Mechanic Does A Big Bulldozer Rebuild | Mega Mechanics | Spark

across Australia the wheels of industry turned 24 hours a day seven days a week these machines are tough and the teams of people running them are even tougher from deep underground to high in the sky these heavy metal marbles are essential to our daily lives but what happens when these massive machines break down teams of mechanics engineers fitters and Boilermakers step up to battle against tight deadlines in some of the harshest working environments on the planet doing the vital repair work to keep these heavy-metal wonders of Industry alive [Music] on this episode of mega mechanics at the world's largest coal export terminal high-voltage cables are causing some real problems for leading traits person dan will and his team there isn't 6600 volts running through this cable a shutdown is ordered but before anything is off the ground there's an issue we've come in our unexpected dramas that we hadn't allowed for big bull dozer rebuilds have the heat on Shane Johnson to stay on track at the Hastings Deering mine shop in Makai whence the pressure on when the customers failed another track bringing these mega machines back to new takes temperature and tools to the extreme so we've got basically an overgrown MIG welder and at the new Aklan coal mine solving the problems that keep the wheels in motion it's the job of the breakdown crews we get something there in miner there's something there in major every day is different the team received constant calls for help to make sure the mines mighty machines stay on the move this one here was gonna look currently Ian Perry has alarm sounding and a train weighing in around 130 tons raised in the air we can't get the framework down so something's not married in properly he needs to get rolling and remove a motored wheel set but safety is the number-one concern port Waratah call services in Newcastle New South Wales is the largest coal export facility in the world with an export capacity of 145 million tons of coal around twelve hundred ships are loaded each year at the port Waratah coal terminal bound for destinations across the globe being the number one global leader requires ongoing preventative maintenance led by Superintendent Ross van Dyck we have a team of tradesmen and supervisors work on a daily basis so we have 46 all up including that includes two supervisors twenty-four fitters twenty-two electricians so we work 24/7 but from a maintenance point of view any sort of delay in any mechanical or electrical breakdown can have effect on the call time meeting the demands of multi-million dollar cult customers in Japan and Southeast Asia means one machine down could delay delivery and right now there's a Fault inside the main power cable on one of the big guns reclaimer 411 is heading in for a super-sized service and electrical specialist Daniel Wilk is on the front line the reason we're changing this cable is the the fiber-optic or has failed inside the cable which is important because these machines are autonomous and they need to communicate with each other and without that fiber-optic cable repairs of this magnitude take months of planning and cost hundreds of thousands of dollars but the advanced technology that these bucket wheels need to function cannot be compromised the job schedule will mean ten days of shutdown which has a huge cost in lost productivity so the decision has been made to capitalize on this time and also repair fatigue damage on the cable rila each bucket wheel reclaimer has its own cable reel er responsible for winding and unwinding kilometres of high voltage cable as the machine moves around the odds for this job the cable will be cut and removed from the enormous 10.5 tonne rotating cable reel er which will then need to be taken off-site repaired then return for reconnection the cable and cable reel have both been faithfully in service for more than 18 years and today that coming off this mega machine to get the job started it's time to hit the brakes cut the power and cut the cable there is six thousand six hundred volts running through this cable and we've isolated everything and with everything ready for it to be disconnected in a safe manner cutting through high-voltage cable with a power saw poses dangerous risks consequences from human error can be fatal Dan's team of experts must sign onto a high voltage permit to give them authority access gap is about to cut the cable we've got a power saw they're ready to go we're not sure how this job's gonna go but should take between half an hour and 45 minutes gavel into hardcore soaring at the power supply box he's through but it's not time to pack away the power tools just yet the cable also means cutting from the real er itself the cable contains a fiber optic core to low voltage control cables and three high voltage cable conductors the end of the trailing cable coming through the middle here and then we terminate those on to the slip ring on the inside and these brushes bring the power onto the machine itself six point six thousand volts travels through those slip rings through these brushes and onto the machine to supply the machine with power this camera was 18 years old and say it's time to give it a good birthday Peter and Shaw and his lifting crew moved straight in to assess the removal refurbishment and reinstallation of the real-life what's the scope of work what other hazards what are the controls and one of the other activities at the other point that we might have conflict on as the 100-ton lifting trade heads on the site repeaters team of finalizing access electrical work and bolt removal set up their access couple under the belt now working at Heights static line that allows the guys to remove the base plates in the bottom frames we've got electrical guys who are disconnecting the 6.6 from the slippering housing watch the pendulum out the bolts are removed with the job as big as this one port Waratahs terminal manager Wayne Carmen is on site to support his staff part of the maintenance guys deals is that they take the machine they do the repairs they return it to us in a timely manner and that when they've returned us to us the operators can push the button and it goes everyone knows there's a need for speed to get reclaimer 4:11 back in business but for Wayne there's only one priority it's about making sure that we give the guys enough time to do it safely in anakata in the controlled way in a planned way rather than put pressure on people we don't do that they know what's got to get done and we'll get an update if the question is now are Peter and his crane crew good to go at this stage I can't see him holding us up but as Peter spoken too soon nine hundred and fifty kilometres north of Brisbane is the coastal city of Makai nicknamed the sugar capital of Australia the region also benefits from a large mining operation in Queensland central Bowen Basin home to the state's richest coal seams with over 37 open-cut mines and 13 underground mines in operation the recent spike in coal price has up to the demand for additional heavy machinery to work the mines the Hastings Deering mine maintenance workshop in Mackay is a massive service centre with 750 employees from trade specialists parts suppliers and support staff Shane Johnson heads up the track and world division his team are specialists in the field and his workshop one of the busiest in the country so tracks are the what moves your dozer they go on your track frame so that's when your dies is moving for their gripping the ground and pushing your dosa forward or back so they're a high wear product on the machine they're in contact with the ground all the time and you've got the whole way that the machine being pushed by these one part so they're always getting worn in higher OC for high abrasive conditions in the workshop today a cat d11 dozer is in for an overhaul that begins with its tracks the tracks on this 100 ton mega machine weigh over six tons each made up of 41 individual plates called shoes and 164 bolts the track must be dismantled piece by piece for full reconditioning the first step in the process is to get the shoes up on the press on these bigger dozers they can be almost a meter wide the plates are either machined clean or an epoxy paint is applied to stop corrosion the shoes are attached to the track chain a series of massive links each of which must be taken apart cleaned resealed oiled and tested for leaks sixteen tracks a week are cleaned and reassembled in a seven day rotation teams work shifts around the clock it's the workshop that never sleeps 40 hours in total for one track is the budget target but if it's from a dozer that's been on a coal stock pile or salt water there's extra machining and blasting needed to get the corrosion off blowing it out to a 56 our task this makes Shane's job scheduling maintenance a constant juggling act when's the pressure on when the custard is failed another track and they need that track back to replace the one that's failed work on the shoes and chains of a dozer track take several days of around-the-clock attention but that's just a small portion of the hundreds of tasks to complete a full overhaul which will see them out of action for six weeks and the next component needs an unusual combination of fire and ice [Music] 25 kilometers from the township of oki and regional Queensland the open cut pit of new Ackland coal mine is already a hive of activity this morning keeping the sights huge fleet of massive machinery on the go is around the cloth job for the breakdown crew a group of experienced mechanical fitters the team constantly travel across the site and for Nathan Sutton his first port of call is dozer 611 this beast of a machine is a cat d11 the largest Ozar in the fleet it packs more than 800 horsepower but it's not up to its usual fighting form the dozer has been given a stop-work order because of an issue with the relief valve relief valves are used to regulate pressure in the dozers hydraulics too much pressure and the system could literally blow apart but too little which is the problem on this dozer and there's not enough pressure for the hydraulics to function correctly we've had the job Troy said it said the pressure again Murs Springs obviously tree damage won't get correct pressure unfortunately the replacement part the team needs isn't on hand so while it's sent for from the warehouse there's a 102 tone mining truck in need of attention Ryanair meets here to start the air-driven starter motor just needs a dose of compressed air and this 5.8 meter tall monster truck is back in business it's not the only mechanical beast that's running low on air this morning Craig Jackson in the supervisors office calls Nathan on the two-way radio 346 [Music] reported politics flat tire Oh water trucks are vital to mining sites they control dust and also play an important role in fire prevention with a full tank these trucks can haul 150 thousand litres of water with one of the four rear tires blown that's a huge wait for the others to bear so letting the sprays run is the simplest way to fix that the solution is a new tire at over 26,000 dollars each it's a trip to the workshop for the tire change now Nathan can return to dozer 611 he's been advised the new relief valve is on its way so he's under the pump to get this 102 ton machine prepped and ready he's on target for now but not if any emergency call-outs come through in Australia's third-largest City Brisbane the main rail Depot is the epic center of City train maintenance on average 53 million people travel on passenger trains every year and schedules need to run on time even the smallest issue can have a compounding effect so when a train not getting full power is reported it's returned to the maintenance Depot for analysis it's up to working group leader Ian Perry to rectify the issue and get this train back on the tracks and fully operational for the PMP we're gonna be checking out water water 3 we've had a reports in the result of rounds what that means is that the bushes aren't good on the comms inside the water so what it says is that when it's outgoing traffic you're only getting 7 more times driving the Train instead of 8 Ian Perry has been a fitter and mechanic across the world from steel works to shipyards and now to trains where he's become a specialist in what they call the jacking Road the jacking road has 12 pairs of jacks one to support each axle of the three-car train as it's raised then to be able to access an individual wheel set body supports are brought up enabling the main jacks to be lowered the wheel set can then be removed and have its motor changed over first Ian and his apprentice Dale West thought raised the body supports well if you didn't have the body support up there you can't do any other thing on this machine you must be in this sport if you didn't have these off and they you bring your whole support down with the body supports in place Ian extends further safeguards to balance the 130 tons of train currently raised in the air the safety on this is mainly on the mortar itself you've got to have a scissor lift underneath you're looking at least one to one and a half ton on a mortar and the wheel set so you've got to be careful all the time it's also a schedule to keep and a lot of work to be done to get this train back on track the team are well aware of the safety risks constantly weighing up the hazards and planning accordingly we have a dedicated team over here and we all know what words well what was some force to do everybody knows their job and obviously we still go around we look up to everybody else the main thing is that without and dedicated crew of a will rejoiced in the town on how long it takes to doli start a jobs electrician Damien fuller is on site he's made short work of disconnecting the necessary cables now we've got into a different mods because we want to drop it down 50 mil then we can get the jacks out but the system has locked and won't budge it's a sophisticated series of checks and balances on a piece of machinery that ian is an expert in operating will his experience shine through and get the engine changed over in time for the p.m. peek back at port Waratah Peter and Shaw and his crew are ready to lift out the 10 and a half ton cable reel er from reclaimer for 11 he goes 100 ton crane come in from boom much he lodged the counterweight the boys are gonna reverse up the ramp come in here parallel with the cable reel ER and that will give us around about a 16 meter radius Oh we'll be well within the lift zone they're ready to lift it off Peters gotta stay on schedule because this real er needs to head out on the road for a major offsite repair contractor visa he's on the phone this morning you know when are we gonna suit because they've got a lot of work to do and they want to get that underway the team at MCM manufacturing know they have a tight turnaround to repair the real life so they're gearing up to receive it back at base the spreader beam is winched into place winter so what's going on then we're ready to go we set up the corrugated area you know cooking up onto the machine and we get started airing on the plan we'll be on target a smile with relief from Peter as the lift begins [Music] but the crime driver signals a problem we've come into unexpected dramas that we hadn't allowed for and we started the lift what we found we had three corners of the Kaabah ruler with it lifted with the crane he reached his 10 tonne capacity hydraulic cylinders on the back of the crane required to stabilize the vehicle have paralyzed Peters plans we can't get him up we can't get him down so we've come to a halt until the mechanic gets on site hopefully gets us out of trouble this is a disaster for Peter and his team their schedule is now way off track and time is ticking put us behind because you've got a crew in the workshop eagerly waiting for the cavalry would turn up to get started the delay has a domino effect jeff gaddy's is waiting to transport the rila on his truck to MCM fabrication workshop a lot a lot of times you get hold up tight person yeah it's out of our control so you just got to sit there and wait and grin and bear MCM awaiting to refurbish the rila Dan and his crew are waiting to replace the cable and terminal manager Wayne Carmen is waiting to get port Waratah fully operational this is a serious setback it's my job is to make sure that the plan that's developed I'd I deliver and when I say I deliver I'm accountable for it and obviously Ross being the maintenance superintendent let me know if something's starting to go haywire after suffering a four-hour stoppage the crane is now giving me all clear and Peter's crew are under the pump chain locks are secured and final checks are made before the big list now fully suspended this is a tense moment for the crew there's a lot of money not to mention time and effort up in the air and a slip a gust of wind or a failure of the crane could be catastrophic but not just the realer but the crew it's all in the crane operators hands cautiously he maneuvers the cable relay and showing his skill and precision guides it safely down finally loaded onto the truck there's not a minute to lose but the truck carrying the relay has come to a standstill because of the the size of this royal it was just on the street point five mark I can't go anywhere with it so I would just sit outside the gate enum white load restrictions on public roads means the real ER is too wide to travel in peak hour traffic they've missed the window of time to get it out in daylight Dan's day is going from bad to worse I get a bit uneasy when there's times like this we need to get moving it's kind of that time where you're sitting still when you know you've got to feel something beep and yeah you know you're going to have to work a bit harder later on to make up for this time while Jeff is truck amber Cable realer take a break the repair team are waiting in their workshop losing valuable hours will they have enough time to be able to repair the real [Music] in the Makai Hastings Deering mine shop the track team is working around the clock to carry out a mid-life service on the dozer tracks that work the Bowen Basin coal fields and today it's not just mechanics but science that's helping things along in the dozer track frame sits the pivot shaft bushes this is where the track frame mounts onto the dozer the shaft is constantly rotating at angles to accommodate the terrain the dose is working at least 20 hours a day on a coal mine that's a lot of wear and tear the mid-life service for these parts means of good clean and then refitting with a perfect seal which involves a process called an interference fit the pivot shaft bushes are submerged into a tank of liquid nitrogen at minus 200 degrees Celsius for around 10 minutes in that time the metal shrinks on the floor the track frames space that the bush has to fit is heated with a gas torch with one metal part expanded from heat and the other contracted from freezing there's a very short window of time for one to slide into the other perfectly right in as each part returns to ambient air temperature friction holds the pivot shaft Bush in permanent place but if it's not timed just right or if the track frame has cooled after heating the bushes expand back to size rapidly that can mean a little bit of old-fashioned coercion inserting a drift slide and hitting with a sledgehammer it's vital the bush seats perfectly it takes much of the load of the 91 ton dozer a poorly fitted Bush won't last the next 8,000 hours of work it has a head even slightly off means cutting the part out and starting over again and if you thought these guys had a tricky task working with sub-zero temperatures the next rebuild in the dozer workshop involves an arduous 10-hour shift at a scorching 300 degrees the new Ackland my min okie and Outback Queensland a place where temperatures can soar above 40 degrees Celsius challenging conditions for a challenging job the extraction of over 13,000 tons of clean coal every day keeping the coal mines extensive range of mega machinery running smoothly is the breakdown crew an experienced dedicated team of mechanical fitters so far Nathan shift has seen him called out to deal with a few mining trucks three six two three five injector and a water cart with a flat tire standing at over four metres this monster towers over the mechanic working to get it back on the moon so did the tires each one nearly three and a half metres tall and weighing in at three times [Music] one machine that's been a real attention seeker this morning is this 11 meter long Hulk a dozer with a damaged relief valve this is the second time Nathan's been inside its belly today a replacement part has been ordered and Nathan's racing the clock to get this 102 tonk dozer primed for the installation every working minute lost out in the pit means less production so it's crucial to get this mighty machine rolling again as soon as possible the new valves arrived along with another mechanic and with two on the job this beast will hopefully be back in business before the shift ends elsewhere on the mine mark Garth from the breakdown truth has been called out to check on truck number 311 this one here we're gonna currently daddy I'm had a tank it's got a leak on it somewhere he obviously was on a break or who's driving and itís the coolant leak and pull her in cold her up it's a four meter climb to get up to the cabin gauges show an empty maybe maybe the operator hasn't seen any lake as such you should saw the gauge when huge machines like this are operating in extremely hot conditions it's better to be safe than sorry Holly gage a quick inspection proves mark right just gonna send it back to work and see it go and with that mark heads off to another caller safety is the number one priority for Ian Perry and the team on the jacking road at the main rail complex they're going through the final checks before removing a one and a half ton motored wheedle set you need people there to help you out and support you and lifting things especially a lot of heavy components it's a complicated job but one Ian Perry is a specialist in you've got to lift the tree and off you've got to support the carriage are then so simplifying it they put a trolley underneath take it out get a new one build up put that back on the trolley and back up again and we bear saw the things have drawn the first charm with a clear plan in his head Ian needs to drop the jacks down but movement is locked calm down the safety interlock on the jacks will prevent any unsafe conditions these checks and balances are designed to protect the workers and equipment the alarm is sounding and it's Ian's job to find out why he knows from experience it's just a matter of going through the process in fine detail nothing needs to be rushed we can't get the framework down so something's not married in properly a delay could impact edges and if there's an issue with the jacks that can't be resolved no work will be able to continue Willie and be able to silence the alarm and get back on track [Music] overnight port Waratahs damaged cable reel er finally made it to MCM s fabrication workshop Richard Tate and his team wasted no time in getting on the tools we lost about four hours because the Train malfunction we've had six men around the clock from then MCN have been commissioned to refurbish the cable reel er it's a gigantic job and these guys won't stop until it's finished 24 hours a day for four days six men on each ship with the cable reel ER in the workshop Richard can properly assess the cause of the problems it's time by vibration the actual motion itself it's been such a light fabrication as it rolls it fatigues and we're repairing fatigue cracks this is a critical repair the cable on reclaimer 411 weighs over 15 tons as the reclaimer moves the cable winds around the spokes of the real er called spiders a breakage could not only tangle and damage the hundreds of thousands of dollars of cable but could result in a massive arc flash or electrical explosion to ensure the recondition real ER is safe and strong enough to last another 20 years Richard inspects every detail you're there gonna be a tight fit because I think the existing holes are 22 mil back at port Waratah dan is feeling the fallout of unprecedented delays to his schedule can he call back time while the real err is off-site just inspecting the electrical components from when the drones been lifted checking that they're all still intact and ready to be reconnected so while that's off site we're doing work to refurbish a lot of that gear for when it returns steaming ahead Richard at MCM is confident about getting the real er back on the road and we've got another shift and a half to go and it's well ahead of schedule it's well planned well means blokes know what they're doing a final push and MCM finish in record time a days early and now we're miles ahead it should make them very happy and here it comes Jeff trucks in the newly refurbished cable Rilla Rilla stern up a day early boys out shop at MCM and done a fantastic job to get us where we are today not only the time frame but the quality is first-class very happy with the quality Dan is also a happy man his shutdown is now back on schedule it's all hands on deck and Dam is ready and raring to get this relock back in [Music] there's only 100 millimeters of clearance it's a tight fit 20 bolts secure it on to the Machine and the refurbished driller is in Haverhill our job on the car Burroughs Scott very well all that's left to do now is blind on the cable and reconnect power with such a straightforward task what could possibly go wrong at the dozer track Division of the mine shop constant shift rotations means these Bay's are in action continuously day and night currently they're tackling dozers due for their midterm service after working 8000 hours on the coalface the team must completely overhaul each machine the next part for restoration is the idler part of the undercarriage which bolts onto the front of the track frame and guides the rollers to line up the track with the load rollers underneath the idler rotates constantly with the track as the machine moves in operation day and night the metal on metal fatigue from the track chains wearing against the idler takes its toll the overhaul involves an arduous sweltering process for both mechanic and machine if the idler steel faces worn below 70% it's hitting a softer mild steel surface which means a complete rebuild to build it back up to spec an LPG burner is fired up to a heat of over 300 degrees it's then applied at a constant rate to the surface for up to 10 hours temperature they'll actually start to crack the surface in the 30 plus degree tropics of makai that constant heat is a concern for workers like Terry they have to make sure they take fatigue breaks and stay well hydrated always mindful of keeping hands well clear of that searing flame with each rotation the wire forms the base material for the world and builds up the surface of the ID line we have a flux granule so that falls on top and the welds performed underneath that grain to keep any impurities out until it's cooled down until we chip it off there for the next world but once the 10-hour weld is complete the idler is put in a hot box to cool gradually a mid-life service also means a complete engine overhaul the d11 dozer engines weigh up to four and a half tonnes depending on the state they're in the engines are either reconditioned or a brand new one is dropped in [Music] and just as one dozer heads back to the mines another is being pulled apart and rolled into the workshop ready for attention it takes eight people every day around the clock for six weeks straight to get one of these machines broken down cleaned up and back out to site again it's a massive amount of manpower but for the machine it's now set to face another year working 20 plus hour days pushing coal at the new Ackland mine near okie it's the start of another busy day the breakdown crew are ready to roll the main focus of this team is to quickly attend to breakdowns and solve the issues as fast as possible but they do have other duties we get a list of minor defects that we have to get to a day can involve that's just going to fix a light bulb or wipe out some of that or to a breakdown where trenee is failed and yeah we might have to pull Axel's minecart back to the workshop we get something there in miner there's something there major every day is different don't know what to get truck number 503 is his first to call out a loose cable needs to be secured in place so basically that this job is just a simple job just putting our clip on that pin there's stuff that from falling out partner is a top now with the truck bed lowered and the letter raised number 503 can roll back into action and Mark can make tracks to his next assignment a broken-down excavator attaching his personal lock to isolate the power supply means that no one can start or operate the machine so he can safely get to the heart of this diggers issues and the problems any saying the excited wire just popped off this place the time you can pick it easy alleys low voltage so it just excited wire come off the old no so wait no for sure we'll check it on there and crimper up a bit better and father girl up and runs marks connected the wire he thinks is causing the issue and for good measure he removes a seized hinge on the engine door a quick fix that a boilermaker can repair properly later on with that locked off time to see if Marc's hunch about the loose wire was right as Sam revs the engine it seems it was and now it's all good to go mark packs up and it's off to check on dozer 618 a machine that's going nowhere fast the track tension problems this powerful d-10 bulldozer rips and stacks cold in the pit it may be the little brother to the D Elevens but at around 70 tons and reaching nearly four and a half meters to the canopy it's definitely not small we got here the loose track boys have tightened it up last night and it's come down again they've got a bit of grease into it last night don't see it's got a problem internally there but looks it a little there now alone service truck coming along little ball pop it up again these machines are battered with tough conditions but a bit of TLC from mark and they've soon got a new lease on life they tried nursing through - until we get a space in the shed where we can now it jobs in keep the grease up to it until we get a bay for it grease is apply to try and prevent excessive wear but while this is a quick fix to get things moving it doesn't solve the larger problem if left a loose track can cause even more issues with the machine it just wears everything you know it'll wear the track frame where you wear your change your oil is looks like this beast of burden will need to be called into the workshop for extensive repair work the safety warning alarm is sounding at the main rail complex in Brisbane the sensors on equipment supporting more than 130 tons of rail cars have alerted the crew to an issue the pressure is on group leader Ian Perry to work out what it is and how to solve it so he can access a moated wheel set that needs to be removed any of these lights out hopefully the solution is as simple as replacing a slide up I call him down if the in solution has worked he should be able to get the moated wheel set out and on the scissor lift [Music] what it's worked sometimes it just jumps out a sink I don't to be a few millimeters not stop all operations success and finally ian is able to drop out the bulky jacks from under the moated wheel set now with the motored wheel set on board the trolley rolls along the tracks to meet the overhead crane the one and a half tonne piece of machinery is carefully loaded onto a specially designed rest I check it out one of the chains is disconnected to free the traction motor then it's guided to a location where the two pieces can be safely separated [Music] in order for a new motor to be fitted the gear cases are removed and the old motor disconnected the gantry crane again swings into action to deliver the wheel set to the newly recondition motor yeah just gonna fall in there and I'll boil it down we've just got to ball to the child you need you got back brush but once that's down we'll go with the wheel set fastened to the motor Ian checks for the all-important backlash compact washing up the team install a copper shim that's about point four of a millimeter thick which creates the space or backlash opening up a small space between the gear teeth that allows for lubrication now come down a little bit more net or just line straight in with a bead of silicon to ensure the gearcase joiners watertight the motor and wheel set are ready to go back into the train and in record time but they're not out of the woods yet figuring that poor Jaffe the one and a half ton wheel set a motor is transported back on the scissor lift lined up precisely with its installation point and raised into position the new traction motor is secured to the bogie of the Train with a bolt through the reaction arm this is what stops the motor from rotating on the axle and instead transfers the force to turn the trains wheels now secure the main jacks can again be raised to take the weight and the scissor lift brought down so the undercarriage can be accessed both tightened electricals reconnected and the team can celebrate a job well done I think it's a sense of achievement that you've done a job and everybody safe and go home safe it says it's like a bit of a port it's an adrenaline rush it really get an adrenaline rush and I like doing a job properly it's no surprise the train was back on track and ready to roll out with the rest of the fleet for the afternoon people harsh conditions push the staff and the huge machines they operate to the limit every day and when that breaking point is reached the mines break down crew are called into action three five three seven Marco got a copy we've had a break fire on dub waited for something better park brakes not coming up you have to check that out for me when an issue with brakes is reported the best way mark can see what's happening for himself is to carry out what's called a rolling test it thinks the front brake lights are on but they're not still rolls top CA electrical error pressure switch playing up make it the front brakes are applied opening up the front cab panel mark inspects the carts electrical system then heads down to check the brake lights after scrambling under the trucks belly searching for clues and applying all the usual fixes he can't uncover what's causing the issue face next to three fine yeah this a double it for water car this was appear to be a quick fix one down there down the ship I found a switch that looked to be unplugged but that didn't fix it little bit more investigation listen the pressure is always on to find a fix and fast but there's only so much that can be done out of the fit and mark knows he's not always going to be successful but after a short test drive it looks like he can celebrate a win after all Thanks it was that bug back at port Waratah the pressure is on to get reclaimer 411 online dans crew are gearing up to finally get stuck into some heavy lifting installing the high voltage cable the cable - its 1.3 kilometers long it's 10 kilos per meter so it's 13 tons of cable we've sourced this cable from Europe it's taken six months to get here and cost nearly half a million dollars today is the pinnacle of the operation but Dan's hopes of getting the job done on time may have just been cut short unpacking the cable and we noticed some damage we've contacted the manufacturer and ask for direction on next there's no backup option and reclaimer 411 cannot operate without it at this late stage in the shutdown a damaged cable is a catastrophe what's required to repair the cable high-voltage fiber-optic jointer Roger Devery arrives to inspect the cable it's just here to sweep damage they'll be doing a falconers repair so we'll take the outer sheet off back to where the damage stops then we'll be wrapping with vulcanizing tapes that won't damage any of the in terms of cabled the power or the pot rock based on with the cable repair pending it's now crucial that Peter and his team stay on target we got some boys on the other side they are setting up the cable ruler wench 3 2 white the UK along the Machine time to lock on the most critical part is getting the cable from this rail and into the machine where we want it to be and that'll be probably the most difficult thing as the cable is wound onto the reconditioned real the first loop is critical they must have clear entry into the slip ring box for reconnecting power so the people inside the drum will be performing a little bit of a chain my main concern is the menu handling aspects of physically using men to maneuver this table 10 kilos per meter means heavy lifting and long hours it's relentless and these guys need a break it's gonna take some time man you got it have to be patient we don't defend the cable too much because of the fiber optics inside and we need to be able to look after it as we're installing it so the more the merrier and less stress on one person the better it is the first loops are secure and Betina use electrical rotation to feed the cable on with a hundred and fifty revolutions to go it'll take some time there another 20 minutes hopefully and we've got the cable on and my time can start to put it back together finally the last of the cable winds on and Dan gives it his magic touch to tie it off done the job diamond we're okay I'm pretty happy running under generator power to complete the connection reclaimer 411 does laps to bed in the cable the Beast is awakened it's back to business and the big boss couldn't be more proud of his team this is just big stuff so the guys take a lot of pride in it they really do there's a lot of pride in making sure it goes well nobody's hurt and it's on Tom port Waratah is a landscape of giants and it's a place where the size and strength of mega machines is only matched by the skill and diligence of a team of mega mechanics

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Rating: 4.7692633 out of 5

Keywords: Spark, Science, Technology, Engineering, Learning, How To, education, documentary, factual, mind blown, construction, building, full documentary, 2017, 2016, 2015, full, space documentary, bbc documentary, Science documentary, mega mechanics, mega mechanics episode 4, engineering documentary, engineering explained, how do bulldozers work, bulldozer engineering, rebuilding a bulldozer, coal export terminal australia, hastings deering mine shop, engineering in australia

Id: nmIajKSScWs

Length: 47min 35sec (2855 seconds)

Published: Wed Apr 15 2020