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: