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Maintainability Design Checklist

The following is a Maintainability Design

Checklist for coal mining equipment. The

purpose of the checklist is to provide a

summary of design review points for the

maintainability assessment of new or existing

underground equipment. It specifically focuses

on the identification of equipment design

features, tasks, or procedures that impact

equipment downtime, repair costs, labor hours

and maintainer skill level requirements. 

Some checklist points are general in nature. 

The checklist was designed to be used across

all categories of underground equipment. The

intent is to draw attention to design features

and maintenance procedures that will increase

maintainability requirements. You are

encouraged to adapt this checklist to site

specific or machine specific requirements by:

C Inserting specific performance criteria for various

categories of maintenance tasks. For example;

all hydraulic lines on a shuttle car should be

replaceable in 15 minutes or 25 minutes, etc.

C Adding or deleting checklist items for different

categories of equipment. You would include

environmental control equipment, for example,

on face equipment and not on shuttle cars or

man trips. 

C Adding additional checklist items based on site

or equipment specific maintenance histories or

experience, company maintenance standards, or

other factors.

Some important checklist definitions include:

C Primary Maintenance Zone - The zone or area

from the side or the end of a mining machine

inward 45 cm (18 in).

C Secondary Maintenance Zone - The area from

a point 45 cm (18 inches) from the side or end of

the machine to a point 45 cm (18 in) from the

opposite side or end of the machine.

C Tertiary Maintenance Point - A maintenance

point outside the primary and secondary

maintenance zone. An example would be a

lubrication point on the end of a conveyer boom.

C Immediately Accessible - A component that

you can reach, removed or repaired without

having to open access covers, remove other

components, or disassemble other components.

C Maintenance Point - Any point on the machine

where you join two components, mount a

component on the machine chassis, or where

you attach hoses, cables and lines to a

component.

The checklist categories include:

1. General Maintenance Reduction

2. Safety and Environmental System Design

Features

3. Design Standardization Features

4. Design Features for Routine Maintenance

5. Design Features for Troubleshooting

6. Design Features for Repair and Replacement

7. Visual Inspections and Accessibility

8. Design for Physical Accessibility

9. Hydraulic System Maintenance Design

10. Mechanical System Maintenance Design

11. Electrical System Maintenance Design

12. Personal Protective Equipment Maintenance

13. Design for Mechanical Safety

14. Storage Battery Maintenance

For additional information on maintainability

design of underground mining equipment

contact:

Pittsburgh Research Laboratory

P.O. Box 18070

Pittsburgh, PA 15236

412-386-5081

Attn: Richard L. Unger

email: pithealth@cdc.gov
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1. General Maintenance Reduction

ADEQUATE

 YES NO

9 9 Hydraulic hoses, electrical cables, and water hoses are securely

attached along their length to protect against abrasive wear,

pinching, or other damage.

9 9 All cables and hoses are protected to minimize exposure to

impact or fall of roof damage.

9 9 Power feed cables enter the machine or the cable reel from the

side to minimize exposure to vehicle wheels or tracks.

9 9 All components, systems, and devices are located where they are

protected from fall of roof damage.

9 9 All exterior mounted machine features and components are

protected from impact, scraping, or collision damage.

9 9 Operator controls and displays are protected from impact, fall of

roof damage, or inadvertent activation.

9 9 Components subject to wear are designed for self-adjustment

where possible.

9 9 Where self-adjustment is not practical, the design provides

components that can be manually adjusted for wear to minimize

the need to tear down.

9 9 Design provides for a self-lubricating system for all bearings,

joints, and other wear points on the machine.
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1. General Maintenance Reduction (cont.)

ADEQUATE

 YES NO

9 9 Design provides for bearings and seals with wear or failure

monitoring capability to permit scheduling of maintenance prior to

actual component failure or component damage.

9 9 Design provides hour meters (e.g., on conveyer circuits), volt

meters and ammeters (e.g., on electric drive motors) to assist in

wear assessment and maintenance management.

9 9 Design provides for gears, bearing, hydraulic cylinders, and other

impact or load-absorbing components of sufficient size or rating to

handle peak impact loads. 

9 9 Design provides for adequate derating for bearings, motors, and

hydraulic systems to minimize overload related failures.

9 9 Vehicle frame is adequately designed to prevent cracking or other

fatigue-induced failures at hydraulic cylinder attachment points.

9 9 Vehicle frame is adequately designed to prevent cracking or other

fatigue-induced failures at articulation points.

9 9 Vehicle frame is adequately designed to prevent cracking or other

fatigue-induced failures at other frame load-bearing points.

9 9 Vehicle frame is adequately designed to prevent cracking or other

fatigue-induced failures at welded seams.

9 9 Provides for shock and vibration isolation of critical components.
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1. General Maintenance Reduction (cont.)

ADEQUATE

 YES NO

9 9 Protective covers are over all body cavities containing

components, hoses, lines, or maintenance points to prevent

buildup of muck and debris.

9 9 Interlocks are provided to prevent vehicle from being trammed or

moved with stab jacks extended.

9 9 Interlocks are provided to prevent vehicle from being trammed or

moved with drill booms deployed or extended.

9 9 Interlocks are provided to prevent vehicle from being trammed or

moved with tail booms extended.

9 9 Interlocks are provided to prevent vehicle from being trammed or

moved with Automated Temporary Roof Supports (ATRS)

extended.

9 9 Interlocks are provided to prevent vehicle from being trammed or

moved with cutting heads deployed or extended.

9 9 Interlocks are provided to prevent vehicle from being trammed or

moved with canopies extended.

9 9 Expanded metal grating is used for floors or other designs to

prevent accumulation of water, mud, and other materials in

equipment bays, crevices, and body cavities.

9 9 Rubber tires are protected by fenders, bumpers, or guards from

collision and rib impact.
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1. General Maintenance Reduction (cont.)

ADEQUATE

 YES NO

9 9 Mechanical linkage systems are protected from impact and fall of

roof.

9 9 Roof bolter geometry is designed to prevent over elevation

damage to boom lift mechanism.

9 9 Disc and drum-type brake systems and components are protected

from coal dust, rock, and other debris to minimize wear and

damage.

9 9 Mounting holes and brackets are designed to permit installation of

functionally similar parts produced by different manufacturers.

9 9 ____________________________________________________

9 9 ____________________________________________________
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2. Safety And Environmental System Design Features

ADEQUATE

 YES NO

9 9 MSHA-required lighting equipment is properly installed and

protected, but easily accessed for repair.

9 9 Fire suppression system is properly installed and protected, but

easily accessed for repair.

9 9 Panic bars are properly installed and protected, but easily

accessed for repair.

9 9 Methane detectors are properly installed and protected, but easily

accessed for repair.

9 9 Dust bins and filters are easily accessed, opened, and serviced.

9 9 Dust control water spray nozzles are easily accessed for

adjustment or replacement.

9 9 Dust control equipment fan motors are readily accessed for repair

or replacement.

9 9 ____________________________________________________

9 9 ____________________________________________________
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3. Design Standardization Features

Design provides for standardization of the following items throughout the

machine:

ADEQUATE

 YES NO

9 9 All mechanical components.

9 9 Hydraulic connectors, valves, hoses.

9 9 Electrical components and connectors.

9 9 Water hoses and connectors.

9 9 Fasteners and other attachment devices.

9 9 Bolts, nuts, and fasteners.

9 9 ____________________________________________________

9 9 ____________________________________________________
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4. Design Features For Routine Maintenance

ADEQUATE

 YES NO

9 9 Fluid-level indicators are provided on fluid reservoirs and in the

primary maintenance zone for ease of inspection.

9 9 Test points for stand-alone or built-in test equipment are located

in the primary maintenance zone.

9 9 All mechanical adjustment points are located in primary

maintenance zones.

9 9 Quick connect type couplers are installed on frequently changed

hydraulic lines, water hoses, and cables.

9 9 Quick-release fasteners are used on doors or covers for routine

inspection points.

9 9 Only one type of hydraulic fluid is used on the machine.

9 9 Oil seals are easy replaceable types.

9 9 Routine service points are not located behind other components

or structural members, in enclosed spaces, or in the secondary

maintenance zone (e.g., more than 46 cm (18 in) from the side or

the end of the machine).
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4. Design Features For Routine Maintenance (cont.)

Routine inspection points are all clearly visible and labeled including:

ADEQUATE

 YES NO

9 9 Relief valves.

9 9 Drain plugs.

9 9 Wear points.

9 9 Hydraulic line connections.

9 9 Personnel safety equipment.

Routine service points are clustered in one or two service locations in the

primary maintenance zone including:

ADEQUATE

 YES NO

9 9 Lube points.

9 9 Hydraulic reservoir tank fill points.

9 9 Hydraulic filters.

9 9 Environmental system filters.

9 9 Fuel tanks on diesel-powered equipment.
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4. Design Features For Routine Maintenance (cont.)

9 9 Belt or chain adjustments.

9 9 Line bleed valves.

Design reduces to a minimum the number of spare parts and components

required to support maintenance:

ADEQUATE

 YES NO

9 9 Common hoses.

9 9 Connectors.

9 9 Valves.

9 9 Drive belts, chain, etc.

9 9 Cables.

9 9 Nuts and bolts.

9 9 Washers.

9 9 ____________________________________________________

9 9 ____________________________________________________
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5. Design Features For Troubleshooting

ADEQUATE

 YES NO

9 9 General layout facilitates visual inspection of major components,

connections, couplers, interfaces, and potential damage points.

9 9 Hydraulic, electrical, and mechanical system schematics

permanently affixed to machine to facilitate troubleshooting.

9 9 Hydraulic, electrical, and other systems can be easily traced

throughout the machine.

9 9 All mechanical interfaces are visible from the sides or end of the

machine.

9 9 Manual test points are located in the primary maintenance zone

for all critical systems or subsystems.

9 9 Test points are designed to eliminate or minimize the need to

remove components for testing.

9 9 Locate test points in one or two locations where practical or in a

single test panel.

9 9 Test points are coded or labeled to identify recommended or

acceptable pressure, temperature, or voltage ranges.

9 9 Test points are labeled and are located close to the control or

display they are associated with.

9 9 Test set instructions for built-in test equipment (BITE) are

attached to the machine at the point of service.
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5. Design Features For Troubleshooting (cont.)

ADEQUATE

 YES NO

9 9 Automatic test equipment (ATE) sensors are provided that

operate without disturbing or loading the system under test.

9 9 Fail-safe design for all ATE where failure of test equipment will

not cause failure of the mining machine.

General design and layout provides for rapid and positive identification of

component malfunction:

ADEQUATE

 YES NO

9 9 Fluid leaks.

9 9 Pressure loss.

9 9 Shorts.

The following pertinent information is immediately available to the

maintainer:

ADEQUATE

 YES NO

9 9 Component or system identification.

9 9 Proper direction of motion or fluid flow.

9 9 Proper adjustment, pressure level, or setting.

9 9 Correct fluids.

9 9 Amperage and other electrical information.
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5. Design Features For Troubleshooting (cont.)

Self-checking features are designed into critical components or systems

where possible:

ADEQUATE

 YES NO

9 9 Major hydraulic systems.

9 9 Cooling systems.

9 9 Electrical circuits.

Built-in test capability and/or test equipment provided to monitor wear on

critical bearings or other wear points such as:

ADEQUATE

 YES NO

9 9 Continuous miner cutter head.

9 9 Gathering arms.

9 9 Articulation bearings on scoops.

9 9 Hydraulic pumps.

9 9 ____________________________________________________

9 9 ____________________________________________________
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6. Design Features For Repair And Replacement

ADEQUATE

 YES NO

9 9 All areas of the machine are designed to be self-cleaning and

designed to eliminate (minimize) the accumulation of rock, coal,

mud, and water.

9 9 All components are labeled to positively identify part numbertype, component ratings, types of lubricant-fuel required, direction

of flow, and other pertinent information.

9 9 All components and interfaces are designed to be installed only

one way - the correct way.

9 9 Design eliminates the need for special tools or jigs to perform

required maintenance.

9 9 All major parts used are available from local suppliers or vendors.

9 9 All mounting bolts are directly accessible and unobstructed to

permit use of required hand tools without having to remove or

disassemble adjoining components.

Provisions are made for adequate towing or movement of disabled

machine to maintenance area:

ADEQUATE

 YES NO

9 9 Tow cable attachment points.

9 9 Designated push points.

9 9 Tow bar attachment points.
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6. Design Features For Repair And Replacement (cont.)

Design features are incorporated to facilitate jacking, hoisting, or lifting of

machine to expedite maintenance and repair:

ADEQUATE

 YES NO

9 9 Designated jack points with jack plates designed to prevent jack

slippage.

9 9 Attachment points for overhead lifting devices.

Design features are incorporated to facilitate lifting, hoisting, or

manipulating heavy components and machine features:

ADEQUATE

 YES NO

9 9 Built-in attachment hooks.

9 9 Lift bolt attachment points.

9 9 Lifting guides or pins.

9 9 Provisions for forklift arms.

9 9 Built in swing boom arm.

9 9 Designated lift points.

9 9 ____________________________________________________

9 9 ____________________________________________________
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7. Visual Inspections And Accessibility

ADEQUATE

 YES NO

9 9 All maintenance points should be visually accessible from the

side or the end of the machine and should provide line-of-sight

inspection capability.

9 9 Design provides for clear and rapid visual identification of parts

that may have to be replaced or repaired.

9 9 Approved glass covers should be installed in all access opening

covers if routine visual inspections are required.

9 9 Access openings should be large enough to permit visual contact

with the component while the work is being performed on it.

9 9 Visual access openings should not be located on the top of

machines unless the average roof height above the top of the

machine is 61 cm (24 in) or more.

9 9 Visual access openings should never be located under the main

chassis or behind components that restrict visibility.

9 9 For less frequently performed maintenance tasks, the

maintenance point may be located behind a protective cover. 

The component, however, should be directly visible when the

protective cover is removed.

9 9 Maintenance and service points should be located no further than

91 cm (36 in) from the maintainer's head at time of inspection.

9 9 ____________________________________________________
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9 9 ____________________________________________________
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8. Design For Physical Accessibility

ADEQUATE

 YES NO

9 9 All components are accessible from the side or the end of the

machine.

9 9 All drain valves for compressor tanks, reservoirs, and sumps are

accessible from the side or end of the machine.

9 9 All other maintenance points are accessible from the sides or

ends of the machine.

9 9 All components that require repair, replacement, or adjustment

every 2,000 h or less should be directly accessible (can be

removed-replaced without having to remove other components)

from the sides or ends of the machine.

9 9 For components with an expected service life of over 2,000 h,

only one other component should have to be removed to access

for removal or replacement (R/R).

9 9 For components that must be disassembled to be repaired or

inspected (e.g., bearings), no more than four R/R task steps (e.g.,

remove part A, remove part B, etc.) should be required to access

the targeted part.

9 9 All components weighing more than 23 kg (50 lb) or more should

be removed from the side or the end of the machine and should

not have to be lifted up and over the machine frame or other

components.

9 9 Hinged or quick-release access opening covers should be used

where practical with the hinges on the side or bottom so that door

will remain open during maintenance.
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8. Design For Physical Accessibility (cont.)

ADEQUATE

 YES NO

9 9 A minimum number of bolts or fasteners should be used on

access covers, equipment bay doors, or other protective

shielding.

9 9 For components weighing more than 45 kg (100 lb), access

openings and work space should be sufficient to permit the

attachment of hoisting or lifting devices.

9 9 Screws, nuts, and bolts should be located to permit use of

requisite hand tools to remove or replace them.

9 9 Access openings should be sufficiently large to permit removal

and replacement of all components contained in that area.

9 9 Non-hinged access opening covers weighing more than 23 kg (50

lb) are designed with built-in handles or lifting device attachment

points.

9 9 All components can be removed and replaced in a straight line

from their place of attachment. (Components do not have to be

maneuvered around or over structural features or components.)

9 9 Design provisions are made to support components weighing

over 23 kg (50 lb) while they are being unbolted or bolted into

place.

9 9 ____________________________________________________

9 9 ____________________________________________________
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9. Hydraulic System Maintenance Design

ADEQUATE

 YES NO

9 9 Fluid reservoirs have adequate storage capacity to ensure

uninterrupted operation between shifts.

9 9 Dual in-tank or stand-alone filters are installed on each fluid

system to minimize component and control valve wear.

9 9 Hydraulic system filters are located in the primary maintenance

zone and use permanent or cartridge-type filters.

9 9 Hydraulic meters and gauges are located in the primary

maintenance zone.

9 9 Quick-disconnect-type hydraulic line connectors are used where

practical.

9 9 Hydraulic systems are designed to be fail safe with the system or

components reverting to a safe or neutral position in event of loss

of power.

9 9 Hydraulic circuits are permanently labeled to identify circuit,

direction of fluid flow, recommended pressure settings, and highand low-pressure lines.

9 9 All hydraulic valves are labeled to positively identify the systemsubsystem operated by that valve; the label should not be on the

valve itself.

9 9 Design uses seals that are visible after installation to ensure that

they are not inadvertently left out during maintenance.
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9. Hydraulic System Maintenance Design (cont.)

ADEQUATE

 YES NO

9 9 Design uses armor-coated flex hoses where hoses are subject to

abrasive wear or impact damage.

9 9 Design provides for automatic bleeding of major hydraulic

system(s).

9 9 Physically incompatible connectors are specified where there is a

danger or mismating connectors from adjoining systems.

9 9 Design provides metal shielding to protect electrical and other

sensitive equipment in the event of hydraulic fluid leak.

9 9 Design prevents the accumulation of hydraulic fluids in the event

of leaks or hose breaks.

9 9 Design provides for hydraulic system drains at the lowest physical

level in the system.

9 9 Hydraulic system fittings and valves are staggered to provide

improved access to each system's connectors.

9 9 ____________________________________________________

9 9 ____________________________________________________
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10. Mechanical System Maintenance Design

ADEQUATE

 YES NO

9 9 Design provides for minimum manual adjustment of all

mechanical systems, except to correct for wear.

9 9 Self-adjustment designs are incorporated where practical.

9 9 Design precludes the need for special tools or hardware to install,

adjust, or align mechanical components.

9 9 Components and mechanical interfaces are designed with the

minimum number or pivots, bearing surfaces, and other moving

part wear points to minimize maintenance requirements.

9 9 Mechanical system locks or locking devices are incorporated

wherever mechanical locking is required for maintenance.

9 9 Design avoids the use of through bolts for installation or assembly

where the nuts are not accessible to the maintainer.

9 9 Design locates high-failure-rate components outboard in the

primary maintenance zone.

9 9 Design provides for coverings or boots for exposed connectors,

universal joints, and other interacting mechanical parts to protect

them from mud, coal dust, and other debris.
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10. Mechanical System Maintenance Design (cont.)

Adjustments that cannot be designed out should:

ADEQUATE

 YES NO

9 9 Be completed without the requirement to disassemble the unit.

9 9 Be reduced to the minimum number of steps possible to

complete.

9 9 Not require removal or replacement (R/R) of other components to

complete.

9 9 Be incorporated into other required maintenance on the same

component.

9 9 Incorporate range limits to prevent over-adjustment damage.

9 9 ____________________________________________________

9 9 ____________________________________________________
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11. Electrical System Maintenance Design

ADEQUATE

 YES NO

9 9 Design routes all electrical cables on machine to avoid damage

from abrasion, pinching, or cutting.

9 9 All electrical cabling is routed to permit easy removal and

replacement. Cabling is not routed under machine chassis, in the

center of boom arms, or in other difficult-to-access locations.

9 9 Electrical connectors are isolated from hydraulic fluid leaks, fuels,

water, and other liquids.

9 9 Quick-disconnect-type electrical connectors are used where

possible.

9 9 All electrical equipment cabinets are equipped with interlock that

terminates power to the unit when the access cover is removed.

9 9 A manual override is provided for all cabinets equipped with

shutoff interlock.

9 9 Breakers and other overload protective devices are in a central

location in the primary maintenance zone.

9 9 Electrical connector pin patterns are coded to permit connecting

cables only to the appropriate receptacle.

9 9 Uses electrical plugs in which the alignment pins extend beyond

the electrical pins.

9 9 Design makes receptacles "hot" or "cold."
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11. Electrical System Maintenance Design (cont.)

ADEQUATE

 YES NO

9 9 Uses contact pins no larger than 30 cm (12 in) to resist being bent

upon insertion and withdrawal of the connector.

9 9 Design uses right-angle plugs to avoid sharp bends in the

electrical cable.

Design provides overload or other electrical protective devices for all major

electrical circuits, each of which is equipped with a "kick out" indicator light

for easy troubleshooting on:

ADEQUATE

 YES NO

9 9 Drive, conveyor, cutter head, and gathering arm motors.

9 9 Lighting.

9 9 Electric power takeoffs.

9 9 ____________________________________________________

9 9 ____________________________________________________
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12. Personnel Protective Equipment Maintenance

Personnel protective equipment is designed and located to facilitate

inspection, repair, and replacement of the following systems:

ADEQUATE

 YES NO

9 9 Dust control.

9 9 Methane monitoring.

9 9 Operator protective canopy (as required).

9 9 Operator panic bars.

9 9 Emergency power cutoff devices.

9 9 ____________________________________________________

9 9 ____________________________________________________
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13. Design For Mechanical Safety

ADEQUATE

 YES NO

9 9 Protective guards are provided on or around all moving

mechanical parts adjoining to where maintenance personnel will

be working.

9 9 Mechanical lockout devices are provided where maintenance

must be performed at location that exposes maintainer to moving

components (e.g., under a cutter head).

9 9 Design prevents components from slipping or falling as they are

being unbolted for repair or replacement.

9 9 Mechanical components are located to prevent maintainer from

being exposed to energized equipment, hazardous fumes, hot

surfaces, or other hazards during repair operations.

9 9 Mechanical components that require the use of heavy springs are

designed so that the springs cannot inadvertently dislodge,

causing damage or personnel injury.

9 9 Design provides for warning plates where mechanical

assemblies, linkages, or components are under high strain or

loading.

9 9 Design routes hot exhaust pipes away from locations where

routine maintenance will be performed.

9 9 Design prevents failure of high-stress-loaded component from

damaging other components or injuring personnel.

9 9 ____________________________________________________
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14. Storage Battery Maintenance

ADEQUATE

 YES NO

9 9 Design isolates routine machine maintenance points from battery

fumes.

9 9 Design prevents leaking battery acid from accumulating in

equipment compartments or operator station.

9 9 Batteries are installed in a location that permits use of overhead

lifting device to remove or replace them.

9 9 ____________________________________________________

9 9 ____________________________________________________