793 Upgrade Process Flow

Open Individual Truck File Pre Strip Inspection Grasberg Disassembly Package chassis &
Work Order (PF2) components
Complete Inspection Report Form
Project Schedule (form 101) Complete Grasberg dispatch form (form
(PF1) 102)

Transport KK CRC to KK CRC Assembly KK CRC Disassembly Transport Grasberg to

Grasberg (PF4) (PF3) KK CRC

Grasberg Assembly and Complete Individual Revisit Service

Commissioning Truck File 250 hour PM
(PF5) (PF6) (PF7)
Process Flow

Truck File Grasberg Disassembly KK CRC Disassembly KK CRC Assembly Grasberg Assembly

PF1 PF2 PF3 PF4 PF5 PF6 PF7

Truck File Strip Machine Disassembly Assembly Assembly Truck File Revist Service

1. Open Work Order 1. Wash truck 1. Unload Containers 1. Set Chassis 1. Unload Containers 1. Parts Used - Listing 1. Perform 250 hour PM

2. Order Allocated/Core Parts 2. Check Steering Tapers 2. Unload Chassis 2. Fit Brake Components 2. Scope In & Out 2.
onto Fixture stands 2. Unload Chassis onto
fixture stands
3. Review Work Scope 3. Break Steering Tapers 3. Wash Chassis 3. Fit Steering 3. Individual Project Files 3.
Components Schedule Vs Performance
3. Install rear axle gp
4. Update Project Schedule 4. De-Gas Susp. Struts 4. Remove and Label Bonnets 4. Fit Chassis Wiring 4. DBS - Cost Analysis 4.
Start & Finish Dates Harnesses Actual Vs Budget
4. Install front struts and
5. Input Component PCR 5. Remove Dump Body 5. Remove and Label Radiator 5. Fit Hoist Valve 5. Inspection Sheets 5.
Hours wheel
and Cylinders
6. Pre-order parts base on 6. Remove and Label Engine 6. Test Sheets 6.
6. Drain Oils 6. Fit Brake Coolers
component hours and Torque converter
5. Install tires
7. Parts Listing 7. Remove RHS platform 7. Strip Truck Chassis and 7. Component Hours 7.
Label Components 7. Fit Grease Tank
PCR Schedule
and Injectors
8. Monitor availabity parts 8. Remove Cab 8. Provide Frame to SSB 6. Install Cab 8. CD Burn 8.
for Refurbishment 8. Fit Brake Lines

9. Parts Completed 9. Remove Cab Supports Assembly 7. Install fenders and Complete Truck File Close Truck File
9. Fit Steering Lines
platform
10. Remove Rear Tyres
10. Fit Hoist Lines
8. Install Fuel Tank
11. Block (with timber)
under cross tube 11. Fit BrakeCooling
Oil Lines

12. Remove front Tyres

12. Fit Engine 9. Fill up all oil systems

13. Block (with timber)

under front casting 13. Fit Radiator
10. Install Dump Body
14. Remove Rear
Power train Assembly 14. Fit Torque Converter

15. Remove Front RHS

Suspension Strut 15. Fit Coolant Lines 11. Testing and adjusting
Engine all systems
16. Remove Front LHS
Suspension Strut 16. Fit Coolant Lines
Brakes
17. Remove Fuel Tank 12. Truck Comissioning
17. Fit Powertrain Lines

18. Place Chassis on Truck

18. Fit Grease Lines 13. Complete Truck File
19. Dispatch from Grasberg
19. Prime Grease Lines
20. Clean Workshop
20. Fill Fluid Levels

Transport
21. Prepare for Testing

22. Filter Carts

23. Start Truck

24. Warm Up Truck

25. Performance Test

26. Fit A Frame

27. Fit Rear Suspension

Cylinders

28. Remove test Equipment

29. Pack for Transport

Transport
Transport