REPORT 1

TECHNICAL REPORT ON MAINTENANCE PLANNING

OF THE MOTORIZATION SYSTEM OF MACHINERY OR
HEAVY VEHICLE

Héctor Echeverria
Carlos Calcina
Members
Pablo Rojas
German Cruz

Subject: Integrated Maintenance and Service Workshop I

Section D-N40-N3-P4-C1/D Calama N4
Academic: Mechanical Engineering in Heavy Machinery and Automotive Vehicles
Date
1. Identification of the assigned machine and/or heavy vehicle.

MINING TRUCK
Type of machinery
KOMATSU
Brand
930E-4SE
Model
KOMATSU YELLOW IP10
Color
A31468
Serial number
500 HRS
Hour meter
PREVENTIVE MAINTENANCE SCHEDULE 500 HRS
Application
RADOMIRO TOMIC-CODELCO NORTH
Customer name

Photograph of the
machine

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3. Safety regulations or rules.

TALK
SAFE WORK PROCEDURE

The work procedure by operational practice is understood as the normalization of

development of a certain work or activity according to guidelines instructions
based on factors as important as safety, quality, and productivity.

The objects of procedures to be achieved are:

The general or specific risks that can occur in places of

work.
The prevention and protection measures to consider, so that the work
be sure.
Comply with the regulations and maintain a preventive attitude.

To this end, it is necessary for workers to be aware of the risks to which they are exposed.
find exposed and adopt safe habits for taking care of yourself and
companions.

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4
The green card

It is an important security tool that allows any worker to...

notice an unsafe condition, they can raise their card and, with that, stop the
operation until the security conditions are adequate, also maintain well
used to stop a dangerous task or work and prevent a work accident, in the face of a
equipment in poor condition.

WORKSHOP

For this type of maintenance, it is necessary to know the type of vehicle, the activities.
to be done, input times and tools to be used, The designation of the model of
KOMATSU truck consists of three numbers and one letter (example 930E), the three
numbers represent the basic model of the truck, the letter "E", when present,
identify an electric drive system for the wheel motor.
The Product Identification Number (vehicle serial number) contains
information that identifies the original manufacturer’s parts list for this
unit. This complete number will be needed to correctly request the
spare parts and/or to make the warranty effective.
For any procedure, one must pay attention to the warnings, (check manual
of procedure).

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PERSONAL PROTECTIVE ELEMENTS SUGGESTED ACCORDING TO ACTIVITY AND
RISK.

The work of mechanics occurs in a risk-filled environment, and that is why it is

the use of industrial PPE is necessary. Thanks to its implementation, the mechanics
they can
feel more secure to review the machinery and equipment.

Is it important for a mechanic to carry personal protective equipment (PPE) with them?
Yes, there is no doubt about the importance of carrying the Protection Equipment with you.
Staff for mechanic, at the time of carrying out a job in the mechanics workshop. And
this is because PPE for mechanics reduces the risk of accidents, since
keeps the worker protected and safe.
In addition to allowing work optimization, it prevents the tools from
mechanics
they are misused.
Now, regarding the Personal Protective Equipment for automotive mechanics
more

suitable for a mechanic, there are:

Nitrile gloves
Paper jacket.
Helmet with goggles
Eye protectors.
Masks.
Non-slip safety shoes
Safety helmet
Protective clothing.
Ear protectors.
Sunscreen.
safety glasses.

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Each of them aims to protect a specific part of the body.
achieving a reduction in the risk of accidents in the mechanic workshop.
TOOLS, INSTRUMENTS, AND EQUIPMENT USED IN MAINTENANCE

Generalities
The tools and equipment used in industrial maintenance are related
directly with the typical activities carried out during the execution of the
maintenance, that is to say that the tools and equipment used in the
typical maintenance activities. There are specific tools for Inspection
of machines and equipment, regulation and adjustment of equipment components, lubrication of
machines and equipment, repair of machines and equipment, cleaning and sanitation of machines,
teams and work areas.

PM CODE DESCRIPTION TOOL MANUAL, CODE REQUIREMENTS

MINIMUMS S/N
SPECIAL INSTRUMENT SPECIAL ESTANDA
INTERNAL
R
A10, A17
A18, A19
A20, A21 Hydraulic testing suitcase HH0018
A22, A23
A24, A25
A02, A28 Industrial Vacuum Cleaner EM0009
A14, A27 Megger or megohmmeter IM0016
A15, A28 Air line Pressure 70 PSI maximum Without standard
B1, B2, B3, B4 vacuum pump oil intake (vampire) HP0062 Fluke 1507
C57 Brake disc wear indicator EF9302(CSS)
C24, C27, C28 Computer, serial cable, AT Monitor Software Without standard
H12 8" tape measure tool box repair in millimeters Without standard (CH001-ITEM 8)
H14 Comparator clock IM0013
H18, H19, H20 Industrial vacuum cleaner for dust and water EM009
I10 Ultrasonic leak detector IM039
I12, I13 Oil dispenser gun Without standard EM0040
I15 Digital metro foot TE033
L13 Manual grease pump EM0038
V04 3/4 manual torque wrench HT0005
V05 3/8 Manual Torque Wrench HT0003
V08 Oil micro filter EM0005
V18 Digital subway foot IM0009
V20 Fog machine HPO69
V21 Removal and installation of magnetic plugs KHF099
V22 Ultrasonic leak detector IMH67
Crown key, removal of lower caps of the lifting filter

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 Hydraulic Testing Kit HH0018

SUPPLIES

Stage and procedures

The engine is one of the most critical parts of the CAEX truck, so its
maintenance is essential to ensure the proper functioning of the vehicle.
continuation, the stages and recommended maintenance procedures are detailed
for the engine:

Preventive maintenance: The most important stage is preventive maintenance. It

you must change the oil and filters according to the manufacturer's recommendations and
from the operation manual. In addition, the fluid levels must be checked and adjusted,
including the coolant, engine oil, and brake fluid. It is also
It is important to conduct visual inspections to identify liquid leaks, wear of
parts and damages.
C
Filters Characteristics

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 Primary oil filter Wear and preventive change
Secondary oil filter Wear and preventive change

Review of the cooling system: The cooling system is fundamental for the
correct functioning of the engine. A periodic inspection of the radiator should be carried out,
the cooling ducts and the thermostat to ensure they are working
correctly. In addition, the refrigerant level should be checked and replaced if it is
necessary.

Fuel system review: The fuel system is also critical for

the correct operation of the engine. It is recommended to check the fuel filter and
replace it if necessary. In addition, the fuel pressure and the must be checked.
injectors to ensure they are functioning correctly.
Air system review: The air system is essential for combustion
engine. A periodic review of the air filter should be carried out and it should be replaced if it is
necessary. The air intake system must also be checked to ensure that
that there are no obstructions.

Filters Characteristic
Primary fuel filter Wear and preventive change
secondary fuel filter Wear and preventive change

By following these stages and maintenance procedures, it can be ensured that

correct functioning of the CAEX truck engine and extend its useful life. In addition,
proper maintenance can reduce operating costs and increase
safety in the mine.

HAZARDOUS AND POLLUTING WASTE.

One of the types of waste that is most important to manage properly

they are called hazardous waste. This type of waste can be
recyclable or not. However, what characterizes this type of waste is that they are
wastes that present a very high risk to both the environment and
the health of people and animals.
Due to this, we are dealing with waste that must be managed in a special way.
That is to say, in a specific way that distinguishes them from other usual waste.

In this regard, each type of hazardous waste has an associated management protocol.
to ensure its proper management and that it does not become a health hazard or the
environment. If you want to know more about hazardous waste, learn about its
classification, some examples and their handling.

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CLASSIFICATION AND EXAMPLES OF HAZARDOUS WASTES. (HW) WASTES

HAZARDOUS CORROSIVES: these wastes are characterized by being corrosive to

to come into contact with a surface. Numerous examples can be found,
especially regarding acids, such as sulfuric acid.

HAZARDOUS WASTE DUE TO CHEMICAL REACTIVITY: this waste is

dangerous when they come into contact with other substances that cause them to react
Chemically. Substances used in the laboratory can be mentioned, as well as
many heavy metals including mercury, cadmium, or lead
among others.

EXPLOSIVE HAZARDOUS WASTE: are waste that can explode upon entry
in contact with heat sources. The clearest case would be that of dynamite or gunpowder.

FLAMMABLE HAZARDOUS WASTES: in this case, it refers to substances that

they can catch fire easily, even becoming explosive in some situations
concrete. Here it would be appropriate to mention substances such as petroleum derivatives or gas
natural among others.

TOXIC HAZARDOUS WASTE: these are wastes that are dangerous for the
health. In the case of inorganic waste, substances such as the
arsenic or mercury, which are considered heavy metals. While in the
In the case of organics, the clearest example can be found in the waste from centers.
of health such as hospitals or laboratories.

RADIOACTIVE HAZARDOUS WASTE: are waste materials that emit radiation, such as
The waste can be from uranium or plutonium. Primarily, it is worth mentioning
the waste produced in nuclear power plants.

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 WASTE MANAGEMENT PROCEDURE.

1. OBJECTIVE

This procedure establishes the general conditions of responsibility and

the description of specific activities for collection, packaging, classification

of waste, internal transportation, and storage.

2. SCOPE

All personnel involved in the task must know and apply the following

procedure.

3. RESPONSIBLE.

General Manager: Provide the necessary resources to carry out the

present procedure.

Workshop manager: Ensure compliance with this procedure

• SGI Manager: To inform, demand and ensure compliance with this procedure.

Advise the chain of command regarding this procedure. Verify the

compliance with the present procedure.

DESCRIPTION OF ACTIVITIES

I. REQUIREMENTS FOR WASTE MANAGEMENT

The company's staff, when handling hazardous waste, must do so under the
following considerations:
The generated waste will be identified and classified according to its level of
risk, using NCh. 2.190 Of. 03 as a basis.
Necessary precautions must be taken to prevent inflammation of the
waste, among others its separation and protection against any source of

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ignition capable of causing such effects.
Take the necessary measures to prevent spills, discharges, or emissions of
waste to the environment.
Hazardous waste cannot be mixed with non-hazardous waste; in case of mixing
accidental or intentional, the total of the shipment will be considered hazardous waste.
• Hazardous waste will only be mixed or come into contact with each other when they are

of a similar or compatible nature, according to D.S. 148/03.

Hazardous waste containers must comply with the following

minimum requirements:
a) Adequate thickness and made with materials that are
resistant to stored residue and leak-proof.
b) Able to withstand the stresses produced during loading,
the download and transfer of waste, ensuring at all
moment that there will be no losses.

c) Keep the containers in good condition during their

storage, in case of deterioration of the
container in its containment capacity, it must be
replaced.
d) To be labeled, indicating visibly, the characteristics
of the hazardous nature of the contained waste, according to NCh 2190 Of.

03, the process in which it originated, and the date of location in the

storage site.
The containers will only be removed manually if their total weight, including the
content, does not exceed 30 kg. If this weight is exceeded, it must be removed.
with the help of mechanical equipment (forklift, boom truck).
Only containers will be reused when it comes to non-incompatible waste,
according to the provisions of DS No. 148/03, unless they have been previously

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decontaminated.
NAME RESIDUE

PRIMARY DANGER

II. INTERNAL PROCEDURE FOR COLLECTION, TRANSFER AND

STORAGE OF HAZARDOUS WASTE.

To carry out these stages, there is infrastructure available for the management of the

hazardous waste.
To comply with the provisions of D.S. 148/03, a warehouse will be implemented.
Hazardous Waste, to be stored for a maximum period of 6 months those
waste generated at Bec Engineering and Construction S.A. facilities
III. CHARACTERISTICS OF TEMPORARY STORAGE SITES

AND TRANSITORY OF HAZARDOUS WASTE.

a. Temporary Storage Site for Hazardous Waste

For the Temporary Storage of hazardous solid and liquid waste in
containers, there is a RESPEL Warehouse, which must comply with the
requirements established in the current regulations for this type of activity.
The estimated operating hours of this venue will be from Monday to Friday at
schedule from 08:30 to 12:30 and 15:00 to 17:00, previously arranged with the boss

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of area.
The standards that the Temporary Storage Site must comply with
Hazardous Waste will be those required by D.S No. 148/03. In particular:
Corresponding authorization from the Health Authority.
Hazardous waste must be located inside in labeled form.
containers and sectors enabled for such use.
The storage period for hazardous waste shall not exceed 6 months.
except for the exceptions that the regulation considers (authorization with extension).

It will have a perimeter fence of 1.80 meters in height to prevent free access.
of people and animals.
Divisions will be implemented inside the site to accommodate separately.
the different types of waste.
The site will have a continuous, waterproof, and structurally resistant base.
chemically to the waste and a capacity to receive spills.
It will be covered with a lightweight roof, which will reduce solar radiation on
the accumulated waste and its respective labeling.
The site will have signage according to the Chilean Standard [Link]. 2.190 Of. 03
and with elements for spill and fire control.
The Temporary Storage Site will be located inside the facilities of
the company.
b. Temporary Storage Tanks for Used Oil.
In the RESPEL warehouse, there is a 200 L metal drum for the
storage of used oils intended for the maintenance of equipment,
Minor Vehicles. The standard that storage sites must meet.
The residual oils will be that required by D.S. 148/03, MINSAL.
c. Characteristics of Temporary Waste Collection Sites
Dangerous.

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The temporary collection sites must have the established characteristics
in the Regulations for Hazardous Waste Storage Sites:
The floor will be compacted, waterproof surface, marked, covered,
fenced and must have access points that allow for safe operation
both for the entry and exit of waste.
Hazardous waste will be disposed of separately, in containers.
and labeled drums, enabled for that use.
The site will have signage in accordance with Chilean Standard [Link]. 2190 Of.
03, elements to contain spills and fire extinguisher for fire control.
If necessary, divisions will be implemented to accommodate accordingly.
separate those incompatible waste.
IV. HAZARDOUS WASTE MANAGEMENT PROCEDURE.

a. Segregation at Origin
Hazardous waste will be segregated at the generation points, in each area.
of work, stored inside labeled containers and segregated,
strategic sites.
The staff in the area will be responsible for arranging the items in the collection sites.

temporary containers when they reach approximately 80% of their

capacity.
Containers will only be removed manually if their total weight, including the
content, does not exceed 30 kg. If this weight is exceeded, it must be removed with the
mechanical equipment assistance.

b. Segregation at the Temporary Collection Sites.

Waste classified at source must be collected in containers.
located close to the operation, waiting to be picked up by the staff
service and transfers to the temporary storage site (RESPEL warehouse).
Hazardous waste will be placed separately inside

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containers labeled according to NCh 2.190 Of. 03.
The area responsible for waste management of the company will have a program.
for collection that allows the removal of containers from each generating area
periodically.
V. SYSTEM FOR RECORDING HAZARDOUS WASTE.

A hazardous waste registration system is established for the entry and exit.
Hazardous Waste Warehouse. BEC-R-M-04.01.
In the waste register, the staff in charge will record the type of waste.
(content), the date of entry, the amount in pesos, area of origin, description of
waste (solid, liquid, sludge), name and signature of the responsible person. It will be

filed to comply with the semiannual hazardous waste income statistics.

Each record will be filed with the purpose of compiling with this data the
monthly statistics on the disposal of hazardous waste, under the responsibility of the

Environmental Management Unit.

In addition, the control sheet must match the declaration sheet.
hazardous waste delivered and issued by the health authority, which will be signed by
the generator, carrier, and final recipient. This must be stored for two
years according to the requirements of D.S 148/2003.

VI. GENERAL RECOMMENDATIONS.

In case of performing a lifting maneuver of special characteristics,

for example: in slope, the A.S.T. will complement the present
procedure with the risks identified and the control measures to be implemented.

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ENVIRONMENTAL RISKS.

We must always bear in mind that when carrying out this type of maintenance, whether it is
preventive or corrective, to the different components of said machinery.

The risks of contamination to the environment are run, making oil a

important component in this issue since at this point it is the component
What is needed to carry out several of the required tasks in the different
heavy machinery.

And being one of the most polluting and dangerous waste for the environment.
environment, as it degrades in its different components of work, which
they are polluting and releasing their various toxic substances and types of metals that are
produced by exposure to high temperatures and pressure exerted by the different
components.

Therefore, when carrying out this type of maintenance, we must keep in mind that we must
to have a fairly wide area and it obviously must be completely clean
the work area for us to perform a clean and appropriate job.

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 General planning.

MAINTENANCE PROGRAM:ANNUALEXTRACTIONTRUCK (CAEX). Note: before intervening on the equipment, the mechanical maintainer must ensure that the equipment is in the workshop without power, that it is stopped and that there is no operator on the equipment.
RESPONSIBLE: HECTOR ECHEVERRIAVALENCIA to then de-energize the equipment through a short current and apply a lock and tag, proceed to secure with a wedge to prevent the equipment from
AREA:MAINTENANCE displace for possible kinetic energy. Before applying the brakes, you must wait for the truck to reach an adequate temperature, this must be measured through a pyrometer.
DATE OF CREATION: JANUARY 4, 2022
SYSTEM: BRAKE SYSTEM FIRSTSEMESTER SECONDSEMESTER
EQUIPMENT: EXTRACTION TRUCK KOMATSU JANUARY FEBRUARY MARCH APRIL MAY JUNE JULIO AGOSTOSEPTIEMBREOCTUBRENOVIEMBRE DICIEMBRE
ACTIVITY: PREVENTIVE MAINTENANCE FREQUENCY START 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
CHECK THE WEAR OF THE BRAKE DISC C/1000 Hrs. (42 days) 1 day P P P P P P P P P P
HYDRAULIC OIL CHANGE (C-4) C/1000 Hrs. (42 days) 1 day P P P P P P P P P P
OILFILTER CHANGE C/1000 Hrs. (42 days) 1 day P P P P P P P P P P
CHECKTHEWEAR OFTHE REAR BRAKE DISC C/1000 Hrs. (42 days) 1 day P P P P P P P P P P
Wheneverareartireisremoved,therearbrakesshouldbeinspectedforwear.
CLEANTHEBRAKESETSVERYWELL INEACHMAINTENANCE
CHECKING OILLEVELS C/500 Hrs. (21 days) 1 day P P P P P P P P P P P P P P P P
VISUAL INSPECTION OF OIL LINES INEACHMAINTENANCE
INSPECTIONOFTHROTTLEANDBRAKEPEDAL C/500 Hrs. (21 days) 1 day P P P P P P P P P P P P P P P P
LUBRICATE HINGE PINSAND PEDALROLLERS C/500 Hrs. (21 days) 1 day P P P P P P P P P P P P P P P
Apply oil between the mounting plate and the piston. C/500 Hrs. (21 days) 1 day P P P P P P P P P P P P P P P P
ENGINEBRAKE C/1000 Hrs. (42 days) 1 day P P P P P P P P P P
AIRMANGERS,CHECKFORLEAKSANDDAMAGE. C/1000 Hrs. (42 days) 1 day P P P P P P P P P P
ELECTRICRETARDER C/1000 Hrs. (42 days) 1 day P P P P P P P P P P