HALAMAN ISI
PRESENTASI TUGAS AKHIR
Troubleshooting Error
Transmission HD 465-7
NAMA : FRIZKY TEGAR J.P
NIS : 70217315
BATCH : 22
KELAS : UT SCHOOL
JAKARTA
LOKASI OJT : BINUNGAN
UT SCHOOL
PROGRAM STUDI MEKANIK
ALAT BERAT
2018
PEMBEKALAN OJT- 1
PRESENTASI TUGAS AKHIR
LATAR BELAKANG
1. Troubleshoting tentang Error Transmission banyak
ditemukan di sekitar kita, tidak hanya di HD 465-7
tetapi juga bisa ditemukan di unit lain.
TUJUAN
1.Mencegah trouble yang sama terulang kembali.
2.Mempermudah pengerjaan trouble yang sama pada
unit HD 465-7.
2
HALAMAN ISI
DATA UNIT
Unit Model : HD 465-7
DATA UNIT
Kode Unit
HM
: HDKM46070
: 34777,9 Hours
Serial No. Unit : 7426
Model Engine : SAA6D170E-3
Serial No. Engine : GA - 312486
Nama Customer : PT. BUMA
Lokasi : TANJUNG REDEP SITE BINUNGAN
Laporan Trouble : ERROR TRANSMISSION
Tanggal Trouble : 29 JUNI 2018
Tanggal Selesai : 29 JUNI 2018
Lama Pengerjaan : 1 shift
3
HALAMAN ISI
METODOLOGI TROUBLESHOOTING
STEP 1 STEP 2 STEP 3 STEP 4
TROUBLESHOOTING OBSERVE &
POSSIBILITIES CAUSES COLLECT DATA
CHART DIAGNOSTIC
STEP 5 STEP 6 STEP 7 STEP 8
ACTION TO
ANALYSIS SUPECTED CAUSE CONCLUSION
IMPROVEMENT
4
Troubleshooting Chart
DDTJKA + 15SDMA (LO CLUTCH ABNORMAL)
SPEED F1
DDTKKA (1ST CLUTCH ABNORMAL)
DDTJKA + 15SDMA (LO CLUTCH ABNORMAL)
SPEED F2
DDTLKA (2ND CLUTCH ABNORMAL)
DDTJKA + 15SDMA (LO CLUTCH ABNORMAL)
SPEED RL
DDTNKA (R CLUTCH ABNORMAL)
PEMBEKALAN OJT- 5
PRESENTASI TUGAS AKHIR
HALAMAN ISI
Troubleshooting Chart
PEMBEKALAN OJT- 6
PRESENTASI TUGAS AKHIR
HALAMAN ISI
Troubleshooting Chart
• Error-error code tersebut muncul apabila:
ERROR DDT * KA
FILL SWITCH SENSOR
COMMAND
T/
M
SH
AF
T
SP
EE
ERROR 15S * MA D
SE
NS
OR
PEMBEKALAN OJT- 7
PRESENTASI TUGAS AKHIR
POSSIBILITIES CAUSE
Defective Transmission Controller
Defective Wiring Command Line / GND
Electrical Controller Line of ECMV
failure
Defective ECMV Solenoid
Defective ECMV Fill Switch
Error
(DDT*KA
&
15S*MA)
Defective Transmission Pump
Hydraulic /
Mechanical Defective Main Relief Valve
failure
Defective Spool of ECMV
Clogging of Hydraulic Line
PEMBEKALAN OJT- 8
PRESENTASI TUGAS AKHIR
OBSERVE & DIAGNOSTIC
Field Observation
• OBSERVE CUSTOMER MECHANIC
– Team BUMA sudah melakukan
a. Pembersihan + inspection pada strainer transmission case.
b. Minor Worn Clutch Material Found.
c. Swap ECMV dari Unit Lain Problem Tetap.
9
HALAMAN ISI
Observe Diagnostic
Field Observation
• OBSERVE DIRECTLY TO MACHINE
– Apabila salah satu gear shift aktif, timbul error yang mengacu
pada clutch yang diaktifkan (DDT*KA & 15S*MA)
PEMBEKALAN OJT- 10
PRESENTASI TUGAS AKHIR
PM Clinic Collect Data
PEMBEKALAN OJT- 11
PRESENTASI TUGAS AKHIR
Collect Data
• Main Relief Transmission Pressure
– STD (Lo Idle): 37 s/d 40 kg/cm2
– Act : 38,5 kg/cm27 kg/cm2
– STD (Hi Idle) : 32,5 s/d 35,5 kg/cm2
– Act : 34,6 kg/cm2 kg/cm2 O
K
NO
• Lo Clutch Pressure
– STD :14 s/d 18 kg/cm2 T
OK
– Act : 0 kg/cm2
PEMBEKALAN OJT- 12
PRESENTASI TUGAS AKHIR
Collect Data
PM Clinic
• 1st Clutch Pressure
– STD : 32 s/d 35 kg/cm2
– Act
NO
: 0 kg/cm2
T
OK
• 2nd Clutch Pressure
NO
– STD : 32 s/d 35 kg/cm2
– Act : 8 kg/cm2 T
OK
PEMBEKALAN OJT- 13
PRESENTASI TUGAS AKHIR
Analysis
PEMBEKALAN OJT- 14
PRESENTASI TUGAS AKHIR
Analysis
PEMBEKALAN OJT- 15
PRESENTASI TUGAS AKHIR
Suspected Cause
Defective Transmission Controller
Defective Wiring Command Line / GND
Controller Line of ECMV
Electrical
failure
Defective ECMV Solenoid
Error 03 Defective ECMV Fill Switch
(DDT*KA
& 15S*MA)
Defective Transmission Pump
Hydraulic /
Mechanical Defective Main Relief Valve
failure
Defective Spool of ECMV
Clogging of Hydraulic Line
PEMBEKALAN OJT- 16
PRESENTASI TUGAS AKHIR
HALAMAN ISI
Suspected Cause
• Inspeksi pada komponen yang paling
mudah : Last Chance Filter.
PEMBEKALAN OJT- 17
PRESENTASI TUGAS AKHIR
HALAMAN ISI
Suspected Cause
• Cleaning Last Chance Filter & re-measurement
Clutch Speed Transmission Pressure.
• Lo Clutch Pressure
– Result : 18.4 kg/cm2
OK
– (STD 14 s/d 18 kg/cm 2)
• 1st Clutch Pressure
– Result : 33.6 kg/cm2 OK
– (STD 32 s/d 35 kg/cm 2)
• 2nd Clutch Pressure
– Result : 32.2 kg/cm2 OK
– (STD 32 s/d 35 kg/cm 2)
PRESSURE LOSS CLOGGING AT LAST CHANCE FILTER
PEMBEKALAN OJT- 18
PRESENTASI TUGAS AKHIR
HALAMAN ISI
Conclusion
POSSIBILITY SOURCE OF WORN MATERIAL
PEMBEKALAN OJT- 19
PRESENTASI TUGAS AKHIR
Conclusion
Inspection Filter & Strainer
• TRANSMISSION OIL PAN STRAINER
• INSPECT BY BUMA TEAM TERDAPAT TIDAK BANYAK
MATERIAL
• TRANSMISSION FILTER
TERDAPAT TIDAK BANYAK
MATERIAL
• BRAKE COOLING FILTER
TERDAPAT BANYAK MATERIAL
20
Root Cause Problem
Conclusion
Error (DDT*KA & 15S*MA) Occures
Fill Switch is Still Off After ECMV Activation
Loss Pressure of ECMV Activation
Clogging at Last Chance Filter
Worn Disc Material Circulated in Transmission Oil
Rear Brake Worn Out
PEMBEKALAN OJT- 21
PRESENTASI TUGAS AKHIR
HALAMAN REFERENSI
Additional Inspection
Conclusion
• Inspect Rear Brake Wear Gauge.
WEAR GAUGE MIS-ASSEMBLY CAN’T BE USED AS REFFERENCE
22
HALAMAN ISI
Action to Improvement
• Wear Gauge Cant be used for Refference
due to mis-assembly.
• Life Time of Rear Brake Rh & LH 18720
Hrs
• Request Replacement Rear Brake
Assembly RH & LH
• Flushing oil
PEMBEKALAN OJT- 23
PRESENTASI TUGAS AKHIR
HALAMAN ISI
SEKIAN DAN TERIMA KASIH
PEMBEKALAN OJT- 24
PRESENTASI TUGAS AKHIR
