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Troubleshooting Error
Transmission HD 465-7
NAMA : FRIZKY TEGAR J.P
NIS : 70217315
BATCH : 22
KELAS : UT SCHOOL
JAKARTA
LOKASI OJT : BINUNGAN

UT SCHOOL
PROGRAM STUDI MEKANIK
ALAT BERAT
2018

PEMBEKALAN OJT- 1
PRESENTASI TUGAS AKHIR
 LATAR BELAKANG
1. Troubleshoting tentang Error Transmission banyak
ditemukan di sekitar kita, tidak hanya di HD 465-7
tetapi juga bisa ditemukan di unit lain.

TUJUAN

1.Mencegah trouble yang sama terulang kembali.

2.Mempermudah pengerjaan trouble yang sama pada
unit HD 465-7.

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 HALAMAN ISI

DATA UNIT
Unit Model : HD 465-7
DATA UNIT
Kode Unit
HM
: HDKM46070
: 34777,9 Hours
Serial No. Unit : 7426
Model Engine : SAA6D170E-3
Serial No. Engine : GA - 312486
Nama Customer : PT. BUMA
Lokasi : TANJUNG REDEP SITE BINUNGAN
Laporan Trouble : ERROR TRANSMISSION
Tanggal Trouble : 29 JUNI 2018
Tanggal Selesai : 29 JUNI 2018
Lama Pengerjaan : 1 shift

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METODOLOGI TROUBLESHOOTING

STEP 1 STEP 2 STEP 3 STEP 4

TROUBLESHOOTING OBSERVE &

POSSIBILITIES CAUSES COLLECT DATA
CHART DIAGNOSTIC

STEP 5 STEP 6 STEP 7 STEP 8

ACTION TO
ANALYSIS SUPECTED CAUSE CONCLUSION
IMPROVEMENT

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 Troubleshooting Chart
DDTJKA + 15SDMA (LO CLUTCH ABNORMAL)
SPEED F1
DDTKKA (1ST CLUTCH ABNORMAL)

DDTJKA + 15SDMA (LO CLUTCH ABNORMAL)

SPEED F2
DDTLKA (2ND CLUTCH ABNORMAL)

DDTJKA + 15SDMA (LO CLUTCH ABNORMAL)

SPEED RL
DDTNKA (R CLUTCH ABNORMAL)

PEMBEKALAN OJT- 5
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Troubleshooting Chart

PEMBEKALAN OJT- 6
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 HALAMAN ISI

Troubleshooting Chart
• Error-error code tersebut muncul apabila:
ERROR DDT * KA

FILL SWITCH SENSOR

COMMAND

T/
M
SH
AF
T
SP
EE
ERROR 15S * MA D
SE
NS
OR

PEMBEKALAN OJT- 7
PRESENTASI TUGAS AKHIR
 POSSIBILITIES CAUSE
Defective Transmission Controller

Defective Wiring Command Line / GND

Electrical Controller Line of ECMV
failure
Defective ECMV Solenoid

Defective ECMV Fill Switch

Error
(DDT*KA
&
15S*MA)
Defective Transmission Pump
Hydraulic /
Mechanical Defective Main Relief Valve
failure
Defective Spool of ECMV

Clogging of Hydraulic Line

PEMBEKALAN OJT- 8
PRESENTASI TUGAS AKHIR
 OBSERVE & DIAGNOSTIC
Field Observation
• OBSERVE CUSTOMER MECHANIC
– Team BUMA sudah melakukan
a. Pembersihan + inspection pada strainer transmission case.
b. Minor Worn Clutch Material Found.
c. Swap ECMV dari Unit Lain  Problem Tetap.

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 HALAMAN ISI

Observe Diagnostic
Field Observation
• OBSERVE DIRECTLY TO MACHINE
– Apabila salah satu gear shift aktif, timbul error yang mengacu
pada clutch yang diaktifkan (DDT*KA & 15S*MA)

PEMBEKALAN OJT- 10
PRESENTASI TUGAS AKHIR
PM Clinic Collect Data

PEMBEKALAN OJT- 11
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 Collect Data
• Main Relief Transmission Pressure
– STD (Lo Idle): 37 s/d 40 kg/cm2
– Act : 38,5 kg/cm27 kg/cm2
– STD (Hi Idle) : 32,5 s/d 35,5 kg/cm2
– Act : 34,6 kg/cm2 kg/cm2 O
K

NO
• Lo Clutch Pressure
– STD :14 s/d 18 kg/cm2 T
OK
– Act : 0 kg/cm2

PEMBEKALAN OJT- 12
PRESENTASI TUGAS AKHIR
 Collect Data
PM Clinic
• 1st Clutch Pressure
– STD : 32 s/d 35 kg/cm2
– Act
NO
: 0 kg/cm2
T
OK

• 2nd Clutch Pressure

NO
– STD : 32 s/d 35 kg/cm2
– Act : 8 kg/cm2 T
OK

PEMBEKALAN OJT- 13
PRESENTASI TUGAS AKHIR
Analysis

PEMBEKALAN OJT- 14
PRESENTASI TUGAS AKHIR
Analysis

PEMBEKALAN OJT- 15
PRESENTASI TUGAS AKHIR
 Suspected Cause
Defective Transmission Controller

Defective Wiring Command Line / GND

Controller Line of ECMV
Electrical
failure
Defective ECMV Solenoid

Error 03 Defective ECMV Fill Switch

(DDT*KA
& 15S*MA)

Defective Transmission Pump

Hydraulic /
Mechanical Defective Main Relief Valve
failure
Defective Spool of ECMV

Clogging of Hydraulic Line

PEMBEKALAN OJT- 16
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Suspected Cause
• Inspeksi pada komponen yang paling
mudah : Last Chance Filter.

PEMBEKALAN OJT- 17
PRESENTASI TUGAS AKHIR
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Suspected Cause
• Cleaning Last Chance Filter & re-measurement
Clutch Speed Transmission Pressure.
• Lo Clutch Pressure
– Result : 18.4 kg/cm2
OK
– (STD 14 s/d 18 kg/cm 2)
• 1st Clutch Pressure
– Result : 33.6 kg/cm2 OK
– (STD 32 s/d 35 kg/cm 2)
• 2nd Clutch Pressure
– Result : 32.2 kg/cm2 OK
– (STD 32 s/d 35 kg/cm 2)

PRESSURE LOSS  CLOGGING AT LAST CHANCE FILTER

PEMBEKALAN OJT- 18
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Conclusion

POSSIBILITY SOURCE OF WORN MATERIAL

PEMBEKALAN OJT- 19
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 Conclusion
Inspection Filter & Strainer
• TRANSMISSION OIL PAN STRAINER
• INSPECT BY BUMA TEAM  TERDAPAT TIDAK BANYAK
MATERIAL

• TRANSMISSION FILTER
 TERDAPAT TIDAK BANYAK
MATERIAL
• BRAKE COOLING FILTER
 TERDAPAT BANYAK MATERIAL

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Root Cause Problem
Conclusion
Error (DDT*KA & 15S*MA) Occures

Fill Switch is Still Off After ECMV Activation

Loss Pressure of ECMV Activation

Clogging at Last Chance Filter

Worn Disc Material Circulated in Transmission Oil

Rear Brake Worn Out

PEMBEKALAN OJT- 21
PRESENTASI TUGAS AKHIR
 HALAMAN REFERENSI

Additional Inspection
Conclusion
• Inspect Rear Brake Wear Gauge.

WEAR GAUGE MIS-ASSEMBLY  CAN’T BE USED AS REFFERENCE

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Action to Improvement
• Wear Gauge Cant be used for Refference
due to mis-assembly.
• Life Time of Rear Brake Rh & LH 18720
Hrs
• Request Replacement Rear Brake
Assembly RH & LH
• Flushing oil

PEMBEKALAN OJT- 23
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SEKIAN DAN TERIMA KASIH

PEMBEKALAN OJT- 24
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