be defined by the load law, considering the roads where the
truck is going to travel (this so as not to damage the existing road).

9.2 Operations
 Load .- load excess material
 Download .- Download the material on site
 Carrying .- Transfers volumes of excavated earth

29
9.3 Scheme

9.4 Applications
It is applied in works where earth movement, loading, hauling and unloading
of large volumes of earth is required.

 Transportation of excess material

 Debris transportation
 Over hauling

9.5 Guys
Haulage Units are classified as follows:
9.5.1 Urban Area
 Transport trucks for machinery
 truck tractor
 Dump truck.-They are used in earth moving works with great mobility and speed
as well as great adaptability for off-road work and on virgin soils, they are in the
tractor trailer category.

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9.5.2 Rural Area
9.5.2.1 Articulated Trucks

This type of equipment has the possibility of relatively independent movement of

the truck's cockpit. With the purpose of facilitating the turning of the machine in
operations.
This type of equipment can have a hopper with rear discharge or side discharge.
There are also dump trucks with this system.

9.5.2.2 Off-road trucks. (TRUK)

They are equipment designed for the transportation of materials and it travels on
the construction site or on paths that are not well leveled, they exist in various
capacities and models.
9.6 Transport
They are generally transported alone.

9.7 Maintenance
Workshop maintenance
 Before starting repairs, it is advisable to clean the area to be repaired.
 Never clean parts with gasoline. Work in a ventilated room.
 Before starting repairs, remove the ignition key, lock the machine and post
signs indicating that the mechanisms should not be tampered with.

31
 If several mechanics work on the same machine, their jobs must be coordinated
and known to each other.
 Let the engine cool before removing the radiator cap.
 Lower the pressure in the hydraulic circuit before removing the drain plug, and
when draining the oil, make sure it is not burning.
 If the arm and bucket have to be left elevated, they will be immobilized before
starting work.
 Evacuate the gases from the exhaust pipe directly to the outside of the
premises.
 When the tension of the engine belts is fixed, the engine will be stopped.
 Before starting the engine, check that no tools have been left on it.
 Use gloves and safety shoes.
 Tire maintenance
 To change a wheel, install the stabilizers.
 Always use an inflation box when the wheel is not on the machine.
 When inflating a tire, do not stay in front of it but on the side.
 Do not cut or weld on top of a rim with the tire inflated.
 Machine examination
 Before starting any work, the machine must be examined in all its parts.
 The exams must be renewed as many times as necessary and fundamentally
when.
 there has been a failure in the material, the machine, the facilities or the safety
devices.
 whether or not an accident has occurred.
 Hopper test.
 Engine maintenance at the mileage specified by its specifications.
 All these examinations will be carried out by the person in charge or competent
personnel designated by him. The name and position of this person will be
recorded in a security log book, which will be kept by the person in charge.

9.8 Industrial Security

The operator who uses or drives a construction truck must:
- Know and comply with your company's security program, ask your superior about
it and request a copy to consult.
- Wear the relevant safety clothing for the work assigned to you; consult your
company's safety manual where they must be specified.
- You must know the capabilities of your truck, as well as its limitations. Familiarize
yourself with the controls, gauges and instruments.

32
- You must know in advance the condition of the work areas, such as: Condition of
the tracks, potholes, mud, heavy traffic, dust, smoke, fog, etc.
- You must know the traffic signs, the signals made with the hands and who are in
charge of the signs, you must respect their instructions.
- Make sure you are aware of the direction of travel and any other internal farm
rules that may differ significantly from normal procedures.
- All dump trucks must have release levers for the dump gates to keep the
operator in a clear space.
- The driver's experience is very important.
- You must necessarily have a cell phone to know the location of the hauling unit.
- The machine must be clean, for this use water or steam directly.
- Operating speed: Urban: 8 - 12 [Km/hr] loaded Rural: 15 - 25 [Km/hr] loaded 10 -
15 [Km/hr] unloaded 20 - 40 [Km/hr] unloaded.

10.- COMPACTION EQUIPMENT

10.1 Definition
It basically consists of the artificial process that is followed to achieve an
increase in the density of a natural or fill soil, in order to obtain the greatest
stability from it. This process is carried out through the use of mechanical or
manual equipment (energy) and the addition of water as necessary.

Four factors influence the achievement of good compaction, and they are these:
 Type of material to be compacted (physical – mechanical behavior).
 Optimum moisture content of the material (Proctor test).
 Correct choice of the equipment to be used.
 Techniques to be used.

Construction Procedure:
• Starting, carrying and extending system
• Pavement thicknesses
• Material characteristics
• More % humidity compared to the optimum
• Compaction method and test sections

Spreading methods:
• Scrapers
• Chain tractor

33
• Compactor pusher blade
• Motor grader

The means or controls followed on site to determine whether adequate

compaction has been achieved vary depending on the type of materials:
• Embankments:
- Dry density
- K = Ev2/Ev1
- Fingerprint
• Pedraplenes:
- Gap index
- Seats (load plates)
- Density (macrocatas)

Dry density is the mass of solid elements in the unit volume of the soil considered.
K = Ev2/Ev1 is the ratio of deformation moduli of the 1st and 2nd loading cycles,
carried out using the plate loading test. The footprint test is the average of the
settlements produced by the passage of a 10 t axle, averaged by leveling.

10.2 Operations
- Compact
- Removal

10.3 Scheme

10.4 Applications
 Compaction of base and sub-base embankment on roads
 Finishing compaction, traffic simulation on the asphalt layer.

10.4.1 Choice of machinery for compaction

34
The choice of compaction equipment depends on the type of soil.
Smooth rollers: Used in mechanically stable gravel and sand.
Pneumatic rollers: Used in uniform sands and cohesive soils, humidity close to
the plastic limit.
” “Padfoot” rollers: Fine soils, humidity between 7 to 20% below the plastic limit.
Vibratory roller: Used especially in granular soils

35
10.5 Guy

10.6 Transport
The Compactor is transported by means of the Low Boy if it cannot be
transported alone, if it is on wheels and the work is nearby it can be transported
alone.

10.7 Maintenance
 Preventive maintenance plan
 Box or hopper operation routines
 Determine the lubrication or connection points and the type of lubricant to use.
 Check oil, coolant, etc. levels.
 Observe the state of the cabin in terms of cleanliness and safety devices.
 Examine the protection of hoses, transmission, suspension, exhaust pipes and
mufflers, batteries, tires, braking system, parking and emergency, steering,
acoustic and visual signaling.
 The post must have a parts manual (spare parts).

10.8 Industrial Security

 You should never jump off the machine. Use the installed means to get down
and use both hands to hold on.
 Keep your machine clean of grease and oil, especially the access to it.
 Adjust your seat belt and seat.

36
 During maintenance and repair work, park the machine on firm ground, place all
levers in neutral position and stop the engine by removing the ignition key.
 Avoid whenever possible handling with the engine hot when it reaches its
temperature, any contact can cause serious burns.
 Always look in the direction of travel to avoid being run over while reversing.
 Do not attempt to make adjustments if it can be avoided, with the machine
engine running.
 Before each intervention in the hydraulic circuit, all auxiliary controls must be
operated in both directions with the key in the ignition position to eliminate
dynamic pressures.
 The cooling system contains alkali, avoid contact with skin and eyes.
 Use gloves and safety glasses when working on the battery.
 Do not weld or torch cut pipes containing flammable liquids.
 Do not attempt to get on or off the machine if you are carrying supplies or tools.

11. MOTOR GRADERS

11.1 Definition
Very versatile machine used to move dirt or other loose material. Its main
function is to level, model or give the necessary slope to the material it works on. It
is considered as a surface finishing machine.
Its versatility is given by the different movements of the blade, as well as the
series of accessories it can have.
It can imitate all types of tractors, but its difference is that the motor grader
is more fragile, since it is not capable of applying the moving or cutting power of
the tractor.
Because of this, it is more used in finishing tasks or precision work.
Motor graders can be trailed or self-propelled, the latter being the most
used and called a motor grader.

37
11.2 Operations
- Dig or Cut
- Carry
- Carry
- Download or Extended
- Return
- Leveling and Small Excavation.
- Slope Combing.
- Construction of Ditches.
- Extended Material.
- Mixing of Insitu Material
- Scarified

11.3 Scheme
They are equipment made up of a cabin, a pneumatic translation system, a
push blade with a varied position depending on the model, and a stop in case of
push. It is a piece of equipment that has the following characteristics: applied in
excavations (refine cutting) in soft and semi-hard soils, its capacity is given by the
cutting and dragging capacity, it is best to perform the cutting operation from top to
bottom.

11.4 Applications
- Level
- Spread the material unloaded by the trucks and subsequent leveling
- Conform
- Refinement of esplanades
- Mix material.
- Excavation, reprofiling and conservation of ditches in the ground

38
- Slope profiling
- Maintain dirt or gravel roads

11.5 Guys
Motor graders are classified as follows:
- According to its weight and power
Power can vary from 115 to 225 HP, with speeds of up to 45 km/h. The motor
graders are equipped with up to 8 forward and 6 rear speeds, so that it is the
machinist who can choose the most suitable one for each job. They get about 40
km/h and about 25 km/h behind.

- Depending on the number of wheels

* Six wheels or three axles
* Four wheels or two axles in small models.
*There are currently larger four-axle models.

11.6 Transport
The Motor Grader is transported by means of the Low Boy if it cannot be
transported alone, if the work is located nearby it can be transported alone.

11.7 Maintenance
- Wheeled equipment must have an hour meter and an odometer.
- Needs preventive, predictive and corrective maintenance.
- A list of suppliers within the city, department, country and countries must be
required.
neighbors and in the last case Europeans, Asians, Americans.

11.8 Industrial Security

To perform maintenance the engine must be stopped.
- Visual inspection
- Idle (Progressive engine warm-up)
- Grease required parts
- Fuel change

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12.- OTHER EQUIPMENT
12.1 Milling machine
The milling machine allows the removal of concrete or asphalt pavements
and eventually the brushing of both, so depending on the type of work to be
carried out, the appropriate milling machine must be chosen.

12.2 tunnel boring machine

Modern tunnel boring machines are being used in the construction of the
tunnels of the new Madrid Metro lines. These machines not only drill the ground to
make the tunnel, but also place the segments (concrete lining), leaving the tunnel
completely finished. The tunnel boring machine is a state-of-the-art machine
thanks to which it is possible to construct tunnels with great safety. It is a
technologically very complete machine, thanks to which a truly surprising advance
is possible.
At the same time as it is excavating, it is mechanically forming and
concreting the new tunnel, so the finish is almost complete as the machine
progresses.
As the machine excavates, conveyor belts are responsible for taking the
extracted material to the back, where it is loaded into wagons, which, pulled by
special locomotives, bring the material to the surface through the new tunnel
already made.

12.3 Asphalt or Agglomerate Paver

40
 It is a machine equipped with a great precision capacity. It has millimeter
accuracy, being able to perform superelevations and give the inclination of slopes
with millimeter accuracy. The good condition and inclination of the pavement on
curves, etc. depends on its perfect use. In the image we can see it working.
At the front end (right) you can see the chipboard storage tank or hopper.
The trucks empty their load into this hopper as the machine moves slowly in this
direction. At its rear end, the agglomerate is spread uniformly, using guides or side
cords that have previously been installed throughout the lateral end of the area to
be paved so that the machine sensor (protruding side rod) towards the ditch) can
interpret the thickness of the asphalt layer at each end and in each specific place.

12.4 Paver
Machinery dedicated to special soil-cement paving, used on airport runways
and other places where great perfection of the surface is necessary. Also on roads
and highways passing through mountain passes and areas with an abundance of
ice and other adverse factors, where it is advisable to use a type of non-slip
pavement in such circumstances.

12.5 Rock Work Machines

41
 In these images you can see two models of machines commonly used in
rock drilling work using the drilling process. Its use is essential for the installation
of dynamite drills in the exploitation of quarries and during the construction of
roads, railway lines, etc., as well as in underground galleries during the
construction of tunnels or mining work.

12.6 Trenchers
The different manufacturers of trenchers combine design and innovative
technology, whatever the need for trenching, there is a wide range of designs
available on the market to satisfy various needs, these are classified into three
large groups according to the depth and width of excavation,
According to the above, there are large, medium and compact trenchers.

42
 CHAPTER II
TYPES OF MAINTENANCE

1.- TYPES OF MAINTENANCE

1.1 Maintenance
Maintenance is the series of tasks or jobs that must be carried out on some
equipment or plant, in order to be able to preserve it efficiently so that it can
provide the service for which it was created.
For the machinery department, the objective of maintenance is the
conservation, above all, of the service that the machinery is providing; This is the
essential point and not, as has been mistakenly believed, that maintenance is
required to conserve such elements. The service is what is important and not the
machinery or equipment that provides them. Therefore, the following essential
factors must be balanced in maintenance tasks: economic quality of the service,
adequate duration of the equipment and minimum maintenance costs.
The acquisition of new equipment entails high costs, since initially its
depreciation is very accelerated, although this is compensated, since it requires
less maintenance costs and the expectation of failure is lower.
As time passes, the equipment deteriorates and its components suffer
wear, which necessarily forces an increase in the frequency of service failures and
maintenance costs increase; Furthermore, the replacement of spare parts is more
expensive due to the difficulty of obtaining them, because they are not available in
the warehouses and because the manufacturer does not guarantee their existence
for very long periods. On the other hand, an increase in the frequency of service
failures causes losses in the income generated by its provision, in such a way that
these costs increase considerably, until they become practically prohibitive at the
end of the life of the machinery.

43
1.1.1. Preventive Maintenance
Preventive maintenance can be defined as planned conservation, and its
function is to systematically know the state of the machines and equipment to
schedule, at the most opportune and least impactful times, the task to be
performed.
Preventive maintenance means that you should not wait for the machines to
fail before making a repair, but rather that replacement parts are scheduled with
the necessary time before they fail; This can be achieved by knowing the technical
specifications of the equipment through their manuals.
The objective of this maintenance is not limited to what is appropriate for
the equipment, but its goal is to consider the work. Machinery and equipment are
serviced, considering the effect on production, personal safety and the equipment
itself. It is then said that preventive maintenance has been used to indicate a
scheduling system, in its secondary benefits.

1.1.2. Predictive Maintenance

Predictive maintenance is based on breakdowns in machinery or equipment
that have already been foreseen, either by some statistical means or by the
manufacturer's instructions, although they have not been located in time. As
already mentioned, predictive maintenance will tell or predict which parts can be
replaced or protected, before they can fail; In addition, it allows planning the
resources that can be used, such as labor, tools, materials and spare parts that
have been acquired or located in advance.
This maintenance method has the drawback that it can only protect vital
elements and not failures of secondary elements.

1.1.3. Corrective maintenance

This type of maintenance is based on making minor corrections to the
machinery to better adapt it to our environment. They are serious repairs that
require a complete overhaul or reconstruction, since sometimes it is better to make
some corrections to the machinery to reduce costs, both in operation and service,
and not prolong them.

44
These corrections require specialized people and under the rigorous supervision
of engineers, as well as the distributor, and to be guided by the manufacturer's
manual, so as not to lose the power of the machine or impair its operation.
It can also occur when performing a preventive maintenance routine.

2.- MACHINERY MAINTENANCE PLAN

A preventive maintenance program aims to constantly keep machinery in
perfect operating condition to achieve maximum performance with minimum cost.
Now, there is some confusion regarding the scope of preventive maintenance.
Some believe that this is reduced to periodic inspections; However, this
maintenance covers not only the activities of eliminating breakdowns or abnormal
behavior, but also normalization, reduction of operating costs and increase in the
useful life of machines and equipment.
A good preventive maintenance plan provides a detailed guide for each
type of equipment, breaking down the entire machine into its various systems and
components, that is, it must have a range of manuals or catalogs to be able to
carry it out.
Machinery records must be kept faithfully. In every maintenance plan, there
must be a consecutive record of all mechanical and service work done on a
machine or equipment. These should be easy to carry, easy to read, and always
available and up to date.

2.1. Conservation recommendations

To keep the machinery in good working order, it is necessary to strictly
follow the recommendations required by all systems.

45
2.1.1. Fuel system
The fuel tank must be filled at the end of each workday, to eliminate
moisture-laden air and prevent condensation. Do not fill the tank to the brim, as
the fuel expands when heated and could overflow.
The fuel level should be checked with the dipstick in the filler opening. Fuel
filters do not have to be filled with fuel before installing. Contaminated fuel can
accelerate wear of system parts.
After changing the fuel filters, the fuel system should be purged and primed
to remove air bubbles from the system.
Water and sediment should be drained from the fuel tank at the beginning
of each work shift or after the tank has been filled and allowed to settle for 5 to 10
minutes.

2.1.2 Hydraulic system

The makeup oil added to the hydraulic system must be mixed with the oil in
the tank.
Water or air can cause pump failure. If the hydraulic oil becomes cloudy, it
means that water or air is entering the system. The fluid must be drained, the
clamps on the hydraulic suction pipes must be retightened, the system purged and
refilled.

2.1.3 air intake system

The primary element can be cleaned up to six times before needing to be
replaced. The primary element is changed once a year, even if it has not been
cleaned six times. When the primary element is serviced for the third time, the
secondary filter must be replaced. Any torn or broken items in the filter material
should be discarded.

46
2.1.4. Electric system
When using an external electrical source to start the machine, turn the main
switch to the off position and remove the key before connecting the auxiliary
cables.
When using jumper cables, you must ensure that they are connected in
parallel: positive (+) to positive (+) and negative (-) to negative (-). The cables
must not be allowed to come together, otherwise they will emit a discharge, which
would threaten the safety of whoever is handling them.
Only use the same voltage for auxiliary starting. Using a higher voltage will
deteriorate the electrical system.

2.1.5. Cooling system

Coolant should never be added to an overheated engine; You have to let
the engine cool before doing this.
Water is always corrosive at engine operating temperatures. Use clean
water low in scale-forming minerals. Do not use chemically softened water. Add
cooling system inhibitor to water for corrosion protection.
When water and permanent antifreeze solutions are used in the cooling
system, the solution must be drained and changed every 2000 hours of service or
once a year. When cooling system inhibitor is added every 500 service hours or 3
months, it is not necessary to drain and refill the system once a year.
The drain period can be extended to every 4000 service hours or 2 years.

2.1.6. Oil analysis

The oil level must be checked periodically and its condition examined by
visual inspection.

2.1.6.1 Correct storage of lubricating oils

47
 Taking into account variations in temperature, the vapors and gases inside
the barrels are continually expanding and contracting, which is why the stoppers
are not completely airtight, so the barrels suck air from the environment.
The barrels should be stored lying down, on pallets, with the caps in the 9
and 3 o'clock positions. In this way, the oil seals the plugs and the barrels no
longer suck in air.
If barrels are stored upright with the plugs up, or even lying down, but
without the oil sealing the plugs, water and moisture can enter and contaminate
the lubricant.

2.1.6.2 Generalities
Grease and oil accumulated in a machine represents a fire hazard, so it
should be cleaned with steam or high-pressure water; every 1000 hours or
whenever a significant amount of oil is spilled on a machine.
Clean all connections, caps and plugs before servicing. You have to stay
alert to watch for leaks; If there are, look for the cause and correct it. Fluid levels
should be checked more frequently than the recommended periods if leaks are
found or suspected.
Water and sediment should be drained from the air tanks at the beginning
of each work day.

2.2. Filling capacities

Capacities given are approximate and should be used as a guide when
filling compartments or systems.

2.3. Lubricant viscosities

Before delving fully into the viscosities of the lubricant, it is essential
Describe the meaning of lubrication. Friction is generally an undesirable
phenomenon, since it produces energy loss and accelerates wear; Both energy
loss and wear increase costs and the need for spare parts. That's why careful use
of friction-reducing lubricants can result in big savings.
The purpose of lubrication is to separate moving parts using a friction-
reducing film. The main functions of lubricants are: separating surfaces, removing

48
heat, and keeping components clean. Its secondary functions are: sealing,
insulating, protecting against corrosion, controlling oxidation, preventing foam
formation, dispersing contaminants, transmitting power, withstanding stresses, etc.

2.3.1. Classification of lubricants

2.3.1.1 Gaseous
Used in equipment with extremely high rpm, for example: centrifuges,
scanning mechanisms, dental equipment, computers, high speed turbines, etc.

2.3.1.2 Liquids
Also known as oils, they are the ones most commonly used today, whether
synthetic or derived from petroleum. Their characteristics are: they resist high
loads, have a moderate viscosity, provide a thick layer, and have an acceptable
cost. Oils derived from petroleum are sensitive to changes in temperature and
oxidize more easily. On the other hand, synthetics are the opposite, they are very
stable with respect to changes in temperature and are resistant to oxidation.

2.3.1.3 Semi-solids
Known as fats. They do not have fluid characteristics, but they are good
lubricants. Its characteristics are: high viscosity, good lubrication retention, ability
to withstand large loads, and have long useful life. Their only disadvantage is that
they cannot provide cooling or cleaning.

2.3.1.4 Solids
They are used in low speed, short duration, low load applications, and
generally have a long life. Among these are: inorganic compounds (graphite and
molybdenum disulfide), solid organic compounds (soaps, fats and waxes), metallic
films (tin and lead). This type of lubrication is used on bearing or bushing surfaces,
on shafts and cutting tools.

49
 Oils are identified primarily by their viscosity and service classification.
Viscosity is the most important property of a lubricant, since its load capacity
depends on it and is defined as the internal resistance that is generated, as one
layer of liquid moves in relation to another, in other words, It is the resistance of a
liquid to flow or it is the internal friction of the liquid.
This frictional quality is classified by a dimensionless number: the viscosity
index (IV).
The most precise definition of the viscosity index is the following: number
dimensionless that indicates the effect of temperature changes on the viscosity of
an oil. The higher the IV, the less the oil's tendency to change its viscosity with
temperature and thus maintain a thicker lubricating film.

2.3.2. Advantages of a multigrade oil over a monograde one

a) Lower oil consumption (up to 50% less)
b) Fuel economy (up to 7%)
c) Reduced engine wear during cold starts, which can double engine life.
d) Higher viscosity at high temperatures, which provides greater protection against
wear.
e) Versatility: can be used in a wide range of temperatures. For example, an SAE
15W40 can replace a 15W, 20W, 30 and 40.

2.4. Break-in of machinery

The undercarriage of a track machine accounts for 40% of the value of the
machine and 60% of the value of the maintenance cost. This makes the operation
and maintenance of the lanes one of the major considerations that must be made
in road zone 11.
To avoid damage to the running system of chain machines, the
tour of the heavy machinery that must be done is divided into three phases:

Phase 1

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This phase shows the maximum distance that the different types of heavy
machinery can travel.

Phase 2
The deterioration of heavy machinery transmissions is due to
a) Bad operation, such as making the unit skid too much.
b) Rolling the machine over very long distances.

It is known to every operator, convoy leader and machinery inspector.

that machines must be moved short distances in projects, both in forward and
reverse direction.
Driving the units over long distances causes heating in the pumps, brakes, and
wheels; This heating of parts is transmitted to the oil, which causes the
deterioration of the additives, and consequently the degradation of the oil as a
result of a high temperature oxidation process.

To move the machinery, the header with its respective platform (low boy) must be
used, as shown in the following figure.

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Phase 3
If for an extraordinary reason it is necessary to travel more than the maximum
distances, proceed as follows:
a) The maximum distance is traveled, then one must stop for a period of 30 to 45
minutes, to continue traveling an equal distance and then the previous
procedure is repeated.
b) It is advisable to move the machinery using a header and platform (low boy).

The routes must be carried out with the machine in slow motion (low speed),
to avoid too much movement (vibration).
It is important to mention the components of the running gear and the
function that these play for better familiarization with the machinery and are:
a) Sprocket: is responsible for receiving the traction force from the final drive and
transmitting it to the chain to move the machine; It is also called cabilla.
b) Guide or tension wheel: its function is to stretch and guide the chain; This is
done at the same time to properly tension the chain by means of the tensioning
device.
c) Lower rollers: they support the weight of the machine in its entirety; at the same
time they keep the chain aligned. They can be found in two forms: simple (one
tab) and double (two tabs).
d) Upper rollers: they have the function of supporting the chain at the top, in order
to prevent it from rattling.
e) Shock-absorbing spring: cushions the shocks received by the running gear; It is
slightly compressed, reducing the impact.
f) Chain link: they are made up of two rails, a pin and a bushing, which allow the
traction and movement of the rollers and guide wheel, at the same time
supporting the total weight of the machine.
g) Chain pin: allow the connection of one link to the other.
h) Chain bushings: they allow the back and forth movement of the chain and allow
it to be accommodated on the guide wheel and the sprocket.

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i) Master pin: found only on conventional chains and allows disassembly of the
chain; It can be easily identified by having a small hole that the other pins do not
have.
j) Master Link: Typically found in sealed and lubricated chains; It consists of a link
split in half in a screw joint. To break the chain, only the shoe and the screws
must be removed; It is more practical than the master pin.
k) Footings: they are those that make direct contact with the ground and there are
various designs. They are manufactured from very high quality carbon steel and
with heat treatments that allow the hardening of surfaces subject to wear. The
most common types are: normal use, heavy duty, self-cleaning, skeleton for
snow, and with rubber for asphalt.

Balancer bar: supports the front weight of the machine which is supported in the
center of the bar and it is supported on the roller frames.
Its function is to allow the tilting movement of the rails and keep the front part of
the machine horizontal.

3.- SERVICE PERIODS

Machinery and equipment manufacturers provide performance
specifications, operating temperatures, oil pressures, maximum speed, and
precise mechanical assembly instructions. These specifications must be observed
since lubrication does not correct mechanical defects.

3.1. When necessary

The services that must be done to the machines when necessary are

53
those in which operations are carried out that are not specifically scheduled at a
specific time.
If necessary, clean the engine air intake system and replace the elements.
It is advisable to inspect the air intake grille to see if it has any accumulation of
dust or debris, as well as the front filter pipes.

The air filters of some of the machines have a two-color service indicator,
which indicates when the primary and secondary air filter is dirty, clogged or needs
changing; This is shown when the yellow piston of the service indicator enters the
red zone, when the engine is at high idle; then it is necessary to stop the engine.

Having finished the previous operations, proceed to install it and

Press a button on the inside of the gauge to adjust it again. If the yellow piston of
the filter service indicator enters the red zone after starting the engine, or the
exhaust smoke is still black after the clean filter is installed, it is necessary to
install a new primary filter. It is also advisable to change the primary filter, after
having cleaned it a maximum of six times or every year.
The secondary filter is recommended to be changed when a primary filter
that is clean and in perfect condition has been installed and the yellow piston of
the

54
service indicator enters the red zone; It may also be replaced when the primary
element is serviced for the third time. It is not recommended to reuse the
secondary filter, even if it has been cleaned.

3.2. Daily or every 10 hours

In daily service, an inspection has to be carried out around the
machine to maintain strict control regarding leaks; the cause needs to be found
and the leaks corrected. Leaks found in the engine compartment must be repaired;
inspecting around all the seals. Fluid levels should also be checked and most
frequently those that are believed or known to be leaking.
The oil level in the engine must not be exceeded; Doing so may cause
engine damage. The dipstick and crankcase oil filler cap are on the right side of
the engines. The measurement can be done with the engine running; Since the oil
is at normal operating temperature, the oil level should be between the add and
full marks on the engine running side of the dipstick. With the engine stopped, the
oil level must be maintained between the low and full marks on the engine stopped
side.

3.3 Machinery maintenance control sheet

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 For a maintenance plan to work, it is necessary to work with a series of
files, because there are different types of information, so that for each machine
there are several different ones in the file.

3.3.1. Machinery sheet

This will be the identification card for each machine and, at the same time,
the column
vertebral in the road zone of roads No. 11, for the development of machinery
maintenance. In the file of each machine, there must be all the information
necessary for its identification. For example, the machine name, brand, model,
DGC number, chassis and engine serial number, as well as maintenance data
must appear to know your needs.

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3.3.2. Failure and breakdown history
The use of this sheet and the importance it has is a fact that should not be
forgotten when you want to implement a maintenance plan. Otherwise, you may
spend time and money making repairs without keeping records, and perhaps
overlook the causes of defects, which defeats the purpose of maintenance.
This sheet will have a record of the repaired components, the work
carried out, the materials and spare parts used, as well as the downtime of each
machine, which plays an important factor in the zv 11-

3.3.3. Machinery inspection control sheet

This sheet will be used by the machinery inspector when he goes to the
work fronts where he will note the status of the parts that are going to be
supervised. It also avoids leaving things in memory, and thus having data to write
down such as the inspection date. It is necessary to make this form simple and
easy to understand or, otherwise, its use will only complicate the paperwork task,
which must be kept to a minimum to be functional.
The use of this sheet is important, since the data recorded will generate
specific work orders for the machines that present a problem in the inspection.

3.3.4. Stoppage control sheet

This is another record or control sheet for each machine that was
developed to have control over stoppages caused by inspections, failures and
breakdowns, in addition to the reasons that caused these stoppages. This is a
control that must be carried out by the convoys or work fronts, and it works as
follows: each machine will have a stoppage control sheet, which will be the only
file that is not in the file, but on the machine. (saved somewhere on the machine).
When the machine stops for any reason, whether or not it has been foreseen in
the maintenance program, the stoppage must be noted. This control will indicate
the date and reason for the strike as well as its duration; Each stoppage that is
recorded will be endorsed by the signature of the machine operator and the
mechanic.

57
 This control will serve both the operator and the convoy leader to justify to
the machinery inspector, and he in turn to the head of the road zone, the reason
why the machine is stopped.

3.3.5. Work order sheet

The work order informs the person in charge of the machinery (machinery
inspector), the head of road zone 11, that there is a fault that needs repair.
It also informs you of the nature of the failure and the necessary repair, as
well as its priority, depending on the work you perform. In addition, the head of the
road zone is informed; This order also requests authorization to carry out the work.
This work order will be filled out at the machinery inspection.
The order will be signed by the operator, machinery inspector and the head
of the road zone, respectively, and will then be delivered to the workshop head so
that it can be fulfilled, it must have a correlative order number to be able to keep
track of whether they are they comply appropriately. All work carried out by means
of a work order must be recorded in the machine's failure history.

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MACHINERY SHEET

59
FAULTS AND FAULTS HISTORY SHEET

60
CONTROL SHEET FOR MACHINERY INSPECTION

61
STOP CONTROL SHEET

62
WORK ORDER SHEET

63
 CONCLUSIONS

1. Most of the heavy machinery that is available suffers deterioration, due to not
having a history or record, which leads to lack of control and poor
administration in the service of the machinery.
2. The basic principles under which heavy machinery works are: engine: which
provides power and power train, both of which must be given priority in
maintenance. The correct lubricant must be applied in the appropriate place,
machine and quantity, to prolong their real life.
3. The deterioration of heavy machinery transmissions is always due to: poor
operation (making the unit skid too much) and rolling the machinery over very
long distances.
4. Driving the units over long distances causes heating in the pumps, brakes and
wheels; This heating is transmitted to the oil, which causes deterioration of the
additives and consequently the degradation of the oil as a result of a high
temperature oxidation process.
5. The D6D tractor air filter has a two-color service indicator that indicates when
the primary and secondary filter is dirty; clogged or needs changing; This is
displayed when the yellow piston of the service indicator enters the red zone.
6. The ideal maintenance and the one recommended in this work is preventive,
although the possibility that everything fails due to fatigue is not ruled out, but
putting this program into practice will improve the operation and useful life of
all the machinery and therefore of all the road area.
7. To keep the machinery in good working order, it is necessary to strictly follow
the recommendations required by all systems and for which there is
information in this document.
8. For the maintenance program to work, it is necessary to work with the
proposed files and place the requested data in each of them in a clear and
understandable way.
9. The existence of spare parts can be optimized, depending on the history of the
machinery (control sheets), since these contain the date and maintenance
carried out on the machinery and based on this the approximate average
duration of the spare parts.
10. The assortment of spare parts is carried out taking into account the urgent
need for preventive maintenance on machinery in the road area.

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 RECOMMENDATIONS

1. Provide a budget for the purchase of safety equipment in the workshop or

maintenance section, since there is currently a lack of protective equipment for
personnel in road zone 11, which represents high possibilities of risk of
accidents.
2. Constantly provide training courses to maintenance personnel and operators
of heavy machinery, to improve their service conditions.
3. Complete the construction of the new facilities, to carry out the transfer of all
administrative personnel and thus improve the efficiency and execution of
projects within the area.
4. Have a good assortment of spare parts and accessories, as well as lubricants
necessary for machinery and equipment. These must be stored in a place that
is easily accessible to the personnel in charge of said work.
5. The machine manager must implement a line of command, both for the
machinery personnel and for the workshop personnel, that allows him to more
efficiently supervise the work carried out by the machinery and workshop
department.
6. Delegate administrative functions to the deputy head of the department,
directly, in order to better supervise the work carried out by the machinery and
workshops department.
7. Maintain good communication with the workshop manager, so that machine
repairs can be coordinated.
8. The following recommended distance for heavy machinery should not be
exceeded: 1.5 km for a crawler tractor, 5 km for a front loader, 10 km for a
motor grader and 8 km for a backhoe.
9. Constantly schedule training courses for all workshop personnel (mechanics,
pilots and operators), to ensure that the personnel maintain a technical level
necessary to satisfy the needs of the workshop, and thus obtain optimal
performance from the workers, thus prevents the deterioration of machinery,
equipment and tools.
10. Acquire at least another backhoe and another vibrocompactor, which will help
and reinforce the current ones due to the service demand of the work convoy.
11. Put this maintenance program into practice as soon as possible, to prevent
heavy and light machinery from further deteriorating.

BIBLIOGRAPHY

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1. Avalone, Eugene A. and Theodore Baumeister. Mechanical Engineer's

Manual

1. Volumes 1 and 2, 3rd ed. Mexico: McGraw-Hill Publishing, 1995

2. American Company. The oil and its engine, steps around the machine.

3. USA: Caterpilar, 1992

4. Caterpilar Inc. Manual of parts and spare parts for different machinery. USA:

1982

5. Caterpilar Inc. Your undercarriage guide. USA: Caterpilar Publishing, 1986

6. Caterpillar America Company. Maintenance Manual for 920 and 930 wheel

loaders. HE USA: Caterpilar, SA

7. Caterpillar America Company. Operation and maintenance manual for 120G

and 130G motor graders. HE USA: Caterpillar, 1190.

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