Case Study: HYTORC AVANTI Optimizes Locomotive Maintenance Safety and Speed in South Africa
Maintenance efficiency is essential in rail transportation. For one of South Africa’s transit organizations, maintaining the engine components of their EMD 645 locomotives presented a significant mechanical and safety hurdle. Traditional maintenance methods weren’t only slow, they were a liability. This case study explores how HYTORC implemented a custom-engineered bolting solution to transform a hazardous task into a streamlined, safer operation.
Bolts are by far the most important detachable joints in any mechanical industry. More than 2/3 of all detachable joints are tightened by means of bolts. In Africa alone, more than 50 billion + bolts are used every year, With safe and user-friendly systems and practice-oriented solutions, HYTORC helps you find the perfect bolted connection with regards to costs, quality and productivity. -John Fairhurst, Corporate Account Manager: Africa
Challenge: Manual Force and Worker Injury
The maintenance of EMD 645 engine components required immense torque to loosen critical bolts. At one facility, technical teams were historically relying on dangerous means to loosen bolts.
The critical issues included:
- Crew Injuries: Workers were being injured while attempting to loosen bolt heads connecting con rods to pistons.
- Dangerous Manual Force: Operators had to apply manual force to loosen torques of approximately 650 Nm or more.
- Unstable Tooling: The use of swivel head socket drivers created an unstable environment, leading to the safety concerns cited by the organization.
HYTORC Solution: Engineering a Safer Standard
HYTORC created a custom fixture designed to incorporate both safety and speed for seamless maintenance. Our custom engineering team developed this specialized solution to alleviate dangers of the previous practices.
1. The AV-7-03-AR Articulating Rod Reaction Fixture: This custom articulating rod reaction fixture was designed specifically for loosening connecting rods from engine pistons. Its primary functions are:
- Stability: Eliminating the dangerous sideways action common with manual swivel drivers.
- Safety Integration: Providing a dedicated reaction point that removes the need for manual counterforce.
2. The AVANTI Hydraulic Torque Tool: To provide the necessary power, HYTORC coupled the fixture with the AVANTI Hydraulic Torque Wrench. This professional-grade tool allowed the transit organization’s team to tackle high-torque bolts with hydraulic precision rather than less precise methods that caused physical strain.
Results: Efficiency Without Compromise
Using the AV-7-03-AR and AVANTI system showed immediate improvements during testing.
- Seamless Loosening: The AVANTI was charged to 8,000 PSI on the pump, which loosened the bolts with ease.
- Precision Stability: The fixture showed little to no sideways action during the bolting process.
- User-Friendly Setup: The entire system was easily set up, meeting the organization’s high expectations for more accurate results and better safety.
HYTORC Improvements
- Safety: Shifted from high injury risks due to manual force and swivel drivers to a stabilized, hydraulic operation.
- Applied Force: Replaced manual exertion of 650 Nm or more with 8000 PSI of controlled hydraulic power.
- Tool Stability: Moved from unstable swivel head drivers to a more stable system with minimal sideways action.
- Efficiency: Transformed a slow, hazardous process into one with a fast, easy setup.
The Track To Success
By transitioning to using HYTORC’s articulating rod reaction fixture, the customer successfully mitigated the risks associated with locomotive engine maintenance. The solution didn't just protect the workforce - it optimized the maintenance lifecycle of the EMD 645 fleet, ensuring South Africa’s rail infrastructure remained on the move.
Is your maintenance team facing safety risks during heavy-duty bolting? Contact HYTORC today to learn more about our custom engineering solutions.
