MEMELIHARA x MEMPERBAIKI

1. MEMELIHARA sasarannya adalah Mesin yang masih baik, sesuai standar, baik spesifik geometri dan performance-nya.

2. MEMPERAIKI sasarannya adalah mesin yang sudah rusak atau menurun kualitas nya, baik spesifik geometri maupun performance-nya.

TUJUAN:1. Agar mesin selalu dalam

kondisi kapasitas desain2. Agar mesin kembali pada

kondisi kapasitas desain.

1. JENIS MESIN1. Nama/sebutan/fungsi

2. SISTEM1. Sub Sistem [mekanis,

elektris, hidrolis, pneumatis]3. UNIT KOMPONEN

1. Komponen [mekanik, elektrik, hidrolik, pneumatik]

2. Elemen4. STANDARISASI

1. Fisik 2. Fungsi3. Performance4. Karakter lain

PERBAIKAN MESIN[PERIODA PELAKSANAAN]

1. PREVENTIVE[ time based]

Repair [s,m] Overhaul

1. PREDIKTIVE[Condition based]

2. SHUT DOWN /BREAKDOWN Ketika tak digunakan/terjadwal

3. EMERGENCY Tak tentu [tak terduga,tak terencana]

MAINTENANCEpakem

PLANNEDPREVENTIVECORRECTIVE

SHUTDOWNBREAKDOW

N

OVERHAUL /MAJOR OH

CLEANING INSPECTION SMALL REPAIR MEDIUM

REPAIR/MINOR OH

RUNNING MAINTENANCE

UNPLANNED

EMERGENCY MAINTENANCE

PERBAIKAN MESIN[JENIS TEKNIS]

SERVICING [cleaning,inspection,repair]

ADJUSTINGLUBRICATING

WELDINGMACHININGREPLACING

PERBAIKAN MESIN[PENGUJIAN]

1. STATIK

1. Destructive

2. Non Destructive

2. DINAMIK

1. Lab

2. Lap

3. EMPIRIK1. User

PERBAIKAN MESIN[DIAGNOSA KERUSAKAN]

1. Logika

2. Kanan-kiri

3. Berurutan

4. Penggantian

5. Visual

6. Temperatur

7. Getaran

8. Power

9. Performance

10.Hasil/produk

PERBAIKAN MESIN[KLASIFIKASI PERBAIKAN]

1.Repair Kecil

2.Repair Medium

3.Repair Besar (Overhaul)

PERBAIKAN MESIN[basic science requerment]1. Standarisasi produk2. Material & heat treatment3. Guide surfaces4. Transmission5. Journal-bearing6. Key fitting7. Spline fitting8. Coupling9. Clutches10. Screw & nut11. Machine spindle12. Vee belt drive13. Chains & sprocket14. Machine hydraulic15. Tail stock16. Chucks17. Welding technology18. Seal & sealing19. Utility machine

[primemover,cranes,hammers,power presser/shear,furnace, handling facilities, measuring instrument]

PERBAIKAN MESIN[Standarisasi Produk]

Suaian dan Toleransi Suaian

Interference fit [suaian sesak]Tipe: shrink; forced; light pressedSimbol: u; s; r

Transition fit [suaian tak tentu]Tipe: heavy keying; medium keying;

light keying; pushSimbol: n; m; k; js

Clearance fit [suaian longgar]Tipe: sliding; close running; normal

running; easy running; loose running; slack running; large clearance

Simbol: h; g; f; e; d; c; b

PERBAIKAN MESIN[Standarisasi Produk]

Penggunaan umum suaian untuk beberapa produk komponen1. Roda gigi

1. Roda gigi luar h8

2. Roda gigi dalam H9

3. Roda gigi cacing h8

4. Ulir cacing h8

5. Rackgear H9

2. Sliding bearing1. On ID H7/h6

2. On OD H7/js6

3. Ball/roller bearing Transmisi roda gigi

1. Housing H7

2. Shaft k6 sd 40d

1. k6,js6 [40 sd.100d]

2. m6 [100 sd 250d]

PERBAIKAN MESIN[Standarisasi Produk]

Pompa sentrifugal,f an dll1. Housing J72. Shaft =transmisi roda

gigi Belt conveyer

1. Housing M7,K72. Shaft g6

Crane wheel1. Housing N72. Shaft n6,m6

Spindle of grinding machine Housing K7,J7 Shaft k6,js6 [sd.40d]

k6,js6 [ballbearing 40-100d]

m6 [roller bearing 40-100d]

n6 [di atas 100d]

PERBAIKAN MESIN[Standarisasi Produk]4. Key fitting

Key fit on shaft and slides in housing

Lebar pasak h8 Lebar alur pada poros W Lebar alur pd housing H9 Lubang dan poros H7/h6 sd.50d H7/f7

[50-100d] H7/e8

[di atas 100d]

Key fixed in housing and slides on shaft

Lebar pasak h9 Lebar alur pd poros W3 Lebar alur pd housing H9 Lubang dan poros sda

PERBAIKAN MESIN[Standarisasi Produk]

Surface finish [IS:3073-1967] Kekasaran rata-rata [ atau N √]∇

Finishing op simbol harga [micron]

Rough machining∇ 8-25Fine machining ∇∇ 1.6-8Grinding finish ∇∇∇ 0.025-1.6Lapping ∇∇∇∇ <0.025

[micro inhci]

Rough machining∇ 250-1000Fine machining ∇∇ 63-250Grinding finish ∇∇∇ 2-63Lapping ∇∇∇∇ <2

PERBAIKAN MESIN[material&heat treatment]Material untuk komponen mesin, baik

komposit maupun sifat-nya yang umum digunakan adalah: baja, besi tuang, bronze, brass, aluminium dll.

BAJA:

C40:sg[7.7], C[0.4], Mn[0.7], Si[0.25], s[60], L[20%] {=>shaft, axles, gears etc, beban ringan-medium}

40Cr2Al Mo18: sg[7.85], C[0.4], Mn[0.6], Si[0.3], Cr[1.6], Mo[0.2], Al[1.0], s [80], t[8] {=>spindel mesin gerinda, mesin bor horizontal}

PERBAIKAN MESIN[material&heat treatment]NOFERROUS:

SI no.4: General purpose bronze, sg[8.7], Cu[r], Zn[4-6], Tin[4-6], Lead[4-6], Imp[1.3], HB[50], s[15], L[6%], {=>general purpose, bush bearing, nut for lead screw, worm wheel etc}

SI no.5: Brass, sg[8.5], Cu[60.5-63.5], Zn[r], Imp[0.5], s [35], L[20], MP[880-970°C], {=>screws, bushes, nuts, tubes, wire netting for lubrication system, sheet packings etc}

PERBAIKAN MESIN[material&heat treatment]

Heat treatment of steels:1.Anealing

2.Normalising

3.Hardening and Tempering

4.Carburising, surface [case] hardening and tempering

5.Nitriding

6.Aging

7.Spark testing composition material.

GUIDE SURFACESKelurusanKerataan

KesejajaranKesikuan

Kemiringan Profil

TRANSMISI RODAGIGI1.Roda Gigi

1.Lurus2.Helix3.Bihelix4.Taper5.Rack6.Worm7.Hypoid

KERUSAKAN &REPAIR RODA GIGI

1.Jenis kerusakan1. Sadis/gagal2. Fatiq /umur3. Aus4. Exident

2.Metoda repair1. Welding2. Surfacing3. Replacing

Kerusakan&repairFRICTION/BUSH

BEARINGDimensiToleransiTipe kerusakan

AusPecahWelded

Metoda perbaikan/repairSurfacingResizingReplacing

Krusakan&repairANTIFRICTION BEARING

StandarisasiTipe kerusakanAnalisis kerusakan

Dismounting & mountimg metode

Lub sistem

Kerusakan&repairKEY FITTING

[pasak&splines]Standarisasi

BentukdimensiToleransi

Tipe kerusakanTerpotongAusDeformasi

RepairResizingWeldingMachiningReplacing

Kerusakan&repairKOPLING

Tipe & standarisasi koplingKopling tetapKopling flexibleKopling gigiKopling pengaman

Tipe kerusakanTerpotongAusDeformasi

RepairResizingWeldingMachiningReplacing

CLUTCHFriction clutch

DiscConeSilindris

Free wheeling clutch

Tipe kerusakan

Repair

LEAD & SCREWSTANDARISASI [matdimtol]

MaterialDimensiToleransi

JENIS KERUSAKANAus DeformasiGagalExident

REPAIRWelding Machiningreplacing

TRANMISSI LAIN

‘V’ beltChains & sprocket

MACHINE HYDRAULICSSISTEMKOMPONENKERUSAKANREPAIR

PERENCANAAN KEGIATAN MAINTENANCE [CPM]

VariabelWaktuSumber dayaKinerja

PERBAIKAN MESINcreated by: