<793C> <Commissioning Form >

Note This Machine is not to be released until this document is completed.

It is only to be released on day shift after representatives from Freeport Maintenance, Freeport
Operations and Trakindo have inspected and signed final paper work.

PTTU OHT Equipment Manager

PTFI Maintenance Manager
PTFI Operations Manager

Task (Job Code): Work Order

Equipment No Responsibility
Serial No Date
CC + MC SMU Reading

JOB SUMMARY

Budget Budget Responsible Complete

Activity Activity Description
Man Hours Duration Yes / No

1 Safety and Risk Control 0.5 0.5

2 Performance Test Engine 2 1.25

3 Performance Test Power Train 3 1.5

4 Performance Test Air & Brake 3 1.75

5 Performance Test Steering 2 1

6 Performance Test Hoist 1 0.5

7 Front Suspension Charging Work Scope

8 Rear Suspension Charging Work Scope

9 Pay Load Calibration

10 Field Operation 2 2

11 Pre Release Form

12 Field Operation 2 2

13 Mandatory Attachments 1 1

BUDGET TOTAL: 20 14

ACTUALS:

* See specific documents

CONTENTS
Job Time sheet Parts Request Advice (PRA) Ref:

Bill of Materials (BOM) Ref: Parts Return Note (PRN) Ref:

SAFETY

Relevant JSA

Completed:
Responsible Person Signature Date /

687976200.doc
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 <793C> <Engine Performance Test >
Serial Number Work Order Number Smart Point
After Recondition ID Number
Engine
Torque Convertor
Transmission
Differential
Final Drive, Brake &
Wheel LH
Final Drive, Brake &
Wheel RH
Front Suspension
Cylinder LH
Front Suspension
Cylinder RH
Rear Suspension
Cylinder LH
Rear Suspension
Cylinder RH
Front Service Brake
LH
Front Service Brake
RH
Lift/Hoist Cylinder LH
Lift/Hoist Cylinder RH
Steering Cylinder LH
Steering Cylinder RH

Particle Count all compartments and kidney lube as needed to meet required
specification

Compartment Specification Before After Duration

Transmission 16/13
Hydraulics 16/13
Steering 16/13
Rear Axle 18/15

687976200.doc
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 <793C> <Engine Performance Test >

Activity 2 Engine Performance Test Equip No:

Date:
WO Number:

Completion Checks: Responsible Person Quality Inspector

Name:

Signature:

Date:

Resource Budget
Labour Special Tools
Trade / Skill Type Hrs Part No Description Qty
ST1 2

Total Budget Man hours: 2

Budget Duration: 1

Environmental Controls*
Std Id Environmental Std Description Std Id Waste Management Control

*Spillage / Clean up & Disposal of Contaminated Materials control sheets are available at work stations

MSDS**
Ref No. MSDS reference

**Material Safety Data Sheets are available at work stations

Labour Assignment ***

Name Salary No JSA Read Name Salary No JSA Read

687976200.doc
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 <793C> <Engine Performance Test >

*** JSA Read field is to be signed by employees indicating they have read and understood the JSA.
If there is not a relevant JSA for this activity then enter n/a.

687976200.doc
4 of 31
 <793C> <Engine Performance Test >

eq Technical Specification (Parts

Record Actual SN

Upgrade
Activity Figure Comment

C To C
Retrofit

B To C
No No, Tooling, Tolerance)
Measurement

Trucks
New
Cooling Temperature (During Test) Specs:
1
Suhu Pendingin (Selama Tes) More than 71 oC (160 oF) ________________
o
C

________________
o
F
Low Idle Rpm Specs:
2
Putaran Mesin Rendah Per Menit 700 + 10 _____________ RPM

High Idle Rpm Specs:

3
Putaran Mesin Tinggi Per Menit 1960 + 10 ______________
RPM

Air Filter Restriction At TC Stall (Maximum Allowed) Specs:

4
Hambatan Filter Udara Pada RPM Tinggi (Batasan 25 in of water 6.2 kPa _____________ kPa
Maksimum)

Crankcase Pressure (Blowby)

5
Tekanan Crankcase (Blowby) _____________ PSI

Inlet Manifold Pressure (Boost) At Tc Stall Specs:

6
Tekanan Inlet Manifold (Boost) Pada Rpm Tinggi) 290 + 10 kPa ______________
(33 + 5 psi) kPa

_____________ PSI

Torque Converter Stall Rpm

7
Putaran Torque Converter Stall Per Menit 1672 + 65 _____________
RPM

Torque Converter Temperature (During Stall Test) Specs:

8
Suhu Torque Converter Stall (Selama Pengetesan More than 80 oC (175 oF) _____________
less than 121 oC (250 oF) RPM

Engine Oil Presure At Low IdleI Specs:

9
Tekanan Oli Engine Pada Saat LI 170 to 600 kPa ______________
kPa

687976200.doc
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 <793C> <Engine Performance Test >

eq Technical Specification (Parts

Activity Record Actual Figure Comment SN

Upgrade
C To C
Retrofit

B To C
No No, Tooling, Tolerance)
Measurement

Trucks
New
______________
PSI

Engine Oil Presure At High Idle Specs:

10
Tekanan Oli Engine Pada Saat HI 365 to 725 kPa _______________
(53 to 87 psi) kPa

_______________
PSI

Engine Oil Filter Differential Presure At High Idle Specs:

11
Tekanan Filter Differential Oli Engine Pada Saat HI Maximum 70 kPa (10 psi) _______________
kPa

_______________
PSI

Fuel Pressure At Torque Converter Stall Specs:

12
Tekanan Bahan Bakar Pada Saat TC Stall 365 to 725 kPa _______________
(52 to 105 psi) kPa

_______________
PSI

Fuel Filter Status [Maximum Restriction 140 Kpa

13
(20si)] Good Repair
Status Filter Bahan Bakar [Maximum Penyaringan
140 Kpa (20 Psi)]
 
Radiator Top Tank Temperature At TC Stall Specs:
14
Suhu Tanki Radiator Bagian Atas Saat TC Stall Less than 110oF over ________________
ambient o
F

Water Pump Outlet Temperature At TC Stall Specs:

15
Suhu Water Pump Outlet Saat TC Stall 8 oF to 20 oF less than top ________________
tank temp/thermostat open o
F
(>88 oC/190 oF
* Ensure all substandard equipment conditions and, or backlogs requiring repair are reported to the Inspector who will complete the Backlog capture form

Completed:

WO No Responsible Person Signature Date / Time

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 <793C> <Engine Performance Test >

687976200.doc
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 <793C> <Power Train Performance Test >

Activity 3 Power Train Performance Test Equip No:

Date:
WO Number:

Completion Checks: Responsible Person Quality Inspector

Name:

Signature:

Date:

Resource Budget
Labour Special Tools
Trade / Skill Type Hrs Part No Description Qty
ST1 3

Total Budget Man hours: 3

Budget Duration: 1.5

Environmental Controls*
Std Id Environmental Std Description Std Id Waste Management Control

*Spillage / Clean up & Disposal of Contaminated Materials control sheets are available at work stations

MSDS**
Ref No. MSDS reference

**Material Safety Data Sheets are available at work stations

Labour Assignment ***
Name Salary No JSA Read Name Salary No JSA Read

687976200.doc
8 of 31
 <793C> <Power Train Performance Test >
*** JSA Read field is to be signed by employees indicating they have read and understood the JSA.
If there is not a relevant JSA for this activity then enter n/a.

687976200.doc
9 of 31
 <793C> <Power Train Performance Test >

Seq Technical
Activity Record Actual Figure Comment SN

Upgrade
C To C
Retrofit
B To C
No Specification
Measurement

Trucks
(Parts No,

New
Tooling,
Tolerance)
Torque Converter Inlet Relief Pressure At Stall Specs:
1
Speed 135 psi +/-5psi
Tekanan Torque Converter Saat Stall
_____________
___ PSI
Torque Convertor outlet relief at stall speed(1672rpm+/-
Specs:
50 rpm)
2
50 to 80 psi

_____________
___ PSI
Pilot pressure at low idle Specs:
3
250+ 10 psi

_____________
___ PSI
Lock Up Clutch Maximum Pressure At 1300 Rpm Specs:
4
Tekanan Maksimum Lock Up Clutch Saat 1300 320 + 10 psi
Rpm
_____________
___ PSI
Maximum Pump Pressure At High Idle Torque Specs:
5
Converter Drive (Lock Up Solenoid Deenergized) 445 psi
Tekanan Maksimum Pump Saat High Idle Torque
Converter Drive (Lock Up Solenoid Deenergize) _____________
___ PSI
Pump Pressure At High Idle In Direct Drive (Lock Specs:
6
Up Clutch Solenoid Energized) 325 + 15 psi
Tekanan Pompa Saat High Idle Di Direct Drive
(Lock Up Clutch Solenoid Energized) _____________
___ PSI
Transmission Lubrication Pressure At Low Idle Specs:
7
Tekanan Pelumasan Transmission Saat Low Idle 0.7 to 9.4 psi

_____________
___ PSI
Transmission Lubrication Pressure At High Idle Specs:
8
Tekanan Pelumasan Transmission Saat High Idle 23 + 7 psi

_____________
___ PSI
Complete pressure test all packs
9

* Ensure All Substandard Equipment Conditions And, Or Backlogs Requiring Repair Are Reported To The Inspector Who Will Complete The Backlog Capture Form
* Do Not Keep The Torque Converter In A Stall Condition For Long Periods Of Time, Damaged Could Occur In The T/C, Engine And Brake.
687976200.doc
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 <793C> <Power Train Performance Test >

Completed:

WO No Responsible Person Signature Date / Time

687976200.doc
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 <793C> <Air and Brake System Performance Test >

Activity 4 Air and Brake System Performance Test Equip No:

Date:
WO Number:

Completion Checks: Responsible Person Quality Inspector

Name:

Signature:

Date:

Resource Budget
Labour Special Tools
Trade / Skill Type Hrs Part No Description Qty
ST1 3

Total Budget Man hours: 3

Budget Duration: 1.5

Environmental Controls*
Std Id Environmental Std Description Std Id Waste Management Control

*Spillage / Clean up & Disposal of Contaminated Materials control sheets are available at work stations

MSDS**Ref No. MSDS reference

**Material Safety Data Sheets are available at work stations

Labour Assignment ***
Name Salary No JSA Read Name Salary No JSA Read

*** JSA Read field is to be signed by employees indicating they have read and understood the JSA.
If there is not a relevant JSA for this activity then enter n/a.

687976200.doc
13 of 31
 <793C> <Air and Brake System Performance Test >

Seq No Technical

New Trucks
Activity Record Actual Figure Comment SN

Upgrade
Specification

C To C
Retrofit
B To C
Measurement
(Parts No,
Tooling,
Tolerance)
Maximum Delivery Specs:
1
Pressure Of The 710 psi
Parking And
Secondary Brake
Control Valve At High _______________
Idle. (Park Brake PSI
Release)
Maksimum tekanan
rem parkir dan kontrol
valve rem cadangan
pada posisi high idle

Minimum Delivery Specs:

2
Pressure Of The 650 psi
Parking And
Secondary Brake
Control Valve At High _______________
Idle. (Park Brake PSI
Release)
Minimum tekanan rem
parkir dan kontrol
valve rem cadangan
pada posisi high idle

Service Brake / Slack Specs:

3
Adjuster Pressure 660 psi
Both At Low Idle
Tekanan rem/ slack _______________
adjuster pada posisi PSI
low idle
Air Charging Test Specs:
4
(110 to 135 Psi) At < 40
High Idle seconds
Test pengisian adjust 120 _______________
kompressor pada high psi PSI
idle

Diagnostic Fault Code

5
Diagnostic kode fault No Active Faults

Service Brake Spec:
6
Residual Pressure:
Sisa tekanan dalam 15.4 psi _______________

687976200.doc
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 <793C> <Air and Brake System Performance Test >

Seq No Technical

New Trucks
Activity Record Actual Figure Comment SN

Upgrade
Specification

C To C
Retrofit
B To C
Measurement
(Parts No,
Tooling,
Tolerance)
system rem PSI
- Lh Front 15.4 psi

- Rh Front 9.9 psi _______________

PSI
- Lh Rear 9.9 psi

- Rh Rear _______________
PSI

_______________
PSI

Tcs Test (AETA)

7
Tes AETA Good Repair
 
Delivery Pressure Of Specs:
8
The Retarder Air
Control Valve In The 85 + 5 psi _______________
Full ON Position. PSI
Tekanan pada retader
air control valve pada 350 psi
posisi on _______________
Maximum Oil PSI
Pressure At The Rear
Slack Adjuster
Tekanan maksimum
pada slack adjuster
belakang
Service Brake Air Specs:
9
Pressure (At The Rear
Brake Master 120 psi _______________
Cylinder). Fully PSI
Depress Brake Pedal.
Tekanan rem 790 psi
belakang saat pedal _______________
ditekan penuh PSI
Oil Pressure At The
Rear Slack Adjuster.
Tekanan oli pada
slack adjuster
belakang
Specs:
10
Electric Powered
687976200.doc
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 <793C> <Air and Brake System Performance Test >

Seq No Technical

New Trucks
Activity Record Actual Figure Comment SN

Upgrade
Specification

C To C
Retrofit
B To C
Measurement
(Parts No,
Tooling,
Tolerance)
Parking & Secondary 550 to 650 _______________
Brake Release Pump psi PSI
Pressure
Tekanan pelepasan
rem dan parkir
* Ensure All Substandard Equipment Conditions And, Or Backlogs Requiring Repair Are Reported To The Inspector Who Will Complete The Backlog Capture Form
* Do Not Allow The Oil To Exceed 124 Degree Celsius.

Completed:

WO No Responsible Person Signature Date / Time

687976200.doc
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 < 793C> <Steering System Performance Test >

Activity 5 Steering System Performance Test Equip No:

Date:
WO Number:

Completion Checks: Responsible Person Quality Inspector

Name:

Signature:

Date:
Resource Budget
Labor Special Tools
Trade / Skill Type Hrs Part No Description Qty
ST1 2

Total Budget Man hours: 2

Budget Duration: 1

Environmental Controls*
Std Id Environmental Std Description Std Id Waste Management Control

*Spillage / Clean up & Disposal of Contaminated Materials control sheets are available at work stations

MSDS**
Ref No. MSDS reference

**Material Safety Data Sheets are available at work stations

Labor Assignment ***
Name Salary No JSA Read Name Salary No JSA Read

687976200.doc
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 < 793C> <Steering System Performance Test >
*** JSA Read field is to be signed by employees indicating they have read and understood the JSA.
If there is not a relevant JSA for this activity then enter n/a.

687976200.doc
18 of 31
 < 793C> <Steering System Performance Test >

Seq Technical
Activity Record Actual Figure Comment SN

Upgrade
C To C
Retrofit
Specification

B To C
No Measurement
(Parts No,

Trucks
New
Tooling,
Tolerance)
Steering Nitrogen Specs:
1
Accumulator Charging 950 + 50 psi
Pressure
Tekanan steering akumulator _______________ PSI
charge

Low Pressure Standby At Specs:

2
Low Idle 300 to 525
Tekanan standby saat low psi
idle _______________ PSI

High Pressure Cut Off Valve Specs:

3
With Engine At Low Idle 3350 + 50 psi
Tekanan cut off saat engine
low idle

To Check/Adjust The High-

Pressure Cut Off Valve On _______________ PSI
The Load Sensing Controller,
Disconnect And Plug The
Tank Drain Line At The
Accumulator Charging Valve
(Labelled “T” Port). After
Adjustment/Check,
Reconnect The Tank Drain
Line On The Accumulator-
Charging Valve.
Untuk menyetel atau
mengecek tekanan cut off
pada kontrol valve load
sensor, buka dan tutup
saluran kuras tangki pada
akumulator charge valve
(saluran tanda “T”). Setelah
selesai pengecekan/
pengontrolannya
sambungkan kembali
salurannya.

Cut Out At Low Idle Specs:

4
Tekanan cut out saat low idle 3100 + 50 psi

687976200.doc
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 < 793C> <Steering System Performance Test >

Seq Technical
Activity Record Actual Figure Comment SN

Upgrade
C To C
Retrofit
Specification

B To C
No Measurement
(Parts No,

Trucks
New
Tooling,
Tolerance)
_______________ PSI

Specs:
Cut in At Low Idle 2785 + 45 psi
Tekanan cut in saat low idle
_______________ PSI

Cycle Time Between Cut-Out Spec:

6
And Cut-In At Low Idle In The Approx 30
Neutral Or No Steer Position. Seconds
Siklus waktu dari cut in ke cut __________ seconds
out saat low idle pada stir
netral
Cycle Time From Cut In To Spec:
7
Cut Out (Steer At One 7–9
Revolution R/L) Seconds __________ seconds
Siklus waktu saat cut in
hingga cut out pada stir
berputar satu kali
Back Up Relief Vale Specs
8
3771+/-58psi
psi
Bleed Down Solenoid
9
Pembukaan solenoid buang Functioning
Yes No
 
* Ensure All Substandard Equipment Conditions And, Or Backlogs Requiring Repair Are Reported To The Inspector Who Will Complete The Backlog Capture Form
* When Testing Or Adjusting Any Steering System Pressure Setting, Always Allow The Accumulator Charge Cycle To Occur At Least Ten Times Before Measuring The Pressure. Failure To
Allow The Charging Cycle To Occur Ten Times Will Result In Inaccurate Readings.

Completed:

WO No Responsible Person Signature Date / Time

687976200.doc
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 < 793C> < Hoist System Performance Test >

Activity 6 Hoist System Performance Test Equip No:

Date:
WO Number:

Completion Checks: Responsible Person Quality Inspector

Name:

Signature:

Date:

Resource Budget
Labor Special Tools
Trade / Skill Type Hrs Part No Description Qty
ST1 1

Total Budget Manhours: 1

Budget Duration: 0.5

Environmental Controls*
Std Id Environmental Std Description Std Id Waste Management Control

*Spillage / Clean up & Disposal of Contaminated Materials control sheets are available at work stations
 The B to C Upgrade trucks are using b hoist cylinders therefore 793b 1hl pressures apply
 C to C retrofit trucks use a mix of 793b or 793c hoist cylinders identify correct cylinders and pressures
before commencing testing

MSDS**
Ref No. MSDS reference

**Material Safety Data Sheets are available at work stations

Labor Assignment ***

Name Salary No JSA Read Name Salary No JSA Read

*** JSA Read field is to be signed by employees indicating they have read and understood the JSA.
If there is not a relevant JSA for this activity then enter n/a.

687976200.doc
21 of 31
 < 793C> < Hoist System Performance Test >

Seq Technical
Activity Record Actual Figure Comment SN

Upgrade
C To C
Retrofit

B To C
No Specification
Measurement

Trucks
(Parts No,

New
Tooling,
Tolerance)
The Hoist Relief Pressure Specs:
1
Raise…. (Engine At High Idle
RPM)
Tekanan Hoist saat posisi naik _______________
high idle PSI

The Hoist Relief Pressure g Specs:

2
Lower…. (Engine At High Idle 500 + 50 - 0
RPM) psi
Tekanan hoist saat turun high _______________
idle PSI

Relief Valve Front Brake Oil Specs:

3
Cooler Pressure 115 + 3 psi
Tekanan relief valve pada oli
rem pendingin _______________
PSI

Pilot Oil (Parking Brake) Specs:

4
Hydraulic Control Valve At High 680 + 30 psi
Idle
Tekanan oli pilot rem parkir _______________
saat high idle PSI

Cycle Time Low To Raise Specs:

5
Position At High Idle 18 to 20
(From Body Frame To Fully Seconds
Raised) ___________
Siklus waktu dari dump posisi seconds
bawah hingga posisi tertinggi
saat high idle
* Ensure All Substandard Equipment Conditions And, Or Backlogs Requiring Repair Are Reported To The Inspector Who Will Complete The Backlog Capture Form
* Hydraulic Oil Should Be Above 38 Degree Celsius, Before You Perform Any Test.
* The Body Position Sensor Rod Must Be Disconnected From The Body And The Sensor Must Be Rotated To The Raise Before The Lower Relief Valve Can Be Tested.
 The B to C Upgrade trucks are using b hoist cylinders therefore 793b 1hl pressures apply
 C to C retrofit trucks use a mix of 793b or 793c hoist cylinders identify correct cylinders and pressures before commencing testing
Completed:

WO No Responsible Person Signature Date / Time

687976200.doc
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 < 793C> < Field Operation >

Activity 12 Field Operation Equip No:

Date:
WO Number:

Completion Checks: Responsible Person Quality Inspector

Name:

Signature:

Date:

Resource Budget
Labor Special Tools
Trade / Skill Type Hrs Part No Description Qty
ST1 1

Total Budget Manhours: 1

Budget Duration: 1

Environmental Controls*
Std Id Environmental Std Description Std Id Waste Management Control

*Spillage / Clean up & Disposal of Contaminated Materials control sheets are available at work stations

MSDS**
Ref No. MSDS reference

**Material Safety Data Sheets are available at work stations

Labor Assignment ***

Name Salary No JSA Read Name Salary No JSA Read

*** JSA Read field is to be signed by employees indicating they have read and understood the JSA.
If there is not a relevant JSA for this activity then enter n/a.

687976200.doc
23 of 31
 < 793C> < Field Operation >

687976200.doc
24 of 31
 < 793C> < Field Operation >

Activity Technical Specification (Parts No, Record Actual Completed Figure Comment SN
No
Tooling, Tolerance) Measurement
Yes No
Pre Operational checks

2 Yes No
Auto Retarder is hard wired (switch
removed)

3 Yes No
Auto Retarder speed is set to 1851 rpm

4 Yes No
Maximum Body up Gear 1st

5 Yes No
Maximum Transmission Speed 4th

6 Yes No
No Active faults

7 Yes No
Fan Control is ON

8 Jockey Pulley is manually lubricated Yes No

9 Yes No
Auto Lube Timer is Set

10 Yes No
Pay Load is Calibrated

11 Yes No
Machine Performed within operational
Tolerances
687976200.doc
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 < 793C> < Field Operation >
Completed:

WO No Responsible Person Signature Date / Time

687976200.doc
26 of 31
 <793> < Mandatory Attachments >

Activity 13 Mandatory Attachments Equip No:

Date:
WO Number:

Completion Checks: Responsible Person Quality Inspector

Name:

Signature:

Date:

Resource Budget
Labor Special Tools
Trade / Skill Type Hrs Part No Description Qty
ST1 1

Total Budget Manhours: 1

Budget Duration: 1

Environmental Controls*
Std Id Environmental Std Description Std Id Waste Management Control

*Spillage / Clean up & Disposal of Contaminated Materials control sheets are available at work stations

MSDS**
Ref No. MSDS reference

**Material Safety Data Sheets are available at work stations

Labor Assignment ***
Name Salary No JSA Read Name Salary No JSA Read

*** JSA Read field is to be signed by employees indicating they have read and understood the JSA.

687976200.doc
27 of 31
 <793> < Mandatory Attachments >

If there is not a relevant JSA for this activity then enter n/a.

687976200.doc
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 <793> < Mandatory Attachments >

No

Upgrade
C To C
Retrofit
Part Number Description Responsibility Completed S/N

B To C

Trucks
New
1 Yes No
Dispatch System PTFI

2 PTFI Yes No
Two way radio

3 Yes No
Fire suppression system PTFI

4 Yes No
Ground level extinguisher PTFI

5 Cabin Extinguisher Yes No

PTFI

6 Yes No
Fire extinguisher fitted to Rhs platform PTFI

7 Yes No
Strobe lights fitted to lhs and rhs air boxes Brackets and lights
supplied by FMI
Fitted by PTTU
8 Yes No
Manual ball valve fitted to main discharge on air tank Supplied by FMI
Fitted by PTTU

9 Yes No
Truck numbers fitted to Radiator Grill, Left, right and rear of Dump Numbers supplied by FMI
body Fitted by PTTU

10 Yes No
Extended mirror bracket on rhs platform to accompany extra mirror Mirror and bracket
supplied by PTFI

687976200.doc
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 <793> < Mandatory Attachments >
Fitted by PTTU

11 Yes No
Left and Right tail lights fitted to lower rear dump body Brackets and lights
supplied by FMI
Fitted by PTTU

687976200.doc
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 <793> < Mandatory Attachments >

Equipment has been inspected and is completed for handover to Freeport Operations :

WO No

Freeport Maintenance
Name Signature Date / Time

Freeport Operations

Name Signature Date / Time

Trakindo
Name Signature Date / Time

Ensure all documentation is completed and attached

Machine Delivery Service Record Attached

Engine Delivery Service Record Attached

687976200.doc
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