Built with safety, efficiency and power in mind, Geographe has rethought how maintenance teams remove seized Caterpillar 777 ball studs.
There are a handful of common methods for removing seized ball studs. Some use sledgehammers, while others rely on hot works or grinders. But what if there was a safer, faster solution?
Building on the global success of the Ball Stud Removal Tool (BSRT) to suit Caterpillar 785, 789 and 793 haul trucks, Geographe has now introduced a BSRT to suit 777 haul trucks.
“Using traditional practices, a customer had been trying to remove a ball stud from their truck for over two hours when we arrived on-site,” draftsperson Siva Thasappan told Australian Mining.
“They had allocated a 12-hour shift to remove it. Once we deployed the prototype 777 BSRT, the stud was released in three minutes.”
Planner and estimator Andre Duckitt took Australian Mining through the process of deploying the new tool.
“One of Geographe’s core values is ‘work it out’, so it was business as usual when we were asked to develop a solution for the Caterpillar 777 trucks,” Duckitt said.
“The key challenge was the smaller size of the truck, which meant less space to work with. We scaled down the original design while ensuring it delivered the same impact as its predecessor.”
Image: Geographe
To ensure the strength and reliability of its specialised tooling, Geographe conducted a finite element analysis (FEA) using computer software to evaluate performance under stress.
By inputting the tool’s load, dimensions and material properties, the analysis reveals how the load is distributed and identifies potential weak points in the tool.
“Various operational scenarios for the tool were considered and optimised through FEA simulations,” Thasappan said.
“Once the design was finalised, a prototype tool was manufactured and testing was conducted.”
The 777 BSRT design also includes improved modifications such as additional clearance that has been provided to accommodate various positioning options for the tool.
In addition, featuring a snap-on/snap-off mechanism for more positive loading of its components ensures a quicker and safer operation.
“With its compact, lightweight design, the 777 BSRT can be transported to any site where ball stud maintenance is required,” Thasappan said.
“Traditional approaches to ball stud removal involve time-consuming, manual and often high-risk activities which can pose a significant risk to maintenance personnel. The 777 BSRT allows maintenance teams to be out from under a haul truck while releasing the seized studs.
“Geographe’s tool is easily installed and uses seamless hydraulic force to release the ball stud. The applied force is localised and does not adversely affect adjacent components.”
Duckitt said the ease of use of the 777 BSRT is a particular highlight of the tool.
“The BSRT can be operated by a single person, and removing a ball stud takes no more than 10 minutes including the set up and operation time,” he said. “Minimising the need for hammering, grinding and hot works, the tool assists in avoiding eye injuries, pinch points and bruising to the hands.
“Maintenance doesn’t need to be hazardous. The 777 BSRT makes our customers’ lives safer and easier. Making maintenance safer is one of the main reasons behind why we do what we do.”
This feature appeared in the February 2025 issue of Australian Mining.
