MECHANICAL FAILURE

TRANSMISSION SCANIA
 Scania Transmission Variant

03 November 2022 Said 2

 GR 905

8+1 Speed
range-change
Type of transport
Long haulage
2200Nm 4x2+1
295Kg
1039mm

03 November 2022 Said 3

1. Input shaft 6. Mainshaft
2. Oil pump 7. Coupling sleeve for reverse and crawl
3. Layshaft gears
4. Synchromesh for third and 8. Intermediate gear for reverse gear
fourth gears 9. Planetary gear with output shaft
5. Synchromesh for first and
second gears

03 November 2022 Said 4

 GRSO 905 /R

Transportation type
Long haulage and Construction
3000Nm 2x3x2+2

03 November 2022 Said 5

 1. Input shaft
7. Synchromesh for first gear
2. Oil pump
8. Coupling sleeve for crawl gear and reverse
3. Layshaft
gear
4. Synchromesh for splitter gear changing
9. Intermediate gear for reverse gear
5. Synchromesh for second and third gears.
10. Planetary gear with output shaft
6. Mainshaft

03 November 2022 Said 6

 GRSO 925 /R

Transportation type
Heavy Transport
3500Nm 2x3x2+2

03 November 2022 Said 7

 1. Input shaft
7. Synchromesh for first gear
2. Oil pump
8. Coupling sleeve for crawl gear and reverse
3. Layshaft
gear
4. Synchromesh for splitter gear changing
9. Intermediate gear for reverse gear
5. Synchromesh for second and third gears.
10. Planetary gear with output shaft
6. Mainshaft

03 November 2022 Said 8

Speed 1&5 tidak bisa masuk
 Wire Lock Lepas

07 Desember 2022 Said 10

 Mekanisme Synchromesh Aus

07 Desember 2022 Said 11

 Mekanisme Synchromesh Aus

Dari data diatas ditemukan bahwa standar celah

antara latch cone dan coupling cone minimal
7.40 - 2.93 - 3.96 = 0.51 mm
Tetapi actual celahnya 0 mm.
Sehingga catch wire dapat keluar dari
dudukannya akibat celah antara driver dan latch
cone membesar menjadi 4,47 mm.

03 November 2022 Said 12

 Penyebab Mekanisme Synchromesh Aus

Karakteristik helical gear

mengakibatkan adanya axial load.
Apabila digunakan untuk torque
tinggi maka axial load akan
membesar pula.

03 November 2022 Said 13

 Penyebab Mekanisme Synchromesh Aus

LATCH CONE &

END PLAY INERTIA FORCE SYNCROMESH INTERMEDIETE
MEMBESAR TINGGI OVERLOAD CONE WORN
OUT

03 November 2022 Said 14

 <3 km/h adalah angkatan
awal unit yang
membutuhkan torsi tinggi.
Semakin tinggi prosentase
<3 km/h berarti semakin
tinggi axial load yang
diterima tapper roller
bearing.
03 November 2022 Said 15
 NO ACTION DATE CODE NUMBER TYPE HM TARGET PRODUCT
1 08-Nov-14 TW181 P380CB6X6 4271 18000 UTR ACHIEVEMENT
2 18-Nov-14 LO092 P380CB6X6 5958 18000 UTR
3 23-Nov-14 TF157 P380CB6X6 6117 18000 UTR FROM TARGET
4 12-Apr-15 TW179 P380CB6X6 4427 18000 UTR
5 21-Apr-16 TW181 P380CB6X6 7477 18000 ON SITE
6 21-Jul-16 TF163 P380CB6X6 13089 18000 ON SITE
7 21-Aug-16 TF159 P380CB6X6 13970 18000 ON SITE
8 02-Oct-16 TW179 P380CB6X6 10680 18000 ON SITE
9 27-Jan-17 TF155 P380CB6X6 14329 18000 ON SITE
10 09-Feb-17 ST030 P380CB6X6 7404 18000 ON SITE
11 05-Mar-17 TF163 P380CB6X6 16832 18000 ON SITE
RATA-RATA UMUR 8772

NO ACTION DATE CODE NUMBER TYPE HM TARGET PRODUCT

1 07-Aug-15 LD622 P380CB6X4 10218 18000 UTR ACHIEVEMENT
2 16-Apr-16 LD645 P380CB6X4 11703 18000 ON SITE
3 27-Nov-16 LD643 P380CB6X4 14351 18000 ON SITE FROM TARGET
4 15-Dec-16 LD646 P380CB6X4 14786 18000 ON SITE
5 15-Jan-17 LD612 P380CB6X4 16046 18000 ON SITE
6 17-Mar-17 LD613 P380CB6X4 17020 18000 ON SITE
7 20-Mar-17 LD622 P380CB6X4 16206 18000 ON SITE
8 20-Apr-17 LD610 P380CB6X4 17105 18000 ON SITE
RATA-RATA UMUR 14461

03 November 2022 Said 16

 Install Synchromesh Assembly Mainshaft Assembly Gear Speed

Install Layshaft Install Mainshaft Install Selector Fork

03 November 2022 Said 17

 Sebelum Perbaikan
0 mm

Sesudah Perbaikan
4,45 mm

03 November 2022 Said 18

 Adjustment Axial Play Mainshaft & Layshaft
Torque method

Measurement method

03 November 2022 Said 19

 Pencegahan Problem

1. Injak pedal clutch dan tahan 5 detik saat akan masuk speed pada Angkatan awal unit mau jalan.
Supaya putaran inertia pada gear transmisi hilang dahulu.

2. Lakukan perawatan linkage transmisi sesuai shop manual.

3. Lakukan perawatan clutch system sesuai shop manual.

03 November 2022 Said 20

Posisi lever masuk speed tapi
transmisi netral
 Range Fork Worn Out

07 Desember 2022 Said 22

 1. Mainshaft 5. Planetary
2. High range 6. ring gear
3. Sun wheel 7. Latch cone
4. Latch cone 8. Low range

03 November 2022 Said 23

 Apabila unit dioperasikan netral coasting
posisi range high maka ring gear akan
diputar oleh roda dengan putaran yang
cepat akibat gear ratio dan air cylinder
tersupplai udara bertekanan. Pada kondisi
ini fork sisi high akan ditekan menempel
pada ring gear yang berputar sehingga fork
mengalami keausan.

High position
HINDARI NETRAL COASTING
03 November 2022 Said 24
Splitter high tidak bisa masuk
 Coupling Disc Splitter Broken

07 Desember 2022 Said 26

 Sosialisasi ke operator bahwa
perpindahan splitter wajib injak
clutch pedal full.
03 November 2022 Said 27
Transmission housing broken
 Spiral Pin Broken

07 Desember 2022 Said 29

 Lepasnya spiral pin mengakibatkan 2 speed masuk
bersamaan sehingga housing transmisi pecah.

Lakukan penggantian spiral pin saat overhaul.

03 November 2022 Said 30
Engine stall saat masuk speed
 Bearing Transmission Broken

07 Desember 2022 Said 32

 Jika towing >500 meter wajib
lepas propeller shaft

03 November 2022 Said 33

Range gear noise
 Coupling Cone High-range Broken

07 Desember 2022 Said 35

 Neutral Position Switch Short
1. Pulse wheel on output shaft
2. Range switch
3. Compressed air
4. Control cylinder for range gear
changing
5. Solenoid valve for low range
6. Solenoid valve for high range
•E30 = Co-ordinator.
•O1 = ICL with low split
•O4 = Tachograph
•T20 = Rotational speed sensor
•B16 = Reversing light switch
•B45 = Neutral position switch
Line explanation
•A = Air line, pressurised
•B = Air line, pressurised/not pressurised
•C = Electric cable
•D = CAN communication
Netral position switch aktif terus ( mengirim ground sinyal terus ke COO ) •E = Pulse train
03 November 2022 Said 36
 Perpindahan range hanya bisa terjadi saat posisi netral.
Controller tau posisi netral saat neutral position switch
mengirim ground signal ke COO.
Jika netral position switch short maka perpindahan range
dapat terjadi sekalipun masih posisi masuk speed,
sehingga terjadi tabrakan antara coupling cone high
range dengan ring gear range yang mengakibatkan teeth
coupling cone pecah.

Lakukan pengecekan rutin netral position switch

03 November 2022 Said 37

 Terima Kasih

03 November 2022 Said 38