Process Documentation

Introduction: This chapter of the guide will provide some examples of repair
procedures and upgrades utilized for the B-C upgrade project. It will also describe
how the rebuild process is organized at a high level, as well as many of the tools that
enable dealer personnel to manage the entire project.

FREEPORT 793B
UPGRADE PROGRAM

Open Presentation
1. Rebuild/Upgrade Project Overview
a. B-C Upgrade Options Not all of the following available upgrades were
completed as part of the 793B-C upgrade project. Some had been
completed previously and others were not included in this project. The
Caterpillar on-site Product Support manager, John Bergin, identified a
challenge with any upgrade is getting the enhancements at a cost-effective
price. Trakindo has found it sometimes cost prohibitive to include an
upgrade in a normal component rebuild when significant machining or
other work is required. In some cases, they can take advantage of
Caterpillar REMAN components to get the upgrade for a reasonable cost.
i. Engine upgrade Caterpillars current recommended engine
upgrade offering is a 3516B High Displacement engine. For
support information refer to the following:
PELE0954 3516B High Displacement Engine Upgrade
REHS1371 Installation of 3516B HD engine in 793B
TELQ3769 3516B HD Engine Upgrade for 793B
PEHJ0037 Caterpillar 3516B High Displacement Engine Upgrade

Because of the altitude restrictions, the HD engine was not an

option for the Trakindo rebuilds. To upgrade to the 3516B (2300
hp) engine requires significant changes to the chassis configuration
(hoses, lines, coolers, pumps, etc) on a 793B to in effect convert it
to a 793C. This can be a cost prohibitive rework but in this case, it
appears to have helped Trakindo achieve other goals of the
machine rebuild. Trakindo opted to use a REMAN 0R-9551
Engine Ar. to update from a 3516A (2150 hp) to the 3516B (2300
hp) short stroke engine to gain the advantage of improved fuel
consumption and higher productivity as per 793B vs. 793C
Performance Report.

ii. TC upgrade To upgrade to the simplified hydraulic arrangement

of the 793C, Trakindo converted to the C-series Torque Converter.
Purchasing a new 128-5691 Housing Ar and other miscellaneous
hardware required to support the simplified hydraulics
arrangement did this. The internal parts of the Torque Converter
are common between the 793B and 793C.
iii. Cab/VIMS upgrade One goal of the cab upgrade was to attain the
capabilities of the latest VIMS ABL system. The cost of refurbing
the existing cabs to give them this capability proved excessive.
Trakindo determined the purchase of a new 124-7684 Cab
Arrangement from Caterpillar, completely assembled and tested
was most economical. They were able to work out a special
arrangement with Caterpillar for this particular project.
Recognizing the benefits and potential market for this kind of
offering, Caterpillar will soon make available retrofit cab
arrangements for both B and C series LOHT rebuilds.
iv. Wire Harnesses Trakindo chose to replace all harnesses with new
to improve reliability and match the new 4AR configuration.
v. Radiator upgrade Though the radiators are the same size with the
same cooling capacity, there are minor differences between the B
and C series radiator top tank to accommodate a new expansion
tank. Trakindo opted not to upgrade either the expansion tank or
radiator in their project. However to achieve commonality and thus
be able to swap radiators between the C series and upgraded B
series units, they modified the top tanks by adding blocks making
them work in either machine. This update procedure is outlined in
the Radiator upgrade document.
vi. Differential Lube Upgrade Satisfied with differential life at this
particular site, Trakindo opted not to include this update in this
project. Special Instruction SEHS9948 is available from Caterpillar
for other dealers wanting to incorporate the rear axle lubrication
and filtration retrofit update into their machines.
vii. Transmission Filter Gp Trakindo upgraded to the C-series filter
group by purchasing the complete 124-7704 Lines Gp Power
Train. If not converting to the new hydraulic arrangement, a filter
retrofit kit (179-6042) which doubles the filter capacity is available
to support an upgrade to the C-series Transmission filter. For
additional information see IRM PELM0929 Dec 99.

b. Frame/Structure related repairs Mainframe fatigue at 50K hours was

Trakindos biggest concern assuming the MARC contract on these units.
Without achieving an agreement with Freeport to have these issues
addressed and included as part of the rebuild, they could not have assumed
responsibility for the maintenance and repair costs of these machines. The
following describes some of the significant frame and structural repairs
completed during the project.
i. Half frame replacement Because of the significant fatigue life
problems found on the trucks, Trakindo chose, at minimum, to
replace the rear half frame on the majority of the B-C upgrade
trucks. Trakindo negotiated with Caterpillar to have a 210-7936
rear half frame made available for ordering. Sanggar Sarana Baja
(SSB), a welding and fabrications company associated with
Trakindo completed the frame and structures repairs. They
developed the frame stand that can be seen in the Rear Half Frame
Replacement Photos.ppt file. The repairs were completed
according to the Caterpillar 793 rear half replacement procedure.
Additional related reference materials for inspecting, repairing, and
reconditioning frames include:
REHS0541 Procedure for the Inspection, Repair, and Component Replacement
on the Frames of Off-Highway Truck/Tractor
REHS0452 Weld Repair Procedure for Field Retrofit of Large Off-Highway
Truck Frame Superstructure
REHS0744 797 Frame Inspections
SEBF8148 General Salvage and Reconditioning Techniques
SEBF2700 Ultrasonics Guide

ii. A-frame repair Trakindo found significant wear in the bearing

bore and cracking between the bolt holes of the A-frame nose
cones. REHS0541 states that either case requires the entire Aframe must be replaced. A new A-frame (1856377) with increased internal wall thickness
was introduced on 793C (ATY00205) and is
available if replacement is required. Other
repair options might be available depending
on the problem with the A-frame and the
repair capabilities of the dealer. Contact your
OHT Service Engineer for more information.
iii. RAX Housing The RAX housing repair included adding stiffener
plates as per Special Instruction REHS0541. These were added in
an attempt to eliminate any future deflection of the RAX housing
that would make it difficult to bolt on the A frames. In cases where
the axle housings had deflected enough that the A-frame could not
be bolted back on, some of the A frame bolt holes on the RAX
housing were welded up and re-tapped. All of the pin bores were

also repaired. The 793 axle housing file includes photos of some of
these repairs.
iv. Steering Box Replacement Caterpillar publication SEBF8271
Salvage of Tapered Steering Bores (785 797A) should be used to
determine if steering bores require replacement. Given the
opportunity of having the trucks stripped to the bare frame, and
with the high hours and associated stresses, Trakindo determined
for the rebuild to replace the complete steering box as outlined in
REHS0541 Procedure for the Inspection, Repair, and Component
Replacement on the Frames of Off-Highway Truck/Tractor. They
also have used the second repair option of replacing only the back
plate and steering anchors but only if a machine requires an
immediate repair. Given more time, the rebuild project manager
indicated they felt they would benefit from greater structural
integrity of a whole casting rather than a fabricated one as it would
become when replacing the rear plate only.
Though not recommended by Caterpillar because of the
introduction of an additional weld joint, Trakindos repair
procedure consists of cutting window plates out of the top portion
of the steering box to allow it to slip over the cast back-up strips on
the ends of the support castings. The window plates are replaced
and the box then welded as per REHS0541.

v. Air Cleaner Box Modification To eliminate cracking and broken

bolts on the L/H air box, Trakindo incorporated a design change
similar to the 793C ATY configuration. This procedure outlines
the modifications and additional parts requirements for this
change.
vi. Bodies, Fender platforms, catwalk and handrails Freeport chose
to have their own Light Industrial Plant (LIP) weld shop rebuild all
bodies, fender platforms, the catwalk and handrails. The LIP scope
of work is defined in the LIP document. These items were painted

then shipped back to the KK facility were the sub-assemblies were

completed and packaged for shipping back to the mine for truck
reassembly. With the favorable labor costs, it was noted that costs
were only slightly less than Trakindo could have purchased new
from Caterpillar.
2. Rebuild Program Process Flows The Level 1 and 2 Process Flows Excel
spreadsheet depicts how the rebuild process is organized at a high level.
3. Project Management Enablers Example of the tools that were developed and
used as a means of managing different aspects of the entire project.
a. Work Order Structure File The Individual Truck File includes 5 tabs that
break down the responsibilities between mine site (Grasberg) disassembly
for shipping, removal and installation activities at CRC, component
rebuilds in the (KK) component rebuild center, weld repairs outsourced to
SSB, and mine site (Grasberg) reassembly and commissioning. Each of
the five tabs represents a Work Order. Each work order tab includes all
segmentation, job description and job and component codes. The work
orders are also printed, laminated and attached to each truck chassis for
the mechanics to reference as required.
b. Inspection Checklist The Pre-Wash/Strip Inspection is an inventory
inspection of what is on the machine when it is taken out of service. This
inspection is done first by Freeport personnel before turning the machine
over to Trakindo for disassembly for shipping. When the machine arrives
on site at the (KK) CRC, it is again inspected against the same checklist
by Trakindo personnel to ensure everything arrived from the mine site that
should have.
c. Project Management Schedules
i. 793B Upgrade Schedule The purpose of this document is to
establish and track all of the major milestones that occur during the
entire upgrade project. Both the Forecast and the Actual dates
are represented in this spreadsheet. This tool also includes a
worksheet that tracks the schedule for the more detailed Frame
Upgrade part of the project. This schedule is maintained
regularly and available for all managers to reference.
ii. Rebuild Project Plan This document is a Microsoft Project Plan
that lays out the work being performed by the mine site (Grasberg)
before it is sent to the rebuild center and the bulk of the R&I work
being performed by the rebuild center (KK). Expected hours are
also recorded for each segment of work.

d. Tracking Reports
i. BO Parts Daily Report This spreadsheet represents the amount of
back ordered parts management that has to occur on a truck-bytruck basis. Parts expeditors are assigned to each specific rebuild
and have the responsibility to inventory, track, order, return all
parts (except component parts) associated with each rebuild. This
back order report gets communicated daily to management to assist
with the tactical planning. By carefully tracking all back orders
daily, it decreases the risk of one missing part holding up a rebuild.
ii. Detailed Logistics Report By Truck The purpose of this
document is to plan and track all of the key movements of the
chassis and main components for each rebuild. This report is a key
management tool that shows method of transport, weights, origin,
departure dates, estimated arrivals dates, current locations and
more. This report exists in 2 different forms for each truck. One
report is created for the transportation from the mine site to KK
and another is created for the transportation from KK back to the
mine site.
iii. Weld Shop WIP Report This purpose of including this document
is to illustrate the type of communication tools that are absolutely
necessary when managing projects of this complexity. Weld
shops, like other specialty areas of the service department, are
normally managed separately and require their own set of
management tools. This Work In Process report enables project
managers to view job specific information such as component
description, start date, estimated completion and comments related
to each job they have sent to the weld shop. Without such a shared
tool, day-to-day planning would be much more difficult.
iv. Components WIP Report Similar to the Weld Shop WIP Report,
this Work In Process report is an essential part of the management
process. Regarding the OHT upgrade project, there are many (820) major components that are tracked using this tool. It benefits
management to be able to access status type information related to
any of these components. The type of information being recorded
in this tool consists of work order #, truck ID, component
description, waiting on parts, etc Each component area
supervisor is charged with maintaining accurate information in this
tool. This allows the entire team to view progress related to
specific areas of the rebuild.
e. Component Tracking A proactive repair before failure management
approach requires careful tracking of component life to be effective. This

can be a significant task for any fleet with components rotating on and off
machines on a normal basis. Trakindo documents in a spreadsheet where
each component is installed as part of this rebuild. This data will serve as a
starting point to plan when component replacements should be due.
Caterpillar has developed a web based Major Component Tracking
System to help dealers track components from cradle to grave through all
life cycles. This system can provide durability data for more accurate
MARC contract quotes. Dealers are granted access to the data when they
provide their own component data to share. For more information, search
for MCTS introduction at catminer.com.
Another aspect of component tracking Trakindo found important during
their rebuild project was simply identification of components. Some
components are serialized from the factory. Many times dealers also
institute their own systems using dealer serial numbers or more advanced
electronic ID systems as Trakindo is in process of implementing. Because
the system was not yet in place, to try and prevent expensive errors,
Trakindo found it essential to tag each component with a machine number
to ensure all would know where it had come from. This was essential
because as was referenced in the machine scheduling section, many times
the repair plan for the machine component varied based on hours.
Trakindo had experienced problems with mistaken identity of components
and a complete rebuild been done when the intent was a simple reseal and
test. These tags are printed, laminated and attached, normally with a zip
tie, to most components to allow immediate visual identification by
anyone on the floor.
f. 793B Upgrade Accessory Status The purpose of including this document
is to illustrate the type of major decisions that have to be made for each
rebuild and how the information is tracked and maintained. Eleven
different items (accessories) are represented in this tool. Key
determinations such as New Full Frame or Half Frame, Steering Box
replacement or repair, A-Frame replacement or repair, Cab refurbish or
replace with new, are all tracked and retained using this tool.
4. Parts Management - According to the service manager of the Kuala Kencana
(KK) facility, parts supply is the most critical task of the rebuild program.
Though parts management is key to any rebuild project, it is critical at KK
because of the remoteness of the job site and logistic requirements associated with
moving parts halfway around the world. In this section, well describe processes
and procedures Trakindo used to manage their parts inventory for the rebuild
project.
Inventory Control - With over 1700 parts (1150 unique part numbers) being
shipped in the Morton Superkit alone, along with all of the other associated parts

to support the rebuilds, inventory control and parts management was critical to the
success of the project. The management team at KK made the statement the
service department cannot manage parts. Recognition of the importance of this
task led the Trakindo management to assign dedicated parts people to the rebuild
team as discussed in the resource planning section. The following parts related
control measures have helped Trakindo successfully complete their project:
a. Parts Kit (super kit) storage and placement The super kit parts associated
with one 793 machine fit into 2x20 sea containers. Once these sea
containers arrive on site at KK, they are inventoried and repacked
according to the order in which they will be used during the machine
assembly. They are located adjacent to the rebuilds but secured and
managed by the parts man who is responsible for checking parts out of the
container as needed for the work order.

b. Common Hardware Bins The kitting cell in Morton does not break
package quantities to fill kits. Therefore to keep kit costs reasonable,
Trakindo ordered package quantity items to support 9 machines as a
separate kit order. These common hardware type items were ordered to
support the fleet rebuild and were inventoried separate. These common
hardware type items are inventoried separately from the super kits but also
located adjacent to the rebuilds in sea containers with built-in bins to store
the items. Parts personnel assigned to the rebuild team are also responsible
for releasing these items.

c. Work-in-process inventory - The parts with less than 100% usage

requirements on the rebuilds are ordered, inventoried, and managed by the
Trakindo parts department. The whole process is very carefully managed
with work-in-process kits consolidated in covered containers and
inventoried in the warehouse until 100% of the required parts are available
and ready to complete a particular work order or segment. As Trakindo
gained experience with known usage levels, these parts were ordered well
in advance to avoid any negative impact to the schedules.

d. Spare Parts As the machines are disassembled and inspected, many parts
to be replaced with new were judged still usable. For these parts, the
equipment strategist did an analysis to determine cost to refurbish and
created a list of parts to retain for future use against the MARC. For
instance, all of the usable pins were sent to the Trakindo Jakarta facility
where metal spray is used to recondition them. They are then retained for
future use against the MARC.
Having a good used-parts plan is a recommended practice for any
Caterpillar Certified or other rebuild as a way of recouping some costs.
Though the standard of quality of the rebuild might not allow use of these
parts, there is still known value there that should be taken advantage of as
Trakindo is doing. Many of these parts could be refurbished and then sold
through your dealer used parts department. For information on this option,
see your used parts manager or reference http://catused.cat.com/.
Caterpillar discourages selling these through non-Caterpillar channels as it
gives these parts resellers an expanded product offering to compete more
aggressively with our Caterpillar dealers in the used parts business.
For parts that are beyond use, many times there is value in selling them as
scrap. This may not always be an option because of local legal restrictions
or transport costs. It should be considered though as another possible
method to generate revenue from the rebuild. When disposing of used
parts as scrap, it is important to ensure the materials cannot be reused
should they get into the hands of the wrong parties.
5. Quality Control Management