Title Page
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Site conducted
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Conducted on
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Prepared by
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Location
test
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Inspection done
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DOCUMENT HEADER
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Document No
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Issue Date
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Version No
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Document Title
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793D PRE PM FUEL FARM EQUIPMENT INSPECTION
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Task Scope
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Mechanical checks & daily service
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Work Order No
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Asset No
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Model
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Serial No. Prefix
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Safety Notice
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Hazard and Control Measures for Safety and Environment
Prior to sign on, Perform a SafeCheck (on the activity and site). If prompted (by the SafeCheck) carry out a JHA
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Before commencing this task check that no abnormal conditions exist. Re-evaluate each section as you enter it to make sure that you have adequately assessed all possible risks before entering and area or starting a task
If unsure, the task shall cease, contact the area supervisor (for guidance)
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Equipment and Special Tools
Serial No
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Tool
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OEM Part No
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Description
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Qty
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Reference Documents (OEM Manuals, Drawings and Procedures)
Document Type
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Document Title and Number
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Hazard List
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Hazard or Environmental Risk
Control
Uncontrolled Release of Energy
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Release All stored Energy before commencing work
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See
Uncontrolled Dropped / Falling Objects
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Apply barricading and information tags to Minimise access
Hazardous substances
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for the applicable SDS
Hot Fluids
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Allow systems to cool before commencing any work
Hot Surfaces
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Allow components to cool before commencing work
Fluid Containment
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Ensure all fluids are contained and disposed of as per site procedures
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See
Manual handling
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There are heavy objects, consider using alternative mechanical lifting devices wherever practical. Use correct Manual handling techniques
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See
Slips, trips and falls
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Ensure good housekeeping at all times and clean up spills immediately should they occur
Heavy Equipment movements
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Ensure site procedures are followed at all times
crush points
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Ensure all personal are aware and away from moving equipment and components
Pinch points (between plant and hand Tools)
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Position hands to avoid contact
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Isolations
Equipment/System Operating
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Isolation Required
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Job Sign On
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All personnel working under this Work Instruction shall sign on below to acknowledge they have read this document
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Document corrections/changes are to be submitted as detailed in Section 9 – Feedback, of this document
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Employee Number
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Name
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Signature
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Initial
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Date
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Work Management Tasks
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Apply Y or N in the work required (wr) box depending on subsequent work required. Raise subsequent notifications and enter the notification number
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This document is used for multiple equipment services. Fill out the table in SECTION 12 – “equipment serviced”, to avoid confusion
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Provide applicable comments associated with each task
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Record, all defects and notifications, in Section 11 – Work Request, of this document
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(Capture additional work as per the work requests section, raise notifications and enter the notification number)
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SPOT truck into fuel bay spoondrain
Tyre Technician to spot truck into fuel bay
Operator-Position and park the equipment as per note: if truck has been idling at fuel bay stop sign then it can be shut down immediately by the operator and not shut down by using the turbo timer;
Operator- Dismount equipment and leave the area. (There is no need to bring the key down to the maintainer)
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Tyre Technician will then initiate the Timer/Counter as follows;
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Press green reset button (underside of activation panel), ensuring reset to 00;00
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Press the red activation button
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DAILY – Mechanical Technician walk around inspection outside footprint engine running
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Tick
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Action
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Inspect for noticeable leaks, abnormal noises and damage from outside footprint
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Inspect vehicle lighting and ID number functions
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inspect tray position sensor and actuation rods
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Information- When prompted to inspect, things to look for;
Misalignment
Security/ attachment
Cracks
Missing or broken hardware
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Wear
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Damage
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Adequate lubrication
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Day 1 - Oil Sampling and mag plug checks
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Action
ISOLATED CHECKS - Sampling – Ensure Correct Sampling procedure Is Followed
NOTE Engine Oil and Rear Final Drives are completed on service
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Tick
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Transmission -
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Steer & Fan
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Hoist & Brake
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Differential
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Coolant
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Pos 1 Hub
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Pos 1 Front Hub Magplug
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Pos 2 Hub
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Pos 2 Front Hub Magplug
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NOTE: Replace any missing sample or fast-fill caps, Ensure all sample and fast-fill caps are clean
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Employee Number
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Crew
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Signature
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Name
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Fleet ID SMU Date
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Day 2 - Steering, Hydraulics, brakes and cylinder inspection
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Action
ISOLATED CHECKS (COMPLETE TRY START) - Inspect Hubs, cylinders and hosing for leaks, damage
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Tick
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Inspect the underside of cab (HMU lines)
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Inspect POS 1 Strut for leaks, damage and corrosion
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Inspect POS 1 Hub Leaking/weeping or damaged hydraulic lines
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Inspect POS 1 Brake wear
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% remaining
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Inspect POS 1 steering cylinder condition include grease line security and leaks
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Inspect Steering tie rod lock sleeve hardware tension/ security
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Inspect Steering tie rod grease lines for leaks and security
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Inspect 2 x steering centre arm pin bolts and retaining plate
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Inspect L/H hoist cylinder condition
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Inspect POS 3 Final Drive Leaking/weeping or damaged hydraulic Lines
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Inspect POS 3 Brake Wear
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% remaining
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Inspect POS 3 Strut for leaks, damage and corrosion
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Check condition of rear suspension covers
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Check for worn/bent rock ejectors and pin hardware
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Inspect POS 4 Strut for leaks
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Inspect POS 4 Final Drive Leaking/weeping or damaged hydraulic lines
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% remaining
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Inspect POS 4 Brake Wear
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Inspect R/H hoist cylinder condition
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Inspect POS 2 steering cylinder condition include grease line security and leaks
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Inspect Steering tie rod lock sleeve hardware tension/security
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Inspect Steering tie rod grease lines for leaks and security
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Inspect Hydraulic pumps mounting, weeping leaking or damaged hoses
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Inspect hydraulic lines Leaking/ weeping or damaged
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Inspect Hoist control valve mounting, weeping leaking or damaged hoses
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Inspect POS 2 Strut for leaks
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Inspect POS 2 Hub Leaking/weeping or damaged hydraulic lines
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Inspect POS 2 Brake Wear
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% remaining
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Signature
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Crew
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Name
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Emp Number
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Fleet ID SMU Date
Day 3 - Fire Suppression, Drive Train and Chassis inspection
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Action
ISOLATED CHECKS Using yellow Isolator
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Tick
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Remove Top deck fire extinguisher & turn upside down. Check extinguisher pull tie seals are in place Fire extinguisher bags, replace if required
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Inspect cab fire suppression actuation point last Inspected tag in place, safety pull pins aren’t seized and charge – green zone /1200 kPa
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Inspect ground level actuation point last inspected tag is in place, safety pull pins aren’t seized and charge – green zone /1200 kPa
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Remove ground level fire extinguisher & turn upside down. Check extinguisher pull tie seals are in place Fire extinguisher bags, replace if required
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Check fire suppression bottle, brackets and mounting
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Inspect Pos 1 front corner platform for cracks
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inspect Pos 1 main frame for cracks
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Inspect Fuel tank clearance Lights, Harness Security, Rub-throughs, Exposed Wiring & Corrosion
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Inspect Fuel tank, mounts and main frame for cracks and leaks
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Inspect Torque Convertor for oil leaks and Harness for Security, Rub-throughs, Exposed Wiring
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Inspect front horseshoe/cross member for cracking
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Inspect main drive shaft slip joints, spiders and loose missing or damaged driveline guards (Visual)
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Inspect A-frame bearing, bolts and mounting bolts
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Inspect Transmission for oil leaks and Harness Security, Rub-throughs, Exposed Wiring
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Inspect Differential for oil leaks
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Inspect Differential Harness Security, Rub-throughs, Exposed Wiring
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Inspect Hyd tank clearance Lights, Harness Security, Rub-throughs, Exposed Wiring
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Inspect Hyd tank, mounts
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Inspect Hyd tank area main frame for cracks
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Inspect Pos 2 main frame for cracks
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Signature
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Employee Number
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Crew
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Name
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Fleet ID SMU Date
Day 4 - Access ways, platforms and Engine checks
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Action
ISOLATED CHECKS Using yellow Isolator
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Tick
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Inspect ladder, step-cylinder and valve group hoses
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Access steps, grab rails & hand rails including access gate hardware
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Anti-slip strips
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Coolant relief valve & gauge display
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Mirror security
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Air Tank for leaks and cracks
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Drain water from main air tank
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Steering oil tank for leaks and cracks
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Bonnet security straps
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Drain water from cab tank
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Exhaust manifold and system for leaks
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Air induction hoses & lines
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Turbo charger clamps tight
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Fuel lines for weeps
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Radiator and Cooling system clamps & hoses
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A/C Compressor, Hoses and Harnesses
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Visual Inspection of alternator and A/C belts
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Jacket water pump tell tail and mount bolts
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Oil cooler hoses
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Aftercooler pump tell tail and mount bolts
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Compressor intake lines
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Engine mounts & hardware
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Crew
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Name
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Signature
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Employee Number
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Fleet ID SMU Date
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Day 5 Front Grease System Inspection
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Action
ISOLATED CHECKS- inspect ball studs and pivot points are adequately greased
notification to be raised if the joint is over or under greased for repair or adjustment
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Tick
Report if components are over or under greased
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Grease ladder pivot points
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Inspect POS 1 strut
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Inspect POS 1 strut grease relief vent is working
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Inspect POS 1,2,5 & 6 ball studs
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Inspect POS 4,3,7 & 8 ball studs
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Inspect POS 1 grease injector bank for leaks
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Inspect POS 2 grease injector bank for leaks
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Inspect POS 2 strut accepting grease
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Inspect POS 2 strut grease relief is working
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Signature
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Crew
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Name
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Employee Number
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Fleet ID SMU Date
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Day 6 Rear Grease System Inspection
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Action
ISOLATED CHECKS- inspect ball studs and pivot points are adequately greased
notification to be raised if the joint is over or under greased for repair or adjustment
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Tick
Report if components are over or under greased
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Inspect LH hoist cylinder pins
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Inspect A Frame Bearing
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Inspect POS 3 strut bearings
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Inspect rear tray pivot pins
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Inspect Dog bone
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Inspect rear grease injector bank for leaks
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Inspect POS 4 strut bearings
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Inspect Hoist cylinder pins
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Name
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Signature
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Crew
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Employee Number
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Fleet ID SMU Date
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Day 7 - Cab checks and inspections
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Action
Yellow Isolator locked out Tyre Technician to complete walk around light inspection
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Tick
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Drain water from Main air tank
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Seat condition include armrests
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Seat adjustment
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Seat belt condition / pull all the way out
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Seat belt operation
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Sun visor condition
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Door & window condition including seals and tint
Running Checks one person in cab only no other personnel in footprint completed after fuel up
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Air filter restriction under load – Record actual
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over 4kpa raise notification to replace on service
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Check/test fire suppression manual alarm (Muirhead) hold test button for 30 – 60 seconds to ensure truck shuts down inform supervisor if it does not shut down
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Signature
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Employee Number
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Name
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Crew
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Fleet ID SMU Date
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NOTIFICATION WORK Request
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On work completion, notifications are to be raised for additional tasks not covered by this Work Instruction, tasks either completed during this job or identified to be planned at a later date. This document is to be returned to the Maintenance Supervisor
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Date
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Emp#
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Defect
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Work Completed (yes or no)
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notification number
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Priority 1, 2 or 3
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Completion
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Remove any rags, rubbish and other debris from the machine and work site
Ensure All steps are complete before going past this point
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Task Confirmation Hold point
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Complete a return to service check list before handing the machine back to operations
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Contact the area supervisor and inform that the equipment maintenance is complete and is ready to be returned to duty
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Technician Sign Off
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Work has been completed as detailed
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Notifications have been raised for additional work/additional tasks not covered by this document or tasks identified that need to be planned at a later date
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Technician’s Name
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Signature
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Date
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Feedback (To support content improvement)
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Were the tasks instructions complete and clear?
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Where applicable, were Isolations and Permit information correct and complete?
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Were the materials, tools and equipment lists complete?
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General Feedback and Updates:
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DOCUMENT CONTROL APPROVAL TABLE
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This section enables readers to track changes and identify authors
Rev
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Date
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Description of changes
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Reviewed By:
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Approved By:
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Scott Jarrold
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James Hay
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Note: Reviewer to complete above table: detailed “Description of Changes” for other people to read; i.e. Annual Review; changes to Section 3 line 2, e
