DAFTAR ISI HALAMAN JUDUL ........................................................................................... i LEMBAR PERSOALAN .................................................................................... ii LEMBAR PENGESAHAN ................................................................................ iii MOTTO .............................................................................................................. iv LEMBAR PERSEMBAHAN ...............................................................................v KATA PENGANTAR ........................................................................................ vi ABSTRACT........................................................................................................ viii INTISARI ........................................................................................................... ix DAFTAR ISI.........................................................................................................x DAFTAR TABEL ............................................................................................. xiii DAFTAR GAMBAR ........................................................................................ xiv
BAB I. PENDAHULUAN 1.1 Latar Belakang ..............................................................................................1 1.2 Tujuan ............................................................................................................3 1.3 Batasan Masalah ...........................................................................................3 1.4 Metode Penelitian..........................................................................................4 1.5 Sistematika Penulisan ...................................................................................5
BAB II. LANDASAN TEORI 2.1 Pengertian Main Control Valve ....................................................................6 2.2 Valve pada Main Control Valve ....................................................................8 2.2.1Pressure Control Valve ..........................................................................8 2.2.1.1 Fungsi Pressure Control Valve.................................................8 2.2.1.2 Tipe Limit Pressure ................................................................10 2.2.2 Directional Control Valve ...................................................................12 2.2.2.1 Check Valve .............................................................................13 2.2.2.2 Spool Valve ..............................................................................15 1.1 Jenis-jenis directional control valve.................................17 1.2 Jenis-jenis spool valve berdasarkan jumlah posisi dan koneksi .......................................................................19
2.2.3 Volume Control Valve ................................................................22 2.3 Cara Kerja Main Control Valve .................................................................25 2.4 Lokasi Pilot Main Control Valve ................................................................27 2.5 Letak Main Control Valve ...........................................................................28 2.6 Komponen ....................................................................................................29 2.6.1 Housing ...............................................................................................29 2.6.2 Spool Valve ..........................................................................................30 2.6.3 Main Relief Valve................................................................................32 2.6.4 Overload Relief Valve .........................................................................34 2.6.5 Make Up Valve ....................................................................................36 2.7 Fungsi Valve pada Control Valve EX 2500-5 ...........................................38
BAB III. ANALISIS KERUSAKAN PADA MAIN CONTROL VALVE EXCAVATOR EX 2500-5 3.1 Kasus Kerusakan Control Valve pada Unit Excavator EX 2500-5 .........41 3.1.1 Analisis Kerusakan Control Valve pada Unit Excavator EX 2500-5....................................................................................................42 3.2 Analisis Kerusakan Control Valve Excavator EX 2500-5 Melalui Proses Remanufacturing ..............................................................50 3.2.1 Pengertian Singkat Proses Remanufacturing .................................50 3.2.2 Safety (Kesehatan dan Keselamatan Kerja) .................................50 3.2.3 APD (Alat Pelindung Diri) ...............................................................52 3.2.3.1 Jenis-Jenis Alat Pelindung Diri dan Penanggulangannya ........52 3.2.4 Pelaksanaan Proses Remanufacturing Control Valve EX 2500-5 .53 3.2.4.1 Persiapan Alat-Alat ..............................................................54 3.2.4.2 Proses Remanufacturing ......................................................56 3.3 Kerusakan pada Komponen Main Control Valve EX 2500-5 .................64 3.4 Analisis Penyebab Kerusakan Komponen Control Valve EX 2500-5 ....65 3.4.1 Masuknya partikel logam karena kontaminasi dari luar sistem control valve EX 2500-5 ....................................................................69 3.4.2 Adanya udara yang terjebak di dalam sistem control valve EX 2500-5 .........................................................................................70 3.4.3 Adanya udara yang terjebak di dalam sistem control valve EX 2500-5 ........................................................................................72
3.5 Akibat dari Kerusakan pada Komponen-Komponen Main Control Valve EX 2500-5.........................................................................................73 3.5.1 Kerusakan pada housing dan spool control valve EX 2500-5 ......75 3.5.2 Kerusakan pada housing dan spool control valve EX 2500-5 ......77
BAB IV. PENCEGAHAN KERUSAKAN PADA MAIN CONTROL VALVE EXCAVATOR EX 2500-5 DAN IMPROVEMENT 4.1 Pencegahan dan Penanganan...................................................................79 4.1.1 Periodical Maintenance ...................................................................79 4.1.2 Predictive Maintenance ...................................................................80 4.1.3 Midlife dan Overhaul.......................................................................81 4.2 Improvement ..............................................................................................83 4.2.1 Penjelasan Singkat Iron Particle Detector ....................................84 4.2.2 Kompoen Iron Particle Detector ....................................................84 4.2.2.1 Main Body ............................................................................85 4.2.2.2 Magnetik Plug ......................................................................85 4.2.2.3 Conector Plug.......................................................................86 4.2.2.4 Conector Cable ....................................................................86 4.2.2.5 Indicator Lamp.....................................................................86 4.2.3 Cara Kerja Iron Particle Dete .......................................................87
BAB VPENUTUP 5.1 Kesimpulan .................................................................................................91 5.2 Saran ...........................................................................................................92
DAFTAR PUSTAKA ........................................................................................93 DAFTAR TABEL Tabel 2.1 Kelebihan dan kekurangan direct acting relief valve .........................10 Tabel 2.2 Kelebihan dan kekurangan pilot operated relief valve
...............11
Tabel 2.3 Perbedaan main relief valve dan overload relief valve ......................36 Tabel 2.4 Fungsi main control valve (kanan bawah...........................................39 Tabel 2.5 Fungsi main control valve (tengah atas) ............................................40 Tabel 2.6 Fungsi main control valve (kiri bawah) .............................................40
Tabel 3.1 Perawatan hose ...................................................................................44 Tabel 3.2 Perawatan pipe ...................................................................................45
DAFTAR GAMBAR
Gambar 2.1 Main control valve ...........................................................................7 Gambar 2.2 Skema Aliran Fluida ........................................................................7 Gambar 2.3 Simbol Pressure control valve ........................................................8 Gambar 2.4 Skema Pressure Reduction control valve ........................................9 Gambar 2.5 Ilustrasi prinsip kerja sederhana pressure control valve .................9 Gambar 2.6 Simulasi direct acting relief valve .................................................10 Gambar 2.7 Ilustrasi cara kerja pilot operate relief valve .................................11 Gambar 2.8 Simbol Directional control valve ..................................................12 Gambar 2.9 Ilustrasi cracking pressure ............................................................13
Gambar 2.10 Ilustrasi check valve .....................................................................13 Gambar 2.11 Simple check valve dengan orifice ...............................................14 Gambar 2.12 Pilot operated check valve –pilot to open check valve ................14 Gambar 2.13 Pilot operated check valve – pilot to close check valve .............................................................15 Gambar 2.14 Ilustrasi directional control valve tipe spool valve......................15 Gambar 2.15 Ilustrasi spool valve pada posisi netral ........................................16 Gambar 2.16 Ilustrasi spool valve pada posisi kiri ............................................16 Gambar 2.17 Ilustrasi spool valve pada posisi kanan ........................................17 Gambar 2.18 Ilustrasi directional control valve – open center .........................17 Gambar 2.19 Simbol directional control valve – open cente ............................18 Gambar 2.20 Ilustrasi directional control valve – close center ........................18 Gambar 2.21 Simbol directional control valve – close center ..........................19 Gambar 2.22 Simbol spool valve 2 posisi 3 koneksi.........................................19 Gambar 2.23 Ilustrasi spool valve 2 posisi 3 koneksi .......................................19 Gambar 2.24 Ilustrasi spool valve 2 posisi 4 koneksi .......................................20 Gambar 2.25 Ilustrasi spool valve 2 posisi 4 koneksi .......................................20 Gambar 2.26 Ilustrasi spool valve 3 posisi 4 koneksi .......................................20 Gambar 2.27 Ilustrasi spool valve 3 posisi 4 koneksi .......................................21 Gambar 2.28 Ilustrasi spool valve 3 posisi 4 koneksi .......................................21 Gambar 2.29 Ilustrasi spool valve 2 posisi 4 koneksi .......................................21 Gambar 2.30 Ilustrasi spool valve 3 posisi 4 koneksi .......................................22 Gambar 2.31 Ilustrasi spool valve 3 posisi 4 koneksi .......................................22 Gambar 2.32 Ilustrasi volume control valve ......................................................23 Gambar 2.33 Ilustrasi slow return valve ...........................................................23 Gambar 2.34 Ilustrasicara kerja volume control valve – proportional flow divider ............................................................24 Gambar 2.35 Skema cara kerja main control valve...........................................25 Gambar 2.36 Skema aliran main control valve ZX 2500-5 ...............................26 Gambar 2.37 Lokasi Pilot Control Valve EX 2500-5 ........................................27 Gambar 2.38 Denah letak main control valve ...................................................28 Gambar 2.39 Main control valve EX 2500-5 ....................................................28 Gambar 2.40 Ilustrasi cutway housing main control valve ...............................29 Gambar 2.41 Housing main control valve.........................................................29
Gambar2.42 Ilustrasi spool valve .....................................................................30 Gambar 2.43 Spool valve pada hydraulic diagram EX 2500-5 .........................30 Gambar 2.44 Foto spool valve ...........................................................................31 Gambar 2.45 Foto spool valve ...........................................................................31 Gambar 2.46 Foto spool valve ...........................................................................32 Gambar 2.47 Foto spool valve ...........................................................................32 Gambar 2.48 Sketch spool valve........................................................................32 Gambar 2.49 Simbol relief valve .......................................................................33 Gambar 2.50 Cutway relief valve ......................................................................33 Gambar 2.51 Komponen main relief valve .......................................................33 Gambar 2.52 Simbol relief valve .......................................................................35 Gambar 2.53 Komponen overload relief valve .................................................35 Gambar 2.54 Cutway overload relief valve .......................................................35 Gambar 2.55 Cutway make up valve .................................................................37 Gambar 2.56 Bagian-bagian make up valve ......................................................37 Gambar 2.57 Main control valve pada excavator 2500-5 .................................38 Gambar 3.1 Excavator 2500-5 dengan flate number EX 268............................41 Gambar 3.2 Skema pemindahan tenaga dari pompa hingga actuator ..............42 Gambar 3.3 Hydraulic cylinder pada bucket EX 2500-5 dengan fleet number EX 269 tidak mengalami leakage ..................................................43 Gambar 3.4 Titik pemeriksaan pada hose. ........................................................45 Gambar 3.5 Titik pemeriksaan pada clamp pipe ...............................................46 Gambar 3.6 Skema sederhana sirkuit hidrolik EX 2500-5 ................................47 Gambar 3.7 Main control valve pada excavator 2500-5 ...................................48 Gambar 3.8 Overload relief valve .....................................................................49 Gambar 3.9 Make-up valve ...............................................................................49 Gambar 3.10 APD (Alat Pelindung Diri) ..........................................................52 Gambar 3.11 Part Assembly Control Valve EX 2500-5 ....................................53 Gambar 3.12 Meja Kerja ...................................................................................54 Gambar 3.13 Palu Plastik ..................................................................................54 Gambar 3.14 Kunci Pas Ring ............................................................................54 Gambar 3.15 Alat Pencongkel...........................................................................54 Gambar 3.16 Penahan Spool .............................................................................55 Gambar 3.17 Impact wrench .............................................................................55
Gambar 3.18 Kunci L ........................................................................................55 Gambar 3.19 Kunci Shock ................................................................................55 Gambar 3.20 Clamp bolt ...................................................................................56 Gambar 3.21 Tang Stel ......................................................................................56 Gambar 3.22 Pengangkatan CV menggunakan crane .......................................56 Gambar 3.23 Control valve di meja kerja .........................................................57 Gambar 3.24 Pelepasan overload valve dengan impact wrench .......................57 Gambar 3.25 Pelepasan plate penutup housing ...............................................58 Gambar 3.26 Pelepasan plug check valve dengan bamboo spatula .................58 Gambar 3.27 Backup dan O-ring check valve .................................................59 Gambar 3.28 Pelepasan cap penutup spool .......................................................59 Gambar 3.29 Pemberian tanda pada spool .......................................................60 Gambar 3.30 Menahan spool end(22) dengan spesial toll ................................60 Gambar 3.31 Pelepasan spool ..........................................................................61 Gambar 3.32 Pelepasan baut dan tie rods ........................................................61 Gambar 2.33 Pemisahan inlet section ..............................................................62 Gambar 3.34 Pemisahan outlet section ............................................................62 Gambar 3.35 Pemberian tanda pada housing ...................................................62 Gambar 3.36 Pemeriksaan kerusakan pada lubang hous .................................63 Gambar 3.37 Kerusakan pada lubang hous .......................................................63 Gambar 3.38 Kerusakan pada spool ................................................................63 Gambar 3.39 kerusakan pada lubang housing cv ..............................................64 Gambar 3.40 kerusakan pada spool .................................................................64 Gambar 3.41 kerusakan pada bulang housing .................................................65 Gambar 3.42 kerusakan pada make-up valve ..................................................65 Gambar 3.43 Kontaminasi gram besi pada oli hidrolik...................................67 Gambar 3.44 ilustrasi masuknya kontaminasi pada sistem .............................68 Gambar 3.45 ilustrasi pengeroposan karena prtikel logam .............................68 Gambar 3.46 ilustrasi masuknya kontaminasi dari luar ..................................69 Gambar 3.47 Ilustrasi pengeroposan pada piston pump ..................................70 Gambar 3.48 Ilustrasi gelembung dalam control valve ...................................70 Gambar 3.49 Ilustrasi kavitasi dalam control valve ........................................71 Gambar 3.50 Ilustrasi pengeroposan bagian komponen control valve ............71 Gambar 3.51 Ilustrasi pergerakan komponen control valve.............................72
Gambar 3.52 Ilustrasi pengikisan komponen control valve .............................72 Gambar 3.53 Pengeroposan pada spool control valve EX 2500-5 ...................73 Gambar 3.54 Pengeroposan pada housing control valve EX 2500- .................73 Gambar 3.55 Disassemble Relief Valve ............................................................74 Gambar 3.56 Pengikisan pada pilot poppet relief valve ...................................74 Gambar 3.57 Ilustrasi aliran oli hidrolik saat cylinder extend .........................75 Gambar 3.58 Ilustrasi kebocoran aliran oli hidrolik saat cylinder extend ........76 Gambar 3.59 Struktur mekanisme pada relief valve ........................................77 Gambar 3.60 Ilustrasi kecbocoran relief valve .................................................78 Gambar 4.1 Iron particle detector .....................................................................84 Gambar 4.2 Main body ......................................................................................85 Gambar 4.3 Magnetik plug ................................................................................85 Gambar 4.4 Conector plug ................................................................................86 Gambar 4.5 Conector cable...............................................................................86 Gambar 4.6 Indicator lamp ...............................................................................87 Gambar 4.7 Ilustrasi pemasangan Iron particle detector ..................................87 Gambar 4.8 Ilustrasi pemasangan Iron particle detector ..................................88 Gambar 4.9 Ilustrasi pemasangan Iron particle detector ..................................89 Gambar 4.10 Ilustrasi penangkapan gram besi .................................................90 Gambar 4.11 Ilustrasi penyalaan lampu indikator.............................................90
