Buku Perawatan Engine Unit Alat Berat 6 Kelas 11 SMK

Materi Perawatan Engine Unit Alat Berat 6

Kata Pengantar ................................ ................................ ..................... iii
DAFTAR ISI ................................ ................................ ............................ iv
PENDAHULUAN ................................ ................................ ..................... 1
1. Informasi Material Safety ................................ ................................ ......... 1
2. Panduan Umum Keselamatan Kerja ................................ ........................ 1
3. Syarat – Syarat Khusus Safety ................................ ................................ 1
4. Safety Dalam Penggunaan Coolant ................................ ......................... 2

TUJUAN SISTEM PENDINGIN ................................ ............................... 3
1. Perlunya Sistem Pendingin ................................ ................................ ..... 3
2. Panas dan Suhu ................................ ................................ ...................... 4
3. Pengaruh Panas ................................ ................................ ...................... 4

KOMPONEN SISTEM PENDINGIN ................................ ........................ 6
1. Water Pump ................................ ................................ ............................ 9
2. Radiator ................................ ................................ ................................ 10
3. Water Temperatur Regulator /Thermostat ................................ ............. 19
4. Radiator Pressure Cap ................................ ................................ .......... 22
5. Cara Kerja Radiator Cap ................................ ................................ ....... 22
6. Expansion Plug (Frost Plug) ................................ ................................ .. 24
7. After -Cooler ................................ ................................ ........................... 26
8. Engine Oil Cooler ................................ ................................ .................. 28
9. Water Cooled Exhaust ................................ ................................ ........... 29
10. Pendingin Engine dengna Menggunakan Udara ................................ ... 29
11. Metode Pendinginan Udara ................................ ................................ ... 30
12. Melepas dan Memasang Radiator ................................ ......................... 31
13. Melepas radiator ................................ ................................ .................... 31
14. Memasang radiator ................................ ................................ ............... 32

IDENTIFIKASI PRODUK ................................ ................................ ....... 33
1. Serial Number/ Product Identification Number ................................ ....... 35
2. Arrangement Number ................................ ................................ ............ 43

PERAWATAN PENCEGAHAN (PREVENTIVE MAINTENANCE) ........ 45
1. Manfaat perawatan pencegahan. ................................ .......................... 48
2. Maintenance (perawtan) Interval ................................ ........................... 49
a. Every setiap 10 service hour/da ily ................................ ................ 49
b. Merawat setiap 50 Jam Operasi (Weekly) ................................ .... 50
c. Merawat setiap 250 jam Operasi ................................ ................. 50
d. Merawat setiap 500 Jam operasi ................................ ................. 51
e. Merawat setiap 1000 Jam operasi ................................ ............... 51
f. Merawat setiap 2000 Jam o perasi ................................ ............... 51

PEMERIKSAAN KELILING (WALK -AROUND INSPECTION) ............. 52
ISO SYMBOLS ................................ ................................ ...................... 53
1. Basic Symbols ................................ ................................ ....................... 53
2. Advanced Symbols ................................ ................................ ................ 54
3. Additional symbol ................................ ................................ .................. 55
4. Basic Safety Symbols ................................ ................................ ............ 56

MENGHIDUPKAN ENGINE ................................ ................................ .. 57
1. Pemeriksaan Engine Saat Hidup ................................ ........................... 57
2. Setelah engine hidup ................................ ................................ ............. 57

PENGOPERASIAN ALAT BERAT ................................ ....................... 58
1. Arah dan pemindahan kecepatan ................................ .......................... 58

PERAWATAN SISTEM PENDINGIN ................................ .................... 60
1. Inspeksi Visual Pada Aliran Udara ................................ ........................ 60
2. Sirkulasi Coolant ................................ ................................ ................... 61
3. Radiator Core Flow ................................ ................................ ............... 62
4. Inspeksi Water Pump ................................ ................................ ............ 63
5. Pengujian Tekanan ................................ ................................ ............... 64
6. Pengujian Tekanan Pressure Cap ................................ ......................... 65
7. Pengujian Water Temperature Indicator ................................ ................ 66
8. Pengujian Thermostat (Temperature Regulator) ................................ .... 67
9. Pembersihan Komponen Bagian Dalam Dari Sistem Pendingin ............ 73

CONTAMINATION ................................ ................................ ................ 75
1. Endapan atau Karat ................................ ................................ .............. 75
2. Reverse -Flush ................................ ................................ ....................... 77
PENGUJIAN SISTEM PENDINGIN ................................ ....................... 78

DIAGNOSA SISTEM PENDINGIN ................................ ........................ 85
1. Overheating ................................ ................................ ........................... 86
2. Pemeriksaan Visual Overheating ................................ .......................... 87
3. Radiator ................................ ................................ ................................ 88
4. Kipas ................................ ................................ ................................ ..... 90
5. Shutter System ................................ ................................ ...................... 92
6. Hose Coolant ................................ ................................ ........................ 93
7. Gasket Water Pump dan Cylinder He ad ................................ ................ 93
8. Pemeriksaan –pemeriksaan Lain ................................ ........................... 94
9. Pengujian – Overheating ................................ ................................ ....... 95
10. Udara, Gas dan Uap dalam Sistem Pendingin ................................ ...... 96
11. Perbedaan Suhu Radiator – Ambient ................................ .................... 99
12. Suhu Torque Converter ................................ ................................ ....... 100
13. Retarder ................................ ................................ .............................. 100
14. Temperature Regulator atau Thermostat ................................ ............. 102
15 . Hambatan Aliran Udara Radiator ................................ ......................... 103
16. Engine Timing ................................ ................................ ..................... 105
17. Kekurangan Coolant ................................ ................................ ............ 106
18. Engine Overcooling ................................ ................................ ............. 110
19. Sistem Shutter ................................ ................................ ..................... 111
20. Thermostat ................................ ................................ .......................... 112
21. Radiator Cap ................................ ................................ ....................... 116
22. Fan Assembly ................................ ................................ ..................... 117
23. Hose dan Clamp ................................ ................................ .................. 118
24. Thermostat ................................ ................................ .......................... 119
25. Water Pump ................................ ................................ ........................ 120
26. Cylinder Head ................................ ................................ ..................... 121
27. Prosedur Pengujian Pada Machine ................................ ..................... 124
28. Engine Sudah Lama Tidak Dioperasikan ................................ ............. 126
29. Galleries ................................ ................................ .............................. 127
30. Kesimpulan Overheating – Masalah Dan Penyebab ............................ 128

MAINTENANCE INTERVAL SCHEDULE ................................ ........... 130
1. Every 10 Service Hours or Daily for Machines Used in Severe Applications ................................ ................................ ........................ 131
2. Every 50 Service Hours or Weekly ................................ ...................... 131
3. Initial 100 Service Hours ................................ ................................ ...... 131
4. Initial 250 Service Hours ................................ ................................ ...... 131
5. Every 250 Service Hours or Monthly ................................ ................... 132
6. Every 500 Service Hours or 3 Months ................................ ................. 132
7. Every 1000 Service Hours or 6 Months ................................ ............... 132
8. Every 2000 Service Hours or 1 Year ................................ ................... 133
9. Every 3000 SERVICE HOURS OR 2 YEARS ................................ ...... 133

LUBRICANT VISCOSITIES AND REFILL CAPACITIES .................... 133
1. Lubricant Viscosities ................................ ................................ ............ 133
2. Transmission/Drive Train Oils ................................ .............................. 135
3. SOS Oil Analysis ................................ ................................ ................. 135
4. Sampling Interval and Location of Sampling Valve .............................. 136
5. Desert Gold (CPG) ................................ ................................ .............. 137
6. Arctic Platinum (CPG) ................................ ................................ ......... 137
7. Grease Gun Storage ................................ ................................ ........... 137

COLD WE ATHER LUBRICANTS ................................ ....................... 138
1. Multipurpose Lithium Complex Grease with Molybdenum (MPGM) ..... 138

SPECIAL PURPOSE GREASE (SPG) ................................ ................ 139
1. Bearing Lubrication (SPG) ................................ ................................ ... 139
2. Water and Temperature Resistant Grease (SPG) ............................... 139
3. Re -refined Base Stock Oils ................................ ................................ . 139
4. After -Market Oil Additives ................................ ................................ .... 140
5. Lubricating Grease ................................ ................................ .............. 140
6. Multipurpose Greases ................................ ................................ ......... 140
7. Final Drive Oil and Swing Drive Oil ................................ ...................... 141

COMMERCIAL BIO DEGRADABLE HYDRAULIC OIL ........................ 144
1. Total Base Number (TBN) and Fuel Sulfur Levels for Caterpillar Direct Injection Diesel Engines ................................ ................................ ..... 145
2. Caterpillar Fluids ................................ ................................ ................. 145

CATERPILLAR DIESEL ENGINE OIL (DEO) ................................ ..... 146
1. Diesel Engine Oil (DEO) ................................ ................................ ...... 146
2. Commercial Diesel Engine Oils ................................ ........................... 14 7
3. Lubricant Specifications ................................ ................................ ....... 147
4. Fuel Recommendations ................................ ................................ ....... 150

CONVENTIONAL COOLANT/ ANTIFREEZE COOLING SYSTEM MAINTENANCE ................................ ................................ .................. 153
1. Cooling System Cleaning ................................ ................................ .... 153
2. SOS Coolant Analysis ................................ ................................ ......... 154
3. Extended Life Coolant (ELC) Cooling System Maintenance ................ 154
4. Proper additions to the Extended Life Coolant ................................ ..... 155
5. Extended Life Coolant Cooling System Cleaning ................................ . 155
6. Cleaning the Heavy -Du ty Cooling System ................................ ........... 155
7. Low Silicate Coolant ................................ ................................ ............ 156
8. Supplemental Coolant Additive (SCA) ................................ ................. 156
9. Contamination of the ELC Cooling System ................................ .......... 157

COOLING SYSTEM SPECIFICATIONS ................................ .............. 157
1. General Coolant Information ................................ ............................... 157
2. Water ................................ ................................ ................................ .. 158
3. Additives ................................ ................................ ............................. 158
4. Glycol ................................ ................................ ................................ .. 159

TORQUES FOR BOLTS AND NUTS ................................ .................. 159
PERAWATAN PADA UNIT TRUK ................................ ...................... 160
1. PM L evel 1 ................................ ................................ .......................... 160

OBTAIN SAMPLE ................................ ................................ ............... 161
1. Engine Oil and Filter ................................ ................................ ............ 162

OIL DR AIN INTERVALS ................................ ................................ ..... 166
1. Total Lube Oil in US. Quarts (Liters) – (Sump and Add Oil) ................. 167

FUEL FILTERS ................................ ................................ .................... 168
1. Replace Final Fuel Filter ................................ ................................ ...... 169
2. Priming the System ................................ ................................ ............. 169
COOLING SYSTEM ................................ ................................ ............ 170
CRANKCASE BREATHER ................................ ................................ . 173
ALTERNATOR, FAN AND ACCESSORY DRIVE BELTS .................. 173
1. Adjus t Alternator Belts ................................ ................................ ......... 174
2. Adjust Fan Drive Belts ................................ ................................ ......... 175
HOSES AND CLAMPS ................................ ................................ ....... 175
1. Inspect/Replace ................................ ................................ ................... 175
ALR -TO -AIR AFTERCOOLER SYSTEM ................................ ............ 176
PM LEVEL 2 ................................ ................................ ........................ 177
1. Engine ................................ ................................ ................................ . 177
2. Turbocharger ................................ ................................ ....................... 177
3. Engine Mounts ................................ ................................ .................... 178
4. Air Compressor ................................ ................................ ................... 179
5. Thermostat ................................ ................................ .......................... 179
PM LEVEL 3 ................................ ................................ .......................... 181
DAFTAR PUSTAKA ................................ ................................ ............ 182