s tm 0902229 table of content
DAFTAR ISI
LEMBAR PENGESAHAN ............................................................................
i
KATA PENGANTAR .....................................................................................
ii
DAFTAR ISI ...................................................................................................
iii
DAFTAR TABEL ...........................................................................................
iv
DAFTAR GAMBAR .......................................................................................
v
DAFTAR NOTASI ..........................................................................................
vi
DAFTAR LAMPIRAN ...................................................................................
vii
BAB I PENDAHULUAN ................................................................................
1.1. Latar Belakang Masalah ...............................................................
1.2. Rumusan Masalah .........................................................................
1.3. Pembatasan Masalah .....................................................................
1.4. Tujuan Penulisan ...........................................................................
1.5. Manfaat Penulisan .........................................................................
1.6. Metode Penulisan ..........................................................................
1.7. Sistematika Penulisan ...................................................................
1
1
2
3
3
3
4
4
BAB II LANDASAN TEORI ........................................................................
2.1. Alat Berat Forklift Komatsu .........................................................
2.2. Pengertian Hidrolik .......................................................................
2.3. Keuntungan dan Kekurangan Sistem Hidrolik .............................
2.3.1. Keuntungan Sistem Hidrolik ............................................
2.3.2. Kekurangan Sistem Hidrolik .............................................
2.4. Fluida Hidrolik .............................................................................
2.4.1. Fluida yang Digunakan .....................................................
2.4.2. Sifat-sifat Fluida Hidrolik .................................................
2.5. Konsep-konsep dalam Hidrolik ....................................................
2.6. Pompa Hidrolik .............................................................................
2.6.1. Positive Displacement .......................................................
2.6.2. Non-Positive Displacement ...............................................
2.7. Gear Pump ....................................................................................
2.7.1. Fungsi ................................................................................
2.7.2. Jenis Gear Pump ...............................................................
2.7.3. Cara Kerja .........................................................................
2.7.4. Komponen-komponen Gear Pump ...................................
2.7.5. Keuntungan dan Kekurangan Gear Pump ........................
2.7.5.1. Keuntungan Pemakaian Gear Pump ...................
6
6
8
9
9
10
10
11
11
13
15
16
18
19
20
21
24
26
26
26
Acep Suhermin, 2012
Analisis Sistem Gear Pump Pada Unit Forklift Komatsu Kapasitas 3 Ton
Universitas Pendidikan Indonesia | Repository.upi.edu
2.7.5.2. Kelemahan Pemakaian Gear Pump ....................
2.7.6. Langkah-langkah Penoprasian Gear Pump .......................
2.7.6.1. Langkah Persiapan ..............................................
2.7.6.2. Langkah Pelaksanaan ..........................................
2.7.6.3. Langkah Setelah Pengoprasian ...........................
27
27
27
28
28
BAB III PEMBAHASAN ................................................................................
3.1. Permasalahan ............................................................................
3.1.1 Flow yang Dihasilkan Kurang ..........................................
3.1.1.1. Gambaran Masalah ..............................................
3.1.1.2. Faktor Penyebab ...................................................
3.1.1.3. Pemecahan Masalah .............................................
3.1.2 Timbul Suara Tidak Normal .............................................
3.1.2.1. Gambaran Masalah ..............................................
3.1.2.2. Faktor Penyebab ...................................................
3.1.2.3. Pemecahan Masalah .............................................
3.2. Prosedur Perbaikan .......................................................................
3.2.1. Persiapan Perbaikan..........................................................
3.2.1.1. Keselamatan Kerja ...............................................
3.2.1.2. Alat .......................................................................
3.2.2. Pembongkaran ...................................................................
3.2.3. Pemeriksaan ......................................................................
3.2.4. Pengukuran ........................................................................
3.2.5. Pemasangan .......................................................................
3.3. Data Hasil Pemeriksaan................................................................
3.5.1. Data Spesifikasi Gear Pump pada Unit Forklift ...............
3.5.2. Kerusakan yang Terjadi pada Gear Pump ........................
3.5.3. Flow Pompa ......................................................................
29
29
29
29
29
30
30
30
31
31
32
32
32
32
32
39
39
43
49
49
50
50
BAB IV KESIMPULAN DAN SARAN .........................................................
4.1. Kesimpulan ...................................................................................
4.1.1. Cara Kerja Pompa Hidrolik Gear Pump ............................
4.1.2. Komponen-komponenGear Pump .....................................
4.1.3. Gangguan dan Cara Perbaikan Gear Pump .......................
4.1.4. Aliran Pompa .....................................................................
4.2. Saran .............................................................................................
52
52
52
52
53
53
53
DAFTAR PUSTAKA ......................................................................................
54
LAMPIRAN ....................................................................................................
55
DAFTAR TABEL
No
Tabel
Halaman
3.1
Data Hasil Pemeriksaan ....................................................................... 50
iv
DAFTAR GAMBAR
No
Gambar
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
3.1
3.2
Forklift Kapasitas 1-3.5 Ton ................................................................
Forklift Kapasitas 3-5 Ton ...................................................................
Forklift kapasitas 3-16 Ton ..................................................................
Letak Komponen Forklift ....................................................................
Prinsip Dasar Sistem Hidrolik .............................................................
Perbedaan Pressure ..............................................................................
Hukum Pascal......................................................................................
Pressure Gauge....................................................................................
Gangguan pada Aliran Oli ...................................................................
Piston Pump.........................................................................................
Gear Pump...........................................................................................
Centrifugal Pump.................................................................................
Jenis-jenis Pompa Roda Gigi ...............................................................
Internal Gear Pump.............................................................................
External Gear Pump............................................................................
Cara Kerja Gear Pump .........................................................................
Komponen-komponen Gear Pump......................................................
Diagram Pemecahan Masalah Flow .....................................................
Diagram Pemecahan Masalah Timbul Suara Tidak Normal pada Gear
Pump.....................................................................................................
Membuka Sisi Inlet Gear Pump ..........................................................
Membuka Sisi Outlet Gear Pump ........................................................
Gear Pump ...........................................................................................
Klem Unit .............................................................................................
Melepas Baut Cover ............................................................................
Membuka Cover Belakang ..................................................................
Membuka Cover Depan .......................................................................
Membuka Drive Shaft dan Driven Shaft ..............................................
Membuka Plat Penahan Drive Shaft dan Driven Shaft ........................
O-Ring Seal ..........................................................................................
Melepas Snap Ring ..............................................................................
Melepas Seal Poros ..............................................................................
Mengukur Diameter Drive Shaft ..........................................................
Mengukur Diameter Driven Shaft ........................................................
Mengukur Celah Gear .........................................................................
Mengukur Panjang Drive Shaft ............................................................
Mengukur Panjang Driven Shaft ..........................................................
Mengukur Diameter Lubang Drve Shaft dan Driven Shaft .................
Mengukur Lubang Plat Penahan ..........................................................
Mengukur Tebal Plat Penahan .............................................................
Seal .......................................................................................................
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
3.20
3.21
3.22
3.23
Halaman
v
6
7
7
8
9
13
14
14
15
17
18
18
20
22
24
25
26
30
31
33
33
34
34
35
35
36
36
37
37
38
38
39
40
40
41
41
42
42
43
43
3.24
3.25
3.26
3.27
3.28
3.29
3.30
3.31
3.32
3.33
3.34
Pemasangan Seal Poros ........................................................................
Memasang SnapRing ...........................................................................
Memasang O-Ring Seal .......................................................................
Plat Penahan Drive Shaft dan Driven Shaft .........................................
Blok Bantalan Drive Shaft dan Driven Shaft .......................................
Blok Bantalan Roda Gigi .....................................................................
Drive Shaft dan Driven Shaft ...............................................................
Memasang Drive Shaft dan Driven Shaft ............................................
Memasang Cover Depan ......................................................................
Memasang Cover Belakang .................................................................
Pemasangan Baut Cover ......................................................................
44
44
45
45
46
46
47
47
48
48
49
DAFTAR NOTASI
η
Q
V
= Putaran engine/putaran pompa (rpm)
= Aliran fluida (cc/menit)
= Volume (cc/putaran)
vi
DAFTAR LAMPIRAN
No
Lampiran
Halaman
1.
2.
3.
4.
5.
6.
Biodata Penulis ....................................................................................
Penunjukan Pembimbing Tugas Akhir ................................................
Lembar Bimbingan Tugas Akhir .........................................................
Hydraulic Circuit Diagram Forklift Komatsu Kapasitas 3 Ton ..........
Poros Power Take Off dan Gear Pump ...............................................
Komponen-komponen Gear Pump dan Alat yang Digunakan ............
vii
56
57
58
59
60
61
LEMBAR PENGESAHAN ............................................................................
i
KATA PENGANTAR .....................................................................................
ii
DAFTAR ISI ...................................................................................................
iii
DAFTAR TABEL ...........................................................................................
iv
DAFTAR GAMBAR .......................................................................................
v
DAFTAR NOTASI ..........................................................................................
vi
DAFTAR LAMPIRAN ...................................................................................
vii
BAB I PENDAHULUAN ................................................................................
1.1. Latar Belakang Masalah ...............................................................
1.2. Rumusan Masalah .........................................................................
1.3. Pembatasan Masalah .....................................................................
1.4. Tujuan Penulisan ...........................................................................
1.5. Manfaat Penulisan .........................................................................
1.6. Metode Penulisan ..........................................................................
1.7. Sistematika Penulisan ...................................................................
1
1
2
3
3
3
4
4
BAB II LANDASAN TEORI ........................................................................
2.1. Alat Berat Forklift Komatsu .........................................................
2.2. Pengertian Hidrolik .......................................................................
2.3. Keuntungan dan Kekurangan Sistem Hidrolik .............................
2.3.1. Keuntungan Sistem Hidrolik ............................................
2.3.2. Kekurangan Sistem Hidrolik .............................................
2.4. Fluida Hidrolik .............................................................................
2.4.1. Fluida yang Digunakan .....................................................
2.4.2. Sifat-sifat Fluida Hidrolik .................................................
2.5. Konsep-konsep dalam Hidrolik ....................................................
2.6. Pompa Hidrolik .............................................................................
2.6.1. Positive Displacement .......................................................
2.6.2. Non-Positive Displacement ...............................................
2.7. Gear Pump ....................................................................................
2.7.1. Fungsi ................................................................................
2.7.2. Jenis Gear Pump ...............................................................
2.7.3. Cara Kerja .........................................................................
2.7.4. Komponen-komponen Gear Pump ...................................
2.7.5. Keuntungan dan Kekurangan Gear Pump ........................
2.7.5.1. Keuntungan Pemakaian Gear Pump ...................
6
6
8
9
9
10
10
11
11
13
15
16
18
19
20
21
24
26
26
26
Acep Suhermin, 2012
Analisis Sistem Gear Pump Pada Unit Forklift Komatsu Kapasitas 3 Ton
Universitas Pendidikan Indonesia | Repository.upi.edu
2.7.5.2. Kelemahan Pemakaian Gear Pump ....................
2.7.6. Langkah-langkah Penoprasian Gear Pump .......................
2.7.6.1. Langkah Persiapan ..............................................
2.7.6.2. Langkah Pelaksanaan ..........................................
2.7.6.3. Langkah Setelah Pengoprasian ...........................
27
27
27
28
28
BAB III PEMBAHASAN ................................................................................
3.1. Permasalahan ............................................................................
3.1.1 Flow yang Dihasilkan Kurang ..........................................
3.1.1.1. Gambaran Masalah ..............................................
3.1.1.2. Faktor Penyebab ...................................................
3.1.1.3. Pemecahan Masalah .............................................
3.1.2 Timbul Suara Tidak Normal .............................................
3.1.2.1. Gambaran Masalah ..............................................
3.1.2.2. Faktor Penyebab ...................................................
3.1.2.3. Pemecahan Masalah .............................................
3.2. Prosedur Perbaikan .......................................................................
3.2.1. Persiapan Perbaikan..........................................................
3.2.1.1. Keselamatan Kerja ...............................................
3.2.1.2. Alat .......................................................................
3.2.2. Pembongkaran ...................................................................
3.2.3. Pemeriksaan ......................................................................
3.2.4. Pengukuran ........................................................................
3.2.5. Pemasangan .......................................................................
3.3. Data Hasil Pemeriksaan................................................................
3.5.1. Data Spesifikasi Gear Pump pada Unit Forklift ...............
3.5.2. Kerusakan yang Terjadi pada Gear Pump ........................
3.5.3. Flow Pompa ......................................................................
29
29
29
29
29
30
30
30
31
31
32
32
32
32
32
39
39
43
49
49
50
50
BAB IV KESIMPULAN DAN SARAN .........................................................
4.1. Kesimpulan ...................................................................................
4.1.1. Cara Kerja Pompa Hidrolik Gear Pump ............................
4.1.2. Komponen-komponenGear Pump .....................................
4.1.3. Gangguan dan Cara Perbaikan Gear Pump .......................
4.1.4. Aliran Pompa .....................................................................
4.2. Saran .............................................................................................
52
52
52
52
53
53
53
DAFTAR PUSTAKA ......................................................................................
54
LAMPIRAN ....................................................................................................
55
DAFTAR TABEL
No
Tabel
Halaman
3.1
Data Hasil Pemeriksaan ....................................................................... 50
iv
DAFTAR GAMBAR
No
Gambar
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
3.1
3.2
Forklift Kapasitas 1-3.5 Ton ................................................................
Forklift Kapasitas 3-5 Ton ...................................................................
Forklift kapasitas 3-16 Ton ..................................................................
Letak Komponen Forklift ....................................................................
Prinsip Dasar Sistem Hidrolik .............................................................
Perbedaan Pressure ..............................................................................
Hukum Pascal......................................................................................
Pressure Gauge....................................................................................
Gangguan pada Aliran Oli ...................................................................
Piston Pump.........................................................................................
Gear Pump...........................................................................................
Centrifugal Pump.................................................................................
Jenis-jenis Pompa Roda Gigi ...............................................................
Internal Gear Pump.............................................................................
External Gear Pump............................................................................
Cara Kerja Gear Pump .........................................................................
Komponen-komponen Gear Pump......................................................
Diagram Pemecahan Masalah Flow .....................................................
Diagram Pemecahan Masalah Timbul Suara Tidak Normal pada Gear
Pump.....................................................................................................
Membuka Sisi Inlet Gear Pump ..........................................................
Membuka Sisi Outlet Gear Pump ........................................................
Gear Pump ...........................................................................................
Klem Unit .............................................................................................
Melepas Baut Cover ............................................................................
Membuka Cover Belakang ..................................................................
Membuka Cover Depan .......................................................................
Membuka Drive Shaft dan Driven Shaft ..............................................
Membuka Plat Penahan Drive Shaft dan Driven Shaft ........................
O-Ring Seal ..........................................................................................
Melepas Snap Ring ..............................................................................
Melepas Seal Poros ..............................................................................
Mengukur Diameter Drive Shaft ..........................................................
Mengukur Diameter Driven Shaft ........................................................
Mengukur Celah Gear .........................................................................
Mengukur Panjang Drive Shaft ............................................................
Mengukur Panjang Driven Shaft ..........................................................
Mengukur Diameter Lubang Drve Shaft dan Driven Shaft .................
Mengukur Lubang Plat Penahan ..........................................................
Mengukur Tebal Plat Penahan .............................................................
Seal .......................................................................................................
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
3.20
3.21
3.22
3.23
Halaman
v
6
7
7
8
9
13
14
14
15
17
18
18
20
22
24
25
26
30
31
33
33
34
34
35
35
36
36
37
37
38
38
39
40
40
41
41
42
42
43
43
3.24
3.25
3.26
3.27
3.28
3.29
3.30
3.31
3.32
3.33
3.34
Pemasangan Seal Poros ........................................................................
Memasang SnapRing ...........................................................................
Memasang O-Ring Seal .......................................................................
Plat Penahan Drive Shaft dan Driven Shaft .........................................
Blok Bantalan Drive Shaft dan Driven Shaft .......................................
Blok Bantalan Roda Gigi .....................................................................
Drive Shaft dan Driven Shaft ...............................................................
Memasang Drive Shaft dan Driven Shaft ............................................
Memasang Cover Depan ......................................................................
Memasang Cover Belakang .................................................................
Pemasangan Baut Cover ......................................................................
44
44
45
45
46
46
47
47
48
48
49
DAFTAR NOTASI
η
Q
V
= Putaran engine/putaran pompa (rpm)
= Aliran fluida (cc/menit)
= Volume (cc/putaran)
vi
DAFTAR LAMPIRAN
No
Lampiran
Halaman
1.
2.
3.
4.
5.
6.
Biodata Penulis ....................................................................................
Penunjukan Pembimbing Tugas Akhir ................................................
Lembar Bimbingan Tugas Akhir .........................................................
Hydraulic Circuit Diagram Forklift Komatsu Kapasitas 3 Ton ..........
Poros Power Take Off dan Gear Pump ...............................................
Komponen-komponen Gear Pump dan Alat yang Digunakan ............
vii
56
57
58
59
60
61