August 2015 Attachment Report

Executive summary

During the month of August 2015 the trainee was attached at Zimasco Kwekwe Division
under the Garage Section Maintenance Department and undertook several tasks in line with
the Skills Proficiency Schedule which included Housekeeping, Gensets maintenance,
hydraulic system related problems and heavy machinery suspension and braking problems.

Tasks covered

1.1 Attend to CAT 25 Lifting Problems (Electro hydraulics) – 03.08.2015

Procedure

 Do pre- task risk assessment identify hazards and implement mitigation controls
 Park vehicle on level ground and put wheel blocks
 Clean the machine
 Put centre hatch articulation lock pin
 Lock out and tag vehicle
 Test the electro-hydraulic circuits by lifting, holding and lowering bucket
 Support H-frame and replace defective solenoids
 Test machine and release it
 Do housekeeping

1.2 Attend to Cat 24 Loose Bell Housing Bolts – 04.08.2015

Procedure

 Do pre- task risk assessment as a team to ascertain potential hazards and their mitigation
controls
 Put wheel blocks to avoid unexpected machinery movement
 Lock out an tag machine
 Clean the machine
 Cool the engine before working on it
 Tighten bell housing bolts and replace missing bolts
 Test the machine. Check for leakages
 Do housekeeping.

1.3 Removing and Fitting D.C.V. on CAT 25 – 05.08.2015

Procedure
 Do pre- task risk assessment as a team to ascertain potential hazards and their mitigation
controls
 Park the machine on level ground and put wheel stoppers
 Put centre hatch locking pin
 Raise H-frame to desired level and support it with wooden blocks
 Isolate machine. Lock out and tag. Test for zero energy by starting
 Do an all-round the machine inspection and do housekeeping
 Remove hoses from the D.C.V. Use dip trays to combat oil spillages
 Plug all hoses and ports to keep contamination out of the system
 Remove mounting bolts
 Lift D.C.V out of the machine using mobile crane. Use proper rigging skills
 Clean the D.C.V while the ports are plugged.
 Lift new D.C.V using mobile crane onto the machine
 Tighten the mounting bolts and connect all the hydraulic hoses
 Take extra care to remove all plugs from ports and hoses
 Fill the hydraulic tank to level
 Test the machine
 Do housekeeping.

1.4 Attend to CAT 25 Hydraulic Leakage- 07.08.2015

Procedure

 Do pre- task risk assessment as a team to ascertain potential hazards and their mitigation
controls
 Park the vehicle on a level ground and put wheel stoppers
 Put centre hatch articulation locking pin
 Clean the machine
 Check for source of leakage
 Lock out and tag. Test for zero energy
 rectify the leakage
 Test run the machine
 Do housekeeping.

1.5 Removing Rear Axle and Fitting New Axle on CAT 18 (13.08.2015-14.08.2014)

Procedure
 Do pretask risk assessment as a team
 Park vehicle on level ground and put wheel stoppers
 Isolate machine. Lock out and tag out. Test for zero energy by starting
 Clean the machine
 Loosen the trunnion support bolts
 Remove brake fluid supply pipes
 Remove rear propeller shaft
 Raise machine rear side using mobile crane
 Remove axle by rolling its wheels out of the machine
 Support the machine on 4 legged stands
 Remove brake calliper sets and fit on new axle
 Fit wheels on new axle
 Raise machine rear frame using frame
 Slide new axle into position
 Fit axle trunnion supports and the rear propeller shaft
 Lower machine and connect brake fluid supply pipes
 Bleed air from the brake fluid circuit
 Test machine
 Do housekeeping

1.6 Attend to CAT 25 Overheating and Hydraulic Leakage – (17.08.2015)

Procedure

 Do pre- task risk assessment as a team

 Inspect the working area and do housekeeping
 Put wheel stoppers. Isolate machine, lock out and tag
 Use dip trays. Attend to hydraulic leakage
 Connect the battery and start the machine
 Check coolant leakage and the fan speed
 Check the water circulation rate
 Check air filter for clogging
 Check the engine oil level
 Test the machine
 Do housekeeping

1.7 Fitting Engine Accessories on Locomotive 07 (18.08.2015)

Procedure
 Do pre- task risk assessment as a team to ascertain potential hazards and their mitigation
controls
 Put wheel blocks
 Do round the Machine inspection
 Fit accessories to the new engine
 Test machine
 Do housekeeping

1.8 Attend to Loco 7 Gearbox Mounting – (19.08.2015)

Procedure

 Do pre- task risk assessment as a team to ascertain potential hazards and implement
mitigation controls
 Park vehicle on level ground and put wheel stoppers
 Isolate machine. Lock out and tag machine
 Fit the missing bolt on gear box mounting
 Release the machine
 Do housekeeping

1.9 Attend to XGMA 958H (26) Hydraulic leakage – (20.08.2015)

Procedure

 Do pre- task risk assessment as a team to ascertain potential hazards and implement
mitigation controls
 Park the machine on level ground
 Put wheel stoppers and centre hatch articulation locking pin
 Inspect the working area for hazards
 Isolate machine. Lock out and tag the machine
 Identify burst hose and remove it. Use dip trays to combat oil spillages
 Fit new hydraulic hose
 Fill hydraulic oil to level
 Test the machine and handover to users
 Do house keeping

2.0 Attend to Standby Gensets at IT and Furnaces – (21.08.2015)

Procedure

 Do pre- task risk assessment as a team to ascertain potential hazards and implement
mitigation controls
 Check if the machine is pre-set at Testing.
 Check the coolant level and oil level
 Check fuel level
 Start the Gensets in the “testing” mode and check the current if lower than expected or
above expected engage electricians
 After testing switch off the Gensets and press the “Auto” button
 Take immediate corrective action if not functioning properly

2.1 Attend to XGMA 3 No Brakes – (27.08.2015)

Procedure

 Do pre- task risk assessment as a team to ascertain potential hazards and implement
mitigation controls
 Park the machine on level ground
 Put wheel stoppers and centre hatch articulation locking pin
 Inspect the working area for hazards
 Remove brake pads from each wheel. Check if pistons are moving
 Fit new brake pads
 Fit new brakes master cylinder (hydra pneumatic ) unit
 Bleed the system and drain the air reservoir
 Start the machine and fill the reservoir to required pressure
 Test the brakes and release the machine
 Do house keeping

FINDINGS

1.1 Attend to CAT 25 Lifting Problems (Electro hydraulics) – 03.08.2015\

 Machine operates well on rack back and dump

 Lowering malfunctioning. Stalling engine at 1½ metres from ground

1.2 Attend to Cat 24 Loose Bell Housing Bolts – 04.08.2015

 Loose and missing bell housing bolts

 Wrong bolt sizes used on the position

1.3 Removing and Fitting D.C.V. on CAT 25 – 05.08.2015

 Damaged seals on pilot line solenoid

 Leaking machine and dry “O” ring seals cracking

1.4 Attend to CAT 25 Hydraulic Leakage- 07.08.2015

 Leaking D.C.V. to tank return pipe

  Wrong fitted static seal “O” type instead of “D” type

1.5 Removing Rear Axle and Fitting New Axle on CAT 18 (13.08.2015-14.08.2014)

 Rusty brake callipers with sticking pistons

 Leaking trunnions and damaged wheel studs

1.6 Attend to CAT 25 Overheating and Hydraulic Leakage – (17.08.2015)

 Broken pilot line from D.C.V

 Overfilled engine oil. Wrong dipstick fitted on machine
 Clogged air filter

1.7 Fitting Engine Accessories on Locomotive 07 (18.08.2015)

 Damaged accelerator rod mechanism

1.8 Attend to Loco 7 Gearbox Mounting – (19.08.2015)

 Damaged bolt on the mounting making it difficult to fit the nut

1.9 Attend to XGMA 958H (26) Hydraulic leakage – (20.08.2015)

 Burst hydraulic hose

2.0 Attend to Standby Gensets at IT and Furnaces – (21.08.2015)

 No defects

2.1 Attend to XGMA 3 No Brakes – (27.08.2015)

 Defective master cylinder

 Sticking piston on rear left side wheel
 Glassy brake pads

RECOMMENDATIONS

1.1 Attend to CAT 25 Lifting Problems (Electro hydraulics) – 03.08.2015

 Consult the machine manual for schematic and operational data

 Change the D.C.V if problem persists attend to the electrical circuits

1.2 Attend to Cat 24 Loose Bell Housing Bolts – 04.08.2015

  Replace the bolts
 Regular checks on the bell housing bolts and other bolts

1.3 Removing and Fitting D.C.V. on CAT 25 – 05.08.2015

 Repair D.C.V and keep as spare

 Clean the machine regularly
 Attend to leaks while minor in order to keep zero leakage system

1.4 Attend to CAT 25 Hydraulic Leakage- 07.08.2015

 Replace the static seals

1.5 Removing Rear Axle and Fitting New Axle on CAT 18 (13.08.2015-14.08.2014)

 Change the rusty callipers

 Repair the broken down axle
 Replace the wheel studs

1.6 Attend to CAT 25 Overheating and Hydraulic Leakage – (17.08.2015)

 Replace the pilot line and other worn out hoses

 Change oil and fill the normal recommended amount
 Fit the correct dipstick
 Clean the air filter with pressurised air

1.7 Fitting Engine Accessories on Locomotive 07 (18.08.2015)

 Engage the boiler shop to fix the accelerator rod mechanism

1.8 Attend to Loco 7 Gearbox Mounting – (19.08.2015)

 Use filing tools to remove the dent on the bolt

1.9 Attend to XGMA 958H (26) Hydraulic leakage – (20.08.2015)

 Engage hydraulic hose suppliers as there is no spare

2.0 Attend to Standby Gensets at IT and Furnaces – (21.08.2015)

 Maintaining a regular schedule for maintenance so as to enhance long life to Gensets

2.1 Attend to XGMA 3 No Brakes – (27.08.2015)

 Replace the brake pads

 Replace the brake master cylinder
CONCLUSION

Conclusively the attachment period was overwhelming as numerous duties enlisted in my

Skills Proficiency Schedule were covered. The trainee is acquired skills in safety measures,
procedures and challenges associated with major services on machine especially on problems
associated with electrohydraulic circuits, axle removal & fitting and brake repair. The
attachee performed major hydraulic leakages which gave him an insight in the intensity of
knowledge and skill required to perform such tasks especially seal and hoses identification
for replacements. During the month of August the trainee considers it a successful training
month without significant constraints

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