PRESENTASI TUGAS AKHIR

PERIODIC SERVICE 1000 H

HD 785-7

NAMA : MUHAMMAD MAULIDI RAZAQ

NIS : 72318037

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SITE BATULICIN

PROGRAM STUDI MEKANIK ALAT BERAT

2018/2019
 PERIODIC SERVICE 1000 H

Latar Belakang Masalah

Alat berat banyak digunakan untuk mempermudah berbagai

pekerjaan khusus dengan efisiensi tinggi, seperti halnya HD 785-7
merupakan alat berat yang paling banyak digunakan untuk proses
penambangan lebih khusus nya di PT. Jhonlin Baratama:

1. Menjaga kondisi unit tetap dalam keadaan fit dan peforma

maksimal
2. Mencegah sebelum terjadinya trouble
3. Meminimalisir adanya backlog pada unit

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Tujuan
Mempelajari tatacara melakukan periodic service yang benar dan agar
dapat mencapai tujuan dari service itu sendiri
a. Menjaga agar suatu unit selalu dalam keadaan siap pakai (High
Availability).
b. Menjaga agar suatu alat selalu dalam kemampuan yang prima (Best
Perfomance).
c. Menjaga agar biaya perbaikan alat menjadi lebih hemat (Reduce
repair cost).

Pembatasan Masalah
a. Materi yang akan di angkat hanya pada unit HD 785-7
b. Pembahasan materi hanya pada action periodic service 1000HM

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 PERIODIC SERVICE 1000 H

PERLENGKAPAN KERJA
“ALAT PENGAMAN DIRI”

Pakaian kerja Safety Helmet Sarung tangan

Safety Glass Safety shoes Common Tools Electrical tool

Danger tag Job Safety Analysis Shop manual

 PERIODIC SERVICE 1000 H

DATA UNIT

Model Unit : HD 785-7

Code Unit : HDK 23
SMR : 7009,7
Serial No. Unit : J30060
Engine Model : SAA12V140E-3
Serial No. Engine : 508404
Nama Customer : PT. JHONLIN BARATAMA
Lokasi : WORKSHOP PT. JB
Tanggal Service : 22 juli 2019
Lama Pengerjaan : 6 Jam

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PERSIAPAN KERJA

Washing Unit Parking Unit Liveling Final Drive

Isolasi Unit
Aktifkan Parking Brake

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PS 1000
HM
PS 500
HM

PS 250
HM

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SERVICE PROSEDURE

EVERY 250 HOURS SERVICE WHEN REQUIRED

1. Check, clean or replace air
1. Check oil level in differential case
cleaner
2. Check oil level in final drive case 2. Check level air cooler in
3. Lubrication reservoir tank
3. Clean air conditioner air filter
4. Check drive shaft
4. Bledding air from fuel circuit
5. Check level of battery electrolyte
6. Check alternator belt tension
EVERY 500 HOURS SERVICE
7. Check AC compressor belt tension
1. Change oil in engine oil pan, replace
8. Clean breathers
engine oil filter cartridge
9. Check braking capacity of foot brake
2. Replace fuel prefilter cartridge
10. Check braking capacity of retarder brake
3. Replace transmission oil filter
11. Check braking capacity of parking brake element
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EVERY 1000 HOURS SERVICE

1. Replace fuel main filter cartridge

2. Change oil in transmission, brake cooling oil tank,

wash strainer

3. Change oil in brake sub-tank

4. Replace transmission brake cooling oil filter

element

5. Replace brake oil filter element

6. Check wear of rear brake disc

7. Check wear of front brake disc

8. Recover oil leaking from floating seal

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ENGINE
Change Oil in Engine Oil Pan

SAE15W 40
Kapasitas 129
liter
Take Oil
Semple PAP Remove Drain The Oli
Drain Plug,
And Lossen
Drain Valve

Drain plug & Drain valve :

68.6 ± 9.8 Nm
(7 ± 1 kgfm / 50.6 ± 7.2 lbft)

Check Oil Level Refill Oil

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Replace engine oil filter cartridge

Part No 600- Prepare pan Lossen Te Filter

211-1341 Cartridge

installing the filter Filler Oil Remove Filter

Cleaning filter
cartridge

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Replace Main Fuel Filter Cartridge

Part No
Remove guard filter Close Fuel Valve turn filter cartridge
600-319-3550
counterclockwise to remove it.

Clean the filter holder, and install the filter cartridge to the install the filter cartridge
filter holder.

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Replace prefuel filter

Turn cup of Remove Cleaning Cup Replace O-ring

600-319-4540 water separator Prefilter

Fill the filter

Instal filter cartridge Replace O-ring Install cup to the bottom of the
with clean new fuel pre-filter cartridge.
fuel

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Check Water Separator, Wash Insade Of filter case

There are two sets of water separators Loosen ring nut remove filter case, and
(one each on left and right)
element from separator base

Cleaning Water
Inspection the glass, element and ring
Separator set
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Install element to the separator base. Check O-ring Fill the filter case
with clean fuel

Tightening ring nut

Open fuel valve

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Bledding Air From Fuel Circuit

Switch priming valve of the fuel Open shut valve at the

pump tank is open. side face of the engine.

Operate switch of the

electric priming pump to
the ON position
Close shut valve at the side face of the engine.

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TRANSMISSION
Change Oil Transmission

TO30 Remove drain plug, Loosen

Remove filler cap drain valve drain the oil
Take Oil Sample

Check Level Check Level Oil

Oil at Engine at Engine Stop
Running Refill capacity: drain the oil
210 liters
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Replace Transmission Filter

569-16-81160 Loosen hexagonal Remove case and

portion 32mm of case Cleaning Case

Cleaning Holder

Install Filter
torque for case: 58.8 to 78.5 N·m Instal fiter Instal Cleaning Replace Cleaning
(6 to 8 kgf·m, 43.4 to 57.9 lbft) element Valve inside case o-ring Trit
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Clean Transmission Strainer

Cleaning and Remove bolts

Install the cover with remove the cover and
bolts take out strainer

Cleaning holder and Replace O-ring Remove any dirt stuck to the strainer, then
wash in clean diesel fuel or flushing oil
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Replace Brake Cooling Filter

Remove bolt Then remove cover

070000-Fs190

Install the new Replace Save the wait, and

Then wash the inside of the
element, then install O-ring inside case Take out the
case and the removed parts
cover with bolt element
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BRAKE
Change oil in brake sub-Tank

Remove drain plug Drain the oil

Sub Tank

add oil to the H level Refill capacity: 36 Then tighten the

liters plug again.
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Drain the oil from the brake chamber on both

the left and right sides

Inside rear brake cooling Remove plug ( bottom ) Save plug

chamber ( up )

Check O- If this plug is removed, it is easier to drain the

ring the plug oil from the brake chamber
Intal Plug
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Replace Brake oil Filter Element

Element: 569-43-83920 Remove filter Take out the wash the inside
O-ring: 07000-12065 case element of the filter case
B/U Ring: 07001-02065

Install Tightening
Assemble a new Replace O-ring,and Wash trit
torque: 8 to 10 kgf·m
element backup ring.
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Check Wearnes Off Disc Brake

Insade Brake Remove cap nut Push in until rod

2. Rod
3. Slit
4. Face
5. Slit
6. Locknut

“Apa bila slit (3) di tekan menyentuh

Face (4), berarti Disc Brake sudah of the gauge contacts
tidak standar (Aus)" the piston
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AIR CLEANER

Remove Clip Hooks of dust Remark*

cup Display 7.5
kPa Check Vacuator Check and Clean
Open Lock
( Valve dust cup
0,76kgf/cm2

Install air cleaner and dust cup Check Part New Air Cleaner
Replace O-ring
of dust cup
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Clean air conditioner air filter

Out cabin Lossen lock Remove air filter Cleaning air filter

In cabin Remove air filter Clean filter

Check level water cooler in reservoir tank

Check level water cooler

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Check Electrolyte Battry

Check Battry in a Check livel electrolite

Fill with ater plus battry, if less
way Visual battry

Check terminal battry

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REAR AXLE
Final Drive RH & LH

Leveling final drave Lossen plug Check oil level Cleaning metal powder
and install plug

Differintial

Check oil level and

Lossen Plug Cleaning metal powder Install plug
take simple pap
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TAKE SAMPLE PAP

( Program Analisa Pelumas )

Hydraulic Oil Differential Oil

Final Draive Oil

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CLEAN BREATHERS

Brake Cooling Oil Tank PTO Steering and Hoist Transmission

Oil Tank

Defferential

Before After

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LUBRICATION

Steering Cylinder, Steering Linkage, Front Suspension

Transmission Mount
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Rear Suspension Rear Axle Support Dump Body Hoist Cylinder Pin
Hinge Pin

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Lubrication Fan and Tension Fully

Fan Pulley Tension Pully

Remove cover
3 nipel

Check and lubrication Drave Shaft ( Front and Rear )

Rear drive shaft Front drive shaft

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Check Ac Compressor And Alternator Belt Thension

Remove cover Lossen the nut ac compressor tension lever

Check tension V-belt Check V-belt Lossen the nut alteernator tension lever
visual
D ALTERNATOR BELT TENSION
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CHECK LENGH OF SUSPENSION CYLINDER
Front Suspension

Check that the bottom of the suspension cylinder over is within

range

Rear Suspension

from the shoulder of the rod head of the suspension Measure

cylinder to the top surface of the flange. dimension
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ADJUSTING SUSPENSION

Preparation Netrogen
Remove nut

Leveling
Instal nut suspension
right left

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CHECK BRAKING CAPACITY OF FOOD BRAKE

Set Shift Lever to Step on food brake and If the Machine does not
the D Position Lower the engine
Gradually Raise The move even when the speed, set shift
Engine Speed engine speed reaches lever at N position
1570rpm, its normaly

*** Make sure the parking

brake is free

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CHECK BRAKING CAPACITY OF RETARDER BRAKE

If the Machine does not move even

pull retarder Set Shift Lever Gradually Raise The when the engine speed reaches
control lever to the D Position Engine Speed 1200 rpm, its normaly

*** Make sure the parking Lower the engine speed, set
brake is free shift lever at N position
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CHECK BRAKING CAPACITY OF PARKING BRAKE

If the Machine does not

parking brake switch Set Shift Lever to Gradually Raise
move even when the engine
to parking the D Position The Engine Speed
speed reaches 1335rpm, its
normaly

*** Make sure the Lower the engine speed, set

retarder brake is free shift lever at N position

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REPORTING

JOB CARD BAPP MAR

From ( Berita Acara Penyerahan ( Mechanics Actifity
PT. Jhonlin Baratama Pekerjaan ) Report )

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FINAL INSPECTION & HOUSE
KEEPING

Check Lamp Front And Rear

House Keeping

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TERIMA KASIH

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