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797B Commissioning
Guidebook
Version 1
Completed:
May 2007
Planning and procurement for this project began at least ten months prior to
commencement of the first truck assembly. It was decided to document the lessons
learnt so that subsequent 797 sites may benefit accordingly.
This guidebook contains details of tooling, procedures and checklists that have been
developed to meet specific needs. They are included within for the reader’s
consideration. In each case, the local dealer took all required steps to risk assess, test
and certify where applicable. This ensured that all dealer, customer, mine specific, and
local statutory requirements have been met or exceeded. Any user of this guidebook
must also risk assess and take appropriate steps to ensure that all work practices
adopted are safe, efficient and allow adherence to any manufacturers guidelines.
Caterpillar offers this document for informational purposes only. The document contains
information that was developed by and helpful to one dealer, and is not meant to be an
all-inclusive guide for every dealer. Each dealer is, as always, responsible for all
aspects of their business, including all aspects that may impact the health and safety of
employees, visitors and customers, and all aspects of legal compliance. The information
contained in the document does not constitute legal advice. This document is also not a
contract, and nothing in this document is meant to alter or modify any agreement or
contract between Caterpillar and any of its dealers.
Special mention must be made of Hastings Deering Australia for their willingness to
share the information contained within. Thanks to the entire assembly crew and in
particular, we wish to recognize the following contributors to this book:
• John Allison, Site Implementation Manager
• Kevin Borg, Site Leading Hand
• Lyndon Morgan, Site Coordinator
Any specific enquiries regarding this book can be made to Tim Mansfield
tmansfield@cat.com
Hastings Deering Assembly Team in front of the first 797B delivered to the customer
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Introduction
This Guidebook is intended for those dealers who have received a customer order for
797B’s and are beginning the planning stages for on-site truck assembly and
commissioning.
Included is a high-level guide to assist the user in knowing what questions to ask and
what things must be kept in mind. It is not meant to be an all-inclusive guide. It will
provide some information and also direct the reader to sites with more information.
Please contact the local district office for any additional information not covered in this
guidebook.
The Special Instruction for 797B Assembly (REHS1507) should be read in its
entirety by anyone planning for the assembly site and assembly process.
Please note that the Greenfield Guidebook will be a useful document to compliment this
guidebook for a greenfield mine site. Go to:
https://catminer.cat.com/cda/components/securedFile/displaySecuredFileServletJSP?file
Id=351949&languageId=7
In a Greenfield site, many of the preparation phases for the whole site will coincide with
the planning for the truck assembly and commissioning. Here they are considered as
two separate functions.
Generally, where you see a term in italics font, it will be defined further in the Glossary of
Terms.
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Table Of Contents
AUTHOR’S FOREWORD 1
3. 797B ASSEMBLY 26
GLOSSARY OF TERMS 63
ADDITIONAL REFERENCES 64
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797B COMMISSIONING PROJECT PROCESS MAP
The process map in Chart 1 depicts, at a very high-level, the preparation for and performing of
the 797B assembly and commissioning. The section depicted in yellow represents the scope of
this guidebook.
Chart 1: Top Level Process Map showing the scope of this guidebook
(depicted in the yellow shaded area)
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1. ASSEMBLY PAD & RESOURCE PLANNING
Chart 2 below provides some of the activities and decisions that need to be considered in
Phase 1 – Assembly Pad & Resource Planning
Customer Dealer Sales Dept Dealer Operations Dept Dealer Engineering Dept Cat Sales Support
(X3)
(X1)Define (X2)
Define
Manpower Define
Capital
Requirem Lifting
Asset
ents Plan
register
(X5) Define
(X6) Define (X4)
Contractor
Assembly Define
requirements
Pad size, training
and
layout and requireme
tendering
specs nts
process
Chart 2: Basic Process Chart for Assembly Pad & Resource Planning
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1.1 DEFINE MANPOWER REQUIREMENTS
Chart 3 depicts a typical 797B Implementation Team structure (the structure below
depicts Hastings Deering’s team at the Assembly Pad).
The number of personnel will vary depending upon the number of trucks expected on the
assembly sites at any given time. This structure was based on a schedule of 3 trucks in
process on the Assembly Pad at any given time. This was also based upon a single shift
per day.
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Draft
Table 1 below includes a very basic job description for these roles. The dealer should
prepare full and detailed job description for all on-site personnel.
It would also be recommended to have a specific role to ensure that VIMS payload, RAC
(Road Analysis Control), TKPH Monitor and other software systems are set in
accordance with customer’s wishes and site-specific criteria (such as target payload, tire
TKPH limits, etc). In the eyes of the customer, small problems in these systems after
delivery can cloud all of the positives in the assembly & commissioning process.
Further, ensure there are resources in place to document product defects, parts shortages
etc and report these back to Caterpillar via the appropriate channels.
1.1.2 Total 797 Build Time
Determination of the target build times for each truck, together with the factory shipment
schedule will be used to assess the number of trucks that will be on the Assembly Pad at
any given time. In turn, this allows us to move a step closer to defining site personnel
requirements.
The assembly times indicated below are for the Standard Cat truck as per Special
Instruction REHS-1507. As the mine spec extras differ from site to site, these have been
omitted to allow for easier comparison and benchmarking.
The histogram and box plot in Chart 4 are for representative purposes only. They show
that the first three trucks took a longer time to assemble.
However, as the team gained hands-on experience, processes were embedded, and the
team documented risk assessments during task completions on truck #1, the Cat standard
truck build time settled to an average of around 900 man-hours. This is based upon the
team structure as depicted in Chart 3 and the Cat standard truck is as per REHS-1507.
The longer build times on the first 2-3 trucks prompted us to review the potential causes
of the additional time. The main causes may be seemingly obvious and are also captured
in the fishbone analysis in Chart 5.
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Machine Man
Team was transferred to site JIT for project
Material Method
The potential causes in red are perceived to have had the greatest impact.
With the benefit of hindsight, the two items that the site team believe would have had the
biggest impact on reducing the build times of the first two trucks are:
• Ideally at least two team members (possibly the Team Leaders) would have
visited another site to witness first hand the assembly of at least two 797’s.
• All of the documentation, checklists and data collection tools would have been
formally pulled together in a central location and fully understood by all team
members before the first truck began. In reality, some of this information
awareness and process flow evolved during the first few builds
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1.1.3 Numbers of Personnel
It is suggested here that the total number of personnel required at the Assembly Pad will
be dependant upon the number of trucks in process (that is, being built) at any given time.
Refer back to Chart 2
This will be a function of the inter-arrival times of consecutive trucks delivered to site
from the wharf, and the planned Assembly Time for each truck.
Managing the entire project such that there is a relatively constant amount of work (i.e.,
number of trucks) on the assembly pad at any given time will make manpower planning
and rostering far simpler (and lessen the potential burden of having to source additional
labour from the local branch Field Service Department)
Following the process indicated in Chart 2 should produce a build plan something like
shown in Chart 6 below. A different and more detailed version of this can be seen in
Appendix 1F.
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Viewing the above project plan allows for an informed decision on how many trucks will
or should be in process at any given time on the Assembly Pad.
In this example, we see that at the snapshot of time denoted by ‘A’ there would be 5
chassis’ on the assembly pad, with only a very small overlap between the planned arrival
of Truck 5 and the expected delivery of Truck 1 to the customer.
Likewise, at the time snapshot denoted by ‘B’, there would be 6 chassis’ on site, again
with a few instances of small overlap.
Conversely, at the moments of time denoted by the green arrows ( ), there is expected
to be only 2 or 3 chassis’ on the assembly pad.
It then becomes a dealership decision on the number of resources to commit. That is, do
we set-up human resources, tooling, assembly pad space and so on to cater for assembly
of six (6) trucks as per point ‘B”. In this case, we’d suggest not.
In this actual scenario, the site team elected to set-up for 3 trucks in-assembly-process at
any one time (effectively three build crews managed by the Site Leading Hand, Site
Coordinator and Implementation Manager team – refer to Chart 3). The assembly pad
site did have the luxury of sufficient space for storage of additional chassis’.
Customer delivery expectation and potential late delivery penalties may also influence
the strategy adopted here.
For any sizable 797 fleets, there will almost certainly be times when additional labour is
needed during the truck build phase. This may be caused by:
- Additional rework required for a given truck or body
- The team is falling behind the delivery schedule to the customer
- Permanent crew go on annual leave or are on sick-leave
A management plan should be in place with the Field Service Leading hands at the
nearby branches for the supply of additional labour as required.
Here we are referring specifically to the project plan for the Assembly Pad & Resource
Appendix 1A includes an actual project plan that you may wish to use. The project plan
may take on many different and effective formats – this is just one example that already
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The Lifting Plan adopted for the chassis’, major components and bodies will impact upon
the optimal assembly pad size and layout.
The dealer’s preferred lifting contractor will probably handle this aspect at most
Australian sites.
In this scenario, it is advisable to discuss & provide the REHS1507 Special Instruction
for 797B assembly as well as the build plans to the selected lifting contractor.
They should then be able to create a suitable plan for material handling. The type of
cranes and other lifting gear to be used will also impact upon the required space to be
allocated between chassis’ on the assembly pad. REHS1507 provides a lot of good
information for developing the lift plan.
In the case of this site, the strategy for the commissioning of 32 x 797B’s was based upon
3 units in process at any one time; the lifting contractor’s crew consisted of:
• 1 x Supervisor
• 2 x Crane Drivers
• 1 x Rigger
(Refer also to Chart 3)
For easy reference, Appendix 1B shows some basic 797B component dimensions and
weights.
Below are some photos depicting the execution of the assembly pad lifting plan.
Template 2: Transmission Installation
Template 3: Body Installation using two cranes for easy body alignment
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1.3 DEFINE ASSET REGISTER
The Asset Register for any given operation may differ for many reasons. This guidebook
does not intend to provide a definitive list of assets, nor identify mandatory specifications
for any of the individual assets. Rather, we aim to provide a sample asset register that
may be used as a checklist for any dealer to add to, or alter to suit.
The Asset Registers for the project site assembly pad are included in Appendices 1C and
1D
Refer to Special Instruction REHS1507 as it includes information on tooling and other
items that will be required for the truck assembly.
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1.4 DEFINE PERSONNEL TRAINING REQUIREMENTS
Training requirements for personnel in the dealer’s 797 Implementation Team will differ
between dealers, between Australian States (and obviously even more so between other
countries).
requirements existed:
(1) Trade Qualified: This refers to the trade qualifications specific to the job being
performed. For example: Auto Electrician qualifications, diesel fitter qualifications etc.
(2) Statutory training: Australian State and Federal governments set certain mandatory
training requirements. These will need to be investigated in each territory where 797’s
are being assembled.
(3) Passport (Generic Mine Induction): The mine owners / operators / State Government
departments have their own specific training requirements before anyone is entitled to
work on site. Successful completion of this training results in a Mine Passport being
issued to that employee.
(4) Mine Specific Induction: The site also has their own mine specific Induction program.
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(5) Black coal competencies (licenses for plant): The Queensland Mining Industry
requires that employees successfully complete the Black Coal Competencies before
operating any heavy mobile plant on a coal mine site.
(6) S1, S2, S3– Supervisory skill certification: This course was completed through the
local Queensland Department of TAFE in order to enhance site personnel supervisory
skills (mandatory for supervisors).
(7) 797B specific training: This refers to any formal 797 specific training, whether it be
service training or otherwise.
It is likely that site will utilize the services of local contractors during the set-up,
assembly and commissioning phases of the project. Table 2 above indicates the
minimum training requirements for contractors to work on this site. Hastings-Deering’s
SMP also outlines the safety requirements for contractors on-site. The mine will also
have their site-specific requirements. These must be assessed in their entirety at any site.
At this project site, contractor services included (but were not necessarily limited to):
• Contractors for site set-up (eg electricians, plumbers, fencing contractors etc),
• For fitting Fire Suppression mine spec extra,
• For conducting Sound Tests on the assembled 797B’s,
• Painting,
• Installation and testing of the Minestar (or similar system).
Here we talk briefly about area required, site layout and compaction of the assembly area.
If suitable space at the assembly pad is limited, then determination of the space required
becomes a critical step. In most on-site assembly pads, space will probably be abundant
and therefore not of great concern.
Appendix 1E includes a basic plan of the assembly pad layout with overall dimensions
included. The photo below shows the layout of the buildings and assembly areas during
the assembly of the first two 797B’s. The site was not limited for space so this allowed
ample area for component storage and for additional chassis’ that arrived later in the
build sequence (refer again to Charts 2 and 6).
Template 6: Initial Assembly Pad Layout depicting the first two trucks in process
In hindsight, if site were to make 3 changes to the assembly site set up, they would have
been:
• Underground services or specific service points. This would have reduced the
need to run cables, electric and air lines over the pad surface. This would
improve safety and also have eliminated the time involved in laying out lines,
marking them with witch’s hats and then packing up the lines afterwards.
• Concrete pads for assembly, as opposed to the compacted dirt and gravel surface.
• Provided shade for employees (temperatures are consistently 35+ degrees C in
summer time, with high levels of UV.)
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Template 7 below shows the initial orientation of chassis’ on the build pad used for the
first few trucks being assembled. For purposes of lift plan the orientation of chassis’
were changed to be at a 45-degree angle to the assembly pad boundary fences (refer to
Template 8). Consultation with your lifting contractors should allow you to arrive at the
best chassis orientation for your site and material handling gear.
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Template 8: Revised orientation of chassis on Assembly Pad
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1.6.2 Compaction & Leveling
Due to the size and weight of components, material handling equipment, and the
completed 797 trucks, the working surface of the Assembly Pad needs to be compact,
stable and able to reasonably withstand adverse weather conditions. For sites that will
not have concrete working surfaces, there are many different variables (climate, soil type,
crane type etc) that may affect the desirable compaction at a given site. We do not intend
Rather, included below are the soil type and compaction rates that have served well for
Hastings-Deering.
The site’s Mine Planning Department should be able to provide adequate information on
the soil type and advise upon the compaction rates required. The dealer should have
discussed with the customer as to who is responsible for leveling and soil compaction
works.
A soil testing and building engineering firm was consulted to perform Dynamic Cone
Penetrometer (DCP) testing on the pad. Using the information provided by site on the
weights of components and machines, the report deemed that “the erection pads would be
482kPa (allowable bearing capacity). A lesser strength area surrounding the main work
The compacted surface performed very well for the entire build sequence. Conditions at
site are predominantly dry all year round, though heavy rains are experienced
sporadically. The surface handled the water well and tended not to deform. Given that
the work surface was compacted earth and gravel, it held up as well as could have been
expected. Nonetheless, as was noted earlier, the site team believes that a concrete build
surface would have been ideal and justifiable given the 32 truck fleet size. Obviously,
the dealer management would have required a capital expenditure justification for
installing concrete pads from the start of the project. Together with providing an ideal
working surface, concrete assembly areas would have benefited Contamination Control
Reference: For those who wish to conduct more research into this area, you may find the
following document useful:
QECB9729: Caterpillar Soil and Asphalt Compaction Manual
There is nothing more important on the assembly pad than the safety of the employees
and visitors.
Hastings Deering employed the services of an external consulting firm to document a
comprehensive Safety Management Plan (SMP). The SMP is not provided within this
document but shown below is the Table of Contents from the SMP.
1.0 Introduction
1.1 Back ground to Hasting Deering
1.1.2 Milestones
1.2 Site Description
1.3 Scope and Dimensions of Services Provided for this Project
1.4 Rules and Regulations
1.5 General Work Process
2.0 Occupational Health and Safety / Training
2.1 Trained, Safety Conscious Personnel
2.2 Selection, Placement and Training
2.3 Health and Safety Policy
2.4 Rehabilitation
2.5 Assessment of Sub-Contractors
2.6 Safety Disciplinary Procedures
3.0 Responsibilities
3.1 Organisational Structure
3.2 Employee Obligations
3.3 Site Senior Executive Obligations
4.0 Communications and Meetings
5.0 Safety Awareness
5.1 Personal Protective Equipment and Clothing
5.2 Control of Dangerous & Hazardous Substances
5.3 Environmental Controls
5.4 Job Safety Analysis (JSA)
5.5 Standard Operating Procedures and Work Instructions for Tasks
5.6 Fatal Risk Control Protocols
6.0 Design Control
7.0 Verification of OH&S Program
As is documented in the SMP, the dealer shall also be aware of, and abide by any Safe
Operating Procedures (SOP’s) that the mine site has in place.
Phase 2 of this guidebook looks at preparation of the assembly area in advance of the first
chassis’ and components arriving at site. Chart 7 below is a top-level process map of
items that may need to be considered. As always, there may be many other ways of
achieving the same end results, so you should not feel bound by anything presented
within.
Customer Dealer Parts Dept Dealer Operations Dept Dealer Purchasing Dept Cat
797B components
ready for delivery
to site
797B Assembly
begins (Phase 3)
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2.1 WORK ORDER STRUCTURE
In the instance of Hastings-Deering, the work order administrative functions (as well as
warranty functions) were performed at the local dealer branch store. The assembly pad
fitters completed service sheets and provided these to the Site Leading Hand. These were
then sent on to the local dealer branch for processing.
Appendix 2A shows the Work Order structure used at the project site.
Please consult with your dealer Warranty department and Decatur’s commissioning team
to verify the correct coding procedures for any warranty claims.
It can be seen in appendix 2A that Mine Spec extras amounted to ~80 segments on each
work order.
As such, it is critical that the tasks to be performed within each of these segments are well
defined, scoped and planned in advance of the first trucks arrival. This may incorporate:
• Customer agreement to the details of the Mine Spec extras plus a sign-off
procedure established with a customer representative
• Engineering Drawings
• Risk Assessments
• Contractor agreements
• Component research and procurement
• JSA (Job Safety Analysis) preparations
• Parts inventory planning and procurement
• Forewarning any engineering firms and suppliers of the quantity and required
dates for all mine extra components. Ensure that they have the planning
capability to cater for your site needs.
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2.3 PROCUREMENT
We saw earlier in section 1.1.5 and Appendix 1A an example of the resource project plan
used at the site. Section 1.3 and appendices 1C and 1D provided us with a Register of
Assets.
The procurement of all of these items is critically important to the success of the project
and for site’s ability to meet to delivery deadlines on the first trucks that arrive at site.
Plan well ahead to get quotations and understand lead times. Your dealership may have
set procurement guidelines that need to be considered.
Your site will almost certainly also rely on local engineering firms to fabricate some of
the mine spec extras as per the engineering drawings that have been developed and risk
assessed. Ensure that these engineering shops have adequate forewarning and planning
capability to handle the quantity of raw materials and engineering requirements.
Almost all of the parts required for assembly of the standard Caterpillar spec truck will
arrive at site from the factory. Obviously consumables, PPE (Personal Protective
Equipment) and other required supplies will need to be held in the on–site inventory.
However, the bulk of the onsite inventory will be for the Mine Spec extras.
Template 10 below shows the on-site parts storage for the project:
Template 10: Onsite parts and inventory storage (this is one of two) containers
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3. 797B ASSEMBLY
The 797B Field Assembly Special Instruction (REHS1507) is available through SIS
Windows subscription or SISWEB. Paper copies of the instructions can be ordered
through Media Logistics. Procedures and recommendations described in these special
instructions should be followed during assembling and commissioning of the products.
Most of the tools, supplies, equipment and materials required for assembly and
commissioning are listed in the Special Instruction. At the time of negotiations with the
customer, dealers need to be aware of additional cost factors, which may be incurred
during the assembling and commissioning process. If ignored, these cost factors may
negatively affect the bottom line. It is a dealer’s responsibility to evaluate which of the
following factors should be included into a deal:
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3.1 STANDARD TRUCK ASSEMBLY
The Special Instruction REHS1507 should be read in its entirety by all involved in the
preparation for the assembly process.
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Contamination Control (CC) procedures and practices are also paramount during the
assembly process, especially given that assembly is quite likely to take place in the open.
All precautions should be taken to avoid contaminant entry into machine components and
systems.
https://catminer.cat.com/cda/layout?m=3590&x=7
Your local Caterpillar District Office should also be able to provide guidance relating to
CC practices.
In order to manage the health and component life of a new 797 fleet, it is imperative to
have comprehensive component records. Appendix 3A includes an Excel file for
capturing vital component information.
Appendix 3B includes an assembly checklist for use during the 797B Assembly process.
Each dealership will also need to create their collection of JSA (Job Safety Analysis)
documents. These will be specific to local site regulations or statutory requirements,
however an example JSA is included in Appendix 1G.
The purpose of this section is to show some of the additional tooling built by Hastings-
Deering. These are not essential for the purpose of 797B assembly, but like Hastings-
Deering, you may find them beneficial to the build process.
The dealer and lifting contractor developed the tools that are pictured below. These were
fabricated by site or by third party engineering firms and had the required load testing
and all necessary certifications applied. Any other dealers intending to build their own
specialist tooling should have it properly tested and certified in order to meet all
statutory, local, mine specific and dealer requirements. The tooling below has not been
tested by Caterpillar, nor is available through Caterpillar.
This tool is used to install the front struts prior to the fenders being fitted onto the truck
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3.5.2 Fender Bracing Screw Jacks
These provide support to the fenders during the assembly phase, allowing easier
alignment of associated components. The screw jacks are used during the “Install the
149-3107 Fender Gp” stage of REHS1507. These screw jacks are commonly used in the
construction industry
Template 13: Dealer Fender Support Screw Jacks and Lift Plan in action
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3.5.3 Chassis Lifting Eyes
The chassis lifting eyes were also built locally. Refer to Appendix 3C for the engineering
print.
The 797B is shipped with lifting eyes (see insert above) in the pictured locations. The
Caterpillar lifting eyes are used for loading and unloading the chassis from the truck as
depicted in Template 15 below.
Template 15: Chassis removal from transport using supplied lifting eyes.
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When it comes time to raise the front end of the truck for front tyre installation,
REHS1507 provides the photo shown in Template 16 and instructs to ‘Use a suitable
Due to the Mine Spec extras (eg. wider access steps) that are fitted to the machine by this
stage, lifting slings were interfered with (and two were actually cut) when trying to lift in
The Caterpillar lift eyes from the insert in template 15 were only ever intended to lift the
chassis as shipped from the factory. By the time that the assembly has progressed to the
point of front tyre installation and certain mine extras have also been fitted, these
Caterpillar lift eyes should not be used to raise the chassis (they are not load rated for that
purpose).
Hastings-Deering therefore had the lifting eyes as depicted in Template 15 built and
certified locally.
Template 16: Raising front of truck for front tyre installation as per REHS1507
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3.5.4 Rear Wheel Install Stand
Used in preference to jacks when installing rear tyres. Note the wood placed under the
rear tyres in the bottom photo. After rear tyre installation, the front of the truck is raised,
causing the chassis to pivot on these wooden blocks, thus raising the chassis off the stand.
The stand is then removed without having to re-connect the crane to the rear. Refer to
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3.5.5 LHS Hoist Pin Access Stand
Due to the narrow access space, this stand fits in beside the fuel tank to allow easy LHS
hoist pin installation. In hindsight, lockable wheels would have been added to the lags of
this stand. The two steps attached to the handrails were included to allow fitters to step
up whilst checking alignment and bore condition.
No engineering drawings exist for this stand so critical dimensions have been included
below.
2000 mm
400 mm
1800 mm
560
mm
Template 18: Allows access beside the Fuel Tank for LHS Hoist Pin Installation
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3.5.6 Chassis Rail Access Work Platform
The frame depicted below was built to improve safety and efficiency whilst working on
the chassis rail area.
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4 797B COMMISSIONING & CUSTOMER SIGN-OFF
The 797 Commissioning test is the final assessment of the truck before it is turned over to
the customer. The Commissioning Tool will record system pressures, transmission data,
engine data, etc. The tests are written such that the truck will either pass or fail certain
requirements. In the event of a failed requirement, problem identification and resolution
will occur before the truck is delivered to the customer. The time required to perform this
will depend on the amount of trouble-shooting that is required.
For those unfamiliar with the final commission test report, an actual 797B commissioning
test report can be viewed via the following Catminer link:
https://catminerpreview.cat.com/cda/layout?m=19574&x=7
For those sites that will be commissioning the 797B themselves, the Caterpillar
commissioning procedure may be used. Refer to Appendix 4A. Further, Appendix 4D
includes a Caterpillar Commissioning checklist.
The Caterpillar Commissioning team traveled to site to commission the initial trucks in
Hastings-Deering. When a dealer commissions these trucks the procedure does differ, as
the tools and software employed are different. A formal Caterpillar Dealer
Commissioning Procedure was not available to Hastings-Deering for the first 797B that
they commissioned alone. For this reason, Hastings-Deering created a process.
You may wish to use elements of this in conjunction with the Caterpillar procedure
described in section 4.2.
For the dealer created procedure, refer to Appendix 4B.
Appendix 4C includes a dealer created Start-Up checklist.
Once the commissioning tests have been completed in their entirety and have met all tests
and specifications, the 797B is ready for delivery to the customer.
Your dealer team should have negotiated a set sign off procedure. This may well include
a summary of Commissioning test results and a sign off checklist.
The dealer had also agreed to a machine sign-off procedure with the customer that
included the Caterpillar Delivery Service Record [Form 01-085314-09 (3515)] and
results of the commissioning tests.
Note that there is also a commissioning & pre-delivery form available in SISWeb service
forms that may also be used a reference.
Appendix 5 includes example process control charts and a responsibility chart that may
be useful in planning for 797B’s within your territory and also in managing the assembly
and commissioning process.
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APPENDICES
The MS Project file for this project plan can be downloading from:
https://catminer.cat.com/cda/layout?m=58121&x=7
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APPENDIX 1B 797B BASIC WEIGHTS AND DIMENSIONS – QUICK REFERENCE
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Draft
Depicted below is an image of the Register of Assets file for the 797B project.
This file, including each of the worksheets indicated below can be downloaded at the
following link:
https://catminer.cat.com/cda/layout?m=58121&x=7
APPENDIX 1D REGISTER OF ASSETS (EXAMPLE) CONTINUED
Further items to consider for assets may be found in the following document.
https://catminer.cat.com/cda/layout?m=58121&x=7
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Draft
The MS Project file for this project plan can be downloading from:
https://catminer.cat.com/cda/layout?m=58121&x=7
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APPENDIX 1G EXAMPLE JOB SAFETY ANALYSIS (JSA)
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APPENDIX 2A WORK ORDER SEGMENTATION (EXAMPLE)
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No 43 9505 Supply Kidney Loop
No 44 7950 Paint Protective Covering
No 45 1073 Install Turbo Heat Shields
No 46 9164 Install Wheel Chocks
No 47 1263 Install Fuel Water Separator
No 48 7405 Engrave Filter Label
No 49 7431 Change VIMS Light Cover
No 50 9194 Install Air Jump Start Hose Reel
No 51 7557 Install Lubrication Data Label
No 52 6129 Install Quickfill Fittings
No 53 7402 Install electrical Air Horn
No 54 7254 Install Emergency Egress
No 55 1431 Install Beacon Lights
No 56 1428 Replace Reversing Lights
No 57 1429 Install Curb Lights
No 58 1429 Move Headlight Clusters
No 59 9264 Remove Fog Lights
No 60 9069 Install Clearance Lights
No 61 1926 Install Telemetry System
No 62 0635 Additional Electrical Component Mounts
No 63 4220 Install Mudflap on Fuel Tank
No 64 4220 Install Mudflap on Hyd Tank
No 65 7950 Paint Cab Floor
No 66 9161 Install Boom Gate
No 67 3024 Install Breather Front Hub
No 68 7319 Additional Mirror RHS
No 69 7319 Additional Mirror LHS
No 70 7950 Install Hyd Site Gauge Guard
No 71 7253 Install Access System Engine Bay
No 72 7254 Install Transmission Access Step
No 73 7187 Install Diff Wiring Guard
No 74 1428 Reversing Light LH Side Cab
No 75 1428 Reversing Light RHS Mirror
No 76 1411 Starter Switch Disconnect Lockout
No 77 7186 Install Cab Splash Deflector
No 78 1372 Install Air Tank Drain
No 79 9112 Install Anti Skid
No 80 7212 Install Bonnet Struts
No 81 6912 Install Lift Point Covers
No 82 9502 Install Rear View Camera
No 83 9098 Supply Missing Parts
No 84 7590 Carryout Delivery Checks
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APPENDIX 3A COMPONENT TRACKING DATABASE
This file, including each of the worksheets indicated below can be downloaded at the
following link:
https://catminer.cat.com/cda/layout?m=58121&x=7
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APPENDIX 3B 797B ASSEMBLY CHECKLIST
This check-list was developed by the dealer. As there is always a possibility that
specifications may be updated or changed and this document has no formal process for
updating, all spec values have been removed and would need to be added by the dealer
before using this form.
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__________ Install Pump Drive Shaft
__________ Torque Pump Drive Shaft Bolts
(add spec here ft. lbs.) DRY
__________ Install Drive Shaft Guards
__________ Connect Rear Brake Lines, Brake Cooler Hoses & Electrical to RAX
__________ Clean Hoist Cylinder Mounting Brackets
__________ Install Hoist Cylinders & Secure to Frame
__________ Torque Hoist Cylinders Bolts
(add spec here ft. lbs.) DRY
__________ Install Hoist Cylinder Hoses
__________ Clean Fuel Tank Mounting Surfaces
__________ Install Fuel Tank
__________ Torque Fuel Tank Frame to Bracket Bolts
(add spec here ft. lbs.) DRY
__________ Torque Fuel Tank Cap Bolts
(add spec here ft. lbs.) DRY
__________ Clean Mounting Surfaces for Front Struts
__________ Install Front Struts
__________ Torque Front Strut Mounting Bolts
Top Bolts (add spec here ft. lbs.) Turn and additional 120 degrees
+/- 5 degrees USE ANTISEIZE
Bottom Bolts (add spec here ft. lbs.) Turn and additional 120 degrees
+/- 5 degrees USE ANTISEIZE
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__________ Clean Steering Mounting Surfaces
__________ Assemble Steering Cylinders & Tie Rods
__________ Torque Steering Cylinder Nuts at Steering BOX
(add spec here ft. lbs.) USE ANTISEIZE
__________ Torque Tie Rod Nuts & Steering Cylinder Nuts at Steering ARM
(add spec here ft. lbs.) USE ANTISEIZE
__________ Install Steering Hoses
__________ Adjust Toe Out (17mm) Align Clamps Horizontal & Tension
__________ Connect Front Brake Lines & Brake Cooler Hoses
__________ Assemble Components to Hydraulic Tank
__________ Clean Mounting Surfaces for Cab Supports
__________ Install Cab Supports
__________ Torque Cab Support Mounting Bolts
(add spec here ft. lbs.) DRY
__________ Prepare Cab (Assemble Components)
__________ Position Cab to Chassis
__________ Torque Cab Mounting Bolts
(add spec here ft. lbs.) DRY
__________ Connect Brake Hoses to Cab
__________ Connect Steering Hoses to Cab
__________ Connect All Electrical to Cab
__________ Install Ladders, Handrails & Mirrors
__________ Assemble Components to Hydraulic Tank
__________
__________ Conduct Pressure Test on Intake System
__________ Fill Rear Strut Collet Bearings & RAX Link Collet Bearings with Oil
__________ Radio
__________ GPS
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TIRES
BODY
COMMISSION TRUCK
------END –
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APPENDIX 3C DEALER FRONT STRUT LIFTING JIG
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https://catminer.cat.com/cda/layout?m=58121&x=7
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APPENDIX 3D DEALER CHASSIS LIFTING EYES
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APPENDIX 3E DEALER REAR WHEEL INSTALLATION STAND
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APPENDIX 4A CATERPILLAR COMMISSIONING PROCEDURE
Further details on the commissioning process can be viewed at the following link:
https://catminerpreview.cat.com/cda/layout?m=19574&x=7
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APPENDIX 4B 797B COMMISSIONING PROCEDURE (DEALER VERSION)
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https://catminer.cat.com/cda/layout?m=58121&x=7
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APPENDIX 4C 797B START-UP CHECK SHEET (DEALER EXAMPLE)
No Item Done
1 Crank Engine without starting for 15 seconds without firing to prime pumps
2 Add oil to Hydraulic Tank till reaches Cold Level
3 Crank Engine without starting for 15 seconds without firing to continue to
prime pumps
4 Add oil to Hydraulic Tank till reaches Cold Level & Check Transmission Oil
Level
5 Start Engine Operate at Low Idle for 10 seconds – Check for Leaks
6 Shut Down Engine
7 Add oil to Hydraulic Tank till reaches Cold Level & Check Transmission Oil
Level
8 Start Engine Operate at Low Idle – Check for Leaks
9 Check Steering System operation
10 Check Park Brake & Service Brake Operation
11 Shut Down Engine
12 Add oil to Hydraulic Tank till reaches Cold Level & Check Transmission Oil
Level
13 Check Brake & Steering Accumulator Pressure
14 Set\Check steering Pump Low Pressure Standby 500PSI Hot
15 Check Grease Injectors are working
16 Upstroke Brake Charge Pump with ET
18 Set Dead-band adjustment on Service Brake pedal
19 Bleed Service & Park Brake Circuits
20 Machine Ready to Move ________
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APPENDIX 4D 797B CAT COMMISSIONING CHECKLIST
Checked
Description Specification Actual
By
Fluid Level Checks Yes/No
Horn Yes/No
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Ground Level Shutdown Switch Yes/No
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1580-1620 RPM
Elevated Low Idle
10-15 Min
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Does Truck Move in 1st Gear at
1500 RPM with Service Brake Yes/No
Applied?
Retarder Brake Application Pressure 650 - 975 PSI
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Fan Calibration Complete Yes/No
Checks
Serial Number : Date :-
No Item Checked
1 Check all Lubricate & Coolant Levels including Fuel
2 Filter Kit ready
3 Have Steering & Brake Accumulators been Checked
4 Check all Points have Grease
5 Check Operation & Maintenance Manual Behind Seat
6 Fire Suppression System is Activated
7 Check Fire Extinguishers have Current Tags
8 Check AM\FM & Mine Radio are Operational
9 Check Height Decal is fitted
10 Config Payload & Turnon Scoreboard Target 347 Metric Tone (PAYCONF)
with Vims connected. Scoreboards are reading 000.
11 Check Cab is Centralised and not Knocking during Commissioning
12 Machine & Cab are Clean & Tidy
13 Check no Brake lines are Rubbing, Front or Rear on Hubs
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Draft
GLOSSARY OF TERMS
Assembly Pad:
The name given to the secured area where the 797B trucks are assembled. In this
guidebook, this will include everything enclosed within the security fence (eg office
buildings, shipping containers for storage, the actual assembly surfaces, etc…)
This describes the truck that would result if built solely as per Special Instruction
REHS1507. Any customer Mine spec extras are not considered part of the Caterpillar
standard truck.
Commissioning Process
Involves the completion of commissioning tests, or the final assessment of the truck
before it is turned over to the customer. The Commissioning Tool will record system
pressures, transmission data, engine data, etc. The tests are written such that the truck will
either pass or fail certain requirements. In the event of a failed requirement, problem
identification and resolution will occur before the truck is delivered to the customer
Contamination is anything in the fluid that doesn't belong. The success formula may be
expressed as:
Clean (Facilities + Parts/Components + Fluids + Repair/Assembly Processes) = Clean Machines/Engines = Longer life
So, quite simply, Contamination control is a reliability and durability initiative aimed at
Lifting Plan:
Most sites in Australia will utilize a crane contractor to take care of much of the material
handling on-site. REHS1507-03 includes information on how to move the various
components and this special instruction should provide information for the lifting
contractor to develop a Lifting Plan. The Lifting Plan will document the lifting
equipment to be used, how much area is required between truck chassis’, the best
component layout plan (a suggested plan is include in REHS1507-03) and so on.
TAFE:
Technical And Further Education learning providers.
ADDITIONAL REFERENCES
Special Instruction:
REHS1507 797B Off-Highway Truck Assembly Procedure
Catminer:
Commissioning information:
https://catminerpreview.cat.com/cda/layout?m=19574&x=7
Other:
Soil preparation (if required):
QECB9729 Caterpillar Soil and Asphalt Compaction Manual
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