SERVICE REPORT NO.

: 0002-PTU5/SMT/02-2023
PEKERJAAN : BC8 GEAR BOX RECONDITION
PO No. :
MACHINE ITEM/TAG NO.: TRIPPER UNIT STRE2
DATE: JANUARY- JUNI, 2023
AREA: PLTU LONTAR
CLIENT: PT. SEMITER

Page: 1/6

SERVICE REPORT

VISUAL JOB DESCRIPTION EVIDENCES PROBLEM ANALISIS PROBLEM SOLVING/ RESULT

Dismantling from site

Handling and moving to

Using Forklift
truck
Moving to work shop

Unloading at the workshop

Dismantling gear box

1.The angle between the pinion Torque cannot be transferred to

Driver Gear/ pinion is damage
and crown gear is not match the system
2.Different hardness between
Driven gear/ crown is damage
pinion and crown gear
Visual investigation to main 3.Too much clearance between
problem pinion and crown ger
4. Overloaded

5. There is a rotational axle

Disassembly gear box

crankcase
Parts identification and
inspections on crankcase
Crown gear chipped condition
Crankcase bearing housing on the
left side is badly worn
Lots of dirt chips
Many lubrication installations are
clogged
Hammering process while
rotating
Bearing was jam
Causing a rotational axle
Poor lubrication
From loose gears
Chips sucked into the
lubrication installation

Disassembly spindle unit
Pinion gear is badly worn
Bearings were damage/ Cooking on
Parts identification and
both sides DE and NDE
inspections
Labirint seal was damage
Shaft on labirint seal area was worn
Bearing housing dented and cooking Miss installation
on NDE side
Dismantling lubrication
pump unit
Lube Pump was light worn
Lube Pump Unit parts Lube installation tube was dirty
identification and
inspections Filter oil was dirty
Radiator was dirty
Diameter : 40.020
Crown gear turning process Total run out : 0 Ok
Corner radius : 4 Ok
Hole diameter : 90.005
VCN 150
Crown gear turning process Raw material :
(Bohler)
Existing shaft diam : 90.025
Not as hard as crown gear
The contact area with the
crown gear is too small
Rotational axle
Over heating/ over loaded
Running on dirty condition
Miss greasing
Bearing over heating
Running on dirty condition
Running on dirty condition
Running on dirty condition
Running on dirty condition
Top tolerance : +0.015
Bottom tolerance : +0.030
Top tolerance : +0.005
Bottom tolerance : -0.005
Top tolerance : +3
Bottom tolerance : +5
Top tolerance : +0.010
Bottom tolerance : -0.005
AISI 4340
Page: 2/6
Diferent material with crown g.
Miss on hardening process
Miss on machining process
Axial movement due bearing
locknut lose
Should be evaluated on spidle
mechanism
Modificated with lipseal/mech.
Seal
Coal dust come into seaal
Rotating plate rubs against the
shaft
Cause the bearing is not centered
Over friction/ over loaded
Needs to be serviced
Still operating well
Needs to be serviced
Replaced with new one
Needs to be serviced
Ok
Ok
Ok
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Universal milling Process Helical volute Modul 5.5 Ok

Top tolerance : +0.005

Hole diameter : 40.000 Ok
Bottom tolerance : -0.005
Pinion gear turning process
VCN 150
Raw material : AISI 4340 Ok
(Bohler)

Universal milling Process Helical volute Modul 5.5 Ok

First Lapping Using corundum 30 micron Not to smooth Not to good

Hardening 850 deg C 820-870 deg C, Oil quencing

Heat tretment process Tempering 650 deg C 580-680 deg C, Ambient/rapid Ok
Hardeness 51 HRC 45-53 HRC

Gear to shaft assembly Hydraulic press 30 T On position Ok

Bearing to spindle shaft Using heater to innering bearing
On position Ok
assy. 32317
Bearing to driven shaft Using heater to innering bearing
On position Ok
assy. 32317

Spindle housing bearing Man. grinding to smooth surface Smooth surface

Ok
recondition DE side Diameter 180.000 Tolerance JS6 +0.011, -0.011
Spindle DE bearing
Press fit with bearing 32316 Press fit Ok
assembly
Spindle NDE bearing
Press fit with bearing 32317 Press fit Ok
assembly
 Page: 4/6

Stationary side is modifated become

OD Lip seal diameter 95 Ok
Labirint sel recondition/ lip seal housing
modification Rotating plate is reconditioned with Tolerance to
0.2 Ok
turning mc. stationary :

Axial clearance to : 0.020 Tolerance : 0.010-0.025 Ok

Spindle unit assembly
Using double locnut and washer in Prevention of bearing
Ok
between looseness

Manual under cutting to 0.05 Using manual turbo grinding Ok

Preheating to 150 deg C Using acetilene burner Ok

Crankcase recondition on
left side Welding cast iron electrode first
TIG welding mc. Ok
layer
Welding cast iron electrode second
TIG welding mc. Ok
layer

Boring process Return to original size Using in situ line boring mc.
Top tolerance +0.005
Bor diameter 180.00 Ok
Bottom tolerance -0.005
QC inspection
Roughness N6 N5-N6 Ok

Second lapping process using corundum 30 micron

 Page: 5/6

Gear box assembly

Crown gear axial clearance Axial clearance
Crown gear axial movement: 0.015 0.01-0.03 Ok
adjusment tolerance :
Bevel gear clearance Radial clearance between pinion and Radial clearance
0.1-0.3 Not to good
adjusment crown gear : 0.4 tolerance :
Manual play Light and smooth Free friction and resinstance Ok

Lube Pump service Clean and light running Ok

Replacement new motor bearing and
Running well Ok
lip seal
Replacement new oil filter As standard Ok
Lube Pump Unit Recodition
Ok
Cleaning all of tube and hose Clean
Radiator Fan, Fin & tube cleaning Clean Ok
service: motor bearing replace Running well
Ok
Instrument checking Standard function

Assembly gear box unit and

Lub pump unit
Standard gear box oil SAE 90-
Filling gear box oil Gear box oil SAE 140, 60 L
SAE 140

Circulation well on discharge Minimum discharge pressure

Ok
Lubrication pump testing pressure 3.3 Bar 2.5 Bar
Pump was very often trip Gear box oil to thic Change oil to SAE 90 -SAE 120
Operation speed : 1400 Rpm
Running at 800 Rpm: Rotating
Vibration without max 2.5 Not checked maximally
Gear Box running test tendency smoothly there is little
load : mm/sec.
noise
Noise: No Not checked maximally

Moving to site

Installation on site
Motor to Axial : 0.03 Axial tolerance : 0.08
Ok
gearbox Radial : 0.04 Radial tolerance : 0.08
Alignment
Conv. to Axial : 0.03 Axial tolerance : 0.08
OK
gearbox Radial : 0.06 Radial tolerance : 0.08
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Vertical Max. 3.30 Vertical tolerance 7.1 Ok

Running test (without load) Vibration Horizontal Max. 3.00 Hrzl. Tolerance 7.1 Ok
Axial Max. 3.31 Axial tolerance 7.1 OK
Noise There is noise in both directions Noise is not permitted Not god, Should be evaluated

ARRANGED BY: PT. PERSADA TANTA UTAMA CLIENT APPROVAL: PT. SEMITER END USER: PLN UPP JBB