Caterpillar-777D-SN 1365-Hand-Out
Caterpillar-777D-SN 1365-Hand-Out
Caterpillar-777D-SN 1365-Hand-Out
Year 2004
Manufacturer Caterpillar
Model 777D
Asset Type Rock Truck
Serial Number CAT0777DHAGC01365
Usage 35,235 hrs
Comes with retarder, A/C, liner, auto lube, 27.00R49
PICTURE TO COME
Repair 1 Details
Complications:
Repair 2 Information
Component - Work Type Complaint Correction
Repair 2 Details
Complications:
Repair Hours Emeco Approval Customer Approval
Segment ST OT Emeco Supervisor Name Signature Customer Name Signature
12
Repair 1 Details
Complications:
Repair 2 Information
Component - Work Type Complaint Correction
Repair 2 Details
Complications:
Repair Hours Emeco Approval Customer Approval
Segment ST OT Emeco Supervisor Name Signature Customer Name Signature
12
Repair 1 Details
Complications:
Repair 2 Information
Component - Work Type Complaint Correction
Repair 2 Details
Complications:
Repair Hours Emeco Approval Customer Approval
Segment ST OT Emeco Supervisor Name Signature Customer Name Signature
12
SAMPLE Initial
Engine mb
Transmission
Hydraulic / Brakes
Steering
Front hubs LH ( ) RH ( )
Differential
Final Drives LH ( ) RH ( )
Cooling system (level 2 analysis) – aftercooler and engine
REPLACE
Engine oil Cap (91 L) mb
Engine oil filters Cut 1 filter open Clean ( x) Metal ( ) mb
Front brake cooling filters (hydraulic) mb
Front Hub oil LH ( ) RH ( ) Cap (5 L each)
Fuel filters mb
Fuel system water separator element
Primary air filters
Transmission oil filter mb
Transmission breather
Hydraulic tank breather
Hoist, torque Converter and Brake tank Breather
Steering system oil filter mb
Park brake release filter mb
Front Axle breather
Differential Breather
CLEAN
Hoist high pressure screens clean ( ) metal ( ) material ( )
Torque converter outlet screens clean ( ) metal ( )
Transmission magnetic screens clean ( ) metal ( ) material ( )
Batteries and terminals mb
Engine breathers clean ( ) change ( )
Engine air Filter Pre-cleaner Assembly
Differential breather
Front hub breathers
Transmission breather
Air conditioner filter
Air/hydraulic cylinder breather clean
Walkways, handrails, cab – controls, screens, floors etc free of grease and oils mb
CHECK
Engine oil level mb
Coolant charge level mb
Drain water and sediment from fuel tank mb
Drain moisture and sediment from air tank mb
Transmission oil level mb
Differential oil level mb
Final drive oil levels mb
Hoist, torque converter and brake oil tanks level mb
Front wheel hub oil levels LH ( ) RH ( )
Steering oil level mb
Fill fuel tank and record litres if applicable ( L)
Verified by: J.Everett © EMECO International Issue Date Review Page No.
MAINTCLF002 – CAT 777BCD Dump Truck
Initial: 1.0 Apr 2006 Apr 2007 Page 1 of 5
500 Hour Service Sheet
GREASE
Fan hub and jockey pulley (hand gun only)
Driveshaft splines and universal joints (hand gun only)
Fill bulk grease tank
CHECK 1 2 3 4
Steering accumulator – using ground level engine shutdown switch stop engine
then check for steering operation.
x
Visual check on duo cone leakage acc hub positions x
Report on any significant coolant usage (to indicate internal leakage) x
Check steering ball joint wear as per service manual, maximum wear in any ball
joint is 1.02mm. Check all ball joint covers are in good condition
x
Check tie rod ends for movement x
Steering (cylinders, valve and joints) x
Air Conditioner – condition and operation x
Air Dryer operation, check for moisture in secondary air tank – note 2 air dryers
fitted to unit (785C only) x
Belts – inspection/adjust/replace x
Rock ejectors x
Induction system for leaks and clamps for tightness x
All hoses for general condition and chaffing x
Cooling system hoses for condition and clamps for tightness x
Brake cooling hoses for leaks, hardness and damage. Replace as required x
Fuel system for loose bolts and fittings x
Download VIMS, check operation and report overspeeds.
Inspect hydraulic hoist cylinder hoses for damage, wear or deteriorated condition. x
Replace hoses as required.
Engine mounts x
Frame and body support pads. Clean and inspect for cracks x
Verified by: J.Everett © EMECO International Issue Date Review Page No.
MAINTCLF002 – CAT 777BCD Dump Truck
Initial: 1.0 Apr 2006 Apr 2007 Page 2 of 5
500 Hour Service Sheet
CHECK 1 2 3 4
ROPS/Cab and chassis attachment points for damage, cracks, corrosion or
loose/missing bolts x
Retarder lever free play x
Radiator for debris (wash if necessary) x
Cooling system pressure cap- clean inspect and replace as required x
Cooling system pressure relief valve - clean x
Engine shutdown system – test operation x
Exhaust system for leaks and clamps for tightness x
All points are receiving grease x
Inspect pre-start book and ensure all defects are repaired or documented x
Suspension cylinder heights (adjust if necessary):
LHF LHR
RHF RHR
SPEC FRONT REAR
Steering accumulator nitrogen pressure: - See table for acceptable pressure.
Use only correct procedure in workshop manual.
21 °C 300 psi
27 °C 306 psi
32 °C 312 psi
43 °C 324 psi
SAFETY CHECKS A B C D E F
Service Brake Operation Stall Test
Spec: 777BCD 1st Gear Stall Test - must hold at 1300 RPM
x
Emergency/secondary brake stall test
Spec: 777BCD 1st Gear Stall Test - must hold at 1300 RPM
x
Park brake operation x
Spec: 777BCD 1st Gear Stall Test - must hold at 1300 RPM
Retarder operation x
Steering operation x
Emergency steering operation x
Seat belt – retainers and operation x
Seats – suspension adjustment/condition x
Horns – air and electric x
Wipers x
Mirrors x
Doors x
Windows x
Verified by: J.Everett © EMECO International Issue Date Review Page No.
MAINTCLF002 – CAT 777BCD Dump Truck
Initial: 1.0 Apr 2006 Apr 2007 Page 3 of 5
500 Hour Service Sheet
SAFETY CHECKS A B C D E F
Gauges x
Audible alarm and warning lights x
Body up reverse inhibitor x
Grab rails x
Steps x
Fire extinguishers – invert & shake to loosen powder & inspect date x
Fire suppression bottle charge x
Tyre condition x
Lights x
Reverse alarm x
Wheel nuts x
Pin retainers x
Cab condition x
Operation of emergency stop x
Accumulation of fuel, oil, grease etc that may cause a fire x
Tray condition x
Rock ejectors condition (bent?) x
Grease system operation x
Two way radio operation x
1 2 3
1 2 3
Hoist cylinder
supports and cross
tube
(Check both sides)
1 2 3
Engine (both 1 2 3
sides) and cab
mounts LEGEND FOR COLUMNS:
Front Strut Mounting 1 – Crack found and repaired
Castings –check weld 2 – Crack on machine, machine still OK
section and flanges 3 – No cracks found
Verified by: J.Everett © EMECO International Issue Date Review Page No.
MAINTCLF002 – CAT 777BCD Dump Truck
Initial: 1.0 Apr 2006 Apr 2007 Page 4 of 5
500 Hour Service Sheet
DEFECTS PARTS SHEET COMPLETED
YES/NO YES/NO
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Comments:
Verified by: J.Everett © EMECO International Issue Date Review Page No.
MAINTCLF002 – CAT 777BCD Dump Truck
Initial: 1.0 Apr 2006 Apr 2007 Page 5 of 5
500 Hour Service Sheet
WORK ORDER HISTORY
Maintenance History for Equipment ID: RDC028
Start Date Job Number / Description Meter Reading (Hrs)
ENGINE HOURS:
DATE:
LHF/FD:
RHF/FD:
F/DIFF:
LHR/FD:
RHR/FD:
R/DIFF:
24-Jun-2015 WOC257697 - SRV > CHANGE DIFF & FINAL OIL 35,016
CARRY OUT DIFF AND FINAL OIL CHANGE
ENGINE HOURS:
DATE:
LHF/FD:
RHF/FD:
F/DIFF:
LHR/FD:
RHR/FD:
R/DIFF:
ENGINE HOURS:
DATE:
LHF/FD:
RHF/FD:
F/DIFF:
LHR/FD:
RHR/FD:
R/DIFF:
ENGINE HOURS:
DATE:
LHF/FD:
RHF/FD:
F/DIFF:
LHR/FD:
RHR/FD:
R/DIFF:
2013/09/13 - SL - 36480
RON DUYVEWAARDT
PERFORMING 2000HR SERVICE.
2013/09/14 - SL - 34680
RON DUYVEWAARDT
CHANGE STEERING OIL AND FILTERS. FINISHED TAKING SAMPLES. REPLACE DIFF BREATHER.
ENGINE HOURS:
DATE:
LHF/FD:
RHF/FD:
F/DIFF:
LHR/FD:
RHR/FD:
R/DIFF:
ENGINE HOURS:
DATE:
LHF/FD:
RHF/FD:
F/DIFF:
LHR/FD:
RHR/FD:
R/DIFF:
ENGINE HOURS:
DATE:
LHF/FD:
RHF/FD:
F/DIFF:
LHR/FD:
RHR/FD:
R/DIFF:
2013-04-30-
GLADIATOR EQUIP
TRAVEL TO CUSTOMER SITE, PICK UP PARTS, PERFORM 250 HR SERVICE ON UNIT, CHANGE TRANS
HOSES
ENGINE HOURS:
DATE:
LHF/FD:
RHF/FD:
F/DIFF:
LHR/FD:
RHR/FD:
R/DIFF:
2013-03-06-
GLADIATOR EQUIP
TRAVEL TO CUSTOMER SITE, SERVICE UNIT, CHANGE OIL, FILTERS, CHANGE FUEL, FILTER, TRANS
FILTER AND GREASE AND CHECK UNIT, RETURN TO LEDUC SHOP
ENGINE HOURS:
DATE:
LHF/FD:
RHF/FD:
F/DIFF:
LHR/FD:
RHR/FD:
R/DIFF:
2013/04/30
GLADIATOR
TRAVEL TO CUSTOMER SITE. PICK UP PARTS. RECEIVE ORIENTATION AND SAFETY COURSE.
PERFORM 500 HOUR SERSVICE ON UNIT
*********************************************************************************
****************************************************************
NEW FORMAT TO BE USED TO TRANSFER REPAIR NOTES:
-NOTE DETAIL A
-NOTE DETAIL B
-NOTE DETAIL C
EXAMPLE:
Removed panels and check for coolant and oil leaks on machine. No leaks. Check oil level, coolant
level and hydraulic levels, ok. There is no leak from engine. Start Unit run fine, let run for about 45
min. No leaks.
*********************************************************************************
***************************************************************
2013-01-05
MATTHEW BIAMONTE
REPLACE PARK BRAKE PUMP, FOUND ALL PIECES OF BROKEN GEAR, DID NOT GET RUNNING DROVE
HOME
2013-01-07
TREVOR VOLPATTI
CHANGE OUT PARK BRAKE FILTER, CUT OPEN TO INSPECT STILL SOME SMALL FLAKES, WILL CHANGE
ONCE MORE IN A SHIFT OR TWO
2013-01-16
SCOTT MCLENNAN
T/S AND REPAIR TRANSMISSION COOLER LEAK, REMOVE AND REPLACE LHS HOIST CYL LIN, ESCORT
ODIE MECHANICAL TO UNIT FOR FIRE SUPPRESSION RE-CERT
2013-01-19
SCOTT MCLENNAN
TRAVEL TO UNIT, PERFORM WEEKLY INSPECTION
2013-03-29-
RON DUYVEWAARDT
INVALID SPEED SENSOR DATA, CLEAN SENSOR AND HARNESS, TEST DROVE UNIT, WARNING GONE,
REPAIRED LEFT HAZARD LAMP, CHECK TILT STEERING COLUMN, ORDERED PARTS
2013-04-15-
CHRIS ROGERSON
TRACK THE MACHINE DOWN ONLY TO FIND OUT THERE WAS A WRONG HOSE, ORDER NEW HOSE
2013-04-20-
GLADIATOR EQUIP
TRAVEL TO CUSTOMER SITE, MOVE UNIT, CHECK PADS, CLEAN PADS OFF, REPLACE 2 PADS,
RECHECK AND PUT BACK INTO SERVICE
2013-04-30-
GLADIATOR EQUIP
PICK UP PARTS AT EMECO, TRAVEL TO CUSTOMER SITE, REPLACE FRONT AXLE BRAKE PADS, REAR
CALIPER ON BOTH SIDES, CUT PAD AND REINSTALL NEW PADS, DISASSEMBLE STEERING COLUMN,
REPLACE BUSHINGS, RETURN TO LEDUC SHOP
2013-05-03-
GLADIATOR EQUIP
TRAVEL TO CUSTOMER SITE, CHECK STEERING COLUMN, REPAIR WIRING ON BOTH LEFT AND RIGHT
FRONT PARK LIGHTS, TEST OK, RETURN TO LEDUC SHOP
2013/08/07 - TA
TREVOR VOLPATTI
REPLACE OPERATOR TO MACHINE BOARDING DEVICE (LADDER)
ATCO54 HRS->8552
ATCO77 HRS->10756
2013/08/08 - TA/EL
TREVOR VOLPATTI
CONFIRM NO SHIFT ISSUE, HOOK UP ET AND CHECK FAULT CODES, TROUBLESHOOT ISSUE, FOUND
ENGINE SPEED SENSOR DIRTY - REMOVED SENSOR AND CLEANED/ADJUSTED TO SPECS, TEST UNIT
2013/06/01
GLADIATOR
TRAVEL TO CUSTOMER WITE. REAPLCE PARK LIGHT - STEERING COLUMN AND ENGINE DIPSTICK.
RETURN TO LEDUC SHOP
2013/08/24 - OT - 32430
MATTHEW BIAMONTE
INSTALL COMPLETE 321 SETUP
COULD NOT GET LAPTOP TO CONNECT WITH CAT COMM ADAPTER. COULD NOT FINISH
REGISTRATION
2013/09/13 - TR - 34680
RON DUYVEWAARDT
REMOVED HOUSING TO REMOVE BROKEN BOLTS. INSTALLED HOUSING WITH NEW BOLTS.
2013/09/14 - 34680
RON DUYVEWAARDT
REPLACE FRONT BRAKE PADS. TRYING TP REPLACE STEERING CYLINDER. NEED TOOLING. REPLACE
HYD. AND TRANS. TANK DRAIN PLUGS. REPLACED MIRROR BRACE. REPLACED O-RING AT BRAKE
COOLING MANIFOLD. ORDERED PARTS.
2013/09/16 - 32480
RON DUYVEWAARDT
REPLACE LEFT STEERING CYLINDER.
2013/09/17 - 32480
RON DUYVEWAARDT
REMOVE LEFT FRONT HUB FOR BEARING AND SEAL REPLACEMENT.
2013/09/18 - FN - OT - 32480
RON DUYVEWAARDT
REPLACE LEFT FRONT WHEEL BEARINGS AND SEAL. REPLACE RIGHT FRONT HUB MAG PLUG. REPLACE
FINAL DRIVE AND DIFF PLUG GASKETS. REPLACE LEFT REAR MUDFLAP. REPLACE COMPANION
SEATBELT.
2013/09/18 - CS - 32480
RON DUYVEWAARDT
REPLACE 3 COOLANT SHUTOFF VALVES
2013/09/19 - 32480
RON DUYVEWAARDT
RESEAL TRANS COOLER BY-PASS PIPE. ASSIST KAL TIRE TO INSTALL LF TIRE. RETURN PRECIOUS
JACK BACK TO MR.ALFIE.
2013/09/13 TA-SS-32511
TREVOR V
REMOVE RH STEERING CYL AND INSTALL NEW ONE. TALK TO OPERATOR, UNIT NEEDS A NEW LHS
BOX LIGHT BOX
ENGINE HOURS:
DATE:
LHF/FD:
RHF/FD:
F/DIFF:
LHR/FD:
RHR/FD:
R/DIFF:
2013-01-14
TREVOR VOLPATTI
START 250 HR SERVICE, CHANGE COOLANT
2013-01-15
TREVOR VOLPATTI
FINISH OFF 250 HR SERVICE
PERFORM CYLINDER CUTOUT TEST WAS UNABLE TO COMPLETE TEST IT KEPT ABORTING, CUT OPEN
ENGINE OIL FILTER AND FOUND NOTHING IN IT, NOT POSITIVE THAT VIBRATION COMPLAINT IS
WORTH LOOKING INTO FURTHER, NEED TO PERFORM CYLINDER CUTOUT TEST AND GET RESULTS,
EXHAUST LEAKS AT CROSSOVER PIPE ON MANIFOLDS
INSPECT FOR PARK BRAKE STUCK ON COMPLAINT, FOUND PARK BRAKE PUMP NO GOOD, NO FLOW,
INSPECT FOR ENGINE NOISE, DID CYL CUT OUT FOUND NUMBER 2 CYL NO GOOD, INSPECT VALVE
TRAIN, EVERYTHING LOOKED GOOD
TRAVEL TO SITE, R&I TORQUE AND PARK BRAKE PUMP, CLEAN OUT TUBE FROM DEBRIS, CHECK
SCREEN IN TANK FOR PARTICLES AND CLEANED, TOPPED UP HYDRAULIC LEVEL, CHANGED INJECTOR
#2 TORQUED MOUNTING BOLT TO 52 LBS, FOUND BROKEN VALVE BRIDGE #2 EXHAUST, ROBBED
FROM A FAILED ENGINE AT THE MINE, INSTALLED ROCKER SHAFT AND TORQUED TO 180LBS, SET
INJECTOR TRIM CODE, COMPLETED VALVE SET, SET TO CAT SPECS, START MACHINE AND RUN UP TO
CHECK FOR LEAKS, WAS OK
START TRUCK, RUN UP TO TEMP AND CHECK OVER, CHECK ALL LEVELS, RELEASE TO MINE, GET
HOURS ON ALL EQUIPMENT, MEETING WITH MARK
CROSSOVER PIPE LEAKING BETWEEN THE MANIFOLDS, ATTEMPTED TO CHANGE OUT, BOLTS ARE
SEIZED AND DIDN'T WANT TO DISABLE THE TRUCK, ORDERED PROPER STAINLESS STEEL BOLTS,
INSPECT ALL EQUIPMENT ON SITE FOR PROPER OPERATION
MORNING CHECK
FOUND A HOSE LEAKING, WENT AND BUILT HOSE, INSTALLED IT, LEAK IS FIXED, HAD A COMLAINT
THAT STRUTS WERE LOW, WENT AND CHARGED UP STRUTS
DAILY INSPECTION
START 2000 HR SERVICE, PULL SOS SAMPLES, INSTALL SWITCH FOR BIRM LIGHT AND BACK UP
LIGHT
ARRIVED AT 123 DRY WAS TOLD THAT MACHINES ALTERNATOR HAS FAILED AND THAT COAL VALLEY
MECHANIC HAS LEFT NEW ALTERNATOR WITH MACHINE, DROVE TO MACHINE INSTALLED NEW
ALTERNATOR, STARTED MACHINE AND NO PROBLEMS PERSISTED, CALLED MACHINE UP, GOT
CALLED BACK TO MACHINE WITH SAME COMPLAINT, DROVE BACK TO MACHINE, BOOSTED MACHINE
AND TESTED ALTERNATOR , FOUND NEW ALTERNATOR WAS NOT PUTTING OUT SUFFICIENT
VOLTAGE WHEN REVED UP, ORDERED A NEW OEM ALTERNATOR AND SEPENTINE BELT, CLEANED ALL
CONNECTIONS AND TESTED WIRING FOR FAULTS NOTHING FOUND
DROVE TO MACHINE REMOVED FAULTY REBUILT ALTERNATOR FROM COAL VALLEY, INSTALLED NEW
ALTERNATOR NEW ALTERNATOR HAS AN EXTRA TERMINAL LABELED I CONSULTED MARK AND WAS
TOLD TO INSTALL AND SEE IF IT WORKS, HAD COAL VALLEY MECH BOOST MACHINE AND CHARGE
BATTEIES FOR APPROX 30 MINS STARTED MACHINE, RECORDED VOLTAGE READING FROM
ALTERNATOR IS WORKING PERFECTLY AND NO DRAINAGE ON BATTEIES CAUSING A STALL, NOTICED
THAT HEATER FAN MOTOR NO LONGER WORKED T/S AND FOUND CORRECT VOLTAGE AT SWITCH
RESISTOR AND MOTOR CONNECTION CONSULTED WITH COAL VALLEY 777'S TO FIND THAT THEY
ARE C SERIES AND NOT D SERIES LIKE RDC028 AND THEY USE A COMPLETELY DIFFERENT MOTOR
ORDERED A NEW MOROT VIA EMECO PARTS DEPT SUPPOSED TO BE READY FOR PICK UP IN AM
DROVE TO MACHINE INSTALLED NEW HEATER MOTOR, BROKE ONE OF THE FAN WHEELS ON
REINSTALLATION , AIRFLOW IN CAB IS STLL SUFFICIENT TO HEAT CAB ADEQUATELY , ORDERED
NEW WHEEL AND WILL INSTALL WHEN MACHIEN IS IN SHOP FOR PM MEASURED CANVAS FOR
WINTER FRONT WIRED CANVAS TO FRONT GRILL SPRAY PAINTED COAL VALLEY UNIT # ON CANVAS
CLEANED UP TOOLING AND WORK AREA
DROVE TO MACHINE TO PERFORM INSPECTION WAS NOTIFIED BY COAL VALLEY MECHANIC THAT
MAHCINE WAS DOWN FOR A BENT ROCK EJECTOR REMOVED BENT ROCK EJECTOR AND ORDERED A
NEW ROCK EJECTOR AND ASSOCIATED PARTS FROM FORT MAC PARTS DEPT, WAS CALLED BACK DUE
TO COMPLAINT OF LHS REAR STRUT SQUATTING TOO MUCH WITH A LOAD ON DROVE TO PIT 29 AND
LOOKED FOR EMECO'S NITROGEN CHARGING KIT BUT IT WAS NO WHERE TO BE FOUND, DROVE
BACK TO MERCOAL PIT , CALLED SHOP FOREMAN AND OK ED WITH HIM TO CHARGE STRUT AT THE
SHOP FOLLOWED BACK TO THE SHOP TO CHARGE THE STRUT, CHARGED THE STRUT BUT RAN OUT
OF TIME TO SEE IF IT WOULD HOLD PRESSURE UNDER A LOAD ADVISED OPERATOR TO KEEP AN EYE
ON IT AND LET ME KNOW WHAT HAPPENS , WILL INSPECT MACHINE IN AM TO SEE IF STRUT HOLDS
PRESSURE OR NOT
DROVE TO 123 MAINTENANCE DRY AND INFORMED FOREMAN BRUCE OF WHAT I WAS DOING TO
RDC028 , DROVE TO MAIN SHOP WHERE MACHINE WAS PARTKED, REMOVED DIPSTICK TUBE THIS
TOOK SOME TIME AND WAS QUITE DIFFICULT DUE TO LOCATION OF DIPSTICK AND SIZE SHAPE OF
DIPSTICK, COULDN'T FIND THE REMAINING PIECE OF THE BROKEN DIPSTICK PUSHED A FISH TAPE
THROUGH AND NOTHING CAME OUT REINSTALLED TUBE AGAIN THIS TOOK SOME TIME AND WAS
DIFFICULT TO DO, INSTALLED NEW GASKET ON MOUNTING FLANGE INSTALLED NEW DIPSTICK
CHECKED OIL LEVEL LEVEL WAS GOOD, STARTED MACHINE AND WARMED IT UP FOR OPERATOR
CALLED DISPATCH AND LET THEM KNOW MACHINE IS UP
OCT 30/12-LUCAS
DAILY INSPECTION
DAILY INSPECTIONS
DROVE TO MACHINE , REPLACED DAMAGED STEP LADDERS WITH NEW PARTS, CLEANED UP WORK
AREA AND TOOLING
DAILY INSPECTIONS
DAILY INSPECTIONS
INSTALLED NEW ROCK EJECTORS ON LHS OF MACHINE, NOTICED LHS REAR STRUT WAS LOW
AGAIN TOLD OPERATOR TO WATCH IT WHEN HE WAS LOADED, OPERATOR CAME BY LATER WITH A
LOAD AND ASKED ME TO CHECK OUT THE STRUT, STRUT WAS FULLY COMPRESSED TOLD OPERATOR
TO DUMP HIS LOAD AND MEET ME AT THE SHOP TO RECHARGE THE STRUT, DROVE TO THE SHOP
AND MET OPERATOR AT THE MACHINE, FOUND PAYLOAD SENSOR/CHARGING VALVE TO HAVE COME
LOOSE OFF OF STRUT, REMOVED VALVE AND CLEANED IT UP REPLACED A DAMAGED O-RING,
REINSTALLED VALVE SENSOR PUT BLUE LOCTITE ON THE MOUNTING BOLTS TO PERVENT IT FROM
COMING LOOSE AGAIN , CHRGED STRUT, CLEANED UP WORK AREA AND TOOLING
DAILY INSPECTIONS
ASKED COAL VALLEY FIELD SUPERVISOR BRUCE IF THERE WAS ANY EXTERNAL MAINTENACE WORK
TO BE DONE FOR COAL VALLEY WAS TOLD THERE WAS NOTHING DROVE BACK TO PIT 29 AND WAS
ON STANDBY IN CASE ANY EMECO MACHINES WENT DOWN, WASHED TRUCK WROTE CROSSOVER
NOTES FOR CHRIS ORGANIZED ANY PARTS NEEDED FOR UPCOMING JOBS
DAILY INSPECTIONS
ENGINE HOURS:
DATE:
LHF/FD:
RHF/FD:
F/DIFF:
LHR/FD:
RHR/FD:
R/DIFF:
GO TO SHOP AND CLEAR BAY SPACE, START MACHINE AND WARM UP, BRING INTO SHOP, CHANGED
TRANS OIL AND FILTERS, CHANGED HYDRAULIC OIL AND FILTERS, CHANGED STEERING OIL AND
FILTERS, CHANGED ENGINE OIL AND FILTERS, CHANGED FRONT HUB OIL AND REPAIRED DRAIN
PLUG THREADS AND REPLACED PLUG, CHANGED DIFFERENTIAL OIL AND FINAL DRIVES, WELDER
REPAIRED STEPS AND BODY PIN, CHECK MAGNETIC SCREENS
INSTALL THE LEFT REAR STRUT BUT COULD NOT FINISH BECAUSE SOME PARTS ARE BACK ORDERED
INSTALL THE VALING FOR THE LEFT REAR STRUT AND ORDER CHARGE VALVES FOR THE STRUT
CHARGE THE REAR STRUT AND DIAGNOSE AND REPAIR A ELECTRICAL PROBLEM WITH THE
STARTING SYSTEM , REPLACED THE MASTER SWITCH WITH ONE THAT I GOT FROM THE CV SHOP
SEPT 29/12
Repair ladder/grille light, tighten diff drain plug, repair antenna wiring.
REPIR BURNT OUT LADDER /GRILLE LIGHT BULB TIGHTEN LOOSE DRAIN PLUG ON REAR DIFF,
REPAIR ANTENNA WIRING TO TWO WAY RADIO EMAIL PICS
oCT 2/12- CHRIS RODGERSON
MORNING CHECKS
MORNING CHECKS
INSPECTED MACHINE , RECORDED HOURS, REMOVED RHS FRONT WHEEL MAGNETIC PLUG, NO
FILLINGS , CUTTINGS FOUND
OCT 8/12LUCAS
Was told that machine had broken down in Yellowhead pit
Drove to machine, found LHS rear strut retaining bolt had sheared off allowing upper pin to walk out
and strut to fall out
Strut had valve sheared off and the lower pin retaining bolt was missing as well
Went through SIS and wrote down necessary parts for repair
Drove to a spot with cell phone service and called in parts order to Fort Mac
Informed pit foreman and maintenance foreman that the machine will be down until parts arrive
WENT BACK TO UNIT AND CHECK RETARDER AIR PRESSURE AS PER MARK, FOUND OIL IN LINES, AIR
PRESSURE LOW. HOOKED UP LAPTOP HAD ARC VALVE STUCK OPEN REMOVED AND CLEANED AND
INSTALLED, AIR PRESSURE NOW 79 PSI OK. PREFORMED BRAKE TESTS ALL WORK FINE AND IN
SPEC. RESEALED AIR LEAK AT BRAKE VALVE AND TESTED NO LEAKS. CALLED FOR OPERATOR AND
RUN UNIT FOR ABOUT 3 HRS ALL WORKED FINE RELEASED TO CUSTOMER AND TALKED TO MARK ON
WHAT WAS FOUND.
PICK UP PARTS AT SEA CAN AND TRAVEL TO UNIT AND PREFORM 500 SERVICE, TAKE OIL
SAMPLES, CHANGE OIL, CHANGE ALL FILTERS AND BREATHERS, REPAIR OIL LEAK AT RIGHT DRIVER.
REPLACE STEERING TILT AND PAW KIT AND TRAVEL BACK TO SHOP
SEPT 20/12 CHRIS RODGERSON, COMPLETE A 1000 HR PM AND TIRE REPORT THE AIR
DRIER DESECANT WAS BACK ORDERED SO CHOLD NOT REPLACE
SEPT 16/12
sept
We tested the brakes and found that the brake where holding at 1200 RPM but started to brake loose
at 1250 RPM which is within finnings
specs but the operator felt unsafe.
We tested all of the pressures and all were within specs, the filters and sceens were clean and the
brake linings were within spec but
close to maximum wear we also found that the linings were badly warped.
Order parts, Pick up parts, drive to mine, repair oil leak, drive back to hotel in edson
FOUND THAT THE LEFT FRONT BRAKE PAD WAS MISSING AND THAT THE RETAINING BOLT WAS
BACKED OUT SO WE INSTALLED A NEW PAD AND LOCKITED ALL OF THE RETAINING BOLTS ON ALL
OF THE CALIPERS, TORQUED THE RETAINING BOLTS TO 38FT LBS ANDMARKED THEM WITH A BLUE
PAINT PEN
ADFASDF
ASDFAS
Completed a in sheet inspection and a tire report and found some minor leaks and small repairs, The
truck has no physical damage and appears to be in good
condition.
REMOVED REAR BRAKE BOOSTER, CLEANED AND DISASSEMBLED IN PREPARATION FOR RESEAL
CHIPMUD AWAY FROM THE TRANSMISSION AND PUMP IT TOOK 2 HOURS THEN REPLACED THE
TRANSMISSION AND PUMP BECAUSE THERE WAS METAL STARTING TO ACCUMULATE IN THE FILTERS
AND SCREENS. THE OIL SAMPLE CAME BACK NORMAL I COULD NOT CHANGE THE COOLER DUE TO
THE AMOUNT OF MUD ON THE ENGINE AND COULD NOT GET IT STEAMED IN TIME
MAY 15/12-
500 HR PM
APR.19.2012-LARRY N
CAB DETAILS REMOVE GARBAGE,SWEEP FLOOR, WIPE DOWN DASH AND WINDOW,SEAT COVER
COMPLETED
NO OTHER INFO
COMPLETED
NO OTHER INFO
COMPLETED BY REECE
VALVE SET AND VALVE TRAIN REPAIRS
COMPLETED
NO OTHER INFO
NOT SIGNED
DONE
NO MORE INFOR
REECE
CHANGED FRONT WHEEL HUB OIL
CHANGE HYDRAULI COIL AND FILTERS
CHANGED L/H FINAL DRIVE OIL
INSTALL STEERING CYLINDER AND TORQUED NUTS
GET BOX READY TO REMOVE
REMOVE CUSTOMER UNIT #'S
INSTALL WINTER FRONT
COMPLETED BY DAN
COMPLETED
NO OTHER INFO
JOE WIPF CALLED IT IN MACHINE AT SUNCOR HE SENT A TRUCK AT NIGHT SHIFT 2 PICK THEM UP
REPLACE 2 FRONTS WITH NEW AND PUT THE FRONTS ON THE REAR, INSTALL THE 2 SUPPLIED RUN
OUTS ON THE REAER
KMC INSTALLED
AUGUST 19,10: L/R UPPER BRAK ECOOLER PIPE, CRACKED AND LEAKING:
DRIVE TO KMC SHOP AT BASE MINE. CHECKED OUT LEAK AT L/R WHEEL. FOUND L/R UPPER BRAKE
COOLING PIPE CRACKED AT FLANGE ON WHEEL END. PICKED UP PARTS AT FINNING.DROVE BACK TO
KMC.REMOVED AND REPLACED PIPE AND CHECKED FOR LEAKS WAS OK. TOPPED UP OIL.
AUGUST 23,10:
1200 HR INSPECTION ON HAULER # RDC028. ENGINE SHUTDOWN WORKS, ACTUATIN GREASED +
TESTED. NO PANEL OR REWIRE AS IT AS MANUAL. HOSING TIGHT AND IN GOOD SHAPE.
PORTABLES UPDATED FOR MONTHLY. 2 NOZZLES CAPS REPLACED.
19 APRIL 10
FEB 27, 10 - MISSING FIRE EXTINQUISHER, AMBER FLOOD LIGHT ON BUMPER SMASHED OFF. -
GRANT
REMOVE SMASHED LIGHT AND ALSO NON DAMAGED LIGHT. INSTALL NEW 20LB FIRE
EXTINQUISHER AND ADJJ BRACKET.
UPON CHECKING HISTORY ON UNIT, WE NOTICED IT WAS DUE. BLEW 1/4", & 3/4" LINES. UPON
DOING ENGINE SHUTDOWN, IT WOULD NOT WORK AFTER TROUBLE SHUTDOWN. WE FOUND WIRE
DISCONNECTED. CONDUCTED ENGIEN SHUTDOWN. CHECKED, CLEANED, REGREASED ACTUARIES.
CHECKED PORTABLE EXTINQUSIHER, DID ANSUL SYSTEM OK.
REMOVED AND GREASED ACTUATORS AND PNEUMATIC ACTUATOR TESTED THEN FUNCTIONED WELL.
REPLACED CRACKED CHECK VALVE, BLEW OUT LINES WITH NITROGEN AND REPLACED . NEEDED
BLOW OFF CAPS AND TESTED SHUTDOWN.
ALL COMPLETED
JACKED UP FRONT WHEELS. DISASSEMBLED CALIPERS/BRAKES. GET READY TO R/R BRAKE DISCS.
BRAKE DISCS ARE ROUGH, PADS ARE WORN. REPLACING CALIPER SEALS AND WHEEL SEAL.
KAL-TIRE INSTALLED REAR TIRES. REMOVED FRONT TIRES
GRANT/GARNET
DISASSEMBLED FRONT BRAKE CALIPERS AND PREPPED FOR CLEANING AND REBUILD.
GRANT/GARNET
R/R BOTH FRONT WHEEL HUBS. CHANGED BOTH BRAKE DISCS, REPLACED DU CONE WHEEL SEALS,
RESHIMED FRONT WHEEL BEARINGS.
GRANT/GARNET
GRANT/GARNET
ALL COMPLETED
FIRE SUPPRESSION WOULD NOT SHUT DOWN ENGINE. FIRE SUPPRESSION WAS HOOKED TO
STARTING AID WIRING. JIM FROM FINNING REWIRED SHUT DOWN INTO ECM
REMOVED ALL BLOCKING LOWERED UNIT. PUTA AWAY ALL BLOCKS/ JACKS CLEANED UP WORK AREA
Finning rebuild
CHANGE DIFF
R/R DIFF
REMOVE PUMP DRIVE LINE AND REAR SEAL
TORQ WHEEL GROUP MOUNTING BOLTS
CHANGED HOSES TRANS FILTER TO TRANS, TRANS SCREEN TO TRANS, TRANS VENT HOSE
CLEANED DIRT OFF COMPRESSOR, SCRAPED GASKET OFF BLOCK AND COMPRESSOR. CLEANED UP
MESS
TIGHTEN BOLTS ON SIDE COVERS, 5 COVERS HAD LOOSE BOLTS. ONLY #12 WAS LEAKING BAD.
CHECKED ALL
FEB 22 - DANIEL P LANCE TWO PINS FOR BOX AND WELD TWO NUTS FOR PULLER
FEB 23 - DANIEL P FINISH LANCING PINS AND REWELD NUTS ON PINS FOR PULLER
FEB 26 - GEAR UP TRUCK AND WENT OVER TO EMECO AND FINISH LANCING LIFT CYLINDER PINS
REMOVED COMPRESSOR
DRAINED AND FILLED COOLANT
CHANGED GASKET
INSTALLED COMPRESSOR
TORQUED MTG BOLTS TO 75 FT LBS
TOOK PICURTES FOR WARRANTY CLAIM
JACKED UP THE MACHINE, REMOVED THE GUARDS, SHAFTS AND A-FRAME MOUNTING BOLTS.
LOWERED THE A-FRAME AND REMOVED THE BLOCKS, PIN AND BEARING. THE BEARING WAS BROKEN
INTO SEVERAL PIECES AND THE BORE WAS ERODED AND WILL BE BUILT UP AND REBORED.
DRAINED THE FUEL TANK. ORDERED PARTS.
Finning removed and replaced engine on site, installed P/X Engine, original engine installed at 16335
hours failure at 18308 hours
Bleow is copy of e mail to SAles Group outlining the failure and action being taken to rectify
Have received verbal confirmation this morning that the engine failure in RDC028 will not
be covered by warranty, failure is related to cold weather running, the elevated idle switch for this
machine was deactivated in line with Petro Canada operating policies
We have been able to secure this engine to rebuilt to our requirements rather than go back into the
Exchange system where the cost to rebuild this engine will be in the $155K mark.
What this means is that we will have to carry out a component change-out within the next 4 months as
we have made a commitment to Finning that we will have their core back to them by July 2009, it also
means that the cost to Petro Canada will be kept to a reasonable amount rather than paying for an
exchange unit, labour to R&R the engine will be to Petro Canada's account
We will have a back-charge quote ready by the end of the week to coincide with Finning's report and
quote to repair
We will have reports by the end of the week from Finning and OEM to support the decline of warranty
on this engine
See attached some photos of the failure, below is earlier findings from the first examination of the
engine, the transmission that failed in the same truck is warranty and not customer related
Attached are pics of the engine some of the early findings / observations are as follows,
" Engine was not dry appears to a lot of oil down both sides of the block and flywheel housing, later
traced this to slobbering from the exhaust end of the turbo's
" Both turbo's are seized, unable to spin these by hand
" Major carbon / soot / oil build up in the exhaust snail trumpets
" #7 exhaust bridge missing
" #2 dropped valve (exhaust)
" Valve lash on some of the cylinders appears to be very excessive
" Engine does not smell good, very acidic smell and sooty
The engine will be apart for inspection on Friday morning, have asked for a SOS, valve clearance
before pulling heads, but at this stage we are looking down the barrel for this one based on the engine
idle switch being in the wrong position, Finning have not said as much but that is the way it will be
looking, not unless something comes out of the strip down, may pay to discuss with Ross and put
Petro Can on notice that this could be their baby
HENRY
RE & RE TRANNY
SUPPLIED ASSISTANCE
Finning:
travel to fort hills
3 hours
customer complained that the machine would not move and that the pump pressure was low. checked
the machine and it would move. checked the trans pump pressure and it was 365 @ idle hot.
checked the suction screen and it was full of clutch material and the magnets were full of metal. the
trans is failing. checked the torque lockup pressure and it was 300psi. installed a photo tach on the
drive shaft to confirm the lockup clutch was not slipping. ok. ordered a trans and pump and all related
parts. arranged for the machine to be steam cleaned.
6.5 hours
traveled to fort hills to remove the trans. the steamers did not show up and the machine was not
steamed. moved the machine and fort hills had agreed to steam the machine. there was 25 tons
frozen in the body. we had the body scraped out and the machine was cleaned. we drained the oils
and removed the trans and installed the new one. hooked up all lines and drive shaft.
9 hours
-----------------
ORDERED PARTS
INSPECT UNIT
LOOK INTO PAYLOAD SCALE NOT WORKING
FIX BOX LIGHTS
DIAGNOSTIC CHECK - STARTED THE MACHINE AND BROGHT IT UP TO TEMPERATURE. CHECKED THE
STEERING PRESSURE AND IT WAS 3000 [SI. CHECKED THE BRAKE AND RETARDER PRESSURE AND
THE BRAKE PRESSURE WAS LOW. CHECKED THE AIR PRESSURE AND RAISED IT TO 120 PSI.
RECHECKED THE BRAKE PRESSURE AND IT WAS 740PSI AND RETARDER WAS 640 PSI. CHECKED
TORQUE LOCKUP. 290 PSI AIR LEAK AT THE BRAKE VALVE. LORNE PARK REPAIRED IT.