Work Instruction

WORK DESCRIPTION: OS-NTP-WI-Truck-777D-Transmission Remove And Install

Purpose: The purpose of this Work Instruction is to maintain a uniform standard for OS-NTP-WI-
Truck-777D-Transmission Remove And Install in a safe, efficient and productive
manner that prevents harm or injury to personnel and damage to machinery and/or
equipment.

GENERAL SAFETY PRECAUTIONS

You must complete a Take-5 hazard assessment prior to commencing any work and
attach the Take-5 record to this Work Instruction. If an unsafe condition is identified,
make safe, tag-out, barricade etc. as necessary and inform your Supervisor immediately.
Further risk assessment and controls may be required.

Safety precautions, include, but should not be limited to the following, as applicable to the work:
1. Equipment should be treated as live at all times until fully isolated. Do not enter footprint of machine until it
is isolated. You must lock onto the isolation point prior to commencing work.
2. Ensure equipment is in a zero-energy state. Implement additional controls to achieve a zero-energy state
or to effectively control the energy.
3. Only use approved tools / equipment and only if competent and authorised to do so. Minimum mandatory
Personal Protective Equipment (PPE) requirements apply. Additional PPE e.g., hearing protection, gloves
etc. should be carried and worn based on risks or as signed / instructed.
4. Hot substances / surfaces, e.g., hot oil or components can cause serious burns. Allow oil and components
to cool, as far as practicable. Avoid skin contact with hot substances, surfaces, or components.
5. Leaking fuel and oil are hazardous to people, harmful to the environment and are a fire hazard, particularly
around hot components. Wear appropriate PPE and clean up all leaks and spills as appropriate.
6. Contact with liquid or gas under pressure, e.g., hydraulic fluid, compressed air etc. can result in severe
injury e.g., burns, injection etc. Depressurise systems as necessary and wear appropriate PPE. Follow
procedures if using pressurised air or high-pressure water.
7. Body stressing during manual tasks, lifting heavy items, repetitive movements and static or awkward
postures can result in serious and long-term injury. Ensure high risk manual tasks are identified and effective
controls implemented.
8. Hand injuries i.e., cuts, fractures, crush injuries, and amputations, commonly occur during manual
maintenance tasks. Wear correct gloves and take precautions to protect hands and fingers e.g., avoid pinch /
nip points, use mechanical aids, never place your hand or fingers near moving parts, etc.
9. Slips, trips and falls to ground, commonly result in injuries in maintenance workshops and during field
maintenance. Check local conditions and ensure walking and working surfaces are free from spills, water,
tools, obstacles or objects that may increase the risk of a slip / trip and/or fall.
10. Changes to work scope, environment or method, must be managed. If a change occurs, stop the work
and escalate to your Supervisor. Ensure an appropriate risk assessment is performed before recommencing.

Version: 2
This document is uncontrolled when printed or downloaded and must be discarded after use. You are responsible for Page 1 of 16
ensuring that you use the most recent version of this document.
Work Instruction

MATERIAL RISKS
Risk Risk Description Controls
Uncontrolled release of stored energy including:
 liquid or gas stored under pressure e.g., De-energise / isolate or contain the
Stored Energy accumulators. energy as per relevant procedures,
 implements suspended by hydraulics. otherwise, do not interact with the
 stored electricity e.g., batteries, capacitors. energy. Contact your supervisor. A risk
assessment will need to be completed to
 objects or materials under tension or compression
develop controls.
e.g., counterweights, tensioners, or springs /
shocks under compression.

Entanglement or crushing due to, part of the body being

Machine caught on, in or between:
Energy
 moving parts of a machine (entanglement), or Isolate the machine. Ensure pinch points
 moving parts and stationary parts of a machine are guarded / identify and avoid pinch
(pinch points), or points.

 objects or material and any part of the machine

(pinch points).

Cranes & Comply with OS Lifting procedure,

Lifting including a lift plan and competent lift
Cranes and lifting risks e.g., dropped loads, uncontrolled
team. Barricade lift zone to prevent
movement of the load, unplanned release of rigging under
unauthorised access. No lifting over
tension etc.
people. Stand clear of load being lifted /
shifted.

HIGH RISK HAZARDS / TASKS

Hazard Risk Description Controls
Body stressing:
 Overexertion handling heavy objects.
Manual Tasks Follow the relevant work procedure and
 Repetitive movements. OS Manual Handling procedure. Use
 Awkward / sustained postures. mechanical aids and lifting devices
wherever practical. Avoid pinch points
 Bending / twisting.
and wear gloves when lifting or
Hands / feet may be pinched / crushed, between objects, manoeuvring objects / materials by hand.
or between the ground and an object, while manually
handling heavy / awkward objects.
Slip / Trip
Check local conditions and ensure walking
Slip / trip and fall at level e.g., slippery surfaces or trip / working surfaces are free from spills,
hazards. water, tools, obstacles, or objects that
may increase the risk of slip / trip and fall.

Version: 2
This document is uncontrolled when printed or downloaded and must be discarded after use. You are responsible for Page 2 of 16
ensuring that you use the most recent version of this document.
Work Instruction

MINIMUM RISK CONTROL PROCESSES

Control Description of Control

A Take-5 hazard analysis must be performed and documented, prior to commencing any work.
This is a minimum standard requirement at BHP.

A job hazard analysis must be performed, if as identified by the Take-5 or in accordance with the
OS Task Based Risk Management procedure.

Exclusive Control must be established for any live testing in accordance with the OS Isolation
and Barricading Procedure.

Isolation and lockout is required, in accordance with the OS Isolation and Barricading procedure
for all tasks not completed under Exclusive Control.

PPE REQUIREMETS
Type Description

 Minimum mandatory clothing requirements in accordance with the OS PPE procedure.

 Helmets shall be worn in designated areas or as determined by a risk assessment.
 Eye protection shall be worn in designated areas or as determined by a risk assessment

Hearing protection is to be carried and worn in designated areas, or as required.

Gloves are to be carried and worn during all tasks, unless a risk assessment determines
otherwise.

Version: 2
This document is uncontrolled when printed or downloaded and must be discarded after use. You are responsible for Page 3 of 16
ensuring that you use the most recent version of this document.
Work Instruction

RESOURCES, SPECIFIC COMPETENCIES, KNOWLEDGE AND SKILLS REQUIRED

 Trained and authorised person

 Maintenance Associate

COVID 19 PRECAUTIONS

 Maintain general hygiene and social distancing i.e. 1.5m between people.
 Wash hands regularly. Do not shake hands with other people.
 Disinfect surfaces, tools / equipment etc. Use disinfectant wipes and other products provided.
 Do not use same tools / equipment, unless disinfected.

ACTIVITY EXECUTION

• Raise subsequent Notifications if required and enter Notification number (ARIS 305 Work
Management).
• Capture additional work requirements as per the additional work identified section, assign
appropriate damage codes, raise Notifications and enter Notification number (ARIS 305
Work Management).
• Complete all relevant safety risk assessments.
• Ensure all correct tools and materials are on hand.
• Ensure adequate lighting exists to execute job tasks.
• Ensure immediate workspace is clear and safe for access.
• Understand scope of work and required expectations.
• Provide applicable feedback (feedback section) to support content improvement.
• Maintain positive contact with operator throughout checks on radio channel - C9.

Version: 2
This document is uncontrolled when printed or downloaded and must be discarded after use. You are responsible for Page 4 of 16
ensuring that you use the most recent version of this document.
Work Instruction

Reference Documentation
Reference Document Description Attached
OS HSE Operations Isolation and Barricading Procedure NO
OS HSE Operations Hazardous Substances Procedure NO
OS HSE Operations PPE Procedure NO
OS HSE Operations Take 5 Booklet NO
OS HSE Operations Lifting and Cranage NO
Mastery Standard – MMS 5.1.1 Flange Type Hydraulic Hose Replacement NO
Mastery Standard – MMS 6.2.1 Create a Work Request Notification NO
OS NTP Work Instruction WI Truck Oil & Coolant Change NO

Tooling and Equipment

Description Designation Description Designation
General Tooling Load Leveller (4778634) A
Suitable Lifting Equipment Machine Access

Consumables
Brake Cleaner Rags

Version: 2
This document is uncontrolled when printed or downloaded and must be discarded after use. You are responsible for Page 5 of 16
ensuring that you use the most recent version of this document.
Work Instruction

Isolate Machine
No Note Task Description
1 1. Ensure machine is isolated and you have locked onto machine.

a. De-energize all hydraulic circuits as per OEM procedures.

b. Apply isolation hasp and locks.

c. Test Machine for Dead and fit personal locks.

No Defect
Have all personal danger locks been fitted to isolation point?
Defect
Is Machine isolated, tested for dead and personal locks fitted
Not Completed

Version: 2
This document is uncontrolled when printed or downloaded and must be discarded after use. You are responsible for Page 6 of 16
ensuring that you use the most recent version of this document.
Work Instruction

Remove Transmission
No Note Task Description
2 1. Remove main drive shaft.

2. Drain oil from transmission system and transmission tank per WI “Oil Change Truck”.

Note: Capacity of transmission tank is 95 L.

Note: Capacity of transmission system is 246 L.

3. Remove bolts (1) & (3), washers, grommet and spacer.

4. Remove guard (2) from speed sensor.

5. Remove clip (not shown) under guard.

6. Remove lock wire (5) that holds wire harness (4) to speed sensor (6).

7. Use Tool (A) (not shown) to disconnect wire harness from speed sensor at electrical
connector.

8. Put identification on two wire harnesses (7) for installation purposes.

9. Disconnect both wire harnesses at electrical connections.

10. Remove bolt (8) and hard washer from transmission.

Version: 2
This document is uncontrolled when printed or downloaded and must be discarded after use. You are responsible for Page 7 of 16
ensuring that you use the most recent version of this document.
Work Instruction

Remove Transmission (Cont.)

No Note Task Description

11. Disconnect hose assembly (10).

12. Disconnect wire harness (9) at electrical connection.

13. Remove two clips (11).

1. Disconnect hose assembly (12) from transmission.

2. Disconnect hose assembly (13) from bottom of transmission.

Version: 2
This document is uncontrolled when printed or downloaded and must be discarded after use. You are responsible for Page 8 of 16
ensuring that you use the most recent version of this document.
Work Instruction

Remove Transmission (Cont.)

No Note Task Description

3. Attach Tool (A) to transmission.

4. Secure Tool (A) to a hoist.

5. Remove 26 full nuts (14) and washers that hold transmission in position.

6. Remove transmission and transfer gears from truck.

Note: Weight of transmission and transfer gears is 1610 kg.

7. Remove O-ring seal from differential.

No Defect
Has Transmission been removed correctly?
Defect
Not Completed

Comments:

Version: 2
This document is uncontrolled when printed or downloaded and must be discarded after use. You are responsible for Page 9 of 16
ensuring that you use the most recent version of this document.
Work Instruction

Install Transmission
No Note Task Description
3 Note: Check all components for wear and damage.

1. Replace worn or damaged components, if necessary.

2. Clean all components with a cloth that is free of loose material (lint).

3. Attach Tool (A) to transmission.

4. Secure Tool (A) to a hoist.

5. Position transmission and transfer gears onto differential, as shown.

Note: Weight of transmission and transfer gears is 1610 kg.

6. Install 26 full nuts (14) and washers that hold transmission into position.

7. Tighten full nuts (14) to a torque of 430 ± 60 Nm.

8. Connect hose assembly (13) to bottom of transmission.

9. Connect hose assembly (12) to transmission.

Version: 2
This document is uncontrolled when printed or downloaded and must be discarded after use. You are responsible for Page 10 of 16
ensuring that you use the most recent version of this document.
Work Instruction

Install Transmission (Cont.)

No Note Task Description

10. Connect hose assembly (10).

11. Connect wire harness (9) at electrical connection.

12. Install two clips (11).

13. Connect two wire harnesses (7) at electrical connections.

14. Install bolt (8) and hard washer.

Note: When installing harness, route to reduce premature wear.

Version: 2
This document is uncontrolled when printed or downloaded and must be discarded after use. You are responsible for Page 11 of 16
ensuring that you use the most recent version of this document.
Work Instruction

Install Transmission (Cont.)

No Note Task Description

15. Connect wire harness (4) to speed sensor (6).

16. Tighten nut clockwise with Tool (C) (not shown) and insert lock wire (5) to next hole in
clockwise direction.

17. Install clip (not shown) under guard.

18. Position guard (2) on speed sensor.

19. Install spacer, grommet, washer and bolt (3).

20. Install bolt (1) and washer.

21. Fill transmission and transmission tank with oil.

Note: Capacity of transmission tank is 95 L.

Note: Capacity of transmission system is 246 L.

22. Install main drive shaft.

No Defect
Has Transmission been installed correctly?
Defect
Not Completed

Comments:

Version: 2
This document is uncontrolled when printed or downloaded and must be discarded after use. You are responsible for Page 12 of 16
ensuring that you use the most recent version of this document.
Work Instruction

De-Isolate Machine
No Note Task Description
4 1. Remove your personal isolator lock.

a) Turn Isolator to ON position.

b) Advise Supervisor once this task is completed.

c) Clean, inspect and return tooling

No Defect
Have all isolation tags and personal locks safely been removed from Isolator?
Defect
Not Completed

Comments:

Version: 2
This document is uncontrolled when printed or downloaded and must be discarded after use. You are responsible for Page 13 of 16
ensuring that you use the most recent version of this document.
Work Instruction

Raising of Subsequent Notifications

No Note Task Description
5 Review defect list identified, create subsequent notifications to capture defects.

No Defect
Have all subsequent, follow up Notifications been raised in Fiori?
Defect
Not Completed

Comments:

Version: 2
This document is uncontrolled when printed or downloaded and must be discarded after use. You are responsible for Page 14 of 16
ensuring that you use the most recent version of this document.
Work Instruction

Additional Work Identified

Maintainable Item Task reference if applicable Notification #

Parts Management
Material # Material Description Repairable Tagged & Returned to Store

Work Order Sign-off

Responsibility Name Surname Initial Signature Date

Version: 2
This document is uncontrolled when printed or downloaded and must be discarded after use. You are responsible for Page 15 of 16
ensuring that you use the most recent version of this document.
Work Instruction

Final Completion of Work

Task Description

Completion of Work
As part of work completion, the following actions are required:
 Measurement Documents created Y N
 Records scanned and attached to Fiori, where required Y N
 History entered into Notification for work completed Y N
 New Notifications created for unrelated new work Y N
 Subsequent Notifications created for related new work Y N
 Unused materials and damaged Repairable Spares returned Y N
 Time confirmations entered for each Maintenance Resource Y N
Document Quality (Continuous Improvement)
 If there are any changes required within this document, use a red pen to mark related areas
 If additional photo(s) are required for any noted job task, please supply them with mark up
 Include feedback to original Notification

Feedback To Support Improvement

Item Feedback
1. Activity Duration

2. Waiting Time and Hold-ups

3. Were the activities and associated

activity information complete and clear

4. Were the material, tools and

equipment list complete

5. General Feedback

Version Details Date

1.0 Initial release 28 Oct 2020

Version: 2
This document is uncontrolled when printed or downloaded and must be discarded after use. You are responsible for Page 16 of 16
ensuring that you use the most recent version of this document.