REPORT

Document Number WIN XXX XXX XXX

Document Owner

MINESTAR TERRAIN FOR LOADING MEASURE UP OF

BOOM PIN
1 Contents
1 Contents................................................................................................................................................................... 1
2 Revision Control....................................................................................................................................................... 1
3 Details...................................................................................................................................................................... 1
4 Issue / Fault Description........................................................................................................................................... 3
5 Pre-site Investigations & Actions..............................................................................Error! Bookmark not defined.
6 Onsite Investigations & Actions................................................................................................................................ 8
7 Post Site Follow Up................................................................................................................................................ 10

2 Revision Control

Prepared Reviewed Approved

Rev Date Description
By By By
Sam
1 21/11/2021 Initial release McNamara-
Haendel
Sam
1.1 27/01/2022 Updated more info McNamara-
Haendel

3 Details

Customer Fortescue Metals Group

Site WesTrac Lot88
Machine Fleet # / Serial # TBA
Machine Make / Model Caterpillar 6040 EX
Related Technology Products Terrain For Loading V7.2
Scope of Work Measuring Point A, AL and AR Using UTS on Ground Level.

Straight Ahead Planning Fault – Service Report Page 1 of 10

Revision: 1.0 Confidential Level: GREEN

This document cannot be modified without the approval of the Document Owner.
This is a controlled quality document whilst remaining on the WesTrac Intranet, all other copies are considered uncontrolled and
therefore may not be the relevant version.
 REPORT
Document Number WIN XXX XXX XXX
Document Owner

Straight Ahead Planning Fault – Service Report Page 2 of 10

Revision: 1.0 Confidential Level: GREEN

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This is a controlled quality document whilst remaining on the WesTrac Intranet, all other copies are considered uncontrolled and
therefore may not be the relevant version.
 REPORT
Document Number WIN XXX XXX XXX
Document Owner

4 Purpose of Improvement Idea

To create a standard procedure for TFL Machines to aid the Surveyor shoot-up process for the 60 series CAT
Diggers/ Front Shovel that you are unable to see the following points: A - Boom pin centre, AL- Boom pin left and AR
– Boom pin right(M0079454-03) as the Machine Carbody blocks this view from all angels. This currently exposes
Techs/ Surveyor to working at Heights, slips, trips, and other risks involved in climbing over hydraulic hoses and railing
on the machine.

The process would involve measuring x4 points along the Boom using a Universal Total Station UTS (X,Y,Z) Whilst
the Boom is safely secured on the ground before the machine is on-site, or when it has arrived on-site before it
installed on the Machine. But this can cause issues as there are other factors that can affect the measurement on-site
i.e. surveyors not being available when needed. The measurement Points are as follows: A - Boom pin centre, B -
Stick pin centre, BC1 – Boom Control 1 and BC2 - Boom Control 2. Using these measurements (BC1-BC2),
you would then mark and install two placards on either side of the boom (total of four). The placards need to be
installed in line with the Boom/Carbody pin and the Boom/Stick pin (See Figure 1). One of the placards will have an
offset printed on it dictating the offset the Surveyor needs to put in to project along the Boom to point A - Boom pin
centre. You would then repeat the above exact steps on the other side of the Boom using the same measured offset.
This will give the Surveyor the ability to see the placards on both side of the machine giving him both the offset to find
point A - centre of the boom pin as well as AL - Boom pin left and AR – Boom pin right.

Figure 1 Measure Points

5 Measurement Process at Lot 88

The following is an outline of the measurement process that I had carried out with the aid from Institute Trainers Ralph
Yee and Jim Robinson at WesTrac Lot 88 on the FMG 6060 F/S. Reference (M0079454-03)

1. Ensure a prestart walk around the work area is complete to ensure no hazards are present that may affect
your work area.
2. Ensure the Boom is placed on stands with flat ground. With clear view to all sides of the Boom.
3. Setup the Total Station, Setup the instrument in a position that allows the best line of sight to all required
points. Ref #(M0079454-03). (Fig 2)

Straight Ahead Planning Fault – Service Report Page 3 of 10

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4. Using the UTS create a local grid using x3 control points in a triangle shape to allow for movement of the UTS
of the left and right side of the Boom.
5. Using a non-reflective tape mark out the Boom, Stick pin bores in a + configuration. This allows you to mark
the very edge of the bore both Horizontal and Vertically. (Fig 3)
6. Find the centre point of the Boom, Stick pin bore using the UTS. Find the Horizontal (left-right) and Vertical
(top-bottom) points, record these points with the UTS and find the mid-point of each of these lines. Where
these measurements intersect will give you the middle of the Bore mark this point for refences for later. (Fig 4)
7. Finding and mark points BC1 and BC2. Create the Horizontal line from the centre point of the Boom bore to
Stick bore using the above measurements recorded. Ensure that there is not any hydraulic hoses or hardware
in the way of the location to mark the BC1 and BC2. Mark and record the location of BC1. Along the same line
mark and record +-1500mm BC2 (ensure that it is visible free from obstruction). (Fig 4)
8. Now that you have marked and recorded BC1, BC2. Using the UTS find the centre point of the Boom pin bore
to point BC2. Clearly mark and record this measurement (Fig 5) as this measurement is the offset used to find
point A – Boom pin as well as AR/AL centre when the Surveyor carries out the Machine Measure-up on-site
9. Move UTS to other side of the Boom using the control points and repeat steps 5 – 8 on the other side of the
Boom (Take care that the BC1/BC2 X/Y/Z points are correct and match the other side measured minus the
width of the Boom). Because you are measuring both sides of the Boom your measurement from BC2 – point
A (Boom pin) should be the same length if done correctly. This will also give points AR – Boom pin
right / AL – Boom pin left.

Figure 2.

Figure 3.

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Figure 4.

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Figure 5.

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6 Proposed Design for the Placard

1. The proposed Placard will be made from 6mm plate steel (100mm x 100mm x 6mm) that will be painted white
foreground, red circle painted in the middle with yellow strip forming a cross configuration. Using a water jet to cut
out the required offsets of pin to allow to the surveyor to see the measurements.

Straight Ahead Planning Fault – Service Report Page 7 of 10

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This is a controlled quality document whilst remaining on the WesTrac Intranet, all other copies are considered uncontrolled and
therefore may not be the relevant version.
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Document Number WIN XXX XXX XXX
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7 Onsite Terrain Machine Measurement.

Ensure you have read and understood Installation of G610 Hardware for Cat® Terrain v6 and v7 for Hydraulic Front
Shovels {7490} (M0079454-03) and have followed all requirements for setting up the Machine for measure-up. Have
the Surveyor setup the UTS as per the instruction in M0079454-03, remove the magnets covering the centre points on
BC1/BC2 on both sides of the Boom before it is installed on the Carbody or use a EWP to access it. Ensure you can
see both BC1 and BC2 as well as the offset measurement on both sides of the Boom. Instruct the Surveyor to setup
on the Left-hand side first, locate point BC1 and align with point BC2 (this will give the Surveyor the line the project
onto point A – Boom pin). Using the offset measured in the above steps project it along the boom towards the boom
pin to give you Points: A – Boom pin centre and AL – Boom pin Left. Repeat this process on the Right-hand side
using the same steps with the same offset to give you Points: A- Boom pin centre and AR – Boom pin Right. Figure
6.

Figure 6.

Straight Ahead Planning Fault – Service Report Page 8 of 10

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This is a controlled quality document whilst remaining on the WesTrac Intranet, all other copies are considered uncontrolled and
therefore may not be the relevant version.
 REPORT
Document Number WIN XXX XXX XXX
Document Owner

Straight Ahead Planning Fault – Service Report Page 9 of 10

Revision: 1.0 Confidential Level: GREEN

This document cannot be modified without the approval of the Document Owner.
This is a controlled quality document whilst remaining on the WesTrac Intranet, all other copies are considered uncontrolled and
therefore may not be the relevant version.
 REPORT
Document Number WIN XXX XXX XXX
Document Owner

8 Post Site Follow Up

Once the machine measure-up has been completed and the CSV.File has been uploaded in the machine. Carry out
the three-point validation as per (M0079454-03) and confirm the machine has RTK High Fix. Complete a review of this
procedure and note what improvements could be made and email me with the information.

Straight Ahead Planning Fault – Service Report Page 10 of 10

Revision: 1.0 Confidential Level: GREEN

This document cannot be modified without the approval of the Document Owner.
This is a controlled quality document whilst remaining on the WesTrac Intranet, all other copies are considered uncontrolled and
therefore may not be the relevant version.