OVERVIEW OF QA/QC PROCEDURE
BEFORE & AFTER REPAIR STRATEGY.
BEFORE & AFTER REPAIR STRATEGY.
Transmissions
• Dismantle planetary section and pre-inspect clutch plates.
• Check condition of modulating vales and solenoids.
• Check condition of input shaft and rotating gears.
• Replace worn parts with genuine OEM parts.
• Crack test planetary and transfer box housings.
• Check condition of output shaft and yokes.
• Dismantle new parts and dyno test.
• Documents and send dyno report to customer.
• Paint, package, fabricate metal stand and prepare for shipping.
Cylinders
• Wash and dismantle cylinder.
• Detach cylinder rod from barrel.
• Measure HZ & RZ of barrel. Cross hone where necessary.
• Check cylinder rod for straightness.
• Check cylinder gland and bolt fastening holes for conformity.
• Grind chrome grind cylinder rod.
• Replace warn parts with genuine spares.
• Assemble cylinder and load test.
• Fit new genuine seals and bushes.
• Document and submit load test report to customer.
• Paint, package and fabricate metal stand for shipping.
Undercarriage
• Measure track pitch, pin diameter, link height and width link for OEM compliance.
• Measure grouser bar height, document and apply corrective action by stripping and re-bonding.
• Line bore and fit new pins and bushes where worn.
• Bushes and pins to be hardened with nitrogen gas methodology.
• Assemble link sections using available track press.
• Fit track pads to links and torque pad bolts to OEM settings (use OEM stretch bolts only).
• Rollouts completely assembled track groups, paint brand color, pallet, strap and prepare for shipping.
Engines
• Inspect induction system. Are there signs of dust entry?
• Problem identified and rectified.
• Brief explanation added in comments.
• Inspect/replace all air inlet pipes & hosing.
• Replace o-rings & gaskets.
• Inspect/replace muffler and exhaust piping.
• Inlet hoses and pipes silastic’d when refitted.
• Ensure all inlet & exhaust clamps are secure.
• Check operation of air filter restriction gauge.
• Replace inner & outer air cleaners. Clean out dust traps.
• Machine fitted with turbo timer.
• Engine oil level correct.
• Fuel system primed.
• Radiator level correct.
• Record temp drop over radiator.
• Engine oil primed with prelube or manually.
• Record high Idle RPM (at operating temp).
• Record stall RPM (at operating temp).
• Record low Idle RPM (at operating temp).
Differentials
• Pre-inspect prior to pre-wash and document any oil leaks.
• Dismantle unit and inspect crown wheel. Pinion gear, spider gears, cross bar, seals, bearings for conformity.
• Draw up parts requisition list and pre-order genuine spares from the O.E.M.
• Re-assemble dill and load test.
• Send test report to customer.
• Paint, package, fabricate metal stand and prepare for shipping.
• Pre-inspect prior to pre-wash and document any oil leaks.
• Dismantle unit and inspect crown wheel. Pinion gear, spider gears, cross bar, seals, bearings for conformity.
• Draw up parts requisition list and pre-order genuine spares from the O.E.M.
• Re-assemble dill and load test.
• Send test report to customer.
• Paint, package, fabricate metal stand and prepare for shipping.
Boom & Stick
• Sandblast and prepare for ND7 testing.
• Use ultrasound testing with magnetic flux to test for hair line cracks.
• Laser weld mating faces where cracks are evident.
• Line bore pin eye holes where non conformity is evident.
• Pre-order OEM genuine web bushes & seals with pins and press.
• Paint, package, fabricate metal stand and prepare for shipping.
Wheel Hub & Final Drive
• Document oil leaks pre-wash.
• Pressure clean, dismantle and pre-inspect loose parts.
• Replace worn parts with genuine O.E.M. parts.
• Check spindle, brake pack, wheel hub and final drive planetary section for O.E.M. conformity using the O.E.M. performance hand book.
• Machine wheel hub around the flanges and bearing landing areas and fit new bearings.
• Check and inspect spindle, wheel hub and mounting holes including the splines.
• Inspect and replace worn planetary gears, locating pins, bushes, ring gear, duo-cone seals and bull gear.
• Assemble, pre-test with loading report.
• Document and send test report to customer.
Torque Converters
• Dismantle housings from torque converter group.
• Inspect stator, rotators, seals, impeller and rotary parts.
• Replace with genuine O.E.M. spares.
• Check condition of charge pump and relief valves.
• Replace with new O.E.M. charge pump.
• Re-assemble torque converter group to torque converter housing with yoke relay valves and with O.E.M. charge pump.
• Run on test bench document and send test report to customer.
• Paint, package, fabricate metal stand and prepare for shipping.
Buckets
• Standardise and construct bucket from O.E.M. drawings.
• Standardise buckets by ordering O.E.M. G.E.T. Swivel pins, 3-piece adaptors etc.
• Line bore and fit adaptor kit.
• Use multi-plus wear package as per standardisation on build list.
• Rollout hardox material and weld with co2 gas weld procedures.
• Fit wear plates across cheek faces and assemble protective shrouds on bucket edge.
• Reinforce bucket linings with additional wear plates and c02 weld.
• Fit and weld heel shrouds where necessary.
• Sand blast and prepare for painting.
