Trouble Shoot EX2500 Hyd Temp (Revisi2)

TROUBLE SHOOTING TREE EX2500-5 NO DOKUMEN : BPOP/01/2010/SOP
TGL. EFEKTIF : 26 October 2010

HITACHI HYDRAULIC TEMPERATURE HALAMAN : 1/15 REVISI : 2
DISUSUN DISETUJUI DISTRIBUSI

PLANT ALL SITE
Plant TO BPOP Reliability Manager Plant Div Head
1. TUJUAN
Standard Operation Procedure (SOP) ini bertujuan untuk :
1.1. Memberikan pedoman kepada PIC (Person In Charge) yang terkait tentang proses pelaksanaan
Analisa naiknya temperatur oli hidrolik.
1.2. Memastikan bahwa proses pelaksanaan Analisa naiknya temperatur oli hidrolik dengan Sistem
Manajemen Mutu yang telah ditetapkan.
1.3. Dapat membantu mengurangi frekuwensi breakdown akibat hidrolik sistem overheat.
2. RUANG LINGKUP
SOP ini digunakan sebagai acuan dalam pelaksanaan Analisa naiknya temperatur oli hydraulic ,di lihat dari
tingginya temperatur yang di tunjukkan temperature gauge dan download dari MIC. Adapun ruang lingkupnya
meliputi Plant Department, Production Department, dan Laboratorium.
3. REFERENSI
3.1 . OPERATIONAL PRINCIPLE EX 2500-5 (TTLA-446-EX)
3.2. MAINTENANCE (TTLA-449-EX)
3.3 . PERFORMANCE CHECK EX 2500-5 (TTLA- 447- EX
3.4 . TECHNICAL MANUAL (TROUBLESHOOTING) (TT141-E-00)
3.5. ELECTRICAL CIRCUIT (WCLA0424 – 0426)\
3.6. HYDRAULIC CIRCUIT (WCLA0422 BACKHOE)
3.7. HYDRAULIC CIRCUIT (WCLA0423 LOADER)
4. DEFINISI
4.1. Meter (HM)
adalah lamanya equipment dioperasikan dalam satuan jam alat. Hour
4.2. Machine Information Center (MIC)
adalah salah satu program monitoring pada unit untuk mengetahui kondisi unit dengan cara melakukan proses
pengambilan data dari pusat penyimpanan data di unit
5. KEBIJAKAN
5.1. Setiap Unit Hitachi harus di download data MIC 1x dalam seminggu.
5.2. MIC harus selalu di update setiap minggu dan dianalisa serta hasilnya dibahas dalam meeting mingguan untuk
memonitor kondisi unit khususnya temperature hydraulic systemnya.
5.3. Untuk menganalisa naiknya tempeature oli hydraulic diperlukan juga data PAP, hystorical penggantian oli hydraulic,
data hystorical penggantian component, data dari special tools ( Infra-red camera, data logger, heat gun, anemometer,
tacho meter ).
5.4. Setiap hasil analisa pelumas yang menunjukkan hasil status tidak normal (attention, urgent, warning) harus ditindak
lanjuti dengan proses perbaikan dan dilaporkan.
5.5. Setiap hasil perbaikan dan penggantian component dari follow up temperautre hydraulic system overheat harus di
buatkan laporannya dalam forum PICA.
5.6. STD site harus membuat trend kondisi hasil perbaikan per bulan untuk dipergunakan sebagai bahan evaluasi dan
pengendalian Plant Manager atas program menurunkan temperature hydraulic system overheat.
5.7. Selama proses follow up temperature hydraulic system overheat harus mengikuti OEM Maintenance ,regular
hydraulic oil and filter replacement termasuk juga washing properly.
6. ALUR PROSES
Proses pelaksanaan analisa temperature hydraulic system yang overheat secara rinci dapat di lihat di bawah ini
NO DOKUMEN : BPOP/01/2010/SOP
PT. PAMAPERSADA TROUBLE SHOOTING TREE EX2500-5
NUSANTARA
HYDRAULIC OIL
TEMPERATURE By MIC or GUAGE
INCREASE’S
NORMAL HITACHI HYDRAULIC SYSTEM OPERATING TEMPERATURE = 80 Degrees Celsius

1. CHECK HYDRAULIC (Temperature operasi normal hitachi )
TEMPERATURE
DIAGHRAM
(Periksa temperatur
hidrolik diaghram)
2. CHECK ALARM HISTORY.

1. HYDRAULIC OIL(LEVEL)
2. HYDRAULIC OIL
TEMPERATURE
3. CONTAMINATION LAMP More than 10 times (lebih dari 10 kali)
PT. PAMAPERSADA
NUSANTARA TGL. EFEKTIF : 26 October 2010
HITACHI HYDRAULIC TEMPERATURE
HALAMAN : 3/15 REVISI : 2
3. CHECK EVENT HISTORY

TO SEE WHICH COMPONENT IS A
PROBLEM
(Periksa event history untuk melihat

Komponen mana yang bermasalah)
EXAMPLE:
SERING CONTAMINASI MAINPUMP 2
( CH 2).
CHECK SENSOR CONTAMINATION

ADA GRAM ATAU TIDAK.( JIKA GRAM
KECIL/HALUS BERSIHKAN LALU
MONITORING LAGI, JIKA SENSOR
MASIH MENYALA DALAM 3X DALAM
1 SHIFT PLAN GANTI MAIN PUMP. Info : Jika sumua contamination, itu
indication hydraulic oil is kotor, ganti oili
JIKA GRAM BESAR DITEMUKAN hydraulic & filters
DALAM PENGECHECKAN PLAN
GANTI MAINPUMP).
JIKA TIDAK ADA GRAM TETAPI

LAMPU SENSOR CONTAMINASI
MASIH MENYALA CHECK WIRING CH = CHANNEL
HARNESS AND SENSOR 1 = MAIN PUMP 1
CONTAMINATION. 2 = MAIN PUMP 2
3 = MAIN PUMP 3
REPAIR TROUBLE 4 = MAIN PUMP 4
5 = MAIN PUMP 5
Note: If replace main pump or motor 6 = MAIN PUMP 6
check oil condition as per step 4. 17 = FRONT SWING MOTOR
Jika lepas main pump atau motor cek 18 = REAR SWING MOTOR
kondisi oli dapat dilihat di step 4 21 = TRAVEL MOTOR
Jika kondisi oli hidrolik jelek
langsung ganti oli , suction filter dan CONTOH GRAM BESAR YANG MENEMPEL PADA SENSOR CONTAMINATION
ganti main pump juga.
Dan ikuti comissioning prosedure
dari hexindo
YES / NO
LAMP ON = CONTAMINATION
LAMP OFF= NO CONTAMINATION
POSITION CONTAMINATION SENSOR CONTROLER BELOW CABIN/ ELECTRICAL CABINET

PT. PAMAPERSADA
HALAMAN : 4/15 REVISI :2
HYDRAULIC OIL
BY TEMPERATURE
TEMPERATURE
GAUGE or MIC
INCREASE’S
4. LEVEL
CHECK
HYDRAULIC OIL
CONDITION YES
LEVEL LOW ADD OIL AND CHECK
(level rendah) LEAKING
(Tambah oli)
CHEK KEBOCORAN
YES
LEVEL HIGH DRAIN OIL
(level tinggi) (buang oli)
NO
Note: Position check oil level above
CHECK OIL
COLOUR DARK YES
(Gelap) REPLACE ALL HYDRAULIC OIL
(warna) Means Oxidation & the DRAIN COMPLETE SYSTEM
CHECK SMELL anti wear properties, Change oil & Suction Filters , clean
are depleted or replace hydraulic tank breathers,
(Burnt) bleeding hydraulic system
NO YES YES
REPLACE ALL HYDRAULIC OIL
RESULT OIL SAMPLE DRAIN COMPLETE SYSTEM
IS ATTENTION/ or Change oil & Suction Filters,
CHECK OIL SAMPLE CRITICAL/ URGENT clean or replace hydraulic tank
BY PAP (hasil contoh oli apakah breather, bleeding hydraulic
perhatian.kritis/darurat) system
(ganti oli dan suction filter,
bersihkan atau lepas breather
GOOD OIL BAD OIL hidrolik tank, buang udara di
hidrolik sistem).
PT. PAMAPERSADA
NUSANTARA
RIPPED,LOOSE,THIN YES
REPLACE SEALING
5. CHECK OIL COOLERS SEALING (ROBEK,LEPAS,TIPIS) WITH A NEW ONE
NO (lepas seal dan ganti

dengan yang baru)
OIL COOLER YES WASHING OIL COOLER

Dirty/clogged FROM INSIDE & OUTSIDE
(Kotor/buntu)
(Cuci oil cooler dari sisi
dalam dan sisi luar)
NO
OIL COOLER WASHING OIL COOLER AFTER WASHING
6.
CHECK RPM HIGH SPEED . FRONT & REAR Temperature hydraulic oil Oil cooler fan speed
CHECK RPM Check fan blade condition 50OC OR LESS SLOW SPEED :180 rpm
FANS HYDRAULIC Worn thin, cracked
(cek kondisi fan dari aus, tipis, retak) 50OC TO 70OC MEDIUM SPEED : 900 rpm
70OC OR MORE HIGH SPEED :1400 rpm
DISCONNECT SOLENOID
1 &2 ELECT CONECTOR
A. RPM FRONT & REAR FAN DIRREFENT SPEEDS
(Lepas solenoid 1 &2)
100 -200 RPM FAN SLOW , REPLACE MOTOR
= 1400 -/+ 50 RPM
EXAMPLE: FRONT SPEED = 1,350 rpm REAR
SPEED = 1,100 rpm, replace REAR FAN MOTOR
B. BOTH FAN SPEEDS ARE SLOW

FAN SPEEDS REMOVE AND INSPECT SOLENOID SPOOL
FRONT & REAR = CONDITION , IF DAMAGED REPLACE WITH NEW
1400 RPM SOLENOID ASSEMBLY
NO DAMAGE TO SPOOL & RPM SLOW

Check hose connections on
Fan pump
(Correct way around)
(Lepas dan cek kondisi spool. Jika rusak
ganti)
DIGITAL TACHOMETER
PT. PAMAPERSADA
NUSANTARA HITACHI HYDRAULIC TEMPERATURE
7. FAN PUMP
CONTROL CHECK
PRESSURE /PILOT PRESSURE
PRESSURE (cek tekanan)
(tekanan control 40 +/- kgf/cm2
pompa kipas)
YES NO
TEST POINTS PPC PRESSURE REDUCING VALVE
NO
ADJUST REDUCING CHECK REDUCING VALVE
VALVE REPLACE REDUCING
(O-RING & SEAL DAMAGE,
(setel reducing valve) YES VALVE
WEAK MATERIAL)
(lepas reducing valve)
REPLACE
NO
REPLACE PILOT PUMP

YES
INSPECT FILTER AND FILTER
CHECK PILOT PUMP
FROM CLOGGED (lepas pilot pump dan filter)
( DAMAGE,NOISE,
OR GRAM
LEAKAGE)
ADJUST FAN PUMP

PRESSURE
(setel tekanan fan pump)
Note: To adjust fan pump

Pressure , disconnect & plug hose’s
NO from 1 x fan motor
CHECK FAN PUMP (Hose input & output block)
PRESSURE Untuk menyetel tekanan fan pump,
140 +/- 10 kgf/cm2 lepas dan blok hose fan motor
(hose masuk dan hose keluar)
IN MARK X
X FAN PUMP CANNOT BE ADJUSTED
REPLACE FAN PUMP

( ganti fan pump)
PT. PAMAPERSADA
8. CHECK ELECTRIC
GAUGE TEMPERATUR M.I.C TEMPERATURE
SENSOR SENSOR
CONTROL HYDRAULIC COOLING
FAN SPEEDS
TEMP OLI RESISTANCE
HYDRAULIC TEMP OILSENSOR
(OC) (KΩ)
NO
0 5.88
A. CHECK MIC TEMPERATURE
10 3.73 SENSOR HYDRAULIC OIL.
REMOVE CONECTOR AND CHECK
20 2.45 ± 0.24 RESISTANCE OF SENSOR see table
(cek sensor MIC temperatur oli hidrolik
30 1.65 Sensor. Lepas konektor dan periksa
Resistansi sensor.)
40 1.14
AT THE BOTTOM OF HYDRAULIC TANK
0.808
B. CHECK CONDITION OF
50 REPLACE SENSOR
CONNECTOR ,WIRING TEMPERATURE OIL
60 0.534 (cek kondisi dari konektor dan kabel) HYDRAULIC
(ganti sensor temperatur
70 0.430 PN Sensor MIC 4250260 oli hidrolik)
80 0.322 ± 0.032 By multimeter and temp gun

NO
REPLACE CONECTOR /
90 0.245
YES WIRING
CHECK FUEL TEMPERATURE SENSOR

CHECK CONDITION OF CONNECTOR,
WIRING & CONTINUITY
PN Sensor 4250260 REPLACE SENSOR
(cek sensor temperatur bahan bakar FUEL TEMPERATURE
Fast Speed 1400 (ganti sensor temperatur
periksa condisi Konektor ,kabel dan bahan bakar)
kelancaran Arus.)
Resistance Same with Hyd. T Sensor
YES NO REPAIR OR REPLACE

HARNESS
REPLACE OR CLEAN
PIN OUT PUT & INPUT
(lepas atau bersihkan pin
keluar dan pin masuk
YES
CHECK MC (A) CTRL IN PUT & OUT PUT
(cek arus yang masuk dan keluar dari MC (A)
CONTROL) SPECIFICATION :
CODE MC A:
INPUT
IN PUT : Fluktuatif max 5 V (depend Resist T Sensor)
PIN ( A 41 ) HYDRAULIC OIL TEMPERATUR
PIN ( A 34 ) FUEL TEMPERATUR
OUTPUT
OUT PUT:Fluktuatif max 24 V (depend Resist T
Sensor)
PIN ( B 23 ) OIL COOLER SOLENOID ( 1 )
PIN ( B 24 )OIL COOLER SOLENOID ( 2 )
PT. PAMAPERSADA
9. PRESSURE OIL COOLERS OIL COOLER PRESSURE

(tekanan oil cooler) TEST POINTS
FRONT OUT
REAR OUT
Connect a 10 Kg/cm2 Gauges to inlet and one to the outlet test ports of Oil Coolers
Hydraulic oil should be + 50 Degrees Celsius temperature
Raise the BOOM and read the pressures on the gauges
Sambung 10 kg/cm2 pressure gauge ke inlet dan outlet port dari oil cooler
Oli hidrolik harus lebih dari 50 derajat celcius
Boom raise dan baca pressurenya.
BYPASS VALVES
FRONT IN
REAR IN
Specification
NO IF THE PRESSURE S ARE HIGHER THAN SPEC, IT

PRESSURE IN PRESSURE OUT MEANS EITHER THE BYPASS VALVE IS STICKING
(tekanan masuk)) (tekanan keluar) CLOSED OR THE OIL COOLERS ARE BLOCKED
2 -3 kgf/cm2 0,5 -1 kgf/cm2 INTERNALLY
JIKA PRESSURE TERLALU TINGGI KEMUNGKINAN

BY PASS VALVE TERTUTUP ATAU OIL COOLER
BUNTU
YES
1.REPLACE BYPASS VALVE
2.REPLACE OIL COOLER/ COOLERS WITH NEW
( GANTI OIL COOLER BRAND NEW )
Note : If replacing with new 3. REPLACE FULL FLOW FILTERS
Oil coolers, the hydraulic oil
Should be replaced to avoid IF THE PRESSURES IN = 0 Kgf/cm2 IN MEANS THE
Contamination and blockage of the BYPASS VALVE IS STUCK OPEN OR BROKEN
new coolers
(jika mengganti dengan oil cooler JIKA PRESSURE IN = 0 kgf/cm2 BERARTI BYPASS
baru, oli hidrolik harus diganti juga VALVE TERBUKA ATAU RUSAK
untuk menghindari contaminasi
dan tersumbatnya oil cooler baru) 1. REPLACE BYPASS VALVE
PT. PAMAPERSADA
10. YES
CHECK CYCLE TIME BOOM,ARM,BUCKET CYLINDER
LOADING SHOVEL
ATTACHTMENT DUMB CYLINDER( SHOVEL)
BACKHOE
Boom Raise 8.2±0.7 sec
Boom Lower 5.0±0.5 sec
Boom Raise 7.7±0.7 sec
Arm Extend 3.4±0.5 sec
Boom Lower 4.7±0.5 sec
Arm Retract 4.2±0.5 sec
Bucket Tilt-In 4.0±0.5 sec

Arm Roll-In 7.1±0.5 sec
Bucket Tilt-Out 2.9±0.4 sec
Arm Roll-Out 6.0±0.5 sec
Bucket Open 2.1±0.4 sec

Bucket Roll-In 5.3±0.5 sec
Bucket Close 2.5±0.4 sec
Bucket Roll-Out 3.9±0.5 sec
Note : Cycle times provided are for unit operating standard bucket , wear package stage 2
A heavily reinforced bucket will effect result s and can cause the unit to overheat
MORE OR LESS
THAN STANDARD YES
PM CLINIC
(Lebih atau kurang AND ADJUSTING
dari standar) SEE TROUBLE SHOOTING FRONT ATTACHMENT T5-4--28
(TECHNICAL_MANUAL_(TROUBLESHOOTING)(TT141-E-01)
11.
CHECK CYCLE TIME SWING SPEED 47±0.5 (sec/3 rev)
SWING
ATTENTION ! PERHATIAN !
IF CYCLE TIME IS TO FAST , ESPECIALLY FOR SWING

THIS INDICATES PUMP FLOW 5& 6 IS TOO HIGH
Jika cycle time terlalu cepat,khususnya untuk swing. Ini MORE OR LESS YES
mengindikasikan pompa 5&6 over flow THAN PM CLINIC
STANDARD
PM CLINIC SHOULD BE DONE BY TESTING
BOOM UP CYCLE TIME WITH ONE PUMP AT A TIME
IF THIS CYCLE TIME IS TO FAST THE PUMP FLOW SEE TROUBLE SHOOTING SWING SYSTEM T5-4-34
RATE MUST BE ADJUSTED BY FLOW METER (TECHNICAL_MANUAL_(TROUBLESHOOTING)(TT141-E-01)
Dalam melakukan PM Clinic harus boom up cylce time
dengan 1 main pump AKTIF , CONTOH pompa 5 yang
aktif dan cek cycle time BOOM UP yang menggunakan
pompa 5. Jika cycle time nya terlalu cepat flow rate pompa
harus di setel dengan menggunakan flow meter
12. Fast Speed Mode

77±4 (sec/3 rev) MORE OR LESS YES
TRAVEL REVOLUTION THAN PM CLINIC
Slow Speed Mode
SPEED STANDARD
109±5 (sec/3 rev)
SEE TROUBLE SHOOTING TRAVEL SYSTEMT5-4-37

(TECHNICAL_MANUAL_(TROUBLESHOOTING)(TT141-E-01)
PT. PAMAPERSADA
SWING DRIFT
CHECK SWING STANDART MORE THAN
DRIFT 740mm/ 180o OR LESS STANDARD
13. IN 5 MINUTES
WHEN ENGINE STOP
YES
REPLACE LOAD HOLDING

CHECK LOAD SCRATCH,WORN,DAMAGE YES
VALVE
15O HOLDING VALVE & WEAK MATERIAL SEAL/O – RING
(lepas load holding valve)
SWING BRAKES (tergores,aus, rusak, material seal/
REPLACE SWING BRAKE
O-ring lemah
(Ganti swing brake)
Note : Load bucket fully to test, park
unit on slope , stop engine and check SEE TROUBLE SHOOTING SWING SYSTEM T5-4-34
for drift (TECHNICAL_MANUAL_(TROUBLESHOOTING)(TT141-E-01)
Note : Bucket must be full and attachment positioned as per above
14. FILL BUCKET ,STOP ENGINE, YES

NOISE OF LEAKING OIL
CHECK CYLINDER DRIFT CHECK FOR NOISE OF OIL LEAKAGE
Suara oili bocor dalam mcv
IN MAIN CONTROL VALVE , CHECK DRIFT
(isi bucket, stop mesin , cek suara dari
kebocoran oli di main control valve)
NO
SPECIFICATIONS DRIFT
CHECK MCV
LOADING SHOVEL BACKHOE
DRIFT MORE THAN CHECK OVERLOAD VALVE
Boom Cylinder 25 or less(mm/5 min) STANDARD CHECK RELIEF / MAKE UP VALVE
Boom Cylinder 25 or less
Arm Cylinder 40 or less (mm/5 min) SPOOL CONTROL VALVE
Arm Cylinder 25 or less
Bucket Cylinder 20 or less Bucket Cylinder 20 or less (mm/5 min)
Bucket Bottom 300 or less Bucket Bottom 200 or less (mm/5 min) NO YES
WORN,SCRATCH,
WEAK MATERIAL OF
SEAL/ O - RING
YES
REPLACE MCV,OVERLOAD VALVE

CHECK FOR INTERNAL LEAKAGE
RELIEF VALVE. / MAKE UP VALVE
BY TEMP GUN( FOR DIFFERENT
TEMPERATURE LH & RH) OR NOISE
AT CYLINDER
DIFFERENT 7 DEGREE YES
REPAIR OR REPLACE
CYLINDER
(cek internal leakage dengan temoeratur (perbaiki atau lepas cilinder)
gun untuk perbedaan panas( beda
temperature LH & RH max 7 derajat
celcius atau cek noise di cylinder.
SEE TROUBLE SHOOTING FRONT
Note : Mark the cylinders with white
ATTACHMENT T5-4--28
marker pen (Spidol putih) as above
(TECHNICAL_MANUAL_(TROUBLESHOOTI
NG)(TT141-E-01)
NO DOKUMEN : BPOP/01/2010/SOP
TROUBLE SHOOTING TREE EX2500-5
PT. PAMAPERSADA TGL. EFEKTIF : 26 October 2010
NUSANTARA
15. CHECK OPERATING TEMPERATURE OF SYSTEM USING INFRA-RED TEMPERATURE GUN/ CAMERA/ DATA LOGGER
FAN MOTOR
SWING MOTOR
MAIN PUMP
Note: Position s for temperature check are indicated on this page
24
25
23
NO DOKUMEN : PLD/02/002/SOP
NUSANTARA HITACHI HYDRAULIC TEMPERATURE HALAMAN : 12/15 REVISI : 2
15. CHECK OPERATING TEMPERATURE OF SYSTEM USING INFRA-RED TEMPERATURE GUN
Note:
1. Perhatikan saat normal temperatur mesin operasi adalah 70 derajat celcius
2. Perhatikan untuk membersihkan hidrolik oil cooler.
3. Perhatikan level oli hidrolik dengan benar.
4. Attachment harus dioperasikan selama pengetesan di normal operasi
(jangan terus menerus stall hidrolik ini akan membuat mesin overheat)
5. Periksa suara abnormal, cavitasi pompa, kebocoran katup, getaran hose hdrolik
Note:
1 To be carried out when machine is at NORMAL operating temperature 70 degrees Celsius
2 To be carried out with clean hydraulic oil coolers
3 To be carried out with correct hydraulic oil level
4 Attachment is to be operated during testing in normal operation
(Do not CONTINUOSLY stall the hydraulics' this will overheat the machine)
5 Check for ABNORMAL noise's, cavitating pumps, leaking valves, vibrating hydraulic hose's
Machine S/N Machine Fleet No

Date Tested Machine SMR
Date Measurement Temperature ( ºC )

No. COMPONENT
1 Ambient temperature
2 Hyd. Tank
3 Control Valve Left
4 Control Valve Right
5 Control Valve centre
6 Main Pump 1
7 Main Pump 2
8 Suction Pipe 1 & 2
9 Main Pump 3
10 Main Pump 4
11 Suction Pie 3 & 4
12 Main Pump 5
13 Main Pump 6
14 Suction Pipe 5 & 6
15 Pipe In to Cooler Front
16 Pipe Out from Cooler Front
17 Pipe In to Cooler Rear
18 Pipe Out From Cooler Rear
19 Fan Motor Cooler Front
20 Fan Motor Cooler Rear
21 Swing Motor Front
22 Swing Motor Rear
23 Pipe Full Flow filter ( Rear cooler )
24 Pipe Full Flow filter ( Front Cooler )
25 Pipe Full Flow Filter ( Swing Motor )
26 Boom Cylinder RH
27 Boom Cylinder LH
28 Arm Cylinder RH
29 Arm Cylinder LH (Level Cylinder Loader)
30 Bucket Cylinder RH
31 Bucket Cylinder LH
32 Dump Cylinder RH
33 Dump Cylinder LH
Fan Speed
Oil Coolers Pres. IN Pres Out Temp IN Temp Out (High)
Standard 2 – 3 kgf/cm2 0.5– 1 kgf/cm2 ∆T > 10ºC 1400 ± 50 rpm
Front
Rear
Front Rear
Slow 180 rpm RPM kgf/cm2 RPM kgf/cm2
Fan Speed ( RPM) & Pressure
Middle 900 rpm RPM kgf/cm2 RPM kgf/cm2
High 1400 rpm RPM kgf/cm2 RPM kgf/cm2
Mechanic Name Foreman Name
Sign Sign
Supervisor checked
Name INFORM RESULTS TO PLANT DEPT BPOP
FOR ASSITANCE OF ANALYSIS
Sign
NUSANTARA HITACHI HYDRAULIC TEMPERATURE HALAMAN : 13/15 REVISI :2
16. CHECK CORRECT PILOT PIPING ON MAIN PUMP

IF THESE PILOT LINES ARE INSTALLED TO INCORRECT POSITION , THE PUMP WILL OPERATE ON MAXIMIUM
STROKE CAUSING THE PUMP TO OVER HEAT & THE UNITS HYDRAULIC SYSTEM TO OVER HEAT
JIKA PILOT CONTROL LINE TERPASANG DALAM KONDISI SALAH, MAKA POMPA AKAN OPERASI DENGAN
LANGKAH MKSIMUM DAN MENYEBABKAN POMPA OVERHEAT & UNIT MENJADI OVERHEAT
No, 1 No,2
No,2 PUMP
No, 3 No,4
No,4 PUMP
NUSANTARA HITACHI HYDRAULIC TEMPERATURE HALAMAN : 14/15 REVISI :2
16. CHECK CORRECT PILOT PIPING ON MAIN PUMP

IF THESE PILOT LINES ARE INSTALLED TO INCORRECT POSITION , THE PUMP WILL OPERATE ON MAXIMIUM
STROKE CAUSING THE PUMP TO OVER HEAT & THE UNITS HYDRAULIC SYSTEM TO OVER HEAT
JIKA PILOT CONTROL LINE TERPASANG DALAM KONDISI SALAH, MAKA POMPA AKAN OPERASI DENGAN
LANGKAH MKSIMUM DAN MENYEBABKAN POMPA OVERHEAT & UNIT MENJADI OVERHEAT
No,5
No,5 No,6
No,6 PUMP
NUSANTARA HITACHI HYDRAULIC TEMPERATURE HALAMAN : 15/15 REVISI : 2
17. CREATE ACTIVITY PLAN P.I.C..A HYDRAULIC OVERHEAT / FOLLOW UP

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TROUBLE SHOOTING TREE EX2500-5 NO DOKUMEN : BPOP/01/2010/SOP

TGL. EFEKTIF : 26 October 2010

DISUSUN DISETUJUI DISTRIBUSI

Plant TO BPOP Reliability Manager Plant Div Head

NORMAL HITACHI HYDRAULIC SYSTEM OPERATING TEMPERATURE = 80 Degrees Celsius

2. CHECK ALARM HISTORY.

3. CHECK EVENT HISTORY

(Periksa event history untuk melihat

CHECK SENSOR CONTAMINATION

JIKA TIDAK ADA GRAM TETAPI

POSITION CONTAMINATION SENSOR CONTROLER BELOW CABIN/ ELECTRICAL CABINET

Note: Position check oil level above

NO (lepas seal dan ganti

OIL COOLER YES WASHING OIL COOLER

OIL COOLER WASHING OIL COOLER AFTER WASHING

70OC OR MORE HIGH SPEED :1400 rpm

B. BOTH FAN SPEEDS ARE SLOW

NO DAMAGE TO SPOOL & RPM SLOW

TEST POINTS PPC PRESSURE REDUCING VALVE

REPLACE PILOT PUMP

ADJUST FAN PUMP

Note: To adjust fan pump

X FAN PUMP CANNOT BE ADJUSTED

REPLACE FAN PUMP

80 0.322 ± 0.032 By multimeter and temp gun

CHECK FUEL TEMPERATURE SENSOR

YES NO REPAIR OR REPLACE

9. PRESSURE OIL COOLERS OIL COOLER PRESSURE

NO IF THE PRESSURE S ARE HIGHER THAN SPEC, IT

JIKA PRESSURE TERLALU TINGGI KEMUNGKINAN

Bucket Tilt-In 4.0±0.5 sec

Bucket Open 2.1±0.4 sec

IF CYCLE TIME IS TO FAST , ESPECIALLY FOR SWING

12. Fast Speed Mode

SEE TROUBLE SHOOTING TRAVEL SYSTEMT5-4-37

REPLACE LOAD HOLDING

Note : Bucket must be full and attachment positioned as per above

14. FILL BUCKET ,STOP ENGINE, YES

REPLACE MCV,OVERLOAD VALVE

Note: Position s for temperature check are indicated on this page

15. CHECK OPERATING TEMPERATURE OF SYSTEM USING INFRA-RED TEMPERATURE GUN

Machine S/N Machine Fleet No

Date Measurement Temperature ( ºC )

Mechanic Name Foreman Name

16. CHECK CORRECT PILOT PIPING ON MAIN PUMP

16. CHECK CORRECT PILOT PIPING ON MAIN PUMP

17. CREATE ACTIVITY PLAN P.I.C..A HYDRAULIC OVERHEAT / FOLLOW UP

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