PT.

Pamapersada Nusantara - Site Mechanic Development Pspn

PETUNJUK CARA PENGISIAN TSR

1 REPORT NO

2 REPORT DATE

3 WO NUMBER

4 DELIVERY DATE

5 CODE NUMBER

6 MACHINE MAKER

7 MACHINE MODEL

8 MACHINE S/N

9 ENGINE MODEL

10 ENGINE NUMBER
APPLICATION

- LOC
11

- WORK

ENVIROMENT

- COND
12

- CARAC

13. OPERATION

- CODE UNIT
13

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PETUNJUK CARA PENGISIAN TSR

13

- OPER TABLE

- Pay load

- Material Carri

- Speed (Km/Hrs)
14
- Olie Made

- Olie Class

- Olie Visc

15 TROUBLE

16 TROUBLE DATE

17 HM

18 KM

NUMBER MAIN PART

19 CAUSING THE PROBLEM

20 PART NAME

21 COMP/ PART GROUP

22 LIFE TIME

23 Analysis

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23 Analysis
PETUNJUK CARA PENGISIAN TSR

24 CAUSED

25 DETAIL OF FAILURE

26 CORRECTION MADE

27 CORRECTION DATE

28 MAN HOUR

29 NRP

30 LEVEL

31 MECHANIC NAME

32 SIGN

33 WORKING PARTNER
34 SUPERVISOR NAME
35 SIGN

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PETUNJUK CARA PENGISIAN TSR

: Diisi No urut / initial mechanic / site / tahun.

Misal : 01/HRT/ADR/01
: Diisi tanggal report di buat.
Misal : 22 03 01
: Diisi nomer Wo Mims yang terdapat pada Wr
Misal : 70557
: Diisi tanggal delivery unit ke site
Misal : 15/01/00
: Diisi code no unit
Misal : PM 464
: Ditulis merk/nama pembuat machine tersebut
Misal : Volvo
: Diisi model machine seperti tertera di unit
Misal : FH16
: Diisi nomer seri machine
Misal : 507696
: Diisi model engine sesuai dengan factory
Misal : D16B520
: Diisi No engine sesuai factory
Misal : 36474

: Diisi lokasi dimana unit tersebut di operasikan

ini bisa dilihat pada application table location
Misal : Main road
: Diisi penggunaan unit tersebut ini bisa dilihat
pada aplication tabel working condition.
Misal : Flat road hauling

: Diisi kondisi lingkungan medan kerja

ini bisa dilihat pada enviroment table ground
condition.
Misal : anpaved even road
: Diisi karakteristik dari medan kerja
ini bisa dilihat pada enviroment table ground
caracter.
Misal : Destructive

: Diisi code operasi unit

ini bisa dilihat pada unit code for operation table
Misal : 22 (primover truck)

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PETUNJUK CARA PENGISIAN TSR

: Diisi operation table

ini bisa dilihat pada kolom operation table

Misal : 03 (heavy duty)
: Diisi beben max load pada unit (hanya untuk DT)
Misal : 180,000 kg
: Diisi material yang sedang di angkut
Misal : Coal
: Diisi kecepatan rata-rata (normal) unit saat operasi
Misal : 60 Km/Hrs
: Diisi Pembuat oli yang digunakan di unit
Misal : Pertamina
: Diisi klasifikasi oli yang di pakai
Misal : CD
: Diisi viscositas oli
Misal : 15W - 40
: Colom code diisi code kerusakan
Misal : 016 (oil pressure drop)
Dibawah colom di isi symptom trouble
Misal : Engine oil pressure drop
: Diisi tanggal terjadi-nya kerusakan
Misal : 20 03 01
: Diisi Hm yang terbaca pada saat terjadi kerusakan
Misal : 002500
: Diisi Km yang terbaca pada saat terjadi kerusakan
Misal : 165060
: Diisi part number dari part penyebab terjadinya -
problem/ trouble
Misal : 965180
: Diisi descrition/ nama part tersebut
Misal : Flange screw
: Diisi code group component standart tabel pama
Misal : 03A (section pipe)
: Diisi life time part component sejak dipasang bila
life time component tidak mungkin terecord -
sebelumnya dapat dikosongkan.
Misal : 2500 Hm.
: Diisi langkah-langkah perbaikan, bagian paling -
penting di dalam TSR berisi :
- Langkah kerja
- Gambar
- Kesimpulan akhir

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PETUNJUK CARA PENGISIAN TSR

- Rekomendasi akhir/ follow up
: Diisi penyebab terjadinya kerusakan
ini bisa dilihat pada Caused table
Misal : 200 (maintenance error)
: Diisi keterangan singkat berisi part problem dan -
penyebab utama part problem
: Diisi aktivitas perbaikan yang dilakukan oleh
mekanik ini bisa dilihat pada correction table
Misal : 100 (adjustment / reposition)
: Diisi tanggal saat dilakukanya perbaikan
Misal : 23 03 01
: Diisi jumlah jam kerja efective yang di perlukan -
untuk mengatasi/ memperbaiki trouble
Misal : 2 Hour
: Diisi nomer induk mechanic yang mengerjakan
Misal : 6100022
: Diisi level mekanik yang mengerjakan
Misal : M2
: Diisi nama mechanic yang mengerjakan
Misal : Robi Jonson
: Diisi Tanda tangan mechanic yang melakukan
pekerjaan
: Diisi rekan mechanic yang melakukan pekerjaan
Misal : Abdul, Badu, Cecep
: Diisi nama Gl/ Pic yang di tunjuk
: Tada tangan Gl/ Pic yang di tunjuk

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LIST OF TROUBLE CODE

NO COMPONENT CODE
001
002
003
004
005
006
007
008
009
010
011
ENGINE & AIR SYSTEM

012
013
014
1 015
016
017
018
019
020
021
022
023
024
025
026
027
028
029
101
102
ELECTRICAL SYSTEM AND PANEL

103
104
105
106
107
108
2
109
110
111
112
113
114
115
116
201
202
203
204
205
206
207
208
209
210
211
212
POWER TRAIN

213
214
3 215
216
217
218
219

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POWER TRAIN
3
LIST OF TROUBLE CODE

NO COMPONENT CODE
220
221
222
223
224
225
226
227
228
229
301
302
303
UNDER CARRIAGE

304
305
306
4 307
308
309
310
311
312
313
401
402
403
404
405
406
407
MACHINE CONTROL

408
409
410
411
5
412
413
414
415
416
417
418
419
420
421
422
501
502
503
504
505
506
507
GUARD AND FRAME

508
509
510
511
6
512
513
514
515
516
517
518
519

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PT. Pamapersada Nusantara - Site Mechanic Development Pspn

LIST OF TROUBLE CODE

NO COMPONENT CODE
520
521
522
601
602
603
604
605
606
HYDRAULIC AND CONTROL

607
608
609
610
611
7
612
613
614
615
616
617
618
619
620
621
622
701
ATTACHMENT/WORK
EQUIPMENT

702
703
704
8 705
706
707
708
709
9 OTHERS 801

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LIST OF TROUBLE CODE

TROUBLE DESCRIPTION
Starting performance is poor - always take times
Starting deffective or badness-no start, not trun, no combustion
Engine does not pic up smoothly
Engine runs abnormally - speed too high, does not stop, hunting
Engine stall during operation
Engine stop during operation
Fuel level goes down / leaking out
Excessive fuel consumtion
Engine lack of power
Exhaust gas is black
Exhaust gas is blue - combustion of oil
Excessive oil consumption - oil leak out
Oil level rises (mixed water or fuel)
Oil quickly becomes dirty
Oil pressure gauge indicator fluctuates abnormally
Drop in oil pressure
Oil in cooling system
Water temperature does not rise
Engine over heat
Water level goes down
Too much vibration
Abnormal noise emtted
Excessive wear of engine parts
Battery does not charge
Air pressure does not rise
Compressor is not relieved
Drop air pressure
Leaking out of air pressure
Others
Abnormally in electrical parts
Fault in electrical part
Abnormality in monitor panel
Mulfunction in monitor panel
Abnormality in gauge
Mulfunction in gauge
Abnormality in caution system
Abnormally in maintenance monitor panel
Mulfunction in maintenance monitor panel
Abnormality in pilot lamp
Mulfunction in pilot lamp
Abnormality in meter system
Mulfunction in meter system
Abnormality in controller system
Fault in controller system
Others
Machine lack of power
Machine does not move / travel
Machine does not travel smoothly
Too much vibration in lower train component
Unusual nois on power train component
Torqoe coventer temperature too high
Torqoe coventer oil perssure is low
Torque coventer lock up clutch does not work
Excessive time lag when starting or shifting gear
Excessive shock when starting or shifting gear
Difficul shifting gear
Transmision does not shift up
Machine move when engine is started
Machine travel in one derrection only
Transmision temperature too high
High low gear does not shift
Machine does not turn
Machine turn in one direction only
Steering clutch does not dis engaged

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LIST OF TROUBLE CODE

TROUBLE DESCRIPTION
Steering clutch slip
Steering brake does not work or ineffective
Upper structure does not swing
Excessive travel deviation
Diff lock does not work
leaking out of lubricant
Wear of power train's part / component
Crack of power train's part / component
Broken of power train's part / component
Others
Under carriage's component wear
Crack or broken of under carriage component
Bend on under carriage component
Under carriage component lost
Abnormal noise on under carriage component
Shimmy / abnormal vibration of wheel
Service brake does not work
Parking brake does not work
Service brake in effective
Parking brake in effective
Service brake dragging
Parking brake dragging
Others
Wear of engine control linkage / lever
Auto deccelaration does not work properly
Operating force of clutch's pedal is heavy
Clutch control mulfunction
Transmission control mulfunction
Transfer control mulfunction
Steering wheel is sluggish or heavy
Steering wheel does not trun
Steering wheel moves unsteadly
Steering wheel shimmy / vibration
Steering wheel does not to neutral position
Motoring the steering wheel
The steered wheel are activated in opposite direct
Steering wheel can be turned continously
Backlash / wheel play too large
Left / Right radius are different
Out of adjustment in control linkkage / lever
Leaking out of oil / fluid
Oil / fluid line blocked
Retarder / exhaust brake mulfunction
Automatic control mulfunction
Others
Guard crack / retak
Guard broken / patah
Guard dent / penyok
Guard bend / bengkok
Guard lost / lepas / hilang
Guard wear / aus /
Cabin / canopy loose / kendor / lepas
Cabin / canopy dent / penyok
Cabin canopy keropos
Cabin canopy unusual noise
Cabin / canopy abnormal vibration
Cab liffting & suspension mulfunction
Cab accessories mulfunction
Air condition / heater mulfunction
Frame bengkok / bend
Frame crack / retak
Frame broken / patah
Mufunction of frame supplement - ring feeder, fift wheel
Suspension component wear

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LIST OF TROUBLE CODE

TROUBLE DESCRIPTION
Suspension poor performance
Suspension component broken
Others
Hyd oil level down / leak / excessive oil consumption
Abnormal noise in hydraulic system
Work equipment does not move
Work equipment move slowly / lack of power
Work equipment slow after reached certain height
Work Equipment force is lack
Work equipment can't be held with hydraulic cyld
Work equipment movement is unsteadly during work
Travel piston rod R-L cylinder is different
Work equipment moves momentarily
Excessive time lag of work equipment
Out put does not charge when operated
Excessive hydraulic drift of hydraulic cylinder
Excessive hydraulic dreift of swing
Overheat in hydraulic system
Insufficient pressure in the system
Pump delveries in insufficient or no fluid
Travel speed does not change
Roller drum vibration mulfunction
Operating force of control lever is heavy / stiffly
Pin puller cylinder does not work
Others
Wear of attchment component
Attachment component dent
Attachment component bend
Attachment component crack
Attachment component broken
Attachment component lost
Attachment component mulfunction / does not work
Attachment poor performent
Others
Machine accident

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COMPONENT / PART GROUP CODE

NO MOJOR COMPONENT CODE SUB COMPONENT CODE MINOR COMPONENT CODE
1 ENGINE 000 Cylinder head group 010 Cylinder head & fitting part 01A
Rocker arm, houshing & cover 01B
Air intake manifold & after cooler 01C
Air cleaner & fitting parts 01D
Exhaust manifold & turbocharger 01E
Muffler & exhaust pipe 01F
Water manifold & thermostat 01G
Water heater & piping 01H
Cylinder block group 020 Cylinder block & liner 02A
Block cover 02B
Front cover & support 02C
Timing gear & idle gear 02D
Crank case & breather 02E
Flywheel & houshing 02F
Crank shaft & demper 02G
Piston & connecting rod 02H
Camshaft & follower 02I
Lubricating oil system 030 Oil pump & section pipe 03A
Oil filter 03B
Lubricating oil piping & jet nozzle 03C
Lubricating oil cooler 03D
Fuel system 040 FIP & mouting 04A
Fuel piping & filter 04B
Nozzle & spill pipe 04C
Auto priming system & start solenoid 04D
FIP coupling 04E
Feed pump 04F
Cooling system 050 Water pump & mounting 05A
Cooling fan & V-belt 05B
Tension pulley & fitting part 05C
Corrosion resistor & piping 05D
Charging & starting 060 Alternator & mounting 06A
system Alternator drive 06B
Starting motor & mounting 06C
Heater wiring 06D
Accessories 070 Front accessories drive 07A
Air compressor & mounting 07B
Air compressor piping & governor 07C
Air reservoir tank & valves 07D
Air driyer 07E
2 ENGINE RELATED AND 100 Elektric system 110 Battery & relay switch 11A
ELECTRIC SYSTEM Electric part & wiring 11B
Power line oil heater 11C
Instrument / 120 Monitor panel & related parts 12A
monitor panel Instrument panel 12B
Relay box 12C
APS control unit 12D
Payload meter 12E
Engine mounting 130 Mounting part 13A
Engine support 13B
Fuel tank & piping 140 Main fuel tank & mounting 14A
Float tank & piping 14B
Fuel piping & water sparator 14C
Quick start system & fuel sender 14D
Radiator & piping 150 Radiator & reservoip tank 15A
Radiator piping 15B
Radiator wind break & seal 15C
Radiator fan guard & pulley 15D
Oil cooler & piping 15E
Radiator shutter & control lever 15F
3 POWER TRAIN 200 Main clutch / 210 PTO case & inner parts 21A
Damper / PTO PTO lubricating & piping 21B
Clutch case & housing 21C
Main clucth inner parts 21D
Inertia brake 21E
Damper case & inner part 21F

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COMPONENT / PART GROUP CODE

NO MOJOR COMPONENT CODE SUB COMPONENT CODE MINOR COMPONENT CODE
Torque conventer 220 T/C case & fitting part 22A
3 POWER TRAIN T/C inner part & lock up clutch 22B
T/C valve & solenoid 22C
Scavaging pump 22D
Toque converter oil piping & filter 22E
U - Joint / 230 U-joint / drive shaft 23A
Propeller shaft Propeler shaft & center bearing 23B
Trasfer 240 Transfer case mounting 24A
Transfer gear & output shaft 24B
Transfer control & linkage 24C
Transmission 250 Transmission case & mounting 25A
Transmission inner parts 25B
Transmission control & selector valve 25C
ECMV & solenoid 25D
Steering & Brake 260 Steering case & cover 26A
Steering bevel gear & shaft 26B
Steering clutch 26C
Brake drum & brake band 26D
Brake clutch 26E
Swing Machinery / 270 Swing circle 27A
Circle Swing machinery 27B
Final Drive / Travel 280 Final drive case & fitting part 28A
Final drive gear & sprocket 28B
Travel motor & fitting parts 28C
Travel piping & drain piping 28D
Motor & piping guard 28E
Exle / Differential / 290 Front axle & knucle 29A
Tandem Drive Rear axle & support 29B
Tandem drive case 29C
Tandem drive gear & chain 29D
Differential case 29E
Diff. Inner part & drive shaft 29F
Differential lock 29G
Planetary gear unit / final drive 29H
4 UNDER CARRIAGE 300 Track Group 310 Track frame & trunion 31A
Recoil spring & HIC 31B
Front idler & yoke 31C
Roller & guard 31D
Track soe 31E
Wheel & Brake System 320 Wheel & roller drum 32A
Front brake 32B
Rear brake 32C
Slack adjuster / chamber 32D
Parking brake & control 32E
Exhaust brake & cylinder 32F
5 CONTROL SYSTEM 400 Engine Control 410 Accelerator pedal & linkage 41A
Deccelerator pedal & linkage 41B
Fuel control lever & linkage 41C
Auto deccelerator & fitting part 41D
Engine stop motor 41E
Transmission Control / 420 Transmission pump & valves 42A
Clutch Control Transmission oil piping & filter 42B
Transmission control lever & linkage 42C
Inching system 42D
Clutch pedal & linkage 42E
Clutch boster & piping 42F
Release bearing & fitting parts 42G
Steering Control 430 Steering wheel & column 43A
Steering linkage & tie rod 43B
Steering gear box & booster 43C
Steering pump & valves 43D
Steering oil piping & filters & reservoir 43E
Steering cylinder / leaning / articulating 43F
Emergency steering motor & piping 43G
Breake Control 440 Brake pedal & linkage 44A
Reservoir & master cylinder 44B

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COMPONENT / PART GROUP CODE

NO MOJOR COMPONENT CODE SUB COMPONENT CODE MINOR COMPONENT CODE
Brake cylinder & oil piping 44C
Brake cooling & piping 44D
5 CONTROL SYSTEM Treadle & relay valve 44E
Brake valve & air piping 44F
Retarder & emergency valve 44G
Exhaust brake switch & air valve 44H
Automatic Control 450 Auto suspension 45A
And Service Boom kick out & bucket positioner 45B
Auto compensation 45C
Auto lubrication 45D
Concentrated piping 45E
Tire inflantion 45F
6 GUARD AND FRAME 500 Guard 510 Radiator guard & grill 51A
Engine hood / bonnet / covers 51B
Battery case & lock 51C
Fender / left side step 51D
Floor frame / plate & ladder 51E
Hydraulic tank guard 51F
Rear cover / under guard 51G
Spack board / mud guard 51H
Drive shaft guard 51I
Bumper 51J
Cabin & Canopy 520 Roops mount & canopy 52A
Operator Compartement / cab 52B
Cab interior / operator seat 52C
Console box / control stand 52D
Dash board / cab accessories 52E
Air conditioner & car heater 52F
Cab lifting system & suspension 52G
Frame 530 Main frame / revolving frame 53A
Mamber frame / sub frame 53B
Front frame 53C
Rear frame 53D
Frame link / turn table (coupler) 53E
Landing jack / tire carrier 53F
Suspension / 540 Equalizer bar / pivot shaft 54A
Equalizer Bar Front suspension 54B
Rear suspension 54C
Trunion & spring seat 54D
Spring & shock absorber 54E
Torq rod & stabilizer 54F
7 HYDRAULIC SYSTEM / 600 Hydraulic System 610 Hydraulic tank & suction pipe 61A
WORK EQUIPMENT Hydraulic pump / OLSS 61B
CONTROL Control valve & others valve 61C
PPC valve & servo valve 61D
PPC piping & accumulator 61E
Swing motor & fitting parts 61F
Swivel joint 61G
Oil piping & filter 61H
Hydraulic cylinder / dump hoist 61I
Work Equipment 620 Work Equip. Control lever & linkage 62A
Control Knop / safety control lever 62B
Travel lever & linkage 62C
Bank cutting & control system 62D
Dump PTO & valve 62E
8 WORK EQUIPMENT / 700 Standart Attachment 710 Blade / bucket / log clamp 71A
ATTACHMENT Frame / lift arms 71B
Boom / arms 71C
Draw bar / circle support 71D
Cylinder stay / blade lifter 71E
Circle reserve gear 71F
Others 71G
Optional Attachment 720 Hydraulic ripper & fitting parts 72A
Wich & draw bar pull 72B
Scharifier 72C
Others 72D

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COMPONENT / PART GROUP CODE

NO MOJOR COMPONENT CODE SUB COMPONENT CODE MINOR COMPONENT CODE
Dump Vesel / Trailer 730 Vasel / tank 73A
Tail gate lock 73B
Body heating 73C
8 WORK EQUIPMENT / Trailer 73D
ATTACHMENT Log bolster 73E
Rock Drill 740 Crawl carrier & fitting parts 74A
Hydraulic system & control 74B
Air system & control 74C
DHD / drifter & fitting parts 74D
Others 74E
Stone Crusher 750 Crusher / jaw / cone 75A
Screen / vibrating feeder 75B
Motor drive 75C
Conveyor 75D
Others 75E

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