basic maintenance

Maintenance Alat BeratHeavy Equipment Maintenance

Focus

Keuntungan apabila,

Produksi dengan

Biaya

Definisi

Usaha untuk mengoperasikan Alat agar:Konsisten penuhi Target ProduksiBiayanya seoptimum mungkinDengan cara:Mengetahui Kinerja Alat sesungguhnyaSehingga secara berkesinambungan dapat malakukan:Optimalisasi Kinerja Alat

V - FormationHeavy Equipment ManagementTahapnya,PemilihanPembelianPengoperasianPerawatanPeremajaan

Harga Beli

Biaya OperasiBiaya tidak ProduktifHarga jual Alat BekasKesiapan AlatProduktivitasPotensi Keuntungan

Menejemen PerawatanPerawatanSederhanaAlat bantu murahWaktu minimBiaya murahResiko rendahPerbaikanRumitAlat bantu mahalWaktu lebih lamaBiaya mahalResiko tinggiPertimbangan

Menejemen PerawatanTujuan

Peristiwa unit berhenti beroperasi karena rusak mendadak bisa diminimumkan.Meningkatkan perolehan keuntungan yang diperoleh.Usia komponen menjadi optimumKesiapan alat tinggi

Biaya Perawatan

Biaya PerbaikanBiaya Bahan BakarBiaya GETBiaya Ban/ UndercarriageBiaya Down TimeBiaya SukucadangRendahnya harga jual alat bekasBiaya Operasi ALAT

Menejemen PerawatanPerawatan/InspeksiPerawatan/InspeksiRusakRusak(parah)Perawatan VS Kerusakan

Delapan Elemen Menejemen PerawatanElemen dari Menejemen Perawatan :Perawatan Berkala / Preventive Maintenance.Kontrol Kontaminasi / Contamination Control.Pengambilan Contoh Oli Secara Berkala / Scheduled Oil Sampling (SOS).Monitor Kondisi / Condition Monitoring.Pelatihan / Training.Penjadwalan / Scheduling.Menejemen Perbaikan / Repair Management.Pencatatan / Recording.

Condition MonitoringDEFINISI

Condition Monitoring adalah aktivitas pemeriksaan, pemantauan atau pengujian pada sistem yang dilakukan secara berkala ataupun apabila ada kondisi khusus.

TUJUAN

Mengetahui kondisi dan unjuk kerja sistem atau komponen.Condition Monitoring

HASILMenekan O&O Cost dengan melakukan: Perbaikan sebelum rusak.Penjadwalan perbaikan.Mendeteksi adanya kerusakan pada komponen sedini mungkin (repair indicator).Rekomendasi langkah langkah apa yang harus dilakukan untuk memperbaiki masalah.Mengetahui sisa usia pakai yang paling optimum.Mencegah timbulnya kerusakan parah.Condition Monitoring

Jenis PemeriksaanDilakukan oleh PelangganPemeriksaan keliling harian (walk around inspection)Periodik; 10, 25, 50, 100, 250, 500, 1000, 2000.Pemantauan display monitoring system

Dilakukan oleh DealerTA I & TA II, CTS, GET Inspection Condition Monitoring

Custom Track Service (CTS)

PROGRAM PEMERIKSAAN BERKALA TERHADAP UNDERCARRIAGECondition Monitoring

Custom Track Service

Tujuan

Menyelaraskan Usia pin & bushing terhadap usia link.Selaraskan usia track roller terhadap usia link.Selaraskan usia track shoe terhadap usia link.Selaraskan waktu perawatan diatas agar dapat dicapai Cost per Hour yang rendah dan produktifitas alat yang tinggi.Condition Monitoring

Custom Hydraulic Service (CHS)

Proses pemeriksaan di lapangan pada sistem hidrolik.Condition Monitoring

Custom Hydraulic Service (CHS)

Seperti program CTS untuk HEX & Machine lain yg Intensive menggunakan system HydraulicTest Kinerja & melakukan DiagnosaMenjalankan Program SOSPemeriksaan berkeliling

Keuntungan:Meningkatkan Produktivitas & Kesiapan Alatnya Menurunkan biaya operasiMeningkatkan keuntungan

Condition Monitoring

Technical Analysis I (CMES) & IITechnical Analysis I merupakan pemeriksaan visual dan pemeriksaan operasional pada sistem. Apabila timbul masalah yang tidak dapat diselesaikan maka di ikuti dengan aktivitas Technical Analysis II.

Technical Analysis II merupakan pemeriksaan tingkat lanjut dengan menggunakan peralatan diagnostik.Condition Monitoring

Repair ManagementDEFINISI

Repair Management adalah pengaturan proses perbaikan terhadap komponen baik yang sudah rusak ataupun belum rusak.

TUJUAN

Melakukan perbaikan sebelum komponen rusak.Repair Management

Repair ManagementIndikasi Kerusakan

Terencana

Problem

HASIL

Proses perbaikan dilaksanakan secara tepat waktu sesuai dengan kondisi dari komponen.Biaya perbaikan menjadi lebih rendah.Perencanaan waktu menganggur menjadi lebih baik.Repair Management

Perbaikan VS Penggantian

Faktor penentu:

Usia.Beban.Konsumsi bahan bakar & pelumas.Biaya perbaikan.Repair Management


TerencanaHasil dari SOS labHMU.Konsumsi Bahan Bakar.Konsumsi Oli.Riwayat alat.Pengalaman.


Tidak TerencanaTenaga kurang.Panas berlebih.Getaran.Suara berisik.Asap hitam.Timbul keausan berlebih.

Konsumsi Cairan PelumasRepair ManagementKondisi Baru, Penambahan 1 Ltr utk setiap 400 Ltr Bahan Bakar yg dikonsumsiKondisi Normal, Penambahan 1 Ltr utk setiap 300 Ltr Bahan Bakar yg dikonsumsiPerlu dicermati,Penambahan 1 Ltr utk setiap 200 Ltr Bahan Bakar yang dikonsumsi

Indikasi Kerusakan Tidak TerencanaRepair ManagementGAUGESASAP / BLOW BYKEMAMPUAN >SERPIHAN/ KEAUSAN KASARSELIP / RESPON YG LAMBAT

Indikasi Kerusakan Tidak TerencanaRepair ManagementPADA ENGINE

TENAGA MENURUNASAP BERLEBIHAN (BIRU/ PUTIH)KONSUMSI BAHAN BAKAR/ OLI BERLEBIHANSERBUK METAL PADA FILTER OLITERDAPAT KEBOCORANTERDENGAR BUNYIAN ANEHSULIT DIHIDUPKANTEMPERATUR KERJA TIDAK NORMAL

Indikasi Kerusakan Tidak TerencanaRepair ManagementPADA TRANSMISSION

BUNYI ANEHGETAR ABNORMALTRANSMISSI SELIPRUBAH GERAK/ KECEPATAN, TIDAK LANCARKEBOCORANTAMBAHAN OLI TIDAK NORMALTEMPERATUR KERJA YANG TINGGI ADANYA SERBUK METAL PD FILTER/ MAGNETIC SCREEN.

Indikasi Kerusakan Tidak TerencanaRepair ManagementPADA FINAL DRIVE

FINAL DRIVE SELIPTERDENGAR BUNYIAN ANEH BEARING SPROCKET HUB KOCLAKADA KEBOCORANTEMPERATUR KERJA DIATAS NORMALDIJUMPAI SERBUK METAL PADA MAGNETIC PLUG

Indikasi Kerusakan Tidak TerencanaRepair ManagementPADA HYDRAULIC PUMP & MOTOR

RESPONS LAMBATTERASA GETAR YANG TIDAK NORMALTERDENGAR BUNYIAN ANEHADA KEBOCORAN LUAR/ DALAMTEMPERATUR KERJA DIATAS NORMALDIJUMPAI SERBUK METAL PADA FILTER

Indikasi Kerusakan Tidak TerencanaRepair ManagementCooling System Pada Engine

HASIL PENELITIAN,40 % PROBLEM PADA ENGINE DIAKIBATKAN OLEH SYSTEM PENDINGIN YGTIDAK BERFUNGSI DENGAN BAIK.

MASALAH COOLING SYSTEMOVERHEATINGOVERCOOLING

Indikasi Kerusakan Tidak TerencanaRepair ManagementINDIKASI OVERHEATING PADA ENGINE:

S.O.S MENDETEKSI TINGKAT KEAUSAN & OKSIDASI YG TINGGIWATER TEMPERATUR GAUGE, MENUNJUKKAN HAL INI.CYLINDER HEAD, RETAKKERUSAKAN PADA TURBOCHARGER

Indikasi Kerusakan Tidak TerencanaRepair ManagementINDIKASI OVERCOOLING PADA ENGINE:

S.O.S, TINGKAT AUS METAL TINGGI TETAPI TIDAK TERDAPAT OKSIDASITEMPERATUR GAUGE TUNJUK KAN SUHU YG RENDAHKONSUMSI BAHAN BAKAR BOROSBEARINGS & PISTON, LECET

When Required Battery - Recycle Battery, Battery Cable or Battery Disconnect Switch - Replace Condenser (Refrigerant) - Clean Cutting Edges and End Bits - Inspect/Replace Engine Air Filter Primary Element - Clean/Replace Engine Air Filter Secondary Element - Replace Engine Air Precleaner - Clean Ether Starting Aid Cylinder - Replace Fuel System - Prime Fuses and Circuit Breakers - Replace/Reset Oil Filter - Inspect Radiator Core - Clean Radiator Pressure Cap - Clean/Replace Ripper Tip and Shank Protector - Inspect/Replace Window Washer Reservoir - Fill Window Wipers - Inspect/Replace Windows - Clean

Every 10 Service Hours or Daily Pemeriksaan setiap 10 jam/Harian

Backup Alarm - Test Brakes, Indicators and Gauges - Test Cooling System Coolant Level - Check Engine Oil Level - Check Fuel System Primary Filter (Water Separator) - Drain Fuel Tank Water and Sediment - Drain Horn - Test Hydraulic System Oil Level - Check Seat Belt - Inspect Transmission Oil Level - Check

Every 50 Service Hours or Weekly Pemeriksaan setiap 50 jam/ mingguan Bulldozer Cylinder Support Bearings - Lubricate Ripper Linkage and Cylinder Bearings - Lubricate Sprocket Hub Bearings - Inspect Track Pins - Inspect Track Roller Frame Bearings - Lubricate Every 100 Service Hours or 2 Weeks Pemeriksaan 1000 jam/2 Minggu Hydraulic Lubricate Control Linkage -

Every 250 Service Hours or Monthly

Belts - Inspect/Adjust/Replace Bulldozer Tilt Brace - Lubricate Fan Drive Bearing - Lubricate Final Drive Oil Level - Check Track - Check/Adjust Every 500 Service Hours or 3 Months

and Filter - Change Engine Oil

Initial 500 Hours (for New Systems, Refilled Systems, and Converted Systems)

Cooling System Coolant Sample (Level 2) - Obtain Every 500 Service Hours

Cooling System Coolant Sample (Level 1) - Obtain Final Drive Oil Sample - Obtain

Every 500 Service Hours or 3 Months Engine Crankcase Breather - Clean Equalizer Bar Pads - Inspect/Replace Fuel System Primary Filter - Clean/Replace Fuel System Secondary Filter - Replace Fuel Tank Cap and Strainer - Clean Hydraulic System Oil Filter - Replace Hydraulic System Oil Sample - Obtain Sprocket Hub Bearings - Inspect Transmission Oil Filter - Replace Transmission Oil Sample - Obtain

Pemeriksaan 1000 jam- 12000 Every 1000 Service Hours Battery - Inspect Every 1000 Service Hours or 6 Months Transmission Magnetic Screen - Clean Transmission Oil - Change Every 2000 Service Hours or 1 Year Engine Valve Lash - Check Engine Valve Rotators - Inspect Final Drive Oil - Change Hydraulic System Oil - Change Sprocket Hub Bearings - Adjust Every Year

Every Year Cooling System Coolant Sample (Level 2) - Obtain Every 3 Years After Date of Installation or Every 5 Years After Date Manufacture Seat Belt - Replace of Every 6000 Service Hours or 3 Years Cooling System Coolant Extender (ELC) - Add Every 12 000 Service Hours or 6 Years Cooling System Coolant (ELC) - Change

Niple untuk lubrikasi

Sprocket Hub Bearing

Track Adjusment

Fan Drive

Machine D6G

Sheet1

ORDER PENGELUARAN PARTS

ORDER KERJA NO.CUSTOMERMODELS/NSMU1UNIT DOWN

2SCHEDULED

PREPARED BYAPPROVED BYDATE/TIME

APPROVED

ITEMPART NUMBERCHANGED TODESCRIPTIONQTYAPPRO-VALUNIT PRICEEXTENDED PRICERECD

ESTIMATEDACTUAL

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

*APPROVAL CODESTOTAL C/F

Sheet1

TRAKINDOCAT

TECHNICALANALYSIS

MACHINE VISUAL INSPECTIN REPORT

Page - 4

WORK ORDERBRCCCUSTOMER NAMENUMBERMAKEMODELSEREAL NUMBERHOURS

DATE :

INSPECTED By:

KOMPONEN DISCRIPTIONSTDREPKETERANGAN

ENGINE (SMOKE)

Turbo chargerV

Air ratio control

Air filter indicatorV

Air filterV

INTAKE & EXHAUST SYSTEM

Cylinder head grpV

Exhaust ManifoldV

After cooler,Intake manifold & pipingVGas leaking

Precleaner/air cleaner assyV

MufflerV

FUEL SYSTEM

Fuel Injection pump and governorV

Fuel transfer pumpV

Fuel priming pumpVFuel leaks

Fuel injection nozzle/lines

Fuel FilterV

LUBRICATION SYSTEM

Oil PumpV

Oil cooler/FilterV

Oil level gauge(deep stick)V

Breather,filler capV

COOLING SYSTEM

Water pumpV

RadiatorV

Fan drive/Fan assy/fan guard/VbeltVUnbalance

Radiator/cap/relief valveV

ELECTRIC SYSTEM

Battery and wiringVpoor condition

Starting motorV

Altenator/chargerV

Dash board/Control Panel/service meterVpoor condition

LampV

Trakindo:ARET

Sheet1

TRAKINDOCAT

TECHNICALANALYSIS

MACHINE VISUAL INSPECTION REPORT

Page - 5

WORK ORDERBRCCCUSTOMER NAMENUMBERMAKEMODELSEREAL NUMBERHOURS

DATE :

INSPECTED By:

KOMPONEN DISCRIPTIONSTDREPKETERANGAN

TORQUE CONVERTER & TRANS

Torque converter

Transmissin controlVNeed Replace/Adjust

Transmission groupV

Transmission pump & linesVNeed recondition

STEERING & BEVEL GEAR GROUP

Steering controlV

Steering/hand metering unitV

Brake systemVNeed Recondition

FINAL DRIVE GROUP

Final drive sealsVReplace seal /oil leak

Deff case/Tandem HousingVCracked need repair

Final drive grpVReplace seal /oil leak

HYDRAULIC SYSTEM

Hydraulic pumpVUnstable pressure output

Hydraulic control valveVToo Much oil leak

Hydraulic swivel joint/linesVPoor condition

HYDRAULIC CYLINDERVOil leaks

OPERATOR COMPARTMENT

CabinV

Seat/chusionV

Control panelVPoor condition

Trakindo:ARET

THANK YOU

**Komponen-Komponen Engine Diesel

Caterpillar develops and builds four-stroke-cycle diesel engines to satisfy the requirements of Caterpillar-built equipment as well as a wide variety of equipment built by other manufacturers.

To effectively perform diagnosis, repair and service, it is necessary to have a complete understanding of the operating principles and construction of diesel engines.

The Caterpillar 3406 engine is used as an example for this learning outcome (Figure 1). The engine component descriptions apply to all Caterpillar and other manufacturers engines.

The 3406 is a heavy-duty, in line, 6-cylinder, diesel engine. It has a 162.56 mm (5.4 inch) bore, 165.1 mm (6.5 inch) stroke and a displacement of 14,633 cc (893 cu.in.).

This engine is used for the on-highway truck market, in Caterpillar products, power generation, and in marine applications.

*The Cylinder (Engine) Block

The Cylinder Block is one of the major components in a diesel engine and houses the main power producing components. It must exhibit high strength and durability because all the resultant forces, pressures and heat from the combustion process are transferred to the engine block. To provide this high strength, the block is a precision casting using a combination of alloy materials.

*

Cylinder (Engine) Blocks come in different designs:

1.In-line engines have the cylinders in-line.

2.V-formation engines separate the cylinders in two rows, sharing the same crankshaft at the bottom, and the block has a V-shape.

*

The Piston transmits the force of combustion, is made up of many parts:1.The Crown, containing the combustion chamber2.The Ring-grooves and Lands that hold the piston rings3.Piston Pin or Gudgeon Pin Bore contains a Piston Pin or Gudgeon Pin that connects the piston to the connecting rod4.The Retaining Ring keeps the piston pin inside the pin bore5.Thrust Skirt that carries side loads.

*

Connecting Rods connect the piston to the crankshaft and transmits combustion force to the crankshaft.There are several parts to a connecting rod:Rod-eye, gudgeon-end or small-end, that holds the piston pin bushing

Piston pin bushing. Bushings are a type of bearing that distribute load and can be replaced when worn.

Shank between small and big ends. It has an I-beam shape for strength and rigidity.

4.The crankshaft journal bore and cap are at the big end of the connecting rod. These surround the crankshaft bearing journal and attach the connecting rod to the crankshaft.

5.Rod-bolts and nuts secure the rod and cap to the crankshaft. This is called the crank end or big end of the connecting rod.

Connecting rod in big-end bearings are in the crank-end. The crankshaft turns inside the connecting rod bearings, which carry the load. The connecting rod transmits combustion force to the crankshaft and transform up and down motion into rotary motion.

The forged connecting rod is hardened and shot peened for stress relief. The tapered-end design provides additional pin to bore contact area during the power stroke. This results in extra strength and durability of the piston & rod assembly.

*The Connecting Rod Bearings top half fits into the connecting rod and is called the upper-half shell. The other half fits in the cap and is called the lower half shell. Normally the upper half shell carries more load. Locating lugs are an integral part of the bearing shells and are used to ensure the shells fit correctly to either the connecting rod or cap.*

The Crankshaft is a carbon steel forging that is totally hardened.The big end of the connecting rod turns the crankshaft, located at the bottom of the engine block. The crankshaft transmits rotary motion to the flywheel and driveline (clutch, transmission and other driven devices), providing energy suitable for work.

The construction of a crankshaft includes the following:1.Connecting rod bearing journals.2.Counterweights.3.Main bearing journal.4.Web.

Crankshafts for in-line engines generally have one connecting rod bearing journal for each cylinder, while V-engines share a single connecting rod-bearing journal between two cylinders.

The example given is a V8 engine that has special split rod journals.

*Cylinder Liners

Cylinder liners form the water jacket wall between coolant and pistons.

*

Blocks are normally cast-iron and contain casts or drilling

1.to allow for the passage of coolants

2.lubrication

*Cylinder Liners

Cylinder Liners (or the cylinders) are made of a cast molybdenum alloy iron for extra hardness. The internal surface of each liner is induction hardened, then honed in a cross-hatched pattern to aid oil control.

O-rings are used to seal the bottom of the liner to the block coolant cavity. A Liner Band is used to seal the top of the liner. The rigid engine block allows these seals to remain seated and provides excellent liner sealing.

The function of the liners is to house and guide the pistons, form the combustion chamber and move heat away from the pistons. It is also possible to have cylinders machined directly into the block:

called a parent bore (1)

instead of removable cylinder liners (2)

*Cylinder Liners


********Cylinder Liners

Cylinder Liners (or the cylinders) are made of a cast molybdenum alloy iron for extra hardness. The internal surface of each liner is induction hardened, then honed in a cross-hatched pattern to aid oil control.

O-rings are used to seal the bottom of the liner to the block coolant cavity. A Liner Band is used to seal the top of the liner. The rigid engine block allows these seals to remain seated and provides excellent liner sealing.

The function of the liners is to house and guide the pistons, form the combustion chamber and move heat away from the pistons. It is also possible to have cylinders machined directly into the block:

called a parent bore (1)

instead of removable cylinder liners (2)

*Cylinder Liners


***************************

basic maintenance

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