MAINTCLF002 CAT 777BCD DUMP TRUCK 500HR SERVICE Unit Number: C001 SMU: 10256 Date: Feb 2, 2014 SAMPLE Initial Engine Transmission Hydraulic / Brakes Steering Front hubs LH (X) RH (X) Differential Final Drives LH (X) RH (X) Cooling system (level 2 analysis) aftercooler and engine REPLACE Engine oil Cap (91 L) Engine oil filters Cut 1 filter open Clean ( X ) Metal ( ) Front brake cooling filters (hydraulic) Front Hub oil LH ( X ) RH ( X ) Cap (5 L each) Fuel filters Fuel system water separator element Primary air filters Transmission oil filter Transmission breather Hydraulic tank breather Hoist, torque Converter and Brake tank Breather Steering system oil filter Park brake release filter Front Axle breather Differential Breather N/A N/A CLEAN Hoist high pressure screens clean ( X ) metal ( ) material ( ) Torque converter outlet screens clean ( X ) metal ( ) Transmission magnetic screens clean ( X ) metal ( ) material ( ) Batteries and terminals Engine breathers clean ( X ) 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 N/A CHECK Engine oil level Coolant charge level Drain water and sediment from fuel tank Drain moisture and sediment from air tank Transmission oil level Differential oil level Final drive oil levels Hoist, torque converter and brake oil tanks level Front wheel hub oil levels LH ( X ) RH (X) Steering oil level Fill fuel tank and record litres if applicable ( L) 500 Hour Service Sheet 1.0 Apr 2006 Apr 2007 Page 1 of 5
GREASE Fan hub and jockey pulley (hand gun only) Driveshaft splines and universal joints (hand gun only) Fill bulk grease tank Ball Stud Inspection 1) Clean all steer cylinder and tie rod ends down. 2) Drive truck in straight line so as not to load up steering geometry. 3) Chock and tag vehicle 4) Bar all tie rod and steer cylinder points to locate any movement. 5) If movement found, set up dial indicator and measure amount of movement. 6) If movement is greater than 1 mm, remove cap and determine is wear is between ball stud and bearing race, or bearing race and housing. Record which area is worn 7) Ball stud wear limits: 0 to 1.02 mm - OK 8) Record measurement: 1.02 to 1.27 mm - schedule for change out 1.27 mm and above - change out ball stud 1.21MM 2.23MM 3.15MM 4.20MM 5.43MM 6.30MM 7.31MM 8.29MM LEGEND FOR COLUMNS: 1 Defect found and repaired 2 Defect on machine, machine still OK 3 OK 4 Not applicable CHECK 4 Steering accumulator using ground level engine shutdown switch stop engine then check for steering operation. Visual check on duo cone leakage acc hub positions Report on any significant coolant usage (to indicate internal leakage) 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 Check tie rod ends for movement Steering (cylinders, valve and joints) Air Conditioner condition and operation Air Dryer operation, check for moisture in secondary air tank note 2 air dryers fitted to unit (785C only) Belts inspection/adjust/replace Rock ejectors Induction system for leaks and clamps for tightness All hoses for general condition and chaffing Cooling system hoses for condition and clamps for tightness Brake cooling hoses for leaks, hardness and damage. Replace as required Fuel system for loose bolts and fittings Download VIMS, check operation and report overspeeds. Inspect hydraulic hoist cylinder hoses for damage, wear or deteriorated condition. Replace hoses as required. Engine mounts Frame and body support pads. Clean and inspect for cracks 500 Hour Service Sheet 1.0 Apr 2006 Apr 2007 Page 2 of 5
CHECK 4 ROPS/Cab and chassis attachment points for damage, cracks, corrosion or loose/missing bolts Retarder lever free play Radiator for debris (wash if necessary) Cooling system pressure cap- clean inspect and replace as required Cooling system pressure relief valve clean Engine shutdown system test operation Exhaust system for leaks and clamps for tightness All points are receiving grease Inspect pre-start book and ensure all defects are repaired or documented Suspension cylinder heights (adjust if necessary): LHF 9.0 LHR 9.0 RHF 9.0 RHR 9.0 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 Tyre pressures: Adjust cold pressure only Radial - 105 psi cold Bias Ply 82 psi cold Pos 1 Pos 2 Pos 3 Actual 100 100 100 Adjusted Pos 4 Pos 5 Pos 6 Actual 100 100 100 Adjusted Magnetic plug conditions*: RHF CLEAN LHF CLEAN RHR CLEAN LHR CLEAN *LEGEND: OK OK P Paste HP Heavy Paste LF Light Flakes HF Heavy Flakes (Return to Foreman) NOTE: Boxes A - F are to be initialled by person carrying out safety checks. Every person carrying out these checks must also sign off Safety Check Sheet before the end of each shift. LEGEND FOR COLUMNS: A Machine is not safe defect must be repaired B Defect found authorisation required before returning to work C Defect found and recorded machine safe to operate D Defect found and repaired E OK F Not applicable SAFETY CHECKS A B C D E F Service Brake Operation Stall Test Spec: 777BCD 1st Gear Stall Test - must hold at 1300 RPM Emergency/secondary brake stall test Spec: 777BCD 1st Gear Stall Test - must hold at 1300 RPM Park brake operation Spec: 777BCD 1st Gear Stall Test - must hold at 1300 RPM Retarder operation Steering operation Emergency steering operation Seat belt retainers and operation Seats suspension adjustment/condition Horns air and electric Wipers Mirrors Doors Windows 500 Hour Service Sheet 1.0 Apr 2006 Apr 2007 Page 3 of 5
SAFETY CHECKS A B C D E F Gauges Audible alarm and warning lights Body up reverse inhibitor Grab rails Steps Fire extinguishers invert & shake to loosen powder & inspect date Fire suppression bottle charge Tyre condition Lights Reverse alarm Wheel nuts Pin retainers Cab condition Operation of emergency stop Accumulation of fuel, oil, grease etc that may cause a fire Tray condition Rock ejectors condition (bent?) Grease system operation Two way radio operation Chassis Crack Inspection Pedestal castings Transition castings (777 & 785 only) Cross tube area (Check both sides) Rear tail casting section Hoist cylinder supports and cross tube (Check both sides) Fuel tank and hydraulic mounts (Check both sides) Engine (both sides) and cab mounts Front Strut Mounting Castings check weld section and flanges LEGEND FOR COLUMNS: 1 Crack found and repaired 2 Crack on machine, machine still OK 3 No cracks found Notes: - Inspect all coloured areas for cracks clean as required - All non repaired cracks to be marked a crack ends and dated using paint marker
500 Hour Service Sheet 1.0 Apr 2006 Apr 2007 Page 4 of 5
DEFECTS PARTS SHEET YES/NO 1. Missing rock ejector right side no 2. Hole in body left side near tail no 3. Air horns poor MOISTURE YES 4. Suspecting oil leakage from brakes into front hubs no 5. Chafed hoses replaced and tied properly Yes 6. Rear suspension cylinders adjusted-sensor replaced Yes 7. Purge valve broken from air tank Yes 8. 9. 10. 11. 12. 13. 14. 15. COMPLETED YES/NO Comments: CARRIED OUT BY: Print Name: Signed: Date: CHECKED & RECOED BY: Print Name: Signed: Date: 500 Hour Service Sheet 1.0 Apr 2006 Apr 2007 Page 5 of 5