03 October 2022

Custom R2900G separation tooling eliminates live work procedures

In a first for Hastings Deering, the team has developed a custom solution for the elimination of live work in separating a Cat R2900G Underground Loader.Designed for high production, low cost-per-ton loading and tramming in underground mining applications, this machine requires regular separation for hitch repairs and bucket change outs.Safety requirements on the site of operation meant there was a need to eliminate live work when performing maintenance, this led to the team working on the development of this new system.

Luke Rietdyk Senior Design Engineer at Hastings Deering said that the customer approached Engineering Services to work on the development of a tool to help them perform these tasks safely, and in accordance with their elimination of live work initiative.

“It was very much a collaborative approach between Hastings Deering and the customer, sharing design reviews and concept images along the design process,” Mr. Rietdyk said.

“Basically, they wanted to perform the hitch repairs and bucket change outs with the machine completely isolated and locked out.”

Over 4 months, the Engineering team at Hastings Deering worked on a design internally, scaling down an original design for a Cat 993K loader.

Custom R2900G separation tooling

Manufactured in Brisbane, the R2900 Frame separation tool was developed and rigorously tested in Alice Springs in late 2021.

The frame separation configuration enables the machine to be driven over a frame and dollies on the workshop floor. 

Once the machine is safely supported at the front and the rear, the dollies are hydraulically actuated and push the front of the machine forward.

“The machine is pushed around 1.8 metres which gives enough space for the repair work to be done on the hitch.”

Once the repair work is done, the front of the machine slides back to meet the rear half with the hitch perfectly aligned.

“This tooling now ensures that there is no longer any need for forklifts or cranes to assist with aligning the machine.”

The second configuration of the tool was developed for the bucket change outs.

The machine is driven onto the dolly and the bucket is lowered onto the supports, the bucket can then be pushed away from the machine and when the new bucket gets dropped on it can be married back up to the loader arms and the pins can be finitely aligned making it much easier to reassemble the bucket. “Using this tooling, we’ve enabled the customer to be able to complete the job, in accordance with their elimination of live work procedures.”

“One person can do the job once the machine is driven on and isolated and pins removed – all power is disconnected, activate hydraulics on the tool which will push the machine forward allowing normal tasks to be performed safely,” said Mr. Rietdyk.

“It’s satisfying to come up with a concept on a computer screen and be able to see that come to life, most of all it’s satisfying to know that we’ve been able to help the customer complete the job quicker and safer.”