Off-Site repair efficiencies at J&S Engineering

Reclaiming bores on large mining equipment is critical to ensure reliability and availability of a remanufactured component and involves cleaning up damaged bores, critical welding to re-establish metal quality and thickness, and then line boring prior to fitting new bushes. This is a time consuming process and difficult to get right. J&S Engineering continues to optimise repair processes to ensure both quality and efficiency are delivered.

Our most recent innovation is to utilise our large Soraluce Travelling Column (STC) to machine bores after welding using the unique interpolation capability of the STC. This approach renders portable line boring equipment obsolete when components are able to be repaired off-site.

The use of the STC on our most recent example of an excavator bucket modification has delivered a 2 day time saving.

This unique approach to reclaiming bores shifts the cost benefit equation in favour of ‘Off-Site Repair’ as opposed to ‘On-Site Repair’ in terms of quality and efficiency. Controlling critical welding of bores cannot be understated, controlling welding parameters including consumables and temperature underpins quality and smart machining dictates efficiency.

Deliverables are:

1. Controlled welding and pre-heat

2. Fast and accurate machining, removing 4 shifts of portable line boring

3. J&S Engineering achieves ‘lowest total cost of ownership’ solution.

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Not all Equaliser Bars are re-manufactured Equally!

J&S Engineering has been re-manufacturing and upgrading Equaliser Bars for more than 30 years. Over this time, we have developed robust procedures and operating practices to deliver ‘best of breed’ outcomes for customers delivering trouble free operations between overhauls.

Observations gathered over recent time continue to indicate that not all repairers have the necessary experience and protocols to deliver reliable products.

Our most recent example highlights a number of issues that ultimately lead to failures in the field and reduced operating life:

  • Strong backs poorly fitted to the body and material thickness undersize.
  • Fillet Welds undersize and poor quality
  • No stress relieving of welds or inadequate stress relieving
  • Bores not reclaimed properly or effectively
  • Poor final machining

The outcome of these shortfalls includes:

  • Fatigue cracking and failure of structural components
  • Reclaimed bores delaminating
  • Poor seal contact in the bore allowing the seal to walk out. The user often has to weld washers on the face of the equaliser to hold the seal in place however this practise induces cracking in the bar.

J&S Engineering integrated re-manufacturing services ensures these types of issues are prevented making Equaliser Bars go the distance and on-going overhaul costs are minimised through less re-work. An Equaliser Bar refurbished at J&S will have bores machined to OEM spec, if any welding was required the bar has been correctly stress relieved, the bar has been MPI and UTS inspected and passed by a third party approved company so quality is assured.

Strong backs poorly fitted to the body and material thickness undersize. Fillet Welds undersize and poor quality

 

Inadequate bore reclamation and poor machining

 

Post Stress Relieving after bores reclaimed at J&S Engineering facility Rutherford.

 

              

J&S Engineering remanufactured Equaliser Bars ready for despatch

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