INTERVIEW NEW HIRE MECHANIC

PT. PUTRA PERKASA ABADI

PPA ACADEMY

NAMA CALON KARYAWAN :

SITE TUJUAN KARYAWAN :
GRADE YANG DIUJIKAN :
NAMA PENGUJI :
NIK PENGUJI :
TANGGAL UJI :
LOKASI UJI :
METODE UJI :
APAKAH SUDAH BMC :
PENYELENGGARA BMC :
UNIT YANG DIKUASAI :
PEKERJAAN YANG DIKUASAI :
UNIT YANG DIUJIKAN : EQ. GROUP 1 EQ. GROUP 2 EQ. GROUP 3

TRAINING YANG DIPERLUKAN : TERDAHULU BERSERTIFIKAT KEBUTUHAN

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SARAN & REKOMENDASI DIBAWAH INI :

DOMISILI ……….
PENGUJIAN PADA ……….. WHEEL
TARGET POINT PENGUJIAN 43
Masukan Foto Harus Lebih Kecil
POINT PENCAPAIAN ……. Dari Ukuran Kotak

REKOMENDASI :
G1A - ……..., Jabatan …….. Wheel
PENGUJI
 KOMPETENSI
SUBJECT PERIODIC SERVICE KETERANGAN
0 1 2 3
I. MAINTENANCE PROCESS & SOP
Menjelaskan Maksud dan Tujuan dari :
1 Periodic Service
2 Program Analisa Pelumas
3 Program Pemeriksaan Machine --
4 Program Pemeriksaan Undercarriage
5 Program Pemeriksaan Attachment TINGKAT
II. LUBRICANTS KOMPETENSI
Menjelaskan secara umum hal dibawah ini :
1 Fungsi Oli secara umum
2 Jenis Oli
3 Klasifikasi Oli
4 Standar kekentalan Hydraulic Oil
5 Standar kekentalan Engine Oil
6 Multi Grade Oil
7 Pengertian Kontaminasi
8 Pengertian Deteriorasi
9 Penyebab Kontaminasi pada oil
10 Penyebab Deteriorasi pada oil
11 Aplikasi Oli
12 Pengertian Oksidasi
--
13 Pengertian Demulsibility
14 Arti Viscosity Index (VI)
15 Mengapa Oli harus diganti
16 Penanganan Oli (penyimpanan & pengisian)
17 Pengertian dan Fungsi Additive
18 Arti dan tujuan Total Base Number (TBN)
19 Pengertian Synthetic Oil
20 Fungsi Grease secara umum
21 Standar kekentalan Grease
22 Klasifikasi Grease
23 Aplikasi Grease
24 Penanganan Grease
III. WATER / COOLANT
SERVICE

Menjelaskan secara umum hal dibawah ini :

1 Syarat penggunaan Air Radiator
2 Alat untuk mengukur Tingkat Keasaman Air --
3 Fungsi Anti Freeze
IV. FUEL
#DIV/0!
Menjelaskan secara umum hal dibawah ini :
PERIODIC

1 Jenis Fuel yang digunakan pada Diesel Engine

2 Pengaruh Sulfur pada Fuel thd. Jadwal Pergantian Oli
--
3 Akibat Fuel campur Kerosine
4 Penanganan Fuel
V. FILTER
Menjelaskan secara umum hal dibawah ini :
1 Fungsi dan klasifikasi Filter
2 Pengertian Filtering Area
3 Arti Mesh dan Micron
--
 --
4 Model Filter
5 Jenis-jenis Air Filter
6 Penanganan Filter
VI. TOOLS
#DIV/0!
Menjelaskan fungsi, aplikasi, penggunaan & satuan alat ukur :
1 Temperature Tester kit
2 Handy smoke Checker
3 Radiator Cap Tester
4 Dial gauge
5 Jangka Sorong (Vernier Caliper)
6 Convex Scale --
7 Hydro Tester/ Refractrometer
8 Wear Gauge Kit
9 PPU Tools
10 PAP Tools
11 Oil Leak Tester
VII. TECHNICAL TERM
#DIV/0!
Menjelaskan pengertian dari istilah berikut :
1 Engine Low Idle
2 Engine High idle
3 Rated Speed
4 Stall Speed
5 Engine Hunting
6 Turbocharger Play --
7 Brake Performance
8 Voltage
9 Resistansi
10 Ampere
11 Specific Gravity

KOMPETENSI
SUBJECT PERIODIC INSPECTION KETERANGAN
0 1 2 3
I. MAINTENANCE PROCCESS / S O P
Menjelaskan Maksud dan Tujuan dari :
1 Daily Check
2 Periodic Inspection
3 Program Back-Log
--
4 Penggunaan Part Book
5 Penggunaan OMM
6 Penggunaan Shop Manual
II. MACHINE COMPONENT
Menjelaskan Letak dan Fungsi Componen :
1 Fungsi Water Separator
2 Fungsi Dust Indicator
3 Fungsi Corrossion Resistor
4 Fungsi Evacuator Valve
5 Fungsi Ejector Pipe
6 Fungsi Pre-Cleaner
ODIC INSPECTION

7 Fungsi Tachograph
8 Fungsi Payload Meter
--
9 Fungsi breathers
10 Engine
11 Damper
PERIODIC INSPECTI
--

12 Torq.Converter
13 Torq.flow Transmission
14 Differential
15 Final drive
16 Hydraulic Pump dan Control Valve
III. INSTRUMENT & CONTROL
Menjelaskan arti simbol dan fungsi panel berikut :
1 Water Temperatur
2 Engine Oil Pressure
3 Power Train Oil Temperatur
4 Radiator Coolant Level
--
5 Pre Heating System
6 Fuel Level
7 Warning Lamp
8 Air Cleaner Clogging Caution
IV. TOOLS
Menjelaskan fungsi, aplikasi, penggunaan & satuan alat ukur :
1 Pressure Gauge
2 Multi Tester
3 Push Pull Scale
--
4 Stop Watch
5 Torque Wrench
6 Commond Tools

KOMPETENSI
SUBJECT MACHINE CONDITON INSPECTION KETERANGAN
0 1 2 3
I. TECHNICAL TERM
Menjelaskan pengertian dari istilah item-item berikut :
1 Blow By Pressure
2 Boost Pressure
MACHINE CONDITION INSPECTION

4 Atmosfir pressure
5 Hydrolic losses
--
6 Cracking pressure TINGKAT
7 Pressure control valve KOMPETENSI
8 VHMS
9 Snapshoot
II. INSTRUMENT & CONTROL
Menjelaskan arti simbol dan fungsi yg terpasang :
1 Action code display
2 Caution item
3 Emergency stop item
4 Meter display portion --
5 Mechatronic caution lamp portion
6 Machine Monitor System
7 Central warning lamp
III. TOOLS
Menjelaskan fungsi, aplikasi, penggunaan & satuan alat ukur :
1 Tachometer
2 Blow By Checker
3 Pressure Gauge --
4 Thermometer / Thermister
5 PH tester / kertas Lakmus

KOMPETENSI
SUBJECT REMOVE INSTALL 1 KETERANGAN
0 1 2 3
 I. SYSTEM
Menjelaskan nama & fungsi komponen pada system:
1 Fuel System
2 Cooling System
--
3 Lubricating System
4 Air & Intake System
II. TECHNICAL TERM
Menjelaskan prosess dan pengertian dari istilah item-item berikut :
1 4-cycle, water-cooled, in-line 6 cylinder, direct injection
2 Adjustment
3 Connect
4 Disconnection
5 Dismounting
6 End Ply of Crank Shaft
7 Engine Oil Drain Plug
REMOVE INSTALL 1

8 Engine hunting
9 Engine Name Plate
10 Engine overheating
11 Engine RPM --
12 Engine Stand
13 Fuel consumption
14 Load Max. Strenght ( SWL )
15 Marking
16 Max. torque
17 Mounting
18 Over Torque of bolt
19 Piston displacement
21 Remove Componen
22 Tightening Torque
III. TOOLS
Menjelaskan fungsi, aplikasi, penggunaan & satuan alat ukur :
1 Shackle
2 Chain block
3 Lifting tools
4 PM clinic tools
--
5 Power wrench
6 Prybar / tomy bar
7 White marker
8 Wire rope/Chain

KOMPETENSI
SUBJECT REMOVE INSTALL 2 KETERANGAN
0 1 2 3
I. SYSTEM
Menjelaskan nama & fungsi komponen pada system:
1 Electrical System
2 Hydraulic System
--
3 Power Train
4 Air System
II. TECHNICAL TERM
Menjelaskan prosess dan pengertian dari istilah item-item berikut :
1 Periodical replacement part
2 Consumable part
3 Vital part
INSTALL 2

4 Losable part
5 Injurable part
REMOVE INSTALL 2
6 Unreusable part
7 Bolt plastic range
8 Bolt elastic range
9 Piston off set
--
10 Press fit
11 Expantion fit
12 Shrinkin fit
13 Rank of part
14 Reusable part book
15 Liquit gasket
16 Lock thread
17 Stud bolt
18 Floating seal
III. TOOLS
Menjelaskan fungsi, aplikasi, penggunaan & satuan alat ukur :
1 Color checker
2 Magmetic flow detector
--
3 Piston ring holder
4 Piston ring grove

KOMPETENSI
SUBJECT MACHINE TROUBLE SHOOTING 1 KETERANGAN
0 1 2 3
I. SYSTEM
Menjelaskan structure & function komponen pada system:
1 Fuel System
2 Cooling System
--
3 Lubricating System
4 Air & Intake System
II. TECHNICAL TERM
Menjelaskan prosess dan pengertian dari istilah item-item berikut :
1 Pump flow-rate
2 Steering wheel play
3 Modulating time
4 ECMV
5 Engine knocking
T R O U B EL S H O O T I N G 1

6 Abnormal noise
7 PPC
8 Direct injection
9 Compretion ratio
10 Air excess ratio
--
11 Long stroke engine
12 Square stroke engine
13 Total piston displacement
14 Boost compensator
15 Bending full length & half bend
16 Interference fit
17 Standard size and tolerance
18 Standard clearance and standard value
19 Standard interference
20 Repair limit and allowable value
III. TOOLS
Menjelaskan fungsi, aplikasi, penggunaan & satuan alat ukur :
1 Water leak tester
2 Spring tester

--
 3 Valve grinding
4 T Adapter --
5 Flow Meter
6 Anemometer
7 Compression test KIT

KOMPETENSI
SUBJECT MACHINE TROUBLE SHOOTING 2 KETERANGAN
0 1 2 3
I. SYSTEM
Menjelaskan structure & function komponen pada system:
1 Electrical System
2 Hydraulic System
--
3 Power Train
4 Air System
II. TECHNICAL TERM
Menjelaskan prosess dan pengertian dari istilah item-item berikut :
1 Clearance limit
2 Interference limit
3 Main failures occurring in wiring harness
4 Disconnecting connectors
5 Connecting connectors
6 Handling controller
T R O U B LE S H O O T I N G 2

7 Points to remember when troubleshooting electric circuits

8 Basic procedure for troubleshooting
9 Check before troubleshooting
10 Classification for troubleshooting
11 fault history function
12 Phenomena looking like troubles and troubleshooting --
13 Oil tighness test
14 User code
15 Failure code
16 Contents of trouble
Action of
17 machine monitor
or controller
18 Disconnection in wiring
19 Defective grounding
20 Hot short defect
21 Short circuit
22 Before troubleshooting of electric system
Troubleshooting
23
charts
III. TOOLS
Menjelaskan fungsi, aplikasi, penggunaan & satuan alat ukur :
1 Dynamo Pressure Gauge
2 Load Meter Gauge
3 Absorbtion type dynamometer
--
4 Harness Checker
5 Air leak tester
6 Modulating checker
 KOMPETENSI KOMPETENSI KOMPETENSI
HD_KOMATSU (ref.HD785-7) 0 1 2 3
KETERANGAN HM_KOMATSU (ref. HM400-3R) 0 1 2 3
KETERANGAN HD_CATERPILLAR (ref. ) 0 1 2 3
KETERANGAN

Menyebutkan lokasi, langkah kerja, model, jumlah, tools & standar yang digunakan : Menyebutkan lokasi, langkah kerja, model, jumlah, tools & standar yang digunakan :(ref. HM400-3R) Menyebutkan lokasi, langkah kerja, model, jumlah, tools & standar yang digunakan : ###
1 Clean or replace air cleaner 1 Clean inside of cooling system 1 ###
2 Clean inside of cooling system 2 Lubricating 2
3 Clean air conditioner air filter 3 Check drive shaft 3
4 Bleed air from rear brake 4 Clean breather 4
5 Bleed air from front brake 5 Clean overflow hose 5
6 Bleed air from raer parking brake 6 Check foot brake performance 6
7 Bleed air from front parking brake 7 Check retarder brake performance 7
8 Check play of output coupling of output shaft 8 Check parking brake performance 8
9 Bleeding air from fuel circuit 9 Check parking brake pad for wear 9
10 Cleaning hydraulic tank strainer 10 Check function of accumulator 10
11 Replace fan belt, adjust auto tensioner 11 Change oil in engine oil pan, replace engine oil filter cartridge 11
12 Check drive shaft 12 Replace fuel pre-filter cartridge 12
13 Change oil in engine oil pan, replace engine oil filter cartridge 13 Lubricate cab mount pins 13
PERIODIC SERVICE

PERIODIC SERVICE

PERIODIC SERVICE
14 Replace fuel prefilter cartridge 14 Check oil level in final drive case, add oil 14
15 Replace transmission oil filter element 15 Check oil level in deferential case, add oi 15
16 Replace fuel main filter cartridge 16 Replace fuel main filter cartridge 16
17 Change oil in transmission, brake cooling oil tank, wash strainer 17 Replace breather element in fuel tank 17
18 Change oil in brake sub-tank -- 18 Replace transmission oil filter element -- 18 --
19 Replace transmission, brake cooling oil filter element 19 Change oil in transmission case 19
20 Replace brake oil filter element 20 Change oil in brake oil tank, replace brake oil filter element 20
21 Check wear of rear brake disc 21 Replace hydraulic oil filter element 21
22 Check wear of front brake disc 22 Check brake disc wear amount 22
23 Recover oil leaking from floating seal 23 Check for looseness of engine intake pipe clamp 23
24 Check of engine air intake piping clamps for looseness 24 Replace breather element in hydraulic tank 24
25 Replace steering, hoist oil tank filter element 25 Change oil in final drive case 25
26 Change oil in final drive case 26 Change oil in deferential case 26
27 Change oil in differential case 27 Clean transmission case strainer 27
28 Clean differential case breather 28 Clean breather 28
29 Check alternator 29 Check engine valve clearance, adjust 29
30 Check, adjust engine valve clearance 30 Change oil in hydraulic tank 30
31 Change oil in steering, hoist oil tank 31 Check alternator and starting motor 31
32 Lubricate drive shaft 32 Check water pump 32
33 Check vibration damper 33 Check air conditioner compressor 33
34 Check starting motor 34 Check for looseness of high-pressure piping clamp, hardening of rubber 34
35 Check water pump 35 Check exhaust pipe fire prevention cover 35
Menyebutkan lokasi, langkah kerja, model, jumlah, tools & standar yang digunakan : Menyebutkan lokasi, langkah kerja, model, jumlah, tools & standar yang digunakan : (ref. HM400-3R) Menyebutkan lokasi, langkah kerja, model, jumlah, tools & standar yang digunakan : ###
1 Check air cleaner 1 Check, clean, and replace air cleaner 1 ###
2 Check level of window washer fluid, add fluid 2 Check window washer fluid level, add fluid 2
3 Check air conditioner air filter 3 Clean air conditioner air filters 3
4 Check refrigerant (gas) level 4 Check level of refrigerant (gas) 4
5 Check dump body 5 Check dump body 5
PERIODIC INSPECTION

PERIODIC INSPECTION

PERIODIC INSPECTION
6 Check length of suspension cylinder 6 Check length of suspension cylinder 6
7 Check water separator, wash inside of filter case 7 Check water separator, clean filter case 7
8 Clean, check radiator fins and after cooler fins 8 Bleeding air of front brake 8
9 Check oil level in differential case, add oil 9 Bleeding air of center brake 9
10 Check oil level in final drive case, add oil
11 Lubrication -- 10 Bleeding air from hydraulic circuit
11 Check play of output coupling of output shaft -- 10
11 --
12 Check level of battery electrolyte 12 Adjust parking brake 12
13 Check alternator belt tension, adjust 13 Collect leaked oil from floating seal 13
14 Check air conditioner compressor belt tension, adjust 14 Check level of battery electrolyte 14
15 Clean breathers 15 Check alternator drive belt tension, adjust 15
16 Check frame 16 Check air conditioner compressor belt tension, adjust 16
17 Check braking capacity of foot brake 17 Check frame and a-arm 17
18 Check braking capacity of retarder brake 18 Check radiator fin, aftercooler fin, and air conditioner condenser fin, clean 18
19 Check braking capacity of parking brake 19 Check accumulator gas pressure 19
20 Engine
Check of speed - High gas pressure
accumulator 20 -- 20
idle - Power & Economy mode
Menjelaskan
(High load/metode pengujuan & tools yang digunakan pada pekerjaan berikut : Menjelaskan metode pengujuan & tools yang digunakan pada pekerjaan berikut : (ref. HM400-3R) Menjelaskan metode pengujuan & tools yang digunakan pada pekerjaan berikut : ###
1 Low
idle load)
- High side / 1 Engine Speed High idle, Power / Economy mode. 1 ###
2 Low side 2 Engine Speed Low idle, Power / Economy mode. 2
3 Boost pressure 3 Boost pressure 3
4 Exhaust temperature 4 Exhaust temperature 4
5 Compression
Exhaust gas color 5 Exhaust gas color 5
6 pressure 6 Compression pressure 6
7 Blow-by gas pressure 7 Blowby pressure 7
MACHINE CONDITON INSPECTION

MACHINE CONDITON INSPECTION

MACHINE CONDITON INSPECTION

8 stall
Engine oil pressure 8 Engine Oil pressure 8
9 speed 9 Engine Oil temperature 9
10 Operating force and stroke for Accelerator pedal 10 Fuel return rate from injector 10
11 Operating force and stroke for Shift lever 11 Leakage from pressure limiter 11
12 Torque converter Inlet oil pressure 12 Torque converter lockup actuated 12
13 Torque converter outlet oil pressure 13 Torque converter stalled 13
14 Transmission Lubricating valve set pressure 14 Shift lever Operating effort / Stroke 14
15 Braking capacity of Parking brake
16 Starting test of Parking brake -- 15 Torque converter inlet pressure
16 Torque converter lockup clutch operating pressure -- 15
16 --
17 Operating force of Steering wheel 17 Brake pedal Operating effort / Stroke 17
18 Steering wheel play 18 Charge valve cut-in / cut-out pressure 18
19 Steering wheel Rotation range 19 Braking performance of service brake / retarder brake 19
20 Steering wheel Turning time 20 Service brake Braking distance of service brake 20
21 Steering valve Relief oil pressure 21 Wear of disc 21
22 Brake pedal operating force 22 Parking brake Braking performance / Braking slope angle / Amount of wear of pad 22
23 Brake pedal stroke 23 Service brake Braking distance of service brake 23
24 Hoist valve relief pressure 24 Steering wheel Operating effort / Play / speed / Turning time 24
25 Dump EPC relief pressure 25 Steering relief pressure 25
26 Dump Body lifting / lowering speed 26 Suspension Installed length cylinder / pressure 26
27 Hydraulic drift 27 Dump lever operating effort 27
28 -- 28 Dump body raise / lower time 28
29 -- 29 Dump Main relief pressure / Pilot relief pressure 29
30 -- 30 Hydraulic drift of dump body 30
Lokasi & fungsi dari komponen berikut : Lokasi & fungsi dari komponen berikut : (ref. HM400-3R) Lokasi & fungsi dari komponen berikut : ###
1 Fuel supply pump 1 Radiator fan pump 1 ###
2 Fuel injector 2 Aftercooler / Radiator fan motor 2
3 Common rail 3 Oil cooler bypass valve 3
4 Cross-over relief valve 4 Steering valve 4
5 Hydraulic pump 5 Flow amplifier valve 5
6 Steering control valve 6 Emergency steering pump / motor 6
7 Hoist valve 7 Steering and hoist pump 7
8 Steering valve 8 Parking brake solenoid and accumulator charge valve 8
9 Steering hoist filter (high pressure circuit) 9 Accumulator 9
10 Dump lever 10 Shut off solenoid valve 10
11 Dump control valve (EPC valve) 11 Brake valve 11
12 Body positioner sensor 12 Proportional pressure reducing valve 12
13 Slack adjuster 13 Slack adjuster 13
14 Secondary brake valve 14 Parking brake 14
REMOVE INSTALL 1

REMOVE INSTALL 1

REMOVE INSTALL 1
15 Brake valve 15 Steering and hoist pump 15
16 Parking brake valve 16 Hoist valve 16
17 Accumulator charge valve 17 Steering pump selector solenoid valve 17
18 proportional reducing valve 18 Dump EPC valve 18
19 Brake system tank -- 19 Brake cooling relief valve -- 19 --
20 Suspension oil pressure sensor 20 -- 20
Menjelaskan langkah pelaksanaan, Critical point, & alat angkat pada pekerjaan : Menjelaskan langkah pelaksanaan, Critical point, & alat angkat pada pekerjaan : (ref. HM400-2R) Menjelaskan langkah pelaksanaan, Critical point, & alat angkat pada pekerjaan : ###
1 Removal and installation of fuel supply pump assembly 1 Removal and installation of engine assembly 1 ###
2 Removal and installation of fuel injector assembly 2 Removal and installation of radiator assembly 2
3 Removal and installation of cylinder head assembly 3 Removal and installation of cooling assembly 3
4 Removal and installation of engine hood assembly 4 Removal and installation of aftercooler assembly 4
5 Removal and installation of radiator assembly 5 Removal and installation of output shaft assembly 5
6 Removal and installation of engine assembly 6 Removal and installation of fuel supply pump assembly 6
7 Removal and installation of engine front oil seal 7 Removal and installation of cylinder head assembly 7
8 Removal and installation of engine rear oil seal 8 Removal and installation of fuel injector assembly 8
9 Removal and installation of hoist valve assembly 9 Removal and installation of engine front seal 9
10 Removal and installation of steering cylinder assembly 10 Removal and installation of engine rear seal 10
11 Removal and installation of steering valve assembly 11 Removal and installation of flow amplifier valve assembly 11
12 Removal and installation of front wheel hub and brake assembly 12 Removal and installation of hoist valve assembly 12
13 Removal and installation of final drive and rear brake assembly 13 -- 13
14 -- 14 -- 14
15 -- 15 -- 15
Lokasi & fungsi dari komponen berikut : Lokasi & fungsi dari komponen berikut : (ref. HM400-3R) Lokasi & fungsi dari komponen berikut : ###
1 Brake cooling oil control valve (BCV) 1 Drive shaft 1 ###
2 Main flow rate selector valve of Torque converter 2 Differential lockup clutch 2
3 Main relief valve of Torque converter 3 Electronic Control Modulation Valve 3
4 Electronic Control Modulation Valve 4 Main relief valve of transmission 4
5 Lubricating oil amount selector valve 5 Torque converter relief valve 5
6 Suspension cylinder 6 Main flow selector valve 6
7 Radius rod 7 Accelerator pedal position sensor 7
8 Arm (A-frame) 8 Ambient pressure sensor 8
9 Emergency steering motor 9 Charge temperature sensor 9
10 Emergency steering pump 10 Coolant temperature sensor 10
11 Accelerator sensor 11 Charge pressure sensor 11
12 Retarder oil temperature sensor 12 Engine oil level sensor 12
13 Coolant level sensor 13 Air cleaner clogging sensor 13
14 Fuel level secsor 14 Torque converter oil pressure sensor 14
REMOVE INSTALL 2

REMOVE INSTALL 2

REMOVE INSTALL 2

15 Transmission oil filter clogging sensor 15 Piston pump oil temperature sensor 15
16 Air cleaner clogging sensor 16 Transmission speed sensor (input shaft) 16
17 Accumulator oil pressure sensor 17 Safety functions 17
18 Tilt switch 18 Hoist control function 18
19 Steering oil pressure switch -- 19 Automatic emergency steering system -- 19 --
20 Steering angle sensor 20 Komatsu Traction Control System 20
Menjelaskan langkah pelaksanaan, Critical point, & alat angkat pada pekerjaan : Menjelaskan langkah pelaksanaan, Critical point, & alat angkat pada pekerjaan : (ref. HM400-2R) Menjelaskan langkah pelaksanaan, Critical point, & alat angkat pada pekerjaan : ###
1 Removal and installation of front drive shaft 1 Removal and installation of transmission and front differential assembly 1 ###
2 Removal and installation of rear drive shaft assembly 2 Removal and installation of center differential assembly 2
3 Removal and installation of output shaft assembly 3 Removal and installation of rear differential assembly 3
4 Removal and installation of torque converter and transmission assemblies 4 Removal and installation of front final drive and brake assembly 4
5 Disconnection and connection of torque converter assembly and transmission assembly 5 Removal and installation of center final drive and brake assembly 5
6 Removal and installation of final drive carrier assembly 6 Removal and installation of rear final drive and brake assembly 6
7 Removal and installation of differential assembly 7 Removal and installation of center axle assembly 7
8 Removal and installation of front wheel assembly 8 Removal and installation of rear axle assembly 8
9 Removal and installation of rear wheel assembly 9 Removal and installation of front/rear suspension cylinder assembly 9
10 Removal and installation of front suspension cylinder assembly 10 Removal and installation of equalizer bar assembly 10
11 Removal and installation of king pin 11 Removal and installation of hitch frame assembly 11
12 Removal and installation of rear suspension cylinder assembly 12 Removal and installation of body assembly 12
13 Removal and installation of body assembly 13 Removal and installation of engine controller 13
14 Removal and installation of engine controller assembly 14 Removal and installation of retarder controller 14
15 Removal and installation of transmission controller assembly 15 Removal and installation of transmission controller assembly 15
Fungsi & cara kerja dari komponen berikut : Fungsi & cara kerja dari komponen berikut : (ref. HM400-3R) Fungsi & cara kerja dari komponen berikut : ###
1 Fuel supply pump 1 Radiator fan pump 1 ###
2 Fuel injector 2 Aftercooler / Radiator fan motor 2
3 Common rail 3 Oil cooler bypass valve 3
4 Cross-over relief valve 4 Steering valve 4
5 Hydraulic pump 5 Flow amplifier valve 5
6 Steering control valve 6 Emergency steering pump / motor 6
7 Hoist valve 7 Steering and hoist pump 7
8 Steering valve 8 Parking brake solenoid and accumulator charge valve 8
9 Steering hoist filter (high pressure circuit) 9 Accumulator 9
10 Dump lever 10 Shut off solenoid valve 10
11 Dump control valve (EPC valve) 11 Brake valve 11
12 Body positioner sensor 12 Proportional pressure reducing valve 12
13 Slack adjuster 13 Slack adjuster 13
14 Secondary brake valve 14 Parking brake 14
15 Brake valve 15 Steering and hoist pump 15
16 Parking brake valve 16 Hoist valve 16
17 Accumulator charge valve 17 Steering pump selector solenoid valve 17
18 proportional reducing valve 18 Dump EPC valve 18
TROUBLE SHOOTING 1

TROUBLE SHOOTING 1

TROUBLE SHOOTING 1

19 Brake system tank 19 brake cooling relief valve 19

20 Suspension oil pressure sensor 20 -- 20
Menjelaskan kemungkinan penyebab, metode pengujian & tools yang digunakan : Menjelaskan kemungkinan penyebab, metode pengujian & tools yang digunakan : (ref. HM400-3R) Menjelaskan kemungkinan penyebab, metode pengujian & tools yang digunakan : ###
1 H-12 Steering wheel is heavy 1 H-14 Steering wheel is heavy to turn 1 ###
2 H-13 Steering wheel does not work
3 H-14 Steering wheel vibrates
-- 2 H-15 Steering wheel does not move
3 H-16 Steering wheel swings
-- 2
3
--
4 H-15 Dump body lifting speed is slow 4 H-17 Dump body raise speed or power is slow 4
5 H-16 Dump body does not work 5 H-18 Dump body does not move 5
6 H-17 Excessive hydraulic drift of dump body 6 H-19 Hydraulic drift of dump body is large 6
7 S-1 Starting performance is poor 7 H-20 Radiator fan speed is abnormal (high, low, or stationary) 7
8 S-2 Engine does not start 8 H-21 Aftercooler fan speed is abnormal (high, low, or stationary) 8
9 S-3 Engine does not pick up smoothly 9 H-22 Unusual noise is heard from around radiator fan 9
10 S-4 Engine stops during operations 10 H-23 Abnormal noise is heard around aftercooler fan 10
11 S-5 Engine does not rotate smoothly 11 S-1 Engine does not crank when starting switch is turned to START position 11
12 S-6 Engine lacks output (or lacks power) 12 S-2 The engine cranks but exhaust smoke does not come out 12
13 S-7 Exhaust smoke is black (incomplete combustion) 13 S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) 13
14 S-8 Oil consumption is excessive (or exhaust smoke is blue) 14 S-4 Engine startability is poor 14
15 S-9 Oil becomes contaminated quickly 15 S-5 Engine does not pick up smoothly 15
16 S-10 Fuel consumption is excessive 16 S-6 Engine stops during operation 16
17 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 17 S-7 Engine runs rough or is unstable 17
18 S-12 Oil pressure drops 18 S-8 Engine lacks power 18
19 S-13 Oil level rises (Entry of coolant or fuel) 19 S-9 Exhaust smoke is black 19
20 S-14 Coolant temperature becomes too high (overheating) 20 S-10 Engine oil consumption is excessive 20
21 S-15 Abnormal noise is made 21 S-11 Oil becomes contaminated quickly 21
22 S-16 Vibration is excessive 22 S-12 Fuel consumption is excessive 22
23 -- 23 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 23
24 -- 24 S-14 Oil pressure drops 24
25 -- 25 S-15 Fuel mixes into engine oil ( 25
Fungsi & cara kerja dari komponen berikut : Fungsi & cara kerja dari komponen berikut : (ref. HM400-3R) Fungsi & cara kerja dari komponen berikut : ###
1 Brake cooling oil control valve (BCV) 1 Drive shaft 1 ###
2 Main flow rate selector valve of Torque converter 2 Differential lockup clutch 2
3 Main relief valve of Torque converter 3 Electronic Control Modulation Valve 3
4 Electronic Control Modulation Valve 4 Main relief valve of transmission 4
5 Lubricating oil amount selector valve 5 Torque converter relief valve 5
6 Suspension cylinder 6 Main flow selector valve 6
7 Radius rod 7 Accelerator pedal position sensor 7
8 Arm (A-frame) 8 Ambient pressure sensor 8
9 Emergency steering motor 9 Charge temperature sensor 9
10 Emergency steering pump 10 Coolant temperature sensor 10
11 Accelerator sensor 11 Charge pressure sensor 11
12 Retarder oil temperature sensor 12 Engine oil level sensor 12
13 Coolant level sensor 13 Air cleaner clogging sensor 13
14 Fuel level secsor 14 Torque converter oil pressure sensor 14
15 Transmission oil filter clogging sensor 15 Piston pump oil temperature sensor 15
16 Air cleaner clogging sensor 16 Transmission speed sensor (input shaft) 16
17 Accumulator oil pressure sensor 17 Safety functions 17
18 Tilt switch 18 Hoist control function 18
19 Steering oil pressure switch 19 Automatic emergency steering system 19
TROUBLE SHOOTING 2

TROUBLE SHOOTING 2

TROUBLE SHOOTING 2

20 Steering angle sensor 20 Komatsu Traction Control System 20

Menjelaskan kemungkinan penyebab, metode pengujian & tools yang digunakan : Menjelaskan kemungkinan penyebab, metode pengujian & tools yang digunakan : (ref. HM400-3R) Menjelaskan kemungkinan penyebab, metode pengujian & tools yang digunakan : ###
1 H-1 Machine does not start 1 H-1 Machine does not start 1 ###
2 H-2 Machine does not travel smoothly (hunting) 2 H-2 Machine does not travel smoothly (engine hunts) 2
3 H-3 Lockup cannot be cancelled -- 3 H-3 Lockup clutch is not disengaged -- 3 --
4 H-4 Excessive shock when starting or shifting excessive 4 H-4 Abnormally large shocks result from starting of machine and gear shifting 4
5 H-5 Transmission does not shift up 5 H-5 Machine does not upshift 5
6 H-6 Machine lacks power or speed when traveling 6 H-6 Machine lacks travel speed or power during travel in lockup drive mode through all gear speeds 6
7 H-7 Time lag is excessive when starting or shifting gear 7 H-7 Machine lacks travel speed or power during travel in torque converter drive mode 7
8 H-8 Torque converter oil temperature is high 8 H-8 Machine lacks travel speed or power during travel in specific gear speed 8
9 H-9 Torque converter oil pressure is low 9 H-9 Machine starts or gear speed shifts with long time lag 9
10 H-10 Front brake is ineffective 10 H-10 Torque converter oil temperature is high 10
11 H-11 Rear brake is ineffective 11 H-11 Torque converter oil pressure is low 11
12 E-1 Engine does not start 12 H-12 Front brake does not work sufficiently 12
13 E-2 Automatic preheating does not operate 13 H-13 Center brake does not work sufficiently 13
14 E-3 Machine monitor does not display all, when starting switch is turned ON 14 Failure code [2F00KM] Dragging of Parking Brake 14
15 E-4 Machine monitor does not operate when starting switch is OFF 15 Failure code [AA10NX] Air Cleaner Clogging 15
16 E-5 Alarm buzzer does not sound 16 Failure code [AB00KE] Charge Voltage Low 16
17 E-6 Alarm buzzer does not stop sounding 17 Failure code [AB00KY] Hot Short of Alternator R Terminal 17
18 E-7 Gauges of machine monitor, caution lamps or character display section do not display properly 18 Failure code [B@BAZK] Engine Oil Level Low 18
19 E-8 A selection of the display in character display section cannot be changed 19 Failure code [B@BCZK] Eng Water Level Low 19
20 E-9 Power mode selecting function does not operate properly 20 Failure code [CA122] Chg Air Press Sensor High Error 20
21 E-10 AISS function does not operate properly 21 Failure code [CA131] Throttle Sensor High Error 21
22 E-11 Seat belt caution lamp does not display properly 22 Failure code [CA144] Coolant Temp Sens High Error 22
23 E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly 23 Failure code [CA221] Ambient Press Sensor High Error 23
24 E-13 Night illumination (lighting) does not work properly 24 Failure code [CA238] Ne Speed Sensor Supply Volt Error 24
25 E-14 Emergency steering does not operate 25 Failure code [CA451] Rail Press Sensor High Error 25
26 E-15 Hoist lever does not operate normally 26 Failure code [CA689] Eng Ne Speed Sensor Error 26
 KOMPETENSI KOMPETENSI KOMPETENSI
GD_KOMATSU (ref.825A-2 ) 0 1 2 3
KETERANGAN WA_KOMATSU (ref. WA480-6 ) 0 1 2 3
KETERANGAN CM_BOMAG (ref. ) 0 1 2 3
KETERANGAN

Menyebutkan lokasi, langkah kerja, model, jumlah, tools & standar yang digunakan : Menyebutkan lokasi, langkah kerja, model, jumlah, tools & standar yang digunakan : (ref. WA480-6 ) Menyebutkan lokasi, langkah kerja, model, jumlah, tools & standar yang digunakan : ###
1 Clean inside of cooling system 1 Clean, replace air cleaner element 1 ###
2 Reverse and replace the end bits and cutting edges 2 Clean inside of cooling system 2
3 Replacing ripper point 3 Clean air conditioner condenser (if equipped) 3
4 Check inching pedal 4 Clean radiator fins and cooler fins 4
5 Change oil in engine oil pan, replace engine oil filter cartridge 5 Turn, replace bolt-on cutting edge 5
6 Check ball joint clearance, adjust 6 Replace bucket teeth 6
7 Replace fuel filter cartridge 7 Replace slow blow fuse 7
8 Check circle guide clearance, adjust 8 Checking function of accumulator 8
9 Check parking brake level stroke, adjust 9 Clean, replace fuel breather filter 9
10 Check, adjust slip load for dry-type clutch for blade rotation gear 10 Clean element in air conditioner fresh / recirculation air filter (if equipped) 10
11 Replace transmission oil filter element 11 Change oil in engine oil pan, replace engine oil filter cartridge 11
12 Change oil in transmission case, clean strainer 12 Replace fuel pre-filter cartridge 12
13 Change oil in final drive case, clean strainer 13 Replace fuel main filter cartridge 13
PERIODIC SERVICE

PERIODIC SERVICE

PERIODIC SERVICE
14 Replace return filter element and clean suction strainer in hydraulic tank 14 Change oil in transmission case and transmission oil filter cartridge, clean strainer 14
15 Change oil in hydraulic tank 15 Clean transmission case breather 15
16 Check looseness in drawbar front ball joint and ball stud 16 Check of engine air intake piping clamps for looseness 16
17 Check toe-in, adjust 17 Change oil in hydraulic tank, replace hydraulic filter element 17
18 Check front wheel bearing play, adjust -- 18 Replace hydraulic tank breather element -- 18 --
19 Replacing air dryer desiccant 19 Check brake disc wear 19
20 Change oil in front wheel bearing 20 Check alternator 20
21 Change oil in circle reverse gear case 21 Check engine valve clearance, adjust 21
22 Change oil in tandem drive case 22 Check vibration damper 22
23 Clean and inspect inching potentiometer sensor 23 Check water pump 23
24 Check alternator, starting motor 24 Check for loose engine high-pressure piping clamps, hardening of rubber 24
25 Check engine valve clearance, adjust 25 Checking for missing fuel spray prevention cap, hardening of rubber 25
26 Check all tightening parts of turbocharger 26 Check starting motor 26
27 Check play of turbocharger rotor 27 -- 27
28 Clean, check turbocharger 28 -- 28
29 Check water pump 29 -- 29
30 Check vibration damper 30 -- 30
31 Check fan pulley and tension pulley 31 -- 31
32 -- 32 -- 32
33 -- 33 -- 33
34 -- 34 -- 34
35 -- 35 -- 35
Menyebutkan lokasi, langkah kerja, model, jumlah, tools & standar yang digunakan : Menyebutkan lokasi, langkah kerja, model, jumlah, tools & standar yang digunakan : (ref. WA480-6 ) Menyebutkan lokasi, langkah kerja, model, jumlah, tools & standar yang digunakan : ###
1 Check, clean and replace air cleaner element 1 Check, clean air cleaner element 1 ###
2 Clean element of air conditioner fresh/recirculation air filter 2 Check transmission oil level, add oil 2
3 Check refrigerant (gas) level 3 Check axle oil level, add oil 3
4 Lubricating 4 Clean axle case breather 4
5 Inspect wear of blade guide 5 Check window washing fluid level, add fluid 5
PERIODIC INSPECTION

PERIODIC INSPECTION

PERIODIC INSPECTION
6 Check oil level in transmission case, add oil 6 Check radiator fins and cooler fins 6
7 Check oil level in final drive case, add oil 7 Check air conditioner (if equipped) 7
8 Check oil level in tandem drive case, add oil 8 Drain water, sediment from fuel tank 8
9 Check oil level in circle reverse gear case, add oil 9 Lubricate rear axle pivot pin 9
10 Check oil level in hydraulic tank, add oil
11 Check level of battery electrolyte -- 10 Check oil level in hydraulic tank, add oil
11 Check battery electrolyte level -- 10
11 --
12 Check fan / alternator / ac belt tension, adjust 12 Check parking brake 12
13 Check, adjust foot brake 13 Check alternator belt tension, adjust 13
14 Clean, check radiator fins 14 Check air conditioner compressor belt tension, adjust (if equipped) 14
15 -- 15 Check for loose wheel hub bolts, tighten 15
16 -- 16 -- 16
17 -- 17 -- 17
18 -- 18 -- 18
19 -- 19 -- 19
20 -- 20 -- 20
Menjelaskan metode pengujuan & tools yang digunakan pada pekerjaan berikut : Menjelaskan metode pengujuan & tools yang digunakan pada pekerjaan berikut : (ref. WA480-6 ) Menjelaskan metode pengujuan & tools yang digunakan pada pekerjaan berikut : ###
1 RPM Engine High/low idling speed 1 Engine speed High idle (E/P-mode) / LOW idle (E/P-mode) 1 ###
2 Boost pressure 2 Exhaust temperature 2
3 Exhaust temperature 3 Boost pressure 3
4 Compression pressure 4 Exhaust gas color 4
5 Blow-by pressure 5 Blow-by pressure 5
6 Engine Oil pressure 6 Directional lever - Operating effort / travel (stroke) 6
7 Fuel injection timing 7 Steering wheel - Play / Operating effort / Turns (Not including play) / Operating time 7
MACHINE CONDITON INSPECTION

MACHINE CONDITON INSPECTION

MACHINE CONDITON INSPECTION

8 Operating effort of accelarator pedal / fuel control lever 8 Clearance between front frame and rear frame 8
9 Travel(stroke) of accelarator pedal / fuel control lever 9 Brake pedal - Pressing effort / Pressing angle / Play 9
10 Inching pedal height / operating effort / travel (stroke) 10 Engine Speed - Torque converter stall / Hydraulic stall / Full stall 10
11 Gear shifting lever operting effort / travel (stroke) 11 Transmission, torque converter - Main relief pressure / Torque converter relief (inlet) oil pressure 11
12 Slippage of transmission 12 Steering relief pressure / Steering control pressure 12
13 Transmission valve main oil pressure 13 Accumulator Charge cut-in / cut-out pressure 13
14 Transmission valve lubricating oil pressure 14 Wheel brake - Brake oil pressure/Lowering of brake oil pressure 14
15 Transmission valve pilot oil pressure
16 Differential lock oil pressure -- 15 Wheel brake - Disc wear/Performance
16 Parking brake solenoid valve basic pressure / Parking brake oil pressure -- 15
16 --
17 Steering
Play of steering
Turningwheel
angle 17 Parking brake - Disc thickness / Performance 17
18 (lock-to-lock) 18 PPC valve basic pressure 18
19 Operating effort of steering wheel 19 PPC valve output pressure (Lift arm RAISE, FLOAT, Bucket DUMP/TILT)/(Lift arm LOWER) 19
20 Runout of tires 20 Work equipment relief pressure 20
21 Wheel Camber / Toe - in / linning angel 21 Work equipment Unload pressure 21
22 Priority flow divider relier valve 22 Work equipment LS differential pressure 22
23 Operating effort of brake pedal 23 Work equipment speed - Lift arm RAISE / Lowwer 23
24 Braking performance stoping distance 24 Work equipment speed (Bucket full stroke Forward/Backward) 24
25 Braking performance Parking brake holding performance 25 Work equipment speed - Moving bucket from level position 25
26 Blade lifting speed / Blade side shift speed with movement of circle / Ripper lifting speed 26 Hydraulic drift (Retraction of lift arm /bucket cylinder rod ) 26
27 Blade side shift speed compared to circle / Blade rotation speed 27 Hydraulic drive fan (Fan drive pressure / Fan reverse solenoid output pressure) 27
28 Priority valve relief pressure 28 Hydraulic drive fan Max./Min. fan speed 28
29 Main control valve relief pressure 29 -- 29
30 Hydraulic drift of blade / of chassis when up with blade / of ripper / of chassis when pushed up with ripper 30 -- 30
Lokasi & fungsi dari komponen berikut : Lokasi & fungsi dari komponen berikut : (ref. WA480-6 ) Lokasi & fungsi dari komponen berikut : ###
1 Steering valve 1 Cooling fan pump / motor 1 ###
2 Double relief valve 2 Steering relief valve 2
3 Emergency steering system 3 Overload relief valve (Operation as relief valve/suction valve) 3
4 Hydraulic pump 4 Orbit-roll valve 4
5 Priority flow divider valve 5 Work equipment pump 5
6 Surge pressure absorbing valve 6 LS / PC valve 6
7 Hydraulic control valve 7 PC-EPC valve 7
8 Pilot check valve (for blade lift r.h.) 8 Pressure compensation valve 8
9 Pilot check valve (for articulate, leaning and drawbar) 9 ECSS control valve 9
10 Pilot check valve (with safety valve) (for blade lift l.h.) 10 Accumulator charge valve 10
11 Circle rotation motor 11 PPC valve 11
12 Accumulator 12 Accumulator (for PPC circuit / ECSS / Brake) 12
13 Circle rotation gear 13 Bucket positioner 13
14 -- 14 Boom kick-out 14
REMOVE INSTALL 1

REMOVE INSTALL 1

REMOVE INSTALL 1
15 -- 15 proximity switch 15
16 -- 16 -- 16
17 -- 17 -- 17
18 -- 18 -- 18
19 -- -- 19 -- -- 19 --
20 -- 20 -- 20
Menjelaskan langkah pelaksanaan, Critical point, & alat angkat pada pekerjaan : Menjelaskan langkah pelaksanaan, Critical point, & alat angkat pada pekerjaan : (ref. WA480-5 ) Menjelaskan langkah pelaksanaan, Critical point, & alat angkat pada pekerjaan : ###
1 Removal & install of nozzle holder assembly 1 Fuel supply pump assembly 1 ###
2 Removal & install of fuel injection pump assembly 2 Fuel injector assembly 2
3 Removal & install of water pump assembly 3 Steering, switch pump, cooling fan drive pump assembly 3
4 Removal & install of engine oil cooler core assembly 4 Torque converter charge, work equipment and ppc pump assembly 4
5 Removal & install of turbo charger assembly 5 Work equipment valve assembly 5
6 Removal & install of cylinder head assembly 6 Hydraulic tank 6
7 Removal & install of engine assembly (incl. Transmission) 7 Steering valve assembly 7
8 Removal & install of hydraulic tank 8 -- 8
9 Removal & install of hydraulic pump assembly 9 -- 9
10 Removal & install of hydraulic control valve 10 -- 10
11 Removal & install of drawbar shift cylinder, blade lift cylinder, lifter guide 11 -- 11
12 -- 12 -- 12
13 -- 13 -- 13
14 -- 14 -- 14
15 -- 15 -- 15
Lokasi & fungsi dari komponen berikut : Lokasi & fungsi dari komponen berikut : (ref. WA480-6 ) Lokasi & fungsi dari komponen berikut : ###
1 Priority valve 1 Transmission 1 ###
2 Pilot reducing valve 2 Flow control valve 2
3 Modulating valve and quick return valve 3 Transmission control valve / Electronic Control Modulation Valve 3
4 Oil cooler bypass valve 4 Main relief valve and torque converter relief valve 4
5 Transmission solenoid valve 5 Limited slip differential (If equipped) 5
6 Emergency spool 6 Steering / Power train pump 6
7 Inching valve (inching valve with modulating valve) 7 Servo valve 7
8 Final drive 8 Emergency steering motor / pump 8
9 Tandem drive 9 Charge valve 9
10 Parking brake 10 Brake valve 10
11 Air drier / governor 11 Slack adjuster 11
12 Automatic drain valve 12 Emergency parking brake release valve 12
13 Brake valve 13 Machine monitor system 13
14 Electronic vehicle monitoring system (evms) / monel 14 Electric transmission control (Controller) 14
REMOVE INSTALL 2

REMOVE INSTALL 2

REMOVE INSTALL 2

15 Transmission controller 15 Speed sensor 15

16 Engine oil pressure switch 16 Steering pump oil pressure sensor 16
17 Engine speed sensor 17 Transmission cut-off oil pressure sensor 17
18 Inching potentiometer 18 Accelerator pedal sensor 18
19 -- -- 19 -- -- 19 --
20 -- 20 -- 20
Menjelaskan langkah pelaksanaan, Critical point, & alat angkat pada pekerjaan : Menjelaskan langkah pelaksanaan, Critical point, & alat angkat pada pekerjaan : (ref. WA480-5 ) Menjelaskan langkah pelaksanaan, Critical point, & alat angkat pada pekerjaan : ###
1 Removal & install of starting motor / alternator assembly 1 Torque converter, transmission assembly 1 ###
2 Transmission 2 Rear axle assembly 2
3 Hydroshift transmission pump 3 Center hinge pin 3
4 Tandem and final drive 4 Ecss assembly 4
5 Front axle 5 Parking brake disk 5
6 Air tank 6 Work equipment assembly 6
7 Blade 7 Cab assembly 7
8 Circle and drawbar 8 Cab, floor frame assembly 8
9 Removal & install of circle rotation gear and hydraulic oil motor 9 Operator’s cab glass 9
10 Removal & install of articulate cylinder 10 -- 10
11 -- 11 -- 11
12 -- 12 -- 12
13 -- 13 -- 13
14 -- 14 -- 14
15 -- 15 -- 15
Fungsi & cara kerja dari komponen berikut : Fungsi & cara kerja dari komponen berikut : (ref. WA480-6 ) Fungsi & cara kerja dari komponen berikut : ###
1 Steering valve 1 Cooling fan pump / motor 1 ###
2 Double relief valve 2 Steering relief valve 2
3 Emergency steering system 3 Overload relief valve (Operation as relief valve/suction valve) 3
4 Hydraulic pump 4 Orbit-roll valve 4
5 Priority flow divider valve 5 Work equipment pump 5
6 Surge pressure absorbing valve 6 LS / PC valve 6
7 Hydraulic control valve 7 PC-EPC valve 7
8 Pilot check valve (for blade lift r.h.) 8 Pressure compensation valve 8
9 Pilot check valve (for articulate, leaning and drawbar) 9 ECSS control valve 9
10 Pilot check valve (with safety valve) (for blade lift l.h.) 10 Accumulator charge valve 10
11 Circle rotation motor 11 PPC valve 11
12 Accumulator 12 Accumulator (for PPC circuit / ECSS / Brake) 12
13 Circle rotation gear 13 Bucket positioner 13
14 -- 14 Boom kick-out 14
15 -- 15 proximity switch 15
16 -- 16 -- 16
17 -- 17 -- 17
18 -- 18 -- 18
TROUBLE SHOOTING 1

TROUBLE SHOOTING 1

TROUBLE SHOOTING 1

19 -- 19 -- 19
20 -- 20 -- 20
Menjelaskan kemungkinan penyebab, metode pengujian & tools yang digunakan : Menjelaskan kemungkinan penyebab, metode pengujian & tools yang digunakan : (ref. WA480-6 ) Menjelaskan kemungkinan penyebab, metode pengujian & tools yang digunakan : ###
1 H-1 Abnormal noise is made (from around pump). 1 S-8 Oil is consumed much (or exhaust gas color is blue) 1 ###
2 H-2 Relief sound is heard (when not operating).
3 H-3 Hydraulic oil overheats (when not operating).
-- 2 S-9 Engine oil becomes contaminated quickly
3 S-10 Fuel consumption is excessive
-- 2
3
--
4 H-4 Work equipment does not move when control lever is operated (steering at neutral). 4 S-11 Coolant contains oil (blows back or reduces) 4
5 H-5 Work equipment is slow, lacks power. 5 S-12 Oil pressure drops 5
6 H-6 There is excessive hydraulic drift of work equipment. 6 S-13 Oil level rises (Water, fuel in oil) 6
7 H-7 Steering wheel does not turn (work equipment at neutral). 7 S-14 Coolant temperature rises too high (Overheating) 7
8 H-8 Turning speed is slow, lacks power (work equipment at neutral). 8 S-15 Abnormal noise is made 8
9 H-9 Feeling when operating steering wheel is strange. 9 S-16 Vibration is excessive 9
10 S-1 Starting performance is poor (Starting always takes time) 10 H-20 Lift arm speed is low or rising force of lift arm is insufficient 10
11 S-2 Engine does not start 11 H-21 When rising, the lift arm comes to move slowly at specific height 11
12 S-3 Engine does not pick up smoothly (Follow-up is poor) 12 H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats) 12
13 S-4 Engine stops during operations 13 H-23 Hydraulic drifts of the lift arm is large 13
14 S-5 Engine does not rotate smoothly (hunting) 14 H-24 The lift arm wobbles during operation 14
15 S-6 Engine lacks output (no power) 15 H-25 Bucket does not tilt back 15
16 S-7 Exhaust gas is black (incomplete combustion) 16 H-26 Bucket speed is low or tilting back force is insufficient 16
17 S-8 Oil consumption is excessive (or exhaust gas is blue) 17 H-27 The bucket comes to operate slowly in the midst of tilting-back 17
18 S-9 Oil becomes contaminated quickly 18 H-28 The bucket cylinder cannot hold down the bucket 18
19 S-10 Fuel consumption is excessive 19 H-29 Hydraulic drifts of the bucket is large 19
20 S-11 Oil is in cooling water, or water spurts back, or water level goes down 20 H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”) 20
21 S-12 Oil pressure lamp lights up (drop in oil pressure) 21 H-31 Lift arm and bucket control levers do not move smoothly and are heavy 21
22 S-13 Oil level rises 22 H-32 During operation of the machine, engine speed lowers remarkably or engine stalls 22
23 S-14 Water temperature becomes too high (overheating) 23 H-33 Large shock is made when work equipment starts and stops 23
24 S-15 Abnormal noise is made 24 H-34 When work equipment circuit is relieved singly, other work equipment moves 24
25 S-16 Vibration is excessive 25 H-35 ECSS does not operate, and pitching, bouncing occur 25
Fungsi & cara kerja dari komponen berikut : Fungsi & cara kerja dari komponen berikut : (ref. WA480-6 ) Fungsi & cara kerja dari komponen berikut : ###
1 Priority valve 1 Transmission 1 ###
2 Pilot reducing valve 2 Flow control valve 2
3 Modulating valve and quick return valve 3 Transmission control valve / Electronic Control Modulation Valve 3
4 Oil cooler bypass valve 4 Main relief valve and torque converter relief valve 4
5 Transmission solenoid valve 5 Limited slip differential (If equipped) 5
6 Emergency spool 6 Steering / Power train pump 6
7 Inching valve (inching valve with modulating valve) 7 Servo valve 7
8 Final drive 8 Emergency steering motor / pump 8
9 Tandem drive 9 Charge valve 9
10 Parking brake 10 Brake valve 10
11 Air drier / governor 11 Slack adjuster 11
12 Automatic drain valve 12 Emergency parking brake release valve 12
13 Brake valve 13 Machine monitor system 13
14 Electronic vehicle monitoring system (evms) / monel 14 Electric transmission control (Controller) 14
15 Transmission controller 15 Speed sensor 15
16 Engine oil pressure switch 16 Steering pump oil pressure sensor 16
17 Engine speed sensor 17 Transmission cut-off oil pressure sensor 17
18 Inching potentiometer 18 Accelerator pedal sensor 18
19 -- 19 -- 19
TROUBLE SHOOTING 2

TROUBLE SHOOTING 2

TROUBLE SHOOTING 2

20 -- 20 -- 20
Menjelaskan kemungkinan penyebab, metode pengujian & tools yang digunakan : Menjelaskan kemungkinan penyebab, metode pengujian & tools yang digunakan : (ref. WA480-6 ) Menjelaskan kemungkinan penyebab, metode pengujian & tools yang digunakan : ###
1 M-1 when starting switch is turned on, monitor panel display does not appear 1 Failure code [2F00MA] (Parking brake: Malfunction) 1 ###
2 M-3 when starting switch is turned on (engine stopped), 2 Failure code [2G43ZG] (Accumulator: Low oil pressure) 2
3 E-1 engine does not start (starting motor works). -- 3 Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) -- 3 --
4 E-2 starting motor does not turn. 4 Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine) 4
5 E-3 parking brake does not work 5 Failure code [B@BAZK] (Engine oil: Low level) 5
6 E-4 parking brake cannot be release 6 Failure code [B@BCNS] (Coolant: Overheating) 6
7 E-5 speed range does not change when transmission lever is switched between fi and f8 / r1 and r8 7 Failure code [b@CENS] (Torque converter oil: Overheating) 7
8 E-6 transmission does not shift to 1st (f and r) 8 Failure code [CA111] (Abnormality in engine controller) 8
9 E-7 transmission does not shift to 2nd (f and r) 9 Failure code [CA122] (Charge pressure sensor high error) 9
10 E-8 transmission does not shift to 3rd (f and r) 10 Failure code [CA131] (Throttle sensor high error) 10
11 E-9 transmission does not shift to 4th (f and r) 11 Failure code [CA135] (Engine oil pressure sensor high error) 11
12 E-10 transmission does not shift to 5th (f and r) 12 Failure code [CA227] (Sensor power supply 2 high error) 12
13 E-11 transmission does not shift to 6th (f and r) 13 Failure code [CA238] (Ne speed sensor power supply error) 13
14 E-12 transmission does not shift to 7th (f and r) 14 Failure code [CA351] (Injectors drive circuit error) 14
15 E-13 transmission does not shift to 8th (f and r) 15 Failure code [CA386] (Sensor power supply 1 high error) 15
16 -- 16 Failure code [CA432] (Idle validation action error) 16
17 -- 17 Failure code [CA442] (Battery voltage high error) 17
18 -- 18 Failure code [CA689] (Engine Ne speed sensor error) 18
19 -- 19 Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) 19
20 -- 20 Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) 20
21 -- 21 Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection) 21
22 -- 22 Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line) 22
23 -- 23 Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection) 23
24 -- 24 Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) 24
25 -- 25 Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection) 25
26 -- 26 Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time) 26
 KOMPETENSI KOMPETENSI KOMPETENSI
DT_MERCY (ref. ) 0 1 2 3
KETERANGAN DT_VOLVO (ref. ) 0 1 2 3
KETERANGAN DT_SCANIA (ref. ) 0 1 2 3
KETERANGAN

Menyebutkan lokasi, langkah kerja, model, jumlah, tools & standar yang digunakan : Menyebutkan lokasi, langkah kerja, model, jumlah, tools & standar yang digunakan : Menyebutkan lokasi, langkah kerja, model, jumlah, tools & standar yang digunakan : ###
1 Change oil in engine oil pan, replace engin oil filter 1 Change oil in engine oil pan, replace engin oil filter 1 Change oil in engine oil pan, replace engine oil filter ###
2 Change oil in transfer gearbox & replace transfer gearbox oil filter 2 Change oil in transfer gearbox & replace transfer gearbox oil filter 2 Change oil in transfer gearbox & replace transfer gearbox oil filter
3 Change oil in rear & front axle 3 Change oil in rear & front axle 3 Change oil in rear, front axle & change filter
4 Change oil in final drive 4 Change oil in final drive 4 Change oil in final drive
5 Replace main fuel filter & water sparator 5 Replace main fuel filter & water sparator 5 Replace main fuel filter & water sparator
6 Replace steering oil filter 6 Replace steering oil filter 6 Replace steering oil filter
7 Clean fuel screen 7 Clean fuel screen 7 Clean fuel screen
8 Chenge air cleaner 8 Chenge air cleaner 8 Chenge air cleaner
9 Bleeding air from clutch system 9 Bleeding air from clutch system 9 Bleeding air from clutch system
10 Replace fan belt 10 Replace fan belt 10 Replace fan belt
11 Adjust brake linning 11 Adjust brake linning 11 Adjust brake linning
12 Change air drier 12 Change air drier 12 Change air drier
13 Change hydraulic oil 13 Change hydraulic oil 13 Change hydraulic oil
PERIODIC SERVICE

PERIODIC SERVICE

PERIODIC SERVICE
14 Replace fuel tank ventilation 14 Replace fuel tank ventilation 14 Replace fuel tank ventilation
15 Check propeller shaft 15 Check propeller shaft 15 Check propeller shaft
16 Adjust toe in & out 16 Adjust toe in & out 16 Adjust toe in & out
17 Bleeding air from fuel circuit 17 Bleeding air from fuel circuit 17 Bleeding air from fuel circuit
18 Check alternator -- 18 Check alternator -- 18 Check alternator --
19 Check starting motor 19 Check starting motor 19 Check starting motor
20 Check water pump 20 Check water pump 20 Check water pump
21 Check gasket exhaust manifold 21 Check gasket exhaust manifold 21 Check gasket exhaust manifold
22 Check ball joint in steering system 22 Check ball joint in steering system 22 Check ball joint in steering system
23 Check steering link system 23 Check steering link system 23 Check steering link system
24 Check intrument function 24 Check intrument function 24 Check intrument function
25 Check front wheel bearing 25 Check front wheel bearing 25 Check front wheel bearing
26 Check Iintake manifold 26 Check Iintake manifold 26 Check Iintake manifold
27 Check cabin suspention 27 Check cabin suspention 27 Check cabin suspention
28 Check anti-roll bar 28 Check anti-roll bar 28 Check anti-roll bar
29 Drain water in water sparator 29 Drain water in water sparator 29 Change sentrifugal filter
30 Check front shock absorbers 30 Check front shock absorbers 30 Check front shock absorbers
31 Check exhaust manifold 31 Check exhaust manifold 31 Check exhaust manifold
32 Check oil level in tilt pump 32 Check oil level in tilt pump 32 Check oil level in tilt pump
33 Check cab tilt, hydraulic cylinder 33 Check cab tilt, hydraulic cylinder 33 Check cab tilt, hydraulic cylinder
34 Check cab shock absorbers 34 Check cab shock absorbers 34 Check cab shock absorbers
35 -- 35 Mode Hybernate 35 Check rear stabilizer
Menyebutkan lokasi, langkah kerja, model, jumlah, tools & standar yang digunakan : Menyebutkan lokasi, langkah kerja, model, jumlah, tools & standar yang digunakan : Menyebutkan lokasi, langkah kerja, model, jumlah, tools & standar yang digunakan : ###
1 Check engine oil level 1 Check engine oil level 1 Check engine oil level ###
2 Check fluid level in clutch fluid reservoir 2 Check fluid level in clutch fluid reservoir 2 Check fluid level in clutch fluid reservoir
3 Check coolant fluid level 3 Check coolant fluid level 3 Check coolant fluid level
4 Check oil level in transfer gearbox 4 Check oil level in transfer gearbox 4 Check oil level in transfer gearbox
5 Check oil level in final drive 5 Check oil level in final drive 5 Check oil level in final drive
PERIODIC INSPECTION

PERIODIC INSPECTION

PERIODIC INSPECTION
6 Check oil level in rear differential 6 Check oil level in rear differential 6 Check oil level in rear differential
7 Check oil level in front differential 7 Check oil level in front differential 7 Check oil level in front differential
8 Check level of window washer fluid, add fluid 8 Check level of window washer fluid, add fluid 8 Check level of window washer fluid, add fluid
9 Check fluid level in steering fluid reservoir 9 Check fluid level in steering fluid reservoir 9 Check fluid level in steering fluid reservoir
10 Check level of battery electrolyte
11 Check rear axle ventilation -- 10 Check level of battery electrolyte
11 Check rear axle ventilation -- 10 Check level of battery electrolyte
11 Check rear axle ventilation --
12 Check air conditioner air filter 12 Check air conditioner air filter 12 Check air conditioner air filter
13 Check spring and U-Bolt 13 Check spring and U-Bolt 13 Check spring and U-Bolt
14 Check chassis frame and crossmembers 14 Check chassis frame and crossmembers 14 Check chassis frame and crossmembers
15 Check brake linning 15 Check brake linning 15 Check brake linning
16 Check bogie lift 16 Check bogie lift 16 Grease turnion
17 Grease steering system 17 Grease steering system 17 Grease steering system
18 Grease shaft brake 18 Grease shaft brake 18 Grease shaft brake
19 Grease pin spring 19 Grease pin spring 19 Grease pin spring
20 Grease tail gate 20 Grease tail gate 20 Grease tail gate
Menjelaskan metode pengujuan & tools yang digunakan pada pekerjaan berikut : Menjelaskan metode pengujuan & tools yang digunakan pada pekerjaan berikut : Menjelaskan metode pengujuan & tools yang digunakan pada pekerjaan berikut : ###
1 Coolant temperature 1 Coolant temperature 1 Coolant temperature ###
2 Oil temperature 2 Oil temperature 2 Oil temperature
3 Oil pressure engine 3 Oil pressure engine 3 Oil pressure engine
4 Engine speed at low idle and high idle 4 Engine speed at low idle and high idle 4 Engine speed at low idle and high idle
5 Feed pressure (check & set engine speed at low idle & high idle) 5 Feed pressure (check & set engine speed at low idle & high idle) 5 Feed pressure (check & set engine speed at low idle & high idle)
6 Crank case pressure 6 Crank case pressure 6 Crank case pressure
7 Air temperature 7 Air temperature 7 Air temperature
MACHINE CONDITON INSPECTION

MACHINE CONDITON INSPECTION

MACHINE CONDITON INSPECTION

8 Fan speed 8 Fan speed 8 Fan speed
9 Cylinder compression 9 Cylinder compression 9 Cylinder compression
10 Fuel consumption 10 Fuel consumption 10 Fuel consumption
11 Turbine axial play 11 Turbine axial play 11 Turbine axial play
12 Toe in & toe out 12 Toe in & toe out 12 Toe in & toe out
13 King pin play 13 King pin play 13 King pin play
14 Clutch wear 14 Clutch wear 14 Clutch wear
15 Bogie lift play
16 Axial play V-stay -- 15 Bogie lift play
16 Axial play V-stay -- 15 Bogie lift play
16 -- --
17 Tachograph 17 Tachograph 17 --
18 Anti roll-bar play 18 Anti roll-bar play 18 --
19 -- 19 -- 19 --
20 -- 20 -- 20 --
21 -- 21 -- 21 --
22 -- 22 -- 22 --
23 -- 23 -- 23 --
24 -- 24 -- 24 --
25 -- 25 -- 25 --
26 -- 26 -- 26 --
27 -- 27 -- 27 --
28 -- 28 -- 28 --
29 -- 29 -- 29 --
30 -- 30 -- 30 --
Lokasi & fungsi dari komponen berikut : Lokasi & fungsi dari komponen berikut : Lokasi & fungsi dari komponen berikut : ###
1 Leaf spring 1 Leaf spring 1 Water pump ###
2 U-bolt 2 U-bolt 2 Anti roll-bar
3 Brake linning 3 Brake linning 3 U-bolt & spring
4 Steering pump 4 Steering pump 4 Power steering pump
5 Shock absorbers rear 5 Shock absorbers rear 5 Shock absorbers rear
6 Reaction rod 6 Reaction rod 6 Torque rod
7 Power steering cylinder 7 Power steering cylinder 7 Power steering cylinder
8 Cooling fan 8 Cooling fan 8 Cooling fan
9 Brake chamber 9 Brake chamber 9 Brake cylinder/brake chamber
10 Propeller shaft 10 Propeller shaft 10 Brake linning
11 King pin 11 King pin 11 King pin
12 Hollow spring/rubber spring 12 Hollow spring/rubber spring 12 Hollow spring/rubber spring
13 V-stay 13 V-stay 13 Intake manifold
14 Support bearing 14 Support bearing 14 Support bearing
REMOVE INSTALL 1

REMOVE INSTALL 1

REMOVE INSTALL 1
15 Ball joint 15 Ball joint 15 Ball joint
16 Pitman arm 16 Pitman arm 16 Pitman arm
17 Cab shock absorbers rear 17 Cab shock absorbers rear 17 Cab shock absorbers rear
18 Cab shock absorbers 18 Cab shock absorbers 18 Cab shock absorbers
19 Cab tilt pump -- 19 Cab tilt pump -- 19 Cab tilt pump --
20 Battery 20 Battery 20 Propeller shaft
Menjelaskan langkah pelaksanaan, Critical point, & alat angkat pada pekerjaan : Menjelaskan langkah pelaksanaan, Critical point, & alat angkat pada pekerjaan : Menjelaskan langkah pelaksanaan, Critical point, & alat angkat pada pekerjaan : ###
1 Remove And installation of Cab tilt Cylinder 1 Remove And installation of Cab tilt Cylinder 1 Remove And installation of Water pump ###
2 Remove And installation of Anti roll-bar 2 Remove And installation of Anti roll-bar 2 Remove And installation of Anti roll-bar
3 Remove And installation of Cab shock absorbers rear 3 Remove And installation of Cab shock absorbers rear 3 Remove And installation of Radiator
4 Remove And installation of Steering pump 4 Remove And installation of Steering pump 4 Remove And installation of Power steering pump
5 Remove And installation of Shock absorbers 5 Remove And installation of Shock absorbers 5 Remove And installation of Shock absorbers
6 Remove And installation of Hollow spring/rubber spring 6 Remove And installation of Hollow spring/rubber spring 6 Remove And installation of Hollow spring/rubber spring
7 Remove And installation of Power steering cylinder 7 Remove And installation of Power steering cylinder 7 Remove And installation of Power steering cylinder
8 Remove And installation of Cooling fan 8 Remove And installation of Cooling fan 8 Remove And installation of Cooling fan
9 Remove And installation of Brake cylinder/brake chamber 9 Remove And installation of Brake cylinder/brake chamber 9 Remove And installation of Brake cylinder/brake chamber
10 Remove And installation of Brake linning 10 Remove And installation of Brake linning 10 Remove And installation of Brake linning
11 Remove And installation of King pin 11 Remove And installation of King pin 11 Remove And installation of King pin
12 Remove And installation of Reaction rod 12 Remove And installation of Reaction rod 12 Remove And installation of Reaction rod
13 Remove And installation of V-stay 13 Remove And installation of V-stay 13 Remove And installation of Torque rod
14 Remove And installation of Support bearing 14 Remove And installation of Support bearing 14 Remove And installation of Support bearing
15 Remove And installation of Pitman arm 15 Remove And installation of Pitman arm 15 Remove And installation of Pitman arm
Lokasi & fungsi dari komponen berikut : Lokasi & fungsi dari komponen berikut : Lokasi & fungsi dari komponen berikut : ###
1 Power steering gearbox 1 Power steering gearbox 1 Power steering gearbox ###
2 Radiator 2 Radiator 2 Radiator
3 EBS control Unit 3 EBS control Unit 3 Feed pump
4 Relay valve parking brake 4 Relay valve parking brake 4 Relay valve parking brake
5 Proportioning relay valve 5 APM 5 APS
6 Clutch Gearbox transmision 6 Clutch Gearbox transmision 6 Clutch Gearbox transmision
7 Turbo Charger 7 Turbo Charger 7 Turbo Charger
8 Bogie lift 8 Bogie lift 8 Bogie lift
9 Gearbox transmision 9 Gearbox transmision 9 Gearbox transmision
10 Quick release valve 10 Quick release valve 10 Quick release valve
11 Solenoid valve ABS 11 Solenoid valve ABS 11 Solenoid valve ABS
12 Axle modulator 12 Clutch Valve Unit CVU 12 Hydraulic Pump
13 ASR 13 Air Valve Unit AVU 13 Cab tilt hydraulic cylinder
14 Feed pump 14 Feed pump 14 Speed sensor
REMOVE INSTALL 2

REMOVE INSTALL 2

REMOVE INSTALL 2

15 Air drier 15 Load sensing valve 15 Flywheel sensor

16 Hydraulic Pump 16 Hydraulic Pump 16 Wheel speed sensor
17 Cab tilt hydraulic cylinder 17 Cab tilt hydraulic cylinder 17 Differential
18 Speed sensor 18 Speed sensor 18 Final drive
19 Flywheel sensor -- 19 Flywheel sensor -- 19 ECA --
20 Wheel speed sensor 20 Wheel speed sensor 20 TC Valve
Menjelaskan langkah pelaksanaan, Critical point, & alat angkat pada pekerjaan : Menjelaskan langkah pelaksanaan, Critical point, & alat angkat pada pekerjaan : Menjelaskan langkah pelaksanaan, Critical point, & alat angkat pada pekerjaan : ###
1 Remove And installation of Power steering gearbox 1 Remove And installation of Power steering gearbox 1 Remove And installation of Power steering gearbox ###
2 Remove And installation of Axle modulator 2 Remove And installation of Control Unit CCIOM 2 Remove And installation of Coordinator
3 Remove And installation of EBS control Unit 3 Remove And installation of EBS control Unit 3 Remove And installation of EBS control Unit
4 Remove And installation of Relay valve parking brake 4 Remove And installation of Relay valve parking brake 4 Remove And installation of Relay valve parking brake
5 Remove And installation of Air drier 5 Remove And installation of APM 5 Remove And installation of APS
6 Remove And installation of Clutch Gearbox transmision 6 Remove And installation of Clutch Gearbox transmision 6 Remove And installation of Clutch Gearbox transmision
7 Remove And installation of Turbo Charger 7 Remove And installation of Turbo Charger 7 Remove And installation of Turbo Charger
8 Remove And installation of Radiator 8 Remove And installation of Radiator 8 Remove And installation of Radiator
9 Remove And installation of Gearbox transmision 9 Remove And installation of Gearbox transmision 9 Remove And installation of Gearbox transmision
10 Remove And installation of Quick release valve 10 Remove And installation of Quick release valve 10 Remove And installation of Quick release valve
11 Remove And installation of Solenoid valve ABS 11 Remove And installation of Solenoid valve ABS 11 Remove And installation of Solenoid valve ABS
12 Remove And installation of Gear sensor SGG 12 Remove And installation of Clutch Valve Unit CVU 12 Remove And installation of Wheel speed sensor
13 Remove And installation of Splitter sensor SSP 13 Remove And installation of Air Valve Unit AVU 13 Remove And installation of Speed sensor
14 Remove And installation of Feed pump 14 Remove And installation of Feed pump 14 Remove And installation of Feed pump
15 Remove And installation of Wheel speed sensor 15 Remove And installation of Wheel speed sensor 15 Remove And installation of Wheel speed sensor
Fungsi & cara kerja dari komponen berikut : Fungsi & cara kerja dari komponen berikut : Fungsi & cara kerja dari komponen berikut : ###
1 Counter Brake shaft 1 Counter Brake shaft 1 Water pump ###
2 Steering Column 2 Steering Column 2 U-bolt & spring
3 Water Pump 3 Water Pump 3 Power steering pump
4 Steering pump 4 Steering pump 4 Shock absorbers
5 Brake linning 5 Brake linning 5 Torque rod
6 Reaction rod 6 Reaction rod 6 Power steering cylinder
7 Power steering cylinder 7 Power steering cylinder 7 Cooling fan
8 Cooling fan 8 Cooling fan 8 Brake cylinder/brake chamber
9 Brake chamber 9 Brake chamber 9 Brake linning
10 Propeller shaft 10 Propeller shaft 10 King pin
11 King pin 11 King pin 11 Support bearing
12 Hollow spring/rubber spring 12 Hollow spring/rubber spring 12 Cylinder exhaust brake
13 V-stay 13 V-stay 13 Hydraulic Control valve
14 Support bearing 14 Support bearing 14 Fuel pressure
15 Ball joint 15 Ball joint 15 Over flow valve
16 Pitman arm 16 Pitman arm 16 Pitman arm
17 Cab shock absorbers rear 17 Cab shock absorbers rear 17 Cab shock absorbers rear
18 Cab shock absorbers 18 Cab shock absorbers 18 Cab shock absorbers
TROUBLE SHOOTING 1

TROUBLE SHOOTING 1

TROUBLE SHOOTING 1

19 Cab tilt pump 19 Cab tilt pump 19 Cab tilt pump

20 Crossmembers 20 Crossmembers 20 Brake soe
Menjelaskan kemungkinan penyebab, metode pengujian & tools yang digunakan : Menjelaskan kemungkinan penyebab, metode pengujian & tools yang digunakan : Menjelaskan kemungkinan penyebab, metode pengujian & tools yang digunakan : ###
1 Engine doesn't Start 1 Engine doesn't Start 1 Steering wheel is heavy ###
2 Engine Can' not running
3 Engine Stop During Operation
-- 2 Engine Can' not running
3 Engine Stop During Operation
-- 2 Steering wheel vibrates
3 Linning brake wear abnormal
--
4 Engine Hunting 4 Engine Hunting 4 Differential lock inter wheel does not work
5 Exhaust Gas is Black 5 Exhaust Gas is Black 5 Engine does not start
6 Exhaust Gas is Blue 6 Exhaust Gas is Blue 6 Exhaust smoke is black
7 Oil Becomes Contaminated Quickly 7 Oil Becomes Contaminated Quickly 7 Engine lacks output
8 Fuel Consumption is excessive 8 Fuel Consumption is excessive 8 Clutch pedal heavy
9 Oil Engine is in cooling water 9 Oil Engine is in cooling water 9 Air pressure is low
10 Oil Pressure Lamp Lights up 10 Oil Pressure Lamp Lights up 10 Over charge air pressure
11 Oil Level Rises 11 Oil Level Rises 11 Parking brake does not release
12 Water Temperatur becomes too High 12 Water Temperatur becomes too High 12 Brake chamber does not release
13 Engine Abnormal Noise 13 Engine Abnormal Noise 13 Alternator does not charger
14 Engine Vibration is Excessive 14 Engine Vibration is Excessive 14 Dump body does not work
15 Machine can,t move 15 Machine can,t move 15 Exhaust brake is ineffective
16 Cab tilt caution lamp does not dispplay properly 16 Cab tilt caution lamp does not dispplay properly 16 Oil pressure drop
17 Alternator does not charger 17 Alternator does not charger 17 Cab tilt caution lamp does not dispplay properly
18 Parking brake does not release 18 Parking brake does not release 18 Oil is in coolant
19 Brake chamber does not release 19 Brake chamber does not release 19 Cab abnormal nois
20 Wheel alignment 20 Wheel alignment 20 Parking brake does not release
21 -- 21 -- 21 Brake chamber does not release
22 -- 22 -- 22 Wheel alignment
23 -- 23 -- 23 --
24 -- 24 -- 24 --
25 -- 25 -- 25 --
Fungsi & cara kerja dari komponen berikut : Fungsi & cara kerja dari komponen berikut : Fungsi & cara kerja dari komponen berikut : ###
1 Power steering gearbox 1 Power steering gearbox 1 Power steering gearbox ###
2 Relay valve parking brake 2 Relay valve parking brake 2 Relay valve parking brake
3 Drive control FR 3 APM 3 APS
4 Clutch Gearbox transmision 4 Clutch Gearbox transmision 4 Clutch Gearbox transmision
5 Turbo Charger 5 Turbo Charger 5 Turbo Charger
6 Bogie lift 6 Bogie lift 6 Bogie lift
7 Gearbox transmision 7 Gearbox transmision 7 Gearbox transmision
8 Quick release valve 8 Quick release valve 8 Quick release valve
9 Solenoid valve ABS 9 Solenoid valve ABS 9 Solenoid valve ABS
10 Tachograph 10 Tachograph 10 Valve unit, crawler gear
11 Counter brake shaft 11 Intermediate shaft 11 Power take off
12 Clutch cylinder 12 Clutch cylinder 12 Bleding ECA
13 Transmission Electronic Control Unit 13 Transmission Electronic Control Unit 13 Retarder
14 Gate sensore SGE 14 Valve unit, crawler gear 14 Coordinator
15 Emergency Shift K-line 15 Limp home 15 TC Valve
16 Power take off 16 Power take off 16 Camshaft position sensor
17 Gate module 17 Volvo engine brake 17 --
18 Gear module 18 Clutch Valve Unit CVU 18 --
19 Range module 19 Air Valve Unit AVU 19 --
TROUBLE SHOOTING 2

TROUBLE SHOOTING 2

TROUBLE SHOOTING 2

20 -- 20 -- 20 --
Menjelaskan kemungkinan penyebab, metode pengujian & tools yang digunakan : Menjelaskan kemungkinan penyebab, metode pengujian & tools yang digunakan : Menjelaskan kemungkinan penyebab, metode pengujian & tools yang digunakan : ###
1 Dump body lifting speed is slow 1 VEB does not operate 1 Retarder does not operate ###
2 Range gear does not operate 2 Dump body lifting speed is slow 2 Dump body lifting speed is slow
3 Splitter and 3rd gear does not work -- 3 Range gear does not operate -- 3 Range gear does not operate --
4 Engine does not start 4 Splitter and 3rd gear does not work 4 Splitter and 3rd gear does not work
5 Transmission cluth does not dissengage 5 Engine does not start 5 Engine does not start
6 Revers gear does not operate 6 Transmission cluth does not dissengage 6 Transmission cluth does not dissengage
7 Over charger in air system 7 Revers gear does not operate 7 Revers gear does not operate
8 Service brake does not operate 8 Over charger in air system 8 Over charger in air system
9 Parking brake caution lamp does not dispplay properly 9 Service brake does not operate 9 Service brake does not operate
10 Transmission abnormal nois is made 10 Parking brake caution lamp does not dispplay properly 10 Parking brake caution lamp does not dispplay properly
11 ABS does not work 11 Transmission abnormal nois is made 11 Transmission abnormal nois is made
12 Parking brake release speed is slow 12 ABS does not work 12 ABS does not work
13 Transmission oil temperatur become too high 13 Parking brake release speed is slow 13 Parking brake release speed is slow
14 Transmission does not shifting 14 Transmission oil temperatur become too high 14 Transmission oil temperatur become too high
15 Differential lock caution lamp does not dispplay properly 15 Transmission does not shifting 15 Transmission does not shifting
16 Machine can,t move 16 Differential lock caution lamp does not dispplay properly 16 Differential lock caution lamp does not dispplay properly
17 Disc clutch abnormal worn out 17 Machine can,t move 17 Machine can,t move
18 Gear shifting difficulty 18 Disc clutch abnormal worn out 18 Disc clutch abnormal worn out
19 Axle beam cracks 19 Gear shifting difficulty 19 Gear shifting difficulty
20 -- 20 Axle beam cracks 20 Axle beam cracks
21 -- 21 -- 21 --
22 -- 22 -- 22 --
23 -- 23 -- 23 --
24 -- 24 -- 24 --
25 -- 25 -- 25 --
26 -- 26 -- 26 --
 RANGKUMAN HASIL UJI INTERVIEW MEKANIK
NEW HIRE
NAMA :
SITE TUJUAN :
JABATAN YG DIUJI :
GRADE YG DIUJI :
Ma s uka n Foto Ha rus Lebi h
NAMA PENGUJI : Kecil Da ri Ukura n Kota k
NIK PENGUJI :
TANGGAL UJI :
LOKASI UJI :
METODE UJI :

HELPER M3 M2 M1 MK
COMPETENCY
COMPETENCY SECTION GRADE 1 GRADE 2 GRADE 3
A B C D E F A B C D E F A B C D E F STD. ACT.
BMC B C C P P P P P P P P P P P P P P P -- --
KNOWLEDGE B C P P P P P P P P P P P P P P -- --
B C P P P P P P P P P P P P P P -- --
PS
B C P P P P P P P P P P P P P P -- --
B C P P P P P P P P P P P P P P -- --
KNOWLEDGE B C C P P P P P P P P P P P P P -- --
PREVENTIVE B C C P P P P P P P P P P P P P -- --
PI
MAINTENANCE B C C P P P P P P P P P P P P P -- --
B C C P P P P P P P P P P P P P -- --
KNOWLEDGE B C P P P P P P P P P P P P -- --
B C P P P P P P P P P P P P -- --
MCI
B C P P P P P P P P P P P P -- --
B C P P P P P P P P P P P P -- --
KNOWLEDGE B C P P P P P P P P P P -- --
REMOVE B C P P P P P P P P P P -- --
INSTALL ENGINE RI_1
AND HYD. B C P P P P P P P P P P -- --
B C P P P P P P P P P P -- --
KNOWLEDGE B C P P P P P P P P P -- --
REMOVE B C P P P P P P P P P -- --
INSTALL ELECT. AND RI_2
PWR. TRAIN B C P P P P P P P P P -- --
B C P P P P P P P P P -- --
KNOWLEDGE B C P P P P P P P -- --
TROUBLE B C P P P P P P P -- --
SHOOTING ENGINE TS_1
AND HYD. B C P P P P P P P -- --
B C P P P P P P P -- --
KNOWLEDGE B C P P P P P P -- --
TROUBLE B C P P P P P P -- --
SHOOTING ELECT. TS_2
AND PWR. TRAIN B C P P P P P P -- --
B C P P P P P P -- --
TOTAL POINT KOMPETENSI 3 EG
TOTAL POINT KOMPETENSI KHUSUS (1EG)
1
1
2
2
10
10
19
18
27
26
35
34
43
45
51
--
59
--
67
--
75
--
83
--
87
--
--
--
-- -- --
-- -- --
--
-- 0 0

PENGUJI