INSPECTION
1.Engine speed (Rpm)
Knowing the engine speed during low idle and high idle, to ensure Fuel fuel throttle control lever or dial voltage (electrical throttle system) normal condition. While to know the engine power, the measurement is done in the operating condition with the maximum load.
Procedure
Radiator coolant temperature: 70-90o (working temperature)
Ensuring fuel throttle lever can be positioned on the stopper Low and High
Turn on the engine and measure the current low and high speed.
2.Compression pressure (kg / cm2)
Knowing the degree of wear on the liner and piston rings, or the condition of the valve guide / steam.
Procedure
Radiator coolant temperature: + 60 ° C
Cracking rpm: 150-250 rpm (to ensure achieved, install a tachometer)
Make sure Intake system conditions are good (not deadlock)
Valve clearance: standard
Remove the nozzle or injector, and plug the adapter (nozzle false), connect with a pressure gauge.
Close the fuel line, position the shut-off to prevent fuel injection.
Play (crangking) engine with battery power alone (engine not live) and measure the compression pressure.
Do it 3-4 times, take the average value.
To be more durable battery, open all nozzle or injector.
3.Blow by pressure (mmH2O, mmAq)
To determine the degree of wear on the liner and piston ring (bebocoran pressure from the combustion chamber)
Procedure
Radiator coolant temperature: 70-90o (working temperature)
Linkage ensure throttle pedal and throttle lever can be positioned on the stopper FIP High.
Check fuel and water system condition is normal.
Replace Blow-by adapter and connect with pressure gauge
Turn on the engine, position the high idle (if possible give a maximum load,
when measuring operating unit then measuring the pressure blow-by.
4.Oil pressure
Ensuring the pressure of oil used for engine lubricating system according to standard, so there is no abnormal wear.
Procedure
Radiator coolant temperature: 70-90o (working temperature)
Oil level within range Low-High
Not happening oil leakage
Attach nipple and connect with a pressure gauge.
Turn on the engine, measuring pressure when the engine low idle and high idle.
5.Intake resistant (mmH20)
To determine the level of air cleaner deadlock and also as an indication of the ability of the suction piston.
Procedure
Radiator coolant temperature: 70-90o (working temperature)
No leak in the intake system
Attach nipple measurement and connect with pressure gauge
Turn on the engine, measure the intake resistance when the maximum load.
6.Exhaust temperature (oC)
To determine the level of quality of combustion, which is determined by the ratio of the incoming air with fuel injected.
Procedure
Radiator coolant temperature: 70-90o (working temperature)
Check fuel and water system condition is normal
Replace temperature sensor and connect with thermometer
Turn on the engine, exhaust temperature measuring maximum load moment.
7.Exhaust color (Bosch Index)
To determine the level of combustion quality, and the level of oil leaks into the combustion chamber (via the steam valve and piston rings).
Procedure
Radiator coolant temperature: 70-90o (working temperature)
Check fuel and water system condition is normal.
Turn on the engine, insert the suction port Smoke checker into the muffler (exhaust pipe) and suction (pull the handle) while the engine is accelerated.
Compare the results of suction exhaust gas contained in the filter paper with a standard table
8.Valve clearance
To know and ensure kerengangan valve (intake and exhaust) as standard, because the valve clearance determines the valve timing and valve stroke total (total amount of incoming air and exhaust gases out), and severely affects engine power.
Procedure
Radiator coolant temperature: + 60 ° C (or depending on the standard factory: Cold / Hot)
Position the cylinder which will diadjust at TDC compression
Enter a feeler gauge (according to standard clearance) between the rocker arm and the crosshead, turn the adjustment screw until feeler gauge was sliding when actuated.
Adjustment valve clearance can be done per Cylinder or with rotary method twice.
9.Oil temperature
To find out and make sure the oil temperature in the range of work, because temperature affects the viscosity of oil that can accelerate wear of the components.
Procedure
Radiator coolant temperature: 70-90o (working temperature)
Oil level within range Low-High
Attach nipple measurement and connect with pressure gauge
Turn on the engine, measuring pressure when the low and high idle.
10. Fuel Injection timing (FIP)
To know and make sure Start of Injection, because it determines the engine power and to prevent knocking or detonation.
Procedures (Delivery method)
Rotate and position at TDC Compression Cylinder no.1 then align mark IJ (start of injection) at
front damper or flywheel with the pointer.
Remove the delivery valve No. 1 and loosen the coupling bolt FIP
Pump feed pump drive shaft while moving FIP, noticed when fuel stops flowing from
delivery valve hole # 1, it means that the injection timing is right.
Mark alignment procedure methode
Rotate and position at TDC Compression Cylinder no.1 then align mark IJ (start of injection) at
front damper or flywheel with the pointer.
Position mark (sign) drive shafts with housing FIP mutually aligned or misaligned.
For Cummins Engine; must use Timing Fixture
11. Radiator pressure valve
To determine the maximum pressure in the cooling system, so there is no pressure over the
can cause leakage (hose, clamps, radiator cores, etc.) and prevent the water inside the radiator can be boiled, if pressurenya too low, so it does not happen cavitasi component (liner).
Procedure
Use the radiator cap tester.
12. Fan belt tension
To ensure the fan can spin at speeds appropriate engine speed (no slip), so that the suction or gusts of wind to cool the cooling water in the radiator can be maximized. Tension belt which standards will also prevent belt damage occurs sooner. (Usually using autotension pulley)
Procedure
Press the belt using the push-pull scale with according to standard pressure.
Measure deviation (deflection) belt
13. Oil consumption ratio
To determine the amount of additional oil that is due to the oil that enters the combustion chamber through the piston rings or valve steam, so it caught fire. Measurement comparisons based on the amount of additional oil to the amount of fuel (fuel) is used.
Note:
For the measurement of hydraulic performance: pressure, drift and cycle time (awork equipment speed) has to do with the condition:
Water coolant temperature: working range 70o - 90oC
Hydraulic oil temperature: 50o - 60oC
Measurements were made as much as 3 x, determine the outcome based on the average the average.
14. Primary pressure
To determine the maximum pressure in the system as an indication of the strength of digging (digging force) within limits (specified pressure) play pump. 320-330 bar.
procedure:
Install the pressure gauge on the HPF block (R984), RH120 can use BCS
Measure pressure, high engine idle time and attactment direliefkan (Stick inclusive)
15. Servo Pump Pressure
To determine the maximum pressure in the pilot control circuit (control of pump and control system). 32 bar
(R984) and 40 bar (RH120)
Procedure
Install the pressure gauge on the Pilot Filter Block (R984), RH120 can use BCS
Measure the pressure when the engine high idle and low idle
16. Pilot PPC pressure
To find out put PPC pilot pressure as the driving spool valve C / V, repositioning piston (close loop swing). 32 bar (R984) and 40 bar (RH120)
procedure:
Install the pressure gauge on the spool cover C / V.
Measure the pressure when the engine high idle and low idle
17. Pressure cut-off (CO Pressure)
To determine the maximum pressure when the cut-off valve works to minimize the angle of the main pump. (310 bar)
procedure:
Install the pressure gauge on the HPF Block and servo valve (R984). R120 - BCS
Lower the setting primary valve, then raise back setting primary valve slowly to read setting pressure cut-off (300 - 310bar), the servo valve pressure gauge drops suddenly
Measure the pressure when the engine high idle and low idle
18. Secondary pressure
To determine the maximum pressure in the system between the C / V and actutor as an indication of the ability of the actuator release the load from the outside and as a result of the movement of the other actuator.
procedure:
Install the pressure gauge on the HPF block (R984), RH120 can use BCS
Raise setting primary valve secondary pressure exceeds setting valve, then slowly reliefkan actuator and valve secondary pressure gauge. Measurements were made for each secondary valve.
19. Swing hydraulic pressure
Pressure during swing
To find out the current working pressure swing, and can be used to determine the mechanical abnormality (circle swing bearing, swing gear box).
procedure:
Parking unit on a flat place
Install the pressure gauge on the pump Swing (R984), RH120 can use BCS
Position the full extend appropriate attachment posture measurement, then measuring the pressure when playing upper structure (swing) 360o.
Swing relief pressure
To determine the maximum pressure in the swing system (closed loop) as an indication of the power of turning the upper structure.
procedure:
Install the pressure gauge on the HPF block (R984), RH120 can use BCS
Measure the pressure when the swing detained (relief)
24. Swing Speed
To determine the rotational speed of upper structure, which can be used as an indication of the magnitude of the flow rate pump swing.
procedure:
Use a stop watch, a parking unit on a flat place and position the appropriate attachment extend full posture measurement
Specify start point measurement, do swing a lap early and then measuring the time it takes for the next 5 rounds.
25. Swing control lever Stroke
To determine the total stroke PPC valve.
Procedure
Take measurements when the engine died. Use the ruler
Measure at the end of the current stickjoy neutral position until the point when the joy stick digerakkam full stroke.
26. Swing control lever operating force
To determine the amount of force required to move stickjoy, and can be used as an indication of normality inner mechanism PPC valve component.
Procedure
Take measurements when the engine died and the use of push-pull scale.
Associate push-pull scale at the end stickjoy, then drag stickjoy and measure the force required.
27. Travel hydraulic pressure
Pressure travel during no load
To determine working pressure without the burden of travel time and can be used to determine the mechanical abnormality (final drive & undercarriage)
procedure:
Install the pressure gauge on the HPF block (R984), RH120 can use BCS
Raise one side of the track to lower the boom, then move the lever full stroke travel to play the track links are lifted.
Pressure during travel under load
To determine the working pressure of travel time, and can be used to determine the ability (interbal leakage) pump, control valve, rotary joint or travel motors
procedure:
Install the pressure gauge on the HPF block (R984), RH120 can use BCS
Run the unit on a flat, straight
Position the corresponding attachment posture of travel, then measuring the pressure when the travel unit.
Pressure relief Travel
To determine the maximum pressure in the travel system as an indication of the strength of the travel gets heavy load motor current (ramp or muddy terrain)
procedure:
Install the pressure gauge on the HPF block (R984), RH120 can use BCS
Measure the pressure when the travel circuit direliefkan.
28. Travel deviation
To determine the deviation direction of travel unit (turn by itself without desired) that due to different round on both sides of the track link.
Procedure
Do it on a level, flat and straight
Run the unit + 10 meters with both the travel lever full stroke, then measuring the deviation of travel in the next 20m. Measurements carried out on the former travel curved in the middle or 10 m from the initial distance.
29. Travel deviation when operating equipment work while traveling
To determine the deviation direction of travel unit (turn by itself without desired) that due to different round on both sides of the track link.
30. Travel Speed
To know the track rotary speed link, which can be used as an indication of the magnitude of the main pump discharge flow.
procedure:
Use the stopwatch
Raise one side of the track to lower the boom, marked on one of the tracks and specify the start point of measurement.
Then move the lever full stroke travel to play the track links are lifted. Measurements were made after the preliminary rounds, for the next five rounds.
31. Hydraulic drift of travel
To determine the ability of travel brake clutch, as a parking brake.
procedure:
Tick on teeth sprocket and track link
Parking unit at an inclination of 15 degrees and lift the attachment, then turn off the engine.
Measure a second shift teeth marks on the sprocket and track link after the next 5 minutes.
32. Internal Leakage of travel motors
To determine the level of internal leakage in the motor swing
procedure:
Prepare a container of oil.
Open internal hose leakage of motor travel, then plug the blind plug in the hose and replace the hose extension in internal port leakage motors.
Travel Reliefkan circuit for 1 minute, and measuring the capacity of oil out of the internal port leakage.
33. Travel control lever Stroke
To determine the total stroke PPC valve.
Procedure
Take measurements when the engine died and the use of push-pull scale.
Associate push-pull scale at the end stickjoy, then drag stickjoy and measure the force required.
34. Travel control lever play
To determine the free movement of lever travel, and can be used as an indication of the effectiveness of the travel movement of the lever. Which is influenced by the ball joint wear and precision adjustment retainer.
35. Travel Control Lever Operating Force
To determine the amount of force needed to move the lever travel, and can be used as an indication of normality inner mechanism PPC valve component.
Procedure
Take measurements when the engine died and the use of push-pull scale.
Associate push-pull scale at the end stickjoy, then drag stickjoy and measure the force required.
36. Boom hydraulic pressure
To determine the maximum pressure in the boom circuit, and can be used as an indication of digging and loading force.
procedure:
Install the pressure gauge on the HPF block (R984), RH120 can use BCS
Measure the pressure when Boom Up / Raise end stroke
37. Arm hydraulic pressure
To determine the maximum pressure in the circuit Arm / Stick and can be used as an indication of digging and loading force.
procedure:
Install the pressure gauge on the HPF block (R984), RH120 can use BCS
Measure the pressure when Stick Out end stroke.
38. Bucket hydraulic pressure
To determine the maximum pressure in the circuit Bucket and can be used as an indication of digging and loading force.
procedure:
Install the pressure gauge on the HPF block (R984), RH120 can use BCS
Measure the pressure when the Bucket Curl end stroke.
39. Bull clamp hydraulic pressure (Shovel)
To determine the maximum pressure in the circuit Rear bucket / Bull Clamp.
procedure:
Install the pressure gauge on the HPF block (R984), RH120 can use BCS
Measure the pressure when Bull Clamp close end stroke.
40. Hydraulic drift
To determine the speed of decline in attachment as an indication of the level of internal leakage in Control Valve (spool-housing) and Hydraulic cylinder (piston seal).
41. Total work equipment (hydraulic drift at the tip of the bucket teeth)
To determine the speed of decline in attachment as an indication of the level of internal leakage in Control Valve (spool-housing) and Hydraulic cylinder (piston seal).
Procedure
Parking unit on a flat surface.
Position the attachment posture: Boom - Full Up, Stick - Out Full, Bucket Full Curl.
Measure the height of the initial teeth bucket to the ground.
Measure the altitude changes every 5 minutes for 15 minutes (3x measurement)
42. Boom cylinder (amount retraction of cylinder)
Same with No. 41.
Measuring the velocity of the cylinder rod into the cylinder housing boom every 5 minutes for 15 minutes (3x measurement)
43. Arm cylinder (amount of extension of the cylinder)
Same with No. 41.
Measuring the velocity of the cylinder rod out of the cylinder housing Stick / Arm every 5 minutes for 15 minutes (3x measurement)
44. Bucket cylinder (amount of retraction of cylinder)
Same with No. 41.
Measuring the velocity of the cylinder rod into the cylinder housing Bucket every 5 minutes for 15 minutes (3x measurement)
45. Work equipment speed
To determine the velocity of attachment, and can be used as an indication of the amount of oil flow to the cylinder attachment.
boom
Procedure
Position the attachment posture: Stick - Out Full, Bucket-Curl Full and Lower Boom-up bucket meyentuh ground.
Measure the time required when driven Boom-Up to the full stroke.
Arm
Procedure
Position the attachment posture: Raise Full-Boom, Stick-In-Full and Bucket Full Curl
Measure the time required when driven from Stick-Out Full to Stick-In Full.
Measure the time required when driven from Stick-In-Full to Stick Out Full.
Bucket
Procedure
Position the attachment posture: Raise Full-Boom, Stick-Out Full and Bucket Full-Curl
Measure the time required when moved from the Bucket Full-Curl up-Dump Bucket Full.
Measure the time required when driven from Dump Bucket Full-up Buckets Full-Curl.
Bull Clamp (Shovel)
Procedure
Position the attachment posture: Raise Full-Boom, Stick-Out Full and Bucket Full-Curl
Measure the time required when driven from Bull Clamp-Open-Close to Bull Clamp
Measure the time required when driven from Bull Clamp-Close to Bull Clamp-Open
50. Internal leakage
To determine the level of internal leakage in the hydraulic cylinder and swivel Center (Rotary)
joint Cylinder
Procedure
Position the cylinder rod extend and turn off the engine.
Go head and attach the hose side blind plug on the hose side C / V her.
Reliefkan circuit for 30 seconds and the capacity of the oil out of the cylinder head side for 1 minute next (permanent relief).
Center swivel joint
See shop manual for the position of each port
51. Alternator output voltage
To find large voltage alternator when the engine is running, so as to ensure the process of recharging the battery during operation of the unit.
Procedure.
Turn on the engine and turn the high idle
Use AVO meter in parallel, measure the alternator terminal B: 27-5 - 29.5 V.
53. Battery relay
To ensure the battery relay can connect a battery terminal unit with the electrical system, so that the battery can be a power source.
54. Starting Switch
To ensure the starting switch serves to position the system unit according to the starting rotation switch. connectivitas measuring inter-terminal sesui position / rotation starting switch.
55. Starting motors
To ensure motor starting can work well when used to play (cranking) engine.
56. Solenoid valve
To ensure the solenoid valve can work when the command currents to flow, to stream or close the flow of oil pressure. (Depending on type: NC or NO)
Measure the resistance value when the solenoid is cold and the operating temperature range.
Make sure the plunger or push pin is not jammed. Announcements
57. Sensor
To determine the value of the resistance or the second contact terminal (sensor switch).
Measure the resistance value changes based on changes in pressure or temperature.
Measure connectivitas both terminals by pressure or movement mechanism. Announcements
59. Connector
To know connectivitas between male and female, so as to ensure the electrical current can flow and system unit can function normally.
Make a visual check Checked <condition connectors, wiring, seal, etc.
Use a multimeter to measure connectivitas for each female and female wiring when installed.
60. Link Pitch
To determine the degree of wear bushing and pin, so that it can be determined residual life within the limits of the bushing and pin still be at TPB.
Procedure
Clean bushings and links that will be measured.
Measure link pitch for a two-pin and five-pin using a ruler with track position is tightened first link (attach wedge between the track link and sprocket)
61. Link Height
To determine the degree of wear / height of the link so it can be determined residual life within the confines of the link can still be direbuild.
Procedure
Clean the link to be measured.
Measure the height link using multi-scale
62. Grouser Shoe
To determine the degree of wear / height of grouser shoe so that it can be determined the age of the rest of the shoe can still be direbuild limits.
Procedure
Clean the link to be measured.
Measure grouser height using multi-scale
63. Track Roller
To determine the degree of wear / track roller diameter so that it can be determined residual life within the limits of the track roller can still direbuild.
Procedure
Clean the roller track to be measured.
Measure the diameter of track roller using a caliper and ruler
64. Carrier Roller
To determine the degree of wear / diameter carrier rollers that can be determined residual life within the limits of carrier rollers can still direbuild.
Procedure
Clean the roller carrier to be measured.
Measure the diameter of the roller carrier using a caliper and ruler
65. Track Tension
To ensure the track tension link, thus reducing wear and tear.
Procedure
Run the unit advanced on a flat place and flat.
Measure and adjust track tension roller according to standard tension
66. Front Idler
To determine the level of front idler wear, so it can be determined residual life within the limits of front idler still be in the rebuild.
Procedure
Clean the front idler
Use multi-scale to measure the height of front idler groove.
67. Sprocket
To determine the degree of wear / height of sprocket teeth, so it can be determined the age of the rest of the usage restrictions do not cause abnormal damage to the bushing.
Procedure
Clean the sprocket teeth to be measured
Use wear gauge to measure the degree of wear / altitude sprocket teeth
68. Bushing
To determine the degree of wear bushing and pin, so that it can be determined residual life within the limits of the bushing and pin still be at TPB.
Procedure
Clean bushings and links that will be measured from the ground.
Use the caliper to measure the diameter of the bushing.
MACHINE TROUBLE ANALYSIS
1. Engine does not start
- There is air trapped fuel system
- Abnormality in the supply pump, shut-off valve
- Cranking rpm is not reached
- Fuel mixed with water, etc.
2. Engine Low Power
- There was an impasse at Air cleaner or fuel filter
- Injection timing is not right
- Abnormality in the supply pump, shut-off valve
- Linkage Current thottle or less than the maximum throttle drive
- Quality fuel ugly: mixed with water, kerosene (kerosene) or other impurities. Announcements
3. Engine does not Stop
- Shut-off solenoid valve broke
- O-ring return leaking fuel injector side, so that the entrance to the port metering.
4. Engine Black Smoke
Basically due to fewer incoming air ratio of fuel injected, so there are some unburned fuel.
- Air cleaner clogged
- Turbocharger abnormal
- Over fueling due to an abnormality in the fuel system control
- Unit operating at high altitude, so that the outside air density is relatively smaller.
5. Engine White Smoke
- Injector tip broke, so there is no injection spray.
- Injection Timing is not right.
6. Engine Can not High Idle
- Fuel control dial (potentiometer) abnormal
- Abnormality in ECM
- Misadjustment engine speed sensor. Announcements
7. Engine Knocking
- Timing injection is too fast or slow
- There was excessive wear on the main bearing
- Adjustment valve clearance is not correct. Announcements
8. Oil Consumption is excessive
- Wear and tear in the liner or piston ring is too big (oil up)
- Wear and tear on the valve guide too large (oil down)
- Damage to the turbocharger, the wear on the bushing or the seal, so that the oil leaking into the blower or impeller. etc.
9. Oil is mixed in coolant
- There was a rift in the cylinder head or the engine block on the side of the waterway.
- O-ring liner leak
- O-ring cylinder head gasket leak.
- Oil cooler leak, etc.
10. Oil level rises
Engine oil level can rise due to fuel or water radiator leaked into the crank case, this can be caused by:
- Wear of Plunger FIP is too big, so that fuel leaking into the case FIP
- Injector nozzle or rupture, so the leaking fuel directly into the combustion chamber and piston rings down through the entrance to the crank case.
- O-ring plunger return port nozzle or leak, etc.
- If the level is getting higher because it is mixed with the water, the cause is the same as engine oil mixed with water above. No. 9.
11. Coolant Temperature rises to high
- Core & Fin radiator clogged
- Air radiator less
- Thermostat jammed
- Vacuum valve (radiator cap) do not work. Announcements
- Impeller water pump slip, or internal leakage is too large, and so on.
12. Hydraulic Low Power
- Setting Primary valve is too low
- Internal leakage in the main pump is too large. Announcements
13. Boom Speed is slow
- Internal leakage in the cylinder excessive boom
- Internal leakage in the main pump is too big
14. Excessive Hydraulic Drift
- Internal leakage in the cylinder excessive
- Internal control valve leakage in redundant
- Setting the secondary valve is too low. Announcements
15. Travel Deviation out of standard
Basically due to the difference in rotation on both sides of the track link.
mechanical:
- The number of links the two sides are not the same, (one already cut)
- Track both sides are not the same tension, etc.
hydraulic
- Travel motors one side abnormal (internal leakage too large)
- Internal leakage at the rotary joint. Announcements
16. Travel Speed is Slow
- Internal leakage in the motor excessive travel
- Internal excessive leakage in the main pump
- Flow pump discharge is too small
- Travel Misadjutment valve linkage PPC, PPC valve so that the output pressure is too small.
17. The Machine Can not Swing
- Swing pump abnormal (internal leakage too large)
- Swing motors abnormal (internal leakage too large)
- Swing brake jammed. Announcements
18. Excessive over-run when stopping swing
- Setting a secondary swing valve is too low
19. Bullclamp can not Open / Close (Shovel)
- PPC bull clamp abnormal valve
- Spool C / V bull clamp jammed.
- Internal leakage in the bull-clamp cylinder is too large. Announcements
20. Track Tension Loose
- Seal adjuster track leaked
- Link pitch is too large.
- HIC piston leak. Announcements
21. Abnormal worn out at the under-carriage
- Too often travel long distances
- Terrain abrasive operation
- Track tension is too tight. Announcements
22. Abnormal play at attachment and frame
- Installation of the shim is not appropriate, so that the large clearance.
- Grease lubricating less, resulting in abnormal wear. Announcements
23. Crack at attachment and frame
- misoperation
- Material fatigue
- Miss maintenance. Announcements
