797B Commissioning Guidebook 07 (Procesos)

Draft
797B Commissioning
Guidebook
Version 1
Completed:
May 2007
The controlled copy of this document can be found at:
https://catminer.cat.com/cda/layout?m=58121&x=7
All printed copies of this document are uncontrolled
AUTHORS FOREWORD
Between June 2006 and July 2007, Australian Caterpillar dealer Hastings-Deering
commissioned a second fleet of 797B's into their territory. This guidebook documents the
preparation and assembly process for the fleet of thirty-two (32) 797B's.
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 readers
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
Caterpillar: Confidential Yellow
May 2007, Revision 1. The controlled copy of this document can be found at:
All printed copies are uncontrolled.
Introduction
This Guidebook is intended for those dealers who have received a customer order for
797Bs and are beginning the planning stages for on-site truck assembly and
commissioning.
The Guidebook documents four main phases, namely:
1. Assembly Pad & Resource Planning
2. Assembly Pad Preparation
3. 797B Assembly Process
4. 797B Commissioning Process
The guide aims to:
Streamline dealer processes & reduce costs to the dealer for 797B assembly site
set-up,
Improve efficiency of 797B on-site assembly & commissioning,
Optimise 797B build quality (highest quality to the customer)
Document Assembly Pad considerations (eg area required per truck, suggested
layout etc),
Document resources required at site assembly pad, and
Present some lessons that have been learnt by others
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.
Table Of Contents
AUTHORS FOREWORD
797B COMMISSIONING PROJECT PROCESS MAP
1.
ASSEMBLY PAD & RESOURCE PLANNING
1.1 DEFINE MANPOWER REQUIREMENTS

1.1.1 RECOMMENDED JOB FUNCTIONS
1.1.2 TOTAL 797 BUILD TIME
1.1.3 NUMBERS OF PERSONNEL
1.1.4 PLAN FOR ADDITIONAL LABOUR
1.2 DEFINE LIFTING PLAN
1.3 DEFINE ASSET REGISTER
1.4 DEFINE PERSONNEL TRAINING REQUIREMENTS
1.5 DEFINE CONTRACTOR REQUIREMENTS
1.6 DEFINE ASSEMBLY PAD PHYSICAL REQUIREMENTS
1.6.1 SIZE OF ASSEMBLY PAD & PAD LAYOUT
1.6.2 COMPACTION & LEVELING
1.7 ENSURING A SAFE WORK PLACE
7
7
9
11
12
13
15
16
17
17
17
21
22
2. PREPARATION FOR TRUCK & COMPONENT ARRIVALS
23
2.1 WORK ORDER STRUCTURE

2.1.1 CODING OF DEFECTS FOR WARRANTY CLAIMS:
2.2 MINE SPECIFICATION EXTRAS (CUSTOMER ADD-ONS) SUMMARY
2.3 PROCUREMENT
2.4 ON-SITE PARTS INVENTORY
24
24
24
25
25
3.
26
797B ASSEMBLY
3.1 STANDARD TRUCK ASSEMBLY

3.2 COMPONENT TRACKING DATABASE
3.3 ASSEMBLY CHECKLISTS
3.4 JOB SAFETY ANALYSIS
3.5 ADDITIONAL DEALER DEVELOPED TOOLING
3.5.1 FRONT STRUT LIFTING JIG
3.5.2 FENDER BRACING SCREW JACKS
3.5.3 CHASSIS LIFTING EYES
27
28
28
28
28
29
30
31
3.5.5 LHS HOIST PIN ACCESS STAND

3.5.6 CHASSIS RAIL ACCESS WORK PLATFORM
34
35
4 797B COMMISSIONING & CUSTOMER SIGN-OFF
36
4.1
4.2
4.3
4.4
36
36
36
37
CATERPILLAR COMMISSIONING TEAM

CATERPILLAR COMMISSIONING PROCEDURE
HASTINGS-DEERING COMMISSIONING PROCEDURE
CUSTOMER SIGN-OFF PROCESS
5 PROCESS CONTROL SYSTEM
37
APPENDIX 1A ASSEMBLY PAD PREPARATION PROJECT PLAN (EXAMPLE)

APPENDIX 1B 797B BASIC WEIGHTS AND DIMENSIONS QUICK REFERENCE
APPENDIX 1C REGISTER OF ASSETS (EXAMPLE)
APPENDIX 1D REGISTER OF ASSETS (EXAMPLE) CONTINUED
APPENDIX 1E ASSEMBLY PAD LAYOUT (EXAMPLES)
APPENDIX 1F: TRUCK BUILD PROJECT PLAN
APPENDIX 1G EXAMPLE JOB SAFETY ANALYSIS (JSA)
APPENDIX 2A WORK ORDER SEGMENTATION (EXAMPLE)
APPENDIX 3A COMPONENT TRACKING DATABASE
APPENDIX 3B 797B ASSEMBLY CHECKLIST
APPENDIX 3C DEALER FRONT STRUT LIFTING JIG
APPENDIX 3D DEALER CHASSIS LIFTING EYES
APPENDIX 3E DEALER REAR WHEEL INSTALLATION STAND
APPENDIX 4A CATERPILLAR COMMISSIONING PROCEDURE
APPENDIX 4B 797B COMMISSIONING PROCEDURE (DEALER VERSION)
APPENDIX 4C 797B START-UP CHECK SHEET (DEALER EXAMPLE)
APPENDIX 4D 797B CAT COMMISSIONING CHECKLIST
APPENDIX 4E 797B DELIVERY CHECKLIST (DEALER EXAMPLE)
APPENDIX 5 PROCESS CONTROL SYSTEM
38
39
40
41
42
43
44
45
47
48
52
53
54
55
56
57
58
62
62
GLOSSARY OF TERMS
63
ADDITIONAL REFERENCES
64
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)
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
Phase 1: Assembly Pad & Resource Planning

Customer
Dealer Sales Dept
Dealer Operations Dept
Dealer Engineering Dept
Cat Sales Support
Form Dealer implementation team for

797 project. It is recommended that a
797 Implementation Manager be
appointed as early as possible
Customer order is
received for 797B fleet
No
Do we have the
required customer
delivery dates?
Cat Product Specialist and

Mining Rep create 797 Build
schedule with serial numbers
and estimated build dates
Yes
Desired 797
delivery dates are
submitted by
customer
Yes
Is Build Schedule
accepted by Dlr &
Customer?
Customer (with Dealer Marketing

Dept) works with to determine Mine
Spec (over and above Cat standard
build (eg fire suppression etc .)
Schedule is reviewed with

factory & dealer until
consensus reached
between all 3 parties
No
797 Delivery Schedule and

Mine Spec summary provided
to Dlr Ops Dept
Dealer Engineering Dept designs,

draws and risk assesses each of the
customer mine spec add-ons (or
sources this externally)
Summary of Mine Spec addons created
Determine target 797B Assembly &

Commissioning timeline
Determine number of trucks planned to

be in-process (that is, being
assembled) at any given time
(X1)Define
Manpower
Requirem
ents
(X2)
Define
Lifting
Plan
(X3)
Define
Capital
Asset
register
(X6) Define
Assembly
Pad size,
layout and
specs
(X5) Define
Contractor
requirements
and
tendering
process
(X4)
Define
training
requireme
nts
Chart 2: Basic Process Chart for Assembly Pad & Resource Planning
1.1 DEFINE MANPOWER REQUIREMENTS

1.1.1 Recommended Job Functions
Chart 3 depicts a typical 797B Implementation Team structure (the structure below
depicts Hastings Deerings 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.
Chart 3: Implementation Team Structure example

(Based upon 3 trucks in process on the Assembly Pad)
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.
Job Title
Implementation Manager
Site Leading Hand
Site Coordinator
Team Leaders
Boiler Makers
Auto Electricians
Painter
Fitters
(Employees & subcontractors)
Primary Functions
* Provide conduit between all involved parties,
(Service Dept, Sales Depart, Transport Depart,
Customer etc),
* Plan and schedule assemblies as per delivery
plan and contract terms,
* Provide leadership & direction,
* Ensure all dealership and site specific polices and
procedures are adhered to
* Provide leadership & direction to workforce.
* Schedule labour requirements,
procedures are adhered to
* Schedule and order all parts required for project
assembly,
* Ensure all registers are kept up to date,
* Ensure all services and supplies are kept in order,
procedures are adhered to,
* Provide leadership & direction to workforce
* Provide leadership & direction to work team,
* Carry out trade tasks as required
* Carry out trade tasks as required
Table 1: Implementation Team Major Job Functions

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 customers 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.
Chart 4: 797B assembly time analysis depicting

the longer build times for trucks 1,2 & 3
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.
Machine
Man
Team was transferred to site JIT for project

No upfront training (not deemed nesessary)
New model in territory
First time in assembly team

for some members
No one from GYRV 797 assmebly team was

part of Dawson build team
Mother Nature
All first time to assemble 797
Ultra-Class size
OHT
Contractor familiarisation
with tasks
Rain
Determining extras required
(eg additional sheathing on hoses,
relocate hose brackets
Individuals havent worked

together before
Heat
Build time for first two

trucks is excessive
No one stop procedural
documentation
Body rework
(+10 days for truck 2)
Checklists developed during first truck build
Build time accuracy.

Are hours on correct
W ork order segments?
New tooling
Not familiar with all tools
Task risk assessments.

Documenting & verifying JSAs
Measure
Cat requested Adjustments
Material
Had not yet refined the

REHS1507 process as performed on-site.
Site has progressively modified their process
Method
Chart 5: Potential Cause for Additional Assembly Time on first trucks

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 797s.
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
10
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.
B
Chart 6: Possible Build Plan for 797B Fleet of 20 trucks

11
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, wed 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.
1.1.4 Plan for Additional Labour

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.
1.1.5 Create a Project Plan
Development of a detailed project plan as early as possible is critical.
Here we are referring specifically to the project plan for the Assembly Pad & Resource
Planning stage (that is, Section 1 of this guidebook).
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
exists for your use.
12
Draft
1.2
DEFINE LIFTING PLAN
The Lifting Plan adopted for the chassis, major components and bodies will impact upon
the optimal assembly pad size and layout.
Template 1: Lifting Plan in action

The dealers 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 797Bs was based upon
3 units in process at any one time; the lifting contractors 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
14
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.
Template 5: Svetruck forklift and tyre handler

used at the assembly pad
Make sure to visit this Assembly & Commissioning references page:

https://catminerpreview.cat.com/cda/layout?m=19574&x=7
15
1.4
DEFINE PERSONNEL TRAINING REQUIREMENTS
Training requirements for personnel in the dealers 797 Implementation Team will differ
between dealers, between Australian States (and obviously even more so between other
countries).
The list below is intended to provide a starting point for consideration.
At this particular Queensland (Australia) coalmine site, the following training
requirements existed:
Training
Trade Qualified(1)
Statutory training (2)
Passport (Mine
Specific) (3)
Mine Specific
Inductions (4)
Black coal
competencies
(licenses for plant) (5)
S1, S2, S3
Supervisory skill
certification (6)
797B specific
training (eg Service
Training) (7)
Implem Leading
Site
Assembly
entation Hand & Coordinator Technicians
Manager Team
Leaders
Contractors
Optional
Table 2: On-Site Training Requirements

(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 797s
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.
16
(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.
1.5
DEFINE CONTRACTOR REQUIREMENTS
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-Deerings
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 797Bs,
Painting,
Installation and testing of the Minestar (or similar system).
1.6
DEFINE ASSEMBLY PAD PHYSICAL REQUIREMENTS
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.
1.6.1 Size of Assembly Pad & Pad Layout
The size of the pad may be influenced by each of the following:
- Number of trucks on the pad at any given time. This was discussed above in
Section 1.1.3.
- Storage area for any chassis awaiting assembly
- Area dedicated for Parts Layout (note that the assembly Special Instruction
REHS1507 includes a recommended parts layout plan)
- Lifting Plan (as discussed in Section 1.2) will influence the amount of area
required around the chassis and around component storage areas. This may
17
-
-
-
vary depending upon the size of cranes, turn circles of forklifts to be used and
so on). The lifting contractor should be able to advise on this
The chosen pad layout
Size of buildings and facilities for the crew
Available space
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 797Bs. 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).
Additional storage containers were
later placed nearer the site offices.
Refer photo on front cover.
No flood lighting was

required as all work was
conducted during the day
Covered area for electrical

work, cab fit-out etc
Assembly Pad Site office, crib

room & toilets
Bunded area for storage of

fluids
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 witchs 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.)
18
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.
Template 7: Original orientation of trucks on the Assembly Pad
Chassis were initially placed parallel to the boundary fences
19
Template 8: Revised orientation of chassis on Assembly Pad
Orientation was then changed so that chassis are all
at 45-degrees to the boundary fences
20
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
to provide a recommendation here, just an example.
Rather, included below are the soil type and compaction rates that have served well for
Hastings-Deering.
The sites 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.
Assembly Pad site:
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
subjected to a variety of loading configurations requiring maximum pad reaction of
482kPa (allowable bearing capacity). A lesser strength area surrounding the main work
area is required to provide 360 kPa allowable bearing capacity.
Refer to Appendix 1E for further details of the general site arrangement.
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
(CC) procedures also.

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

21
1.7
ENSURING A SAFE WORK PLACE
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
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
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
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
Responsibilities
3.1
Organisational Structure
3.2
Employee Obligations
3.3
Site Senior Executive Obligations
Communications and Meetings
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
Design Control
Verification of OH&S Program
Reporting, Recording, Investigation & Analysis
8.1
Site Procedures, First Aid, Emergency Procedures and Road Rules
Evacuation & Emergency Planning
Control of Documents and Records
PLAN ACTION LIST
Risk Management Guide
Attachment List
An example Job Safety Analysis (JSA) is included in Appendix 1G.

As is documented in the SMP, the dealer shall also be aware of, and abide by any Safe
Operating Procedures (SOPs) that the mine site has in place.
Refer also to Section 1.4 Define Personnel Training Requirements
22
2. PREPARATION FOR TRUCK & COMPONENT ARRIVALS
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.
Phase 2: Assembly Pad Preparation

Customer
Note: Customer & Dealer

will negotiate over who is
responsible for co-ordinating
& paying for the schedule of
works required in order to
ready the Assembly Pad for
commencement of work. For
the purpose of this document
these functions have been
designated as a dealer
function.
Dealer Parts Dept
Dealer Parts
Inventory for
site are
finalised
Dealer Operations Dept
Dealer Implementation team

receive full Mine Spec summary,
plus Engineering drwaings for all
Mine Spec add-ons (as previously
defined by the customer
Work Order system

is established for
the pending
assembly and
commissioning
process (refer to
Appendix 2A
Dealer Purchasing Dept
Cat
This information was

determined in Phase 1
Asset Register as
determined in
Stage 1
Storage Systems for

parts are determined
(eg Racks, Cabinets,
Bins etc).
Size of Parts Storage

building is determined. It is
highly likely that this may be
shipping container(s) with
cabinets and shelving within.
Sections 1.1 1.6 in Phase 1, together

with other inputs determines:
- Schedule of Works (Project Plan)
required to prepare the Assembly Pad
for 797B component delivery &
assembly. An is provided in Appendix
1A
- Assembly Pad design & layout. Refer
to Appendix 1E
Dealer Purchasing Dept

follow Dealer guidelines to
procure all approved Assets
as determined in Phase 1
Execute Project Plan of

Assembly Pad to
completion (refer to
Appendix 1A
797B components
ready for delivery
to site
797B Assembly
begins (Phase 3)
Chart 7: Basic Process Chart for
Phase 2: Preparation for Truck & Component Arrivals
23
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.
2.1.1 Coding of Defects for Warranty Claims:
Please consult with your dealer Warranty department and Decaturs commissioning team
to verify the correct coding procedures for any warranty claims.
2.2
MINE SPECIFICATION EXTRAS (CUSTOMER ADD-ONS) SUMMARY
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.
Template 9: Mine Spec Extra Engineering Drawings were

compiled into folders and kept in the Leading Hand Office.
24
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 sites 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.
2.4
ON-SITE PARTS INVENTORY
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 onsite 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
25
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 dealers responsibility to evaluate which of the
following factors should be included into a deal:
Crane Rental Cost
Electricity & Lighting Cost
Air Conditioner Service
Lifting Cables, Slings, Chains
Manpower Transportation
Manpower Meal and Lodging
Security
Communication Systems
Safety Articles
Lubricants, Oils, Grease and Coolant

Tire Handling
Fire Suppression Installation
Assembly Stands and Jigs
Cleaning Materials
Air Compressor
Consumables (rags, paint, lock-tite, etc.)
Paint Stripping Tools
Supervisory Staff
Make sure to visit this Assembly & Commissioning references page:

26
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.
Chart 5: 797B High Level Assembly Process
27
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.
CatMiner provides some useful resources relative to Contamination Control. Go to:
Your local Caterpillar District Office should also be able to provide guidance relating to
CC practices.
3.2
COMPONENT TRACKING DATABASE
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.
3.3
ASSEMBLY CHECKLISTS
Appendix 3B includes an assembly checklist for use during the 797B Assembly process.
Appendix 4C includes the 797B Start-Up Checklist.
Further, REHS1507 acts as its own form of checklist.
3.4
JOB SAFETY ANALYSIS
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.
3.5
ADDITIONAL DEALER DEVELOPED TOOLING
The purpose of this section is to show some of the additional tooling built by HastingsDeering. These are not essential for the purpose of 797B assembly, but like HastingsDeering, 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.
28
3.5.1 Front Strut Lifting Jig

This tool is used to install the front struts prior to the fenders being fitted onto the truck
Template 11: Dealer Front Strut Lifting Jig

Refer to Appendix 3C for the engineering print.
29
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 12: Dealer Fender Support Screw Jacks
Template 13: Dealer Fender Support Screw Jacks and Lift Plan in action
30
3.5.3 Chassis Lifting Eyes

The chassis lifting eyes were also built locally. Refer to Appendix 3C for the engineering
print.
This insert shows the Caterpillar lifting eyes
Template 14: Dealer Chassis Lifting Eyes in Use

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.
Taken from REHS1507
31
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
lifting device in order to raise the front of the truck.
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
a manner similar to that depicted in Template 16 below.
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
32
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
Appendix 3C for the engineering print.
Template 17: Rear Wheel Install Stands

33
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
34
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.
Template 19: Dealer Chassis Rail Access Platform
Template 20: Dealer Chassis Rail Access Platform in use

35
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:
4.1
CATERPILLAR COMMISSIONING TEAM
Any potential involvement of Caterpillars commissioning team should have been

clarified during the sales process with the CGM team. If the commissioning team is to be
involved (even if only for the first few trucks) then minimal planning should be required
for this stage.
The Caterpillar Commissioning team will bring custom commissioning software for the
797B OHT as well as proprietary tooling.
4.2
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.
4.3
HASTINGS-DEERING COMMISSIONING PROCEDURE
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.
36
4.4
CUSTOMER SIGN-OFF PROCESS
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.
Appendix 4E includes a 797B Delivery Checklist as used at the project site.
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.
5 PROCESS CONTROL SYSTEM

Appendix 5 includes example process control charts and a responsibility chart that may
be useful in planning for 797Bs within your territory and also in managing the assembly
and commissioning process.
37
APPENDICES
APPENDIX 1A
ASSEMBLY PAD PREPARATION PROJECT PLAN (EXAMPLE)
The MS Project file for this project plan can be downloading from:
38
APPENDIX 1B
797B BASIC WEIGHTS AND DIMENSIONS QUICK REFERENCE
Other sources of details may be found in:

Caterpillar Performance Handbook
Via CatMiner at: https://catminer.cat.com/cda/layout?m=30171&x=7
Assembly Special Instruction REHS1507-03
797B Mining Truck Technical Sales Presentation (part of cornerstone series):
AEXC0643
39
Draft
APPENDIX 1C
REGISTER OF ASSETS (EXAMPLE)
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:
APPENDIX 1D
REGISTER OF ASSETS (EXAMPLE) CONTINUED
Further items to consider for assets may be found in the following document.
41
Draft
APPENDIX 1E
ASSEMBLY PAD LAYOUT (EXAMPLES)
Depicted below is an image of the Assembly Pad layout file

APPENDIX 1F:
TRUCK BUILD PROJECT PLAN
The MS Project file for this project plan can be downloading from:
43
APPENDIX 1G
EXAMPLE JOB SAFETY ANALYSIS (JSA)
44
APPENDIX 2A
Segment
No1
No 2
No 3
No 4
No 5
No 6
No 7
No 8
No 9
No 10
No 11
No 12
No 13
No 14
No 15
No 16
No 17
No 18
No 19
No 20
No 21
No 22
No 23
No 24
No 25
No 26
No 27
No 28
No 29
No 30
No 31
No 32
No 33
No 34
No 35
No 36
No 37
No 38
No 39
No 40
No 41
No 42
WORK ORDER SEGMENTATION (EXAMPLE)
Comp Code
7000
9288
9004
7000
0116
0653
7306
7338
7337
9276
9097
9157
9162
9162
5500
9272
7254
9013
7405
7000
1382
9501
1435
1463
9499
1411
9499
0651
7418
7418
7401
7419
7419
7513
1395
7540
9503
7000
1408
9504
4305
0653
Description
Assemble Machine
Travel Expenses
Hire of Equipment
Paint Machine
Sound Test
Install Labels to Body
Install Windscreen Washer Bottle
Install Radio
Install Two Way Radio
Install Extended Aerial Mount Post
Install VIMS Label
Install Access Lights
Install Front Access System Lower Stair
Install Front Access System Upper Stair
Install Stair Control Group
Manufacture Cab Walkway Extensions
Paint Step Edges Yellow
Paint Jacking and Lifting Points
Install Jacking Stand Label
Sign Write Machine
Install Coxon Radiator Caps
Identify Test Points
Relocate Park Brake Switch
Install Jump Start Receptacle
Install Ancillary Panel Bumper
Install Battery Disconnect Lockout
Install Ancillary Panel Cab
Electrical Compartment Sealing
Emergency Shutdown Cab
Emergency Shutdown Switch Ground Level
Install Fire Suppression
Install Fire Extinguisher Deck
Install Fire Extinguisher Bumper
Install Quickfill System
Drain and Refill Coolant
Install Autolube System
Identify Sample Point
Identify Machine
Electrical Schematic, Wiring & Brackets
Install Manual
Install Steering Pin Retaining Strap
Vehicle Operating Height Label
45
No 43
No 44
No 45
No 46
No 47
No 48
No 49
No 50
No 51
No 52
No 53
No 54
No 55
No 56
No 57
No 58
No 59
No 60
No 61
No 62
No 63
No 64
No 65
No 66
No 67
No 68
No 69
No 70
No 71
No 72
No 73
No 74
No 75
No 76
No 77
No 78
No 79
No 80
No 81
No 82
No 83
No 84
9505
7950
1073
9164
1263
7405
7431
9194
7557
6129
7402
7254
1431
1428
1429
1429
9264
9069
1926
0635
4220
4220
7950
9161
3024
7319
7319
7950
7253
7254
7187
1428
1428
1411
7186
1372
9112
7212
6912
9502
9098
7590
Supply Kidney Loop

Paint Protective Covering
Install Turbo Heat Shields
Install Wheel Chocks
Install Fuel Water Separator
Engrave Filter Label
Change VIMS Light Cover
Install Air Jump Start Hose Reel
Install Lubrication Data Label
Install Quickfill Fittings
Install electrical Air Horn
Install Emergency Egress
Install Beacon Lights
Replace Reversing Lights
Install Curb Lights
Move Headlight Clusters
Remove Fog Lights
Install Clearance Lights
Install Telemetry System
Additional Electrical Component Mounts
Install Mudflap on Fuel Tank
Install Mudflap on Hyd Tank
Paint Cab Floor
Install Boom Gate
Install Breather Front Hub
Additional Mirror RHS
Additional Mirror LHS
Install Hyd Site Gauge Guard
Install Access System Engine Bay
Install Transmission Access Step
Install Diff Wiring Guard
Reversing Light LH Side Cab
Reversing Light RHS Mirror
Starter Switch Disconnect Lockout
Install Cab Splash Deflector
Install Air Tank Drain
Install Anti Skid
Install Bonnet Struts
Install Lift Point Covers
Install Rear View Camera
Supply Missing Parts
Carryout Delivery Checks
46
APPENDIX 3A
COMPONENT TRACKING DATABASE
This file, including each of the worksheets indicated below can be downloaded at the
following link:
47
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.
SERIAL NUMBER
START DATE
COMPLETION DATE
________________
________________
________________
__________ Position Chassis on Two Assembly Stands

__________ Position Rax on Assembly Stand behind Chassis
__________
__________ Install Radiator handrails
__________ Clean All Mounting Surfaces for RAX Links
__________ Install RAX Links to Chassis (BOTTOM LINKS FIRST)
__________ Assemble RAX to Chassis (TOP LINKS FIRST)
__________ Install Rear Struts
__________ Torque 24 Collet Bolts ( fill with oil now )
Follow Procedure (add spec here ft. lbs.) USE ANTISEIZE

__________ Install Transmission
Install Main Drive Shaft

__________ Torque Main Drive Shaft Bolts
(add spec here ft. lbs.) ) DRY (check if uncertain of procedure)
__________ Connect Hoses to Transmission & TC
48
__________ 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
__________ Install Hoist Cylinder Hoses
__________ Clean Fuel Tank Mounting Surfaces
__________ Install Fuel Tank
__________ Torque Fuel Tank Frame to Bracket Bolts
__________ Torque Fuel Tank Cap Bolts
__________ 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
__________ Install Cab Supports ( outriggers )
__________ Torque Cab Support Mounting Bolts
Position & Weld RH Platform to Chassis
__________ Measure location for air box mounting brackets
__________ Install Exhaust Tubes
__________ Install Air Box
__________ Install Air Intake Tubes
49
__________ 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
__________ Prepare Cab (Assemble Components)
__________ Position Cab to Chassis
__________ Torque Cab Mounting Bolts
__________ 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
__________ Install Hoods
__________ Install Batteries
__________ Install Grease Lines
__________ Fill Rear Strut Collet Bearings & RAX Link Collet Bearings with Oil
__________ Fill Truck With Fluids
__________ Top Off Fluids
__________ Check Truck for Hose Rubs & Leaks
DEALER ADDED ATTACHMENTS
__________ Fire Suppression
__________ Radio
__________ GPS
50
TIRES
__________ Clean Rim Mounting Surfaces & Studs on Wheels
__________ Remove Split Rings from Rear Wheels (Mark Position)
__________ Clean Rims
__________ Install Front Tires & Rims
__________ Install Rear Inside Tires & Rims
__________ Torque (4) Rims to Wheels (Stanley Torque Tool)
__________ Re-install Four Split Rings to Rear Wheels (In Proper Position)
__________ Torque Split Rings to Wheel Stations
__________ Install Outside Dual Tires & Rims
__________ Torque Outside Dual Rims to Wheels
BODY
__________ Assemble Mud Flaps to Body
__________ Assemble Safety Cables to Body
__________ Install Body Decals
__________ Clean Body Pivot Pins & Pivot Bores
__________ Position & Pin Body
__________ Pin Hoist Cylinders
__________ Weld Body Rocker Shoe Brackets to Chassis CrossBeam
__________ Weld Body Guides to Crossbeam
__________ Install Rocker Shoes
__________ Shim Body
__________ Weld Rock Knocker Brackets to Body
__________ Assemble Rock Knockers to Body
__________ Charge Struts with Nitrogen
COMMISSION TRUCK
------END
51
APPENDIX 3C
DEALER FRONT STRUT LIFTING JIG
This file may be down loaded from:

52
APPENDIX 3D
DEALER CHASSIS LIFTING EYES
This file may be downloaded from:

53
APPENDIX 3E
DEALER REAR WHEEL INSTALLATION STAND
This file may be downloaded from:

54
APPENDIX 4A
Further details on the commissioning process can be viewed at the following link:
55
APPENDIX 4B
797B COMMISSIONING PROCEDURE (DEALER VERSION)
This entire 49-page file depicted below can be downloaded at the following link:
56
APPENDIX 4C
Serial Number :
797B START-UP CHECK SHEET (DEALER EXAMPLE)

Date :
Checks
No
1
2
3
4
5
6
7
8
9
10
11
12
Item
Checked
Air Tank Fill with Air

Coolant Level
Differential, Differential Carrier & Final Drive Oil Level
Engine Coupling Oil Level
Check both Engine Oil Levels
Check Fuel System is Primed and no Leaks
Hydraulic Oil Level
Check all Drive Shafts are Clear of Hoses and Wiring
Check Breather Tube Covers are removed
Confirm Intake Test has been Carried out on Assembly Check sheet and
remove Dust Covers
Check there are no obstacles around Fan
Check Front Hub Levels
Start Procedure
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
19
20
Item
Done
Crank Engine without starting for 15 seconds without firing to prime pumps
Add oil to Hydraulic Tank till reaches Cold Level
Crank Engine without starting for 15 seconds without firing to continue to
prime pumps
Add oil to Hydraulic Tank till reaches Cold Level & Check Transmission Oil
Level
Start Engine Operate at Low Idle for 10 seconds Check for Leaks
Shut Down Engine
Level
Start Engine Operate at Low Idle Check for Leaks
Check Steering System operation
Check Park Brake & Service Brake Operation
Shut Down Engine
Level
Check Brake & Steering Accumulator Pressure
Set\Check steering Pump Low Pressure Standby 500PSI Hot
Check Grease Injectors are working
Upstroke Brake Charge Pump with ET
Set Dead-band adjustment on Service Brake pedal
Bleed Service & Park Brake Circuits
Machine Ready to Move
________
57
APPENDIX 4D
797B CAT COMMISSIONING CHECKLIST
797 Commissioning Procedure Check List

Description
Specification
Fluid Level Checks
Yes/No
Operators Seat
Yes/No
Seat Belt
Yes/No
Steering Column Adjustability
Yes/No
Battery Power
Yes/No
Cab Dome Light
Yes/No
VIMS Self Test
Yes/No
Windshield Wipers
Yes/No
Cigar Lighter
Yes/No
Hazard Lights
Yes/No
Panel and Running Lights
Yes/No
Turn Signal Lights
Yes/No
Reverse Lights & Back-up Alarm
Yes/No
Fog Lights
Yes/No
Ladder Light
Yes/No
Engine Compartment Light
Yes/No
VIMS Port Check
Yes/No
Horn
Yes/No
Neutral Start Switch
Yes/No
Climate Control
Yes/No
Actual
Checked
By
58
Ground Level Shutdown Switch

Master Engine Module
Yes/No
Engine Serial Number
ECM Serial Number
Software Part Number
Front Engine Module

ECM Serial Number
Rear Engine Module

ECM Serial Number
Transmission
ECM Part Number

ECM Serial Number
Chassis Control
ECM Part Number

ECM Serial Number
Brake
ECM Part Number

ECM Serial Number
VIMS
ECM Part Number

ECM Serial Number
Analysis Module
ECM Serial Number

Clear Fault Codes
Yes/No
Activate Controls
Yes/No
Download VIMS
Yes/No
Fuel Tank Attachment Code
Yes/No
59
Elevated Low Idle

Transmission Calibration Complete
1580-1620 RPM
10-15 Min
Yes/No
Transmission System Pressure
300-350 PSI
Transmission Clutch #7 Pressure
300-350 PSI
Hoist Calibration Complete
Yes/No
Hoist Up Pressure
3350 -3550 PSI
Hoist Down Pressure
500 - 2300 PSI
Body Raise Time
20 - 27 Seconds
Body Lower Time
15 - 21 Seconds
Transmission Neutralizer Test

Steering Stand-by Pressure
@ Low Idle
Yes/No
0 - 500 PSI
Steering Cut-In Pressure

@ Low Idle
3150 - 3350 PSI
Steering Cut-Out Pressure

@ Low Idle
3450 - 3600 PSI
Steering Stand-by Pressure

@ High Idle
0 - 500 PSI
Steering Cut-In Pressure

@ High Idle
3150 - 3350 PSI
Steering Cut-Out Pressure

@ High Idle
3450 - 3600 PSI
Truck Steers from Right to Left

While Pressure Drops
Main Air Pressure
Brake Stand-by Pressure
@ Low Idle
Yes/No
115 - 125 PSI
5 Minutes
0 - 300 PSI
Brake Cut-In Pressure

@ Low Idle
2000 - 2300 PSI
Brake Cut-Out Pressure

@ Low Idle
2950 - 3050 PSI
Service Brake Application Pressure
860 - 940 PSI
60
Does Truck Move in 1st Gear at

1500 RPM with Service Brake
Applied?
Retarder Brake Application Pressure
1500 RPM with Retarder Applied?
Secondary Brake Application
Pressure
1500 RPM with Retarder and
Secondary Brake Applied?
Towing Pump Pressure
Yes/No
650 - 975 PSI
Yes/No
860 - 1050 PSI
Yes/No
550 - 750 PSI
Pump Drive Diverter "OFF", and

Final Drive Bypass "ON"
@ Low Idle
Differential Oil Filter

Pressure 9 - 55 PSI
Final Drive Oil Filter
Pressure 4 - 13 PSI
Pump Drive Diverter "ON", and

@ Low Idle

Pressure 0 - 2 PSI
Pressure 0 - 2 PSI

Final Drive Bypass "OFF"
@ Low Idle

Pressure 13 - 54 PSI
Pressure 9 - 72 PSI

@ High Idle

Torque Converter Inlet Pressure

@ Low Idle
15 - 35 PSI
Torque Converter Outlet Pressure

@ Low Idle
10 - 30 PSI
Torque Converter Inlet Pressure

@ High Idle
90 - 130 PSI
Torque Converter Outlet Pressure

@ High Idle
50 - 90 PSI
Does Transmission Upshift from 1st

Gear Through 7th gear?
Yes/No
Does Transmission Downshift from

7th Gear Through 1st gear?
Yes/No
61
Fan Calibration Complete
Yes/No
Clear Fault Codes
Yes/No
Download VIMS
Yes/No
Calibrate Payload
Yes/No
Set Pay Configuration
Yes/No
Reset SMH to "0"
Yes/No
APPENDIX 4E
Checks
Serial
Number :
No
1
2
3
4
5
6
7
8
9
10
11
12
13
797B DELIVERY CHECKLIST (DEALER EXAMPLE)
Date :-
Item
Checked
Check all Lubricate & Coolant Levels including Fuel

Filter Kit ready
Have Steering & Brake Accumulators been Checked
Check all Points have Grease
Check Operation & Maintenance Manual Behind Seat
Fire Suppression System is Activated
Check Fire Extinguishers have Current Tags
Check AM\FM & Mine Radio are Operational
Check Height Decal is fitted
Config Payload & Turnon Scoreboard Target 347 Metric Tone (PAYCONF)
with Vims connected. Scoreboards are reading 000.
Check Cab is Centralised and not Knocking during Commissioning
Machine & Cab are Clean & Tidy
Check no Brake lines are Rubbing, Front or Rear on Hubs
APPENDIX 5
PROCESS CONTROL SYSTEM
A copy of an example process control plan may be found at:

62
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)
Caterpillar Standard Truck
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 Control (CC)
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
providing superior value to Caterpillar's customers.
Job Safety Analysis (JSA):

A process whereby hazards associated with each step of a job are identified and control
measures are put in place to minimize the risk to personnel, environment and property
(definition courtesy of Hastings-Deering SHEQ form 1021)
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.
Mine Spec Extras (Add-Ons):
The standard Caterpillar 797B is as per the assembly special instruction REHS1507-03.
The collection of all additions in excess of this are referred to as the Mine Spec (or mine
spec add-ons).
Safety Management Plan (SMP)
This is a controlled document that applies to the 797B truck assembly by Hastings
Deering. It is the intent of the SMP to document that the persons working on the project
own the process of reviewing and improving the safety management systems of the
project. The SMP aims to ensure compliance with all site specific in regard to
assembling 32 x 797B off-highway trucks.
TAFE:
Technical And Further Education learning providers.
ADDITIONAL REFERENCES
Special Instruction:
REHS1507 797B Off-Highway Truck Assembly Procedure
Catminer:
Commissioning information:
Contamination Control information:

Other:
Soil preparation (if required):
QECB9729 Caterpillar Soil and Asphalt Compaction Manual
64

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797B COMMISSIONING PROJECT PROCESS MAP

ASSEMBLY PAD & RESOURCE PLANNING

1.1 DEFINE MANPOWER REQUIREMENTS

2. PREPARATION FOR TRUCK & COMPONENT ARRIVALS

2.1 WORK ORDER STRUCTURE

3.1 STANDARD TRUCK ASSEMBLY

3.5.5 LHS HOIST PIN ACCESS STAND

4 797B COMMISSIONING & CUSTOMER SIGN-OFF

CATERPILLAR COMMISSIONING TEAM

5 PROCESS CONTROL SYSTEM

APPENDIX 1A ASSEMBLY PAD PREPARATION PROJECT PLAN (EXAMPLE)

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797B COMMISSIONING PROJECT PROCESS MAP

Caterpillar: Confidential Yellow

1. ASSEMBLY PAD & RESOURCE PLANNING

Phase 1: Assembly Pad & Resource Planning

Dealer Sales Dept

Dealer Operations Dept

Dealer Engineering Dept

Cat Sales Support

Form Dealer implementation team for

Cat Product Specialist and

Customer (with Dealer Marketing

Schedule is reviewed with

797 Delivery Schedule and

Dealer Engineering Dept designs,

Summary of Mine Spec addons created

Determine target 797B Assembly &

Determine number of trucks planned to

1.1 DEFINE MANPOWER REQUIREMENTS

Chart 3: Implementation Team Structure example

Caterpillar: Confidential Yellow

Site Leading Hand

Table 1: Implementation Team Major Job Functions

1.1.2 Total 797 Build Time

Chart 4: 797B assembly time analysis depicting

Caterpillar: Confidential Yellow

Team was transferred to site JIT for project

New model in territory

First time in assembly team

No one from GYRV 797 assmebly team was

All first time to assemble 797

Individuals havent worked

Build time for first two

Checklists developed during first truck build

Build time accuracy.

Task risk assessments.

Had not yet refined the

Chart 5: Potential Cause for Additional Assembly Time on first trucks

Caterpillar: Confidential Yellow

1.1.3 Numbers of Personnel

Chart 6: Possible Build Plan for 797B Fleet of 20 trucks

1.1.4 Plan for Additional Labour

Planning stage (that is, Section 1 of this guidebook).

exists for your use.

Caterpillar: Confidential Yellow

DEFINE LIFTING PLAN

Template 1: Lifting Plan in action

Template 2: Transmission Installation

Caterpillar: Confidential Yellow

DEFINE ASSET REGISTER