A CAT 777 Service Module, Redesigned For Safe Fill & 600 LPM Dispensing

Client

CAT 777 Midlife Upgrade

Location

Papua New Guinea

SCope of Work

CASE STUDY · HEAVY EQUIPMENT & REBUILDS · 2023

600 LPM Banlaw dry-break	8 lubes + diesel + coolant	Digital Fill-level indicators	Turnkey Design to commission

Capability
Heavy Equipment & Rebuilds

Sector
Mining

MTIS was contracted to upgrade and rebuild the SMA service module fitted to a CAT 777 service vehicle during midlife. Three subsystems redesigned, installed and commissioned in-house: a safe-fill loading station for diesel, coolant, and eight Shell-grade lubricants on digital indicators; a 600 LPM Banlaw dry-break heavy-vehicle dispensing system; and a new integrated pump control panel.

Scope

Service module redesign: hydraulic and dispensing layout drawn against operator throughput targets, on the SMA platform.
Safe-fill oil and fuel loading station: diesel, coolant, and eight lubricants (Rimula 15W40, Spirax 60W / CX10W / CX30, Tellus 68W, Omala 220W, Corena 68W) on Banlaw FillSafe Power overfill protection and colour-coded dry-break connectors.
Digital fill-level indicators per fluid line, visible at the panel face, with no guesswork at the loading station.
Dry-break HV fuel dispensing system: dispensing pipework and flow rate uplifted to 600 LPM through a Banlaw HV coupling for faster heavy-vehicle refuelling at the face.
Internal manifold rebuild: electric-actuator valves and stainless pipework replacing legacy hydraulic plumbing.
Pump control panel: control and switchgear redesign tying loading, dispensing and indication under a single operator interface.
Commissioning, flow verification, and hand-over to the mining operator.

Approach

A midlife service is the right window to rebuild the service module rather than refurbish it, because nothing has to come out twice. MTIS owned the full chain on the SMA platform: hydraulic redesign for the safe-fill loading station, Banlaw dry-break on both loading (per fluid) and HV dispensing (600 LPM), a new digital fill-indication system at the panel face, and an internal manifold rebuild on electric-actuator valves to clean up the old hydraulic plumbing. Pre-fabrication kept on-truck install time short; commissioning was run on site alongside the operator’s mechanical team.

Safe-fill loading station panel on a CAT 777 service module during MTIS midlife upgrade in PNG

Safe-fill loading station layout.

Digital fill-level indicators and pump control panel for a CAT 777 service module upgraded by MTIS in PNG

Digital fill-level control panel.

Internal hydraulic manifold and pipework during CAT 777 service module rebuild by MTIS in Papua New Guinea

Internal manifold rebuild.

Banlaw valves and stainless pipework.

Outcome

The rebuilt service module loads diesel, coolant, and eight lubricants through a single Banlaw safe-fill station with digital indicators per fluid, and dispenses fuel to heavy vehicles at 600 LPM through a Banlaw dry-break HV coupling, cutting refuelling time at the face. The new control panel and rebuilt internal manifold tie loading, dispensing, and indication under one operator interface.

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