How do you remove seized 777 ball studs?

Common methods include using sledgehammers, grinders, or hot works; while these methods may have assisted in the past, did you know they are hazardous, labour-intensive, and time-consuming? What if there was a safer, faster alternative?

Building on the success of the Ball Stud Removal Tool (BSRT) designed for Caterpillar 785, 789, and 793 haul trucks, Geographe has now introduced a BSRT specifically engineered for Caterpillar 777 haul trucks as a solution to traditional extraction methods.

“Using traditional methods, we discovered one customer who had been trying to remove a ball stud from their truck for over two hours when we arrived on-site,

They had allocated a 12-hour shift to remove it. Once we deployed the prototype 777 BSRT, the stud was released in three minutes.", Siva Thasappan, Geographe draftsperson.  

Engineering Innovation in Action

“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,

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.” Andre Duckitt, Planner and estimator. 

To ensure the tool’s strength and reliability, Geographe conducted finite element analysis (FEA) simulations. By evaluating how the tool performs under stress, the team optimised its design for maximum efficiency and durability.

Improved Features for Better Performance

The 777 BSRT incorporates several key improvements to ensure seamless operation:

• Compact Design: Scaled for smaller truck dimensions, allowing for greater flexibility in tight spaces.

• Two-part split retainers: Ensures the tool securely locks into place.

• Additional Clearance: Offers multiple positioning options for enhanced usability.

“The BSRT’s compact, lightweight design allows it to be transported to any site where ball stud maintenance is required,” Thasappan said. “Traditional approaches involve time-consuming, manual, and high-risk activities. The 777 BSRT eliminates those risks, allowing maintenance teams to work more safely and efficiently.”

Safety and Efficiency at the Forefront

The 777 BSRT uses hydraulic force to safely release ball studs without damaging adjacent components. Its ease of use is a standout feature, the tool can be operated by a single person, with a typical removal taking less than 10 minutes, including setup time.

“Minimising the need for hammering, grinding, and hot works helps avoid injuries like eye damage, pinch points, and hand bruising,” Duckitt added. “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 what we do.”

With the 777 BSRT, you can improve safety, and efficiency during ball stud removals on your site. No need to go back to traditional removal methods, your new mate is here to assist. 

For more information on this tool, visit our page today: info.geographe.com.au/777bsrt