PT PAMAPERSADA NUSANTARA

PLANT DIVISION QA4 : COMPONENT INSTALLATION SHEET

PAMA DUMP TRUCK – HD785-7
C/N Date Job Site 1.

E/N SMR 2.
Control Check
Sub Component To Be Check Critical of Failure Remarks
Mech. QA / GL
QA/GL

1. Assembly of damper assembly 1. No crack, no

2. Coats mounting surface of damage & no dirty
flange(16) of outer body (13) 2. Coat LG-6
with gasket sealant (LG-6)
3. Coat Outer body inner surface 3. Coat LG-LI (ENS
with grease (LG-LI) grease P/N 427-
Damper Assembly

4. Coat cushion contact surface of 12-118710

inner body with grease (G2-LI) 4. Coat LG-LI ENS
grease P/N 427-
12-118710
5. After assembly fill clearance 5. Refill grease 80 g
(a)(16 point) 30% amount of the between rubber
space and body
6. Tightening torque of bolt 6. Torque bolt flange
6 – 7.5 kgm
7. Coupling (2) Mounting bolt (1) 7. Torque bolt
End play Before & After
tightening torque of bolt coupling 25 – 31,5
kgm 8. : 9. :
8. Crank shaft end paly before 8. Std. end play
installed with other component 0.140 – 0.315 mm

9. Alignment the cover damper 9. End play must

when install to Engine (OJI.. & standard
check crank shaft end again
10. Body Mounting bolt to fly wheel 10. Torque Plug drain
10-12.5 kgm
11. Drain plug of damper torque 11. Torque drain plug
6 -8 kgm
12. Tightening torque engine 12. Torque mounting
mounting bolt bolt 35 – 43.5 kgm

Mechanic Inspected by QA / GL

(…………………………………………….….) (…………………………………………….….)
( Name ) ( Name )
INM/2014/QA4-HD785-7 1
 PT PAMAPERSADA NUSANTARA
PLANT DIVISION QA4 : COMPONENT INSTALLATION SHEET
PAMA DUMP TRUCK – HD785-7
C/N Date Job Site 1.

E/N SMR 2.
Control Check
Sub Component To Be Check Critical of Failure Remarks
Mech. QA / GL
QA/GL

1. Radiator core & Fin condition #1 1. No clogged & no

- #2 - #3 damage
2. After cooler fin condition & 2. No clogged & no
connection damage
3. Charged air cooler flange and 3. Coat LG-6 for
duct tube flange (3) with gasket duct & tube
sealant (LG-6)
4. Radiator sheet (sponge) condition 4. No damage &
between each core radiator complete
5. Oil cooler hose connection & 5. No loose, No
Clamping damage
Radiator, after cooler, oil Cooler & Fan Motor

6. Rubber mounting of radiator, 6. No loose, No

after cooler & oil cooler damage
7. Neatness (kerapihan) of hoses 7. Good clamping
installation & clamping & neatness
8. After cooler hose tightening 8. No loose &
torque of clamp [*1] complete
9. Radiator Cap {0.9 kPa} function & 9. No leakage &
condition total [*2] damage
10. Water level sensor function & 10. Specification [*1] notes
condition [*3] When the current hose is
11. Radiator Cooling fan bleed 11. No Crack or reused Clamp tightening bot
condition deformation Min. 0.6 kgm.
12. Oil Cooler cooling Fan & motor 12. No loose & no
connection & condition deformation When a new hose is used
13. No loose & tightening (a) dimension
13. Air condenser accessories
become 7 – 10 mm
connection neatness
14. Water sub tank connection & 14. No loose & no
condition Crack
15. Drain valve water function 15. No clogged &
easy rotate
16. Radiator grill & fan guard 16. No loose & good
condition
17. Radiator mounting bolt 17. No loose
18. Radiator guard mounting bolt 18. No loose Notes
19. Check tension belt 19. No loose [*2]. Test by radiator Cap
tester
[*3] Test electric current

Mechanic Inspected by QA / GL

(…………………………………………….….) (…………………………………………….….)
( Name ) ( Name )
INM/2014/QA4-HD785-7 2
 PT PAMAPERSADA NUSANTARA
PLANT DIVISION QA4 : COMPONENT INSTALLATION SHEET
PAMA DUMP TRUCK – HD785-7
C/N Date Ob site 1.

E/N SMR 2.
Control Check
Sub Component To Be Check Critical of Failure Remarks
Mech. QA / GL
QA/GL

1. Install Transmission module assembly 1. Clear of

complete with the hydraulic pumps mounting power
2. Make sure clamping position for the train area
suction pipe (4) and others of 2. No loose and
hydraulic Pumps used new gasket
3. Keep the discharge of the pumps gear 3. Prevent dust in
from dust to gear pump
4. Make sure , take care when installing 4. Be careful
the Power train assembly to chassis
Installation Power Train Assembly and Hydraulic line

5. Tighten mounting bolt (1) of Power 5. Std. torque

Module as is specification 15-31,5 kgm
6. Alignment universal joint and 6. Alignment max 3
tolerance Max. 3 mm with adjust mm
amount of the shim at rear of the
transmission mounting
7. Adhesive (LT-2) for mounting Bolt & 7. Std. torque :
Tighten universal joint mounting bolt 50 – 62 kgm
as is specification
8. Refill oil to the discharge of Pumps 8. Refill Oil to
and install the hose or tube to control discharge before
valve install hoses
9. Check connection & clamping of the 9. Neatness
hose from power module to oil cooler installed
10. Control valves are mounting position 10. No loose and no
damage
11. Install hydraulic Tank assembly 11. No loose &
correct place Up side
12. Make sure connection of the tube 12. No loose and no
from control valve to the hydraulic wrong connected
tank
13. Check the flange contact of the tube 13. No loose, fixed &
or hoses to the control valve correct mounting

14. Used Hydraulic Puller to Install the 14. No loose of the

bush of the Torque Rod on the chassis bush

Mechanic Inspected by QA / GL

(…………………………………………….….) (…………………………………………….….)
( Name ) ( Name )
INM/2014/QA4-HD785-7 3
 PT PAMAPERSADA NUSANTARA
PLANT DIVISION QA4 : COMPONENT INSTALLATION SHEET
PAMA DUMP TRUCK – HD785-7
C/N Date Job Site 1.

E/N SMR 2.
Control Check
Sub Component To Be Check Critical of Failure Remarks
Mech. QA / GL
QA/GL
1. Take care when Install the rear axle 1. Take care when
assembly, approx. 12 Ton, end then reinstall rear Axle
put 2 stands to support the axle ass’y

2. Install the drive shaft assembly 2. Mounting bolt

between output transmission and tightener:
input differential , and tighten of 343-427 Nm
mounting bolt of the drive shaft {35-43.5 Kgm}

3. Install the Cab assembly and connect 3. Take care during

the wiring harness from out side of connect the
the cab wiring connector

4. Install the rear tires and tighten of the 4. Tightener of the

Final Drive and Undercarriage

wheel Nut wheel Nut :

1.519 – 1.852 Nm
{155-189 Kgm}
5. Take care, used the rubber for reduce 5. The gasket make
the vibration when installed the by self with the
Accumulator assembly rubber

6. Adjustment level Suspension follow 6. Dimension (a) 82 a

the procedure adjustment Jack the + 3 mm
chassis until suspension move to
upper until get the (a) dimension
7. Set the pressure gas in to Suspension 7. Approx. 3.9 Mpa
approx. {40 Kg/cm²}

8. So, when adjustment the rear 8. For completely,

Suspension must at the same time Better used the
Shop Manual on
page 31 – 34 for
testing &
Adjusting rear
Suspension
cylinder

9. Take care when

Mechanic Inspected by QA / GL
install the Vessel
(…………………………………………….….) (…………………………………………….….)
( Name ) ( Name )
INM/2014/QA4-HD785-7 4