Technology that makes its mark

Trouble shooting Dewatering and Dredger Pump

PT KSB Indonesia – Mining Department
Jl. RE Martadinata
Komplek Pergudangan Arafuru - Blok A2
RT 011 RW 007 Kelurahan Sungai Buah
Kecamatan Ilir Timur II - Palembang 30118 Telp : 0711 - 8859840 Telp/Fax : 0711 5625756 Email : felix.sri@ksb.co.id

© Copyright KSB Aktiengesellschaft 2013

Dewatering and Dredger Pump

3
No CONTENTS Page

I Unit Dewatering Pump 7

II Part list of DnD 9

III Trouble shooting list 21

III.1 Engine doesn’t start/ON ( engine tidak dapat di start atau dinyalakan ) 25

III.2 Pump doesn’t suck ( Pompa tidak bisa menghisap ) 41

III.3 Pump low flow rate ( Debit pompa kecil ) 58

III.4 Pump high flow rate/over flow ( Debit pompa terlalu besar ) 68

III.5 High temperature of bearing pump ( Suhu bearing pompa tinggi ) 71

III.6 Pump high vibration ( Getaran pompa tinggi ) 75

III.7 High noise pump ( Pompa bekerja dengan suara kasar ) 75

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III.8 Smoked Pump ( Pompa berasap ) 83

III.9 Pump Casing is hot ( Rumah pompa panas ) 85

III.10 Pump operation doesn’t work automatically ( Kerja Pompa tidak bisa 90
otomatis )
III.11 99
Engine high temperature ( Suhu engine tinggi )

III.12 Engine leakage ( Engine terdapat kebocoran ) 103

III.13 Engine doesn’t take high speed ( Kecepatan engine tidak dapat dinaikkan ) 105

III.14 Engine doesn’t work suddenly ( Engine tiba – tiba Mati/OFF ) 111

III.15 Engine black smoke ( Asap engine hitam ) 119

III.16 Engine white smoke ( Asap engine putih ) 121

III.17 Database of engine is blank ( data base engine hilang/operation ) 124

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IV Performance Limit Value for monitoring unit ( Monitoring nilai batasan 126
kinerja pompa
V Position pump set on pontoon ( Penempatan pompa diatas pontoon ) 127

VI Recommendation of spare parts ( Rekomendasi spare part ) 129

VII Thank you 136

6
I. Unit Dewatering Pump

7
I. Unit Dewatering Pump

8
II. Part list of DnD

9
II. Part list of DnD
Bare Pump Accessories

No Description Qty Unit

1 LCC H150-500.4K AB M1 1 unit
2 Stuffing Box Cover LCC 150,SS304 1 Pc

3 Bolt UNC 1”-8 Length 65 mm Hex.Head Full 6 Set

thread C/W washer spring

4 Drain line for LCC Pump 1 Set

10
II. Part list of DnD

Diesel Engine assembly

No Description Qty Unit

1 Coupling Martin 1 Set

2 Stub Shaft 1 Set
3 Muffler bracket 2 Set
4 Exhaust pipe 1 Set
5 Diesel engine Volvo 1 Set
6 Bracket for battery 1 Set
7 Battery, Maintenance Free 2 Pcs

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II. Part list of DnD
No Description Qty Unit
Priming System
1 Vacuum Tank , SS 304 1 Set
2 Level Sensor 2 Set
3 Air Filter 2 Set
4 Floating valve for Vacuum Tank 1 Set

5 Sensor Level switch cover, SS 304 1 Pc

6 Vacuum Pump 1 Unit

7 Coupling Shaft Magnetic Clutch 1 Pc

8 Magnetic Clutch 1 Pc
9 V- Belt 2 Pc
10 Pulley 1 Pc
11 Rubber hose 1 Pc
12
II. Part list of DnD
Suction line assembly

No Description Qty Unit

1 Strainer 1 Set
2 Double clamp suction 1 Set
3 Suction hose 1 Set

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II. Part list of DnD
Discharge line assembly

No Description Qt Unit
y
1 Rubber expansion 1 Pc
2 Elbow 2 Pc
3 Swing check valve sisto 1 Pc
4 Discharge pipe 1 Set
5 U-Clamp pipe 3 Pc
6 Pressure gauge diaphragm model 1 Pc

7 Butterfly valve for discharge 1 Pc

8 Butterfly valve for drain 1 Pc
9 Flange discharge 8 Pc

14
II. Part list of DnD
Base Frame and Roof Assembly

No Description Qty Unit

1 Pump skid 1 Set

2 Roof canopy 1 Set
3 Roof pillar 1 Set
4 Strobe lamp 1 Pc

15
II. Part list of DnD
Boom Assembly

No Description Qty Unit

1 Connecting links 1 Set

2 Chain 2 Set
3 Boom lifting for DnD 1 Set
4 Winch manual 1 Unit
5 Wire rope 1 Set

16
17
18
Completed assembly unit dewatering ( Pemasangan lengkap unit dewatering )

19
Position pump set on pontoon ( Penempatan pompa diatas pontoon )

20
III. Trouble Shooting

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I. Trouble shooting list :

1.Engine doesn’t start/ON ( engine tidak dapat di start atau dinyalakan )

2.Pump doesn’t suck ( Pompa tidak bisa menghisap )

3.Pump low flow rate ( Debit pompa kecil )

4.Pump high flow rate/over flow ( Debit pompa terlalu besar )

5. High temperature of bearing pump ( Suhu bearing pompa tinggi )

6. High vibration pump ( Getaran pompa tinggi )

7. High noise pump ( Pompa bekerja dengan suara kasar )

22
8. Smoked Pump ( Pompa berasap )

9. Pump casing is hot ( rumah pompa panas )

10. Pump operation doesn’t work automatically ( Kerja Pompa tidak bisa otomatis )

11. Engine high temperature ( Suhu engine tinggi )

12. Engine leakage ( Engine terdapat kebocoran )

13. Engine doesn’t take high speed ( Kecepatan engine tidak dapat dinaikkan )

23
14. Engine doesn’t work suddenly ( Engine tiba – tiba Mati/OFF )

15. Engine black smoke ( Asap engine hitam )

16. Engine white smoke ( Asap engine putih )

17. Database of engine is blank ( data base engine hilang/operation )

24
III.1.Engine doesn’t start/ON ( engine tidak dapat di start atau dinyalakan )

25
II.1. Engine doesn’t start/ON ( Engine tidak bisa distart/dihidupkan )

5 There are some points need to check

( Ada beberapa poin yang harus diperiksa ) :
3 1. Battery ( accu )
6 2. Engine oil ( oli engine )
2 3. Engine coolant ( Air radiator )
4. Fuel ( BBM )
4 5. Electrical connections ( Sambungan kelistrikan )

26
II.1. Engine doesn’t start ( Engine tidak bisa distart/dihidupkan )

1. Things to do for battery ( Hal – hal yang harus dilakukan untuk battery ):
a. We need the special tools for measuring ampere . Battery the most important
for accu is ampere not voltage. ( kita butuh alat khusus untuk mengukur arus
aki. Pada aki sangat penting adalah ampere bukan voltase/ tegangan).
b. Model of testing of battery can be seen on the picture below, see direction of
arrow . Let it start from a to c( Cara pengetesan battery bisa dilihat pada
gambar di bawah, lihat arah panah. Dimulai dari a sampai c )
c. a. Model of testing ( cara pengetesan )
d. b. Clamp ampere ( tang ampere )
e. c. Result of ampere battery ( hasil pengetesan )

b c

27
II.1. Engine doesn’t start ( Engine tidak bisa distart/dihidupkan )
2. Things to do for engine oil ( Hal – hal yang harus dilakukan untuk oli engine ):

a. Please check the specification of oil. Please refer to the

standard oil for engine.( Mohon diperiksa spesifikasi oli. Mohon
mengacu pada standard oli dari engine ).

b. Please check level oil with dipstick . Make sure the level of oil is
“ OPERATION LEVEL” as a recommendation of engine or make
sure it has reached oil level from stick ( Mohon dicheck level oli
dengan stik check oli. Pastikan oli engine pada “ level operasi “
sesuai dengan rekomendasi engine atau pastikan sudah
mencapai batas oli dari stick )

2. Engine oil

28
II.1. Engine doesn’t start ( Engine tidak bisa distart/dihidupkan )
3. Things to do for engine coolant ( Hal – hal yang harus dilakukan untuk pendingin engine ):

a. Please check the specification of engine coolant. Please refer to

recommendation coolant standard of engine coolant ( Mohon
diperiksa spesifikasi oli. Mohon mengacu pada standard coolant dari
engine ).

b. Please make sure the level of coolant engine on top level as a

recommendation of engine or make sure it is on coolant top level. (
Pastikan coolant engine pada “ top level“ sesuai dengan
rekomendasi engine atau pastikan sudah mencapai batas coolant ).

c. Please open up cap No.1 for checking level of coolant ( Buka cap
no.1 untuk memeriksa level coolant )

3. Engine coolant

29
II.1. Engine doesn’t start ( Engine tidak bisa distart/dihidupkan )

4. Things to do for fuel engine ( Hal – hal yang harus dilakukan untuk Fuel engine ):

Before we talk about the problem of fuel, is better we should to

know about the travelling of fuel in engine.

Remarks :
1. Fuel took from fuel tank ( 1 )
2. Fuel will enter to secondary filter ( separator filter ) ( 2 ).
3. Fuel will be pumping to the system by fuel transfer pump ( 3 )
4. The next process fuel entry to governor ( 5 ), in the governor it
will process in timing advance mechanism ( 6 ), and the next
enter to fuel ratio control ( 7 )and finally the fuel can control
supply to the burning system by injector ( nozzle ) ( 10 ).
5. The next process excess of fuel transfer to the return line.

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II.1. Engine doesn’t start ( Engine tidak bisa distart/dihidupkan )

4. Things to do for fuel engine ( Hal – hal yang harus dilakukan untuk fuel engine ):

The Fuel is taken from fuel tank of unit Dnd before

it comes into the engine, it should through to
separator additional filter for keeping particles,
solid or water. Although from the original engine, it
has already installed of water separator. ( Fuel
diambil tangki unit DnD, sebelum masuk ke engine
harus masuk dahulu ke filter tambahan untuk
mencegah masuknya partikel, pasir atau air.
Walaupun dari engine sudah terpasang filter water
separator )

Filter separator

Filter separator form engine Fuel tank

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II.1. Engine doesn’t start ( Engine tidak bisa distart/dihidupkan )

4. Things to do for fuel engine ( Hal – hal yang harus dilakukan untuk fuel engine ):

If the engine does not get supply of fuel, please pump the fuel with
hand pump. Then please loosen the bleeding nozzle ( red arrow ) ,
please ensure the fuel come out from nozzle. Please check and see
the material blowing is fuel not bubbles or air. Tighten again the
nozzle, and the engine is ready to start.

Jika engine tidak mendapat tersuplai fuel, mohon fuel dipompa dengan
pompa tangan . Kendorkan nozzle bleeding ( Arah panah ), pastikan yang
keluar adalah fuel dan bukan gelembung atau udara dari nozzle.
Kencangkan kembali nozzle tersebut dan engine siap untuk dinyalakan.

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II.1. Engine doesn’t start ( Engine tidak bisa distart/dihidupkan )

4. Things to do for fuel engine ( Hal – hal yang harus dilakukan untuk fuel engine ):

Frequently they were found so many contamination with other materials( water, slurry,
particles etc ). Please change it ( element of filter )every 250 hours.
Sering ditemukan banyak terkontaminasi dengan material lain ( air, lumpur, partikel dan lain –
lain ). Mohon untuk dilakukan penggantian ( element filter )tiap 250 HM.

Filter separator
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II.1. Engine doesn’t start ( Engine tidak bisa distart/dihidupkan )

4. Things to do for electrical connections ( Hal – hal yang harus dilakukan untuk electrical connections ):

1. Switch Battery
2. Motor Starter ( Dinamo starter )
3. Alternator.

5. Electrical connection

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II.1. Engine doesn’t start ( Engine tidak bisa distart/dihidupkan )
5. Things to do for Electrical connections ( Hal – hal yang harus dilakukan untuk electrical connections ):
Switch Battery

B C
A
1. The function of switch battery is to connect and in and out to power from battery ( B ) . Sometimes switch battery need to
be checked and ensure the condition.
2. During the usage, sometimes the switch battery doesn’t work. Sometimes it caused humidity , some times contaminated
with water and short circuit. Please check with Multitester , if there is no connection or it doesn’t connect .
3. If doesn’t work , please install the system connection with direct connection type or without switch ( C ).
1. Fungsi dari switch battery adalah untuk menghubungkan atau melepaskan hubungan power dari battery ( B ). Kadang – kadang
battery harus dicheck dan memastikan kondisinya.
2. Selama penggunaannya, kadang – kadang battery tidak bekerja, kadang karena lembab, kadang terkontaminasi dengan air atau
hubungan pendek. Mohon dicheck dengan multitester, jika tidak terdapat hubungan.
3. Jika tidak dapat dilakukan lagi, mohon dilakukan pemasangan secara hubungan langsung ( C )
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II.1. Engine doesn’t start ( Engine tidak bisa distart/dihidupkan )
5. Things to do for Electrical connections ( Hal – hal yang harus dilakukan untuk electrical connections ): Motor
Starter

5. Electrical connection 36
5. Things to do for Electrical connections ( Hal – hal yang harus dilakukan untuk electrical connections ): Motor
Starter

Note :
Working principle : Using electric motor, which it combines with magnetic
switch ( Solenoid starter ) to push a pinion gear . It will rotate inside or
outside from connection ring gear in the flywheel engine. ( Prinsip kerja :
Menggunakan electrik motor, yang mana dikombinasikan dengan magnetic switch
( solenoid starter ) yang kemudian mendorong pinion gear. Itu akan memutarkan
ke dalam atau keluar dari hubungan ring gear di dalam flywheel )
Problem ( Masalah ) :

1. Cable or switch damage ( Kabel atau switch rusak ).

Please check all of cable connection and switch ( Mohon di periksa semua
kabel koneksi dan switch)

2. Make sure all of cable are not broken ( Pastikan semua kabel tidak ada yang
rusak ).

3. Used up carbon brush ( carbon brush habis ), please change it with new
carbon or total repair. ( mohon ganti carbon tersebut atau perbaikan total )

37
5. Things to do for Electrical connections ( Hal – hal yang harus dilakukan untuk electrical connections ): Motor
Starter

4. Solenoid or coil of motor starter broken ( high temperature )( Solenoid atau

gulungan motor starter rusak karena temperature tinggi )

This problem due to frequently use electric starter, it will cause high
temperature and perhaps make a solenoid is burning. Sometimes
starting of engine for priming of fuel. ( Problem ini karena sering menstart
engine, itu mengakibatkan suhu tinggi dan memungkinkan membuat terbakar
solenoid dan gulungan motor starter. Kadang – kadang juga menstart engine
untuk priming fuel engine )

Preventive action ( Tindakan preventive ) :

• Please do not often starting motor of engine ( jangan terlalu sering
menstarting engine )

• Please check periodically ampere and voltage battery( Mohon diadakan

pemeriksaan secara berkala ampere dan voltage accu )

• Please keep electric connection from the water or something make it

humidity and provide in stock for back up ( Mohon di jaga koneksi kabel
dari air atau apapun membuat menjadi lembab dan menyediakan spare part
untuk back up )

38
5. Things to do for Electrical connections ( Hal – hal yang harus dilakukan untuk electrical connections ):
Alternator

Note :
Alternator is one of important thing for start system in engine. This parts is
also usefully to make higher voltage DC for charging battery and lighting.
( Alternator adalah salah satu bagian penting untuk system start up engine.
Spare parts ini juga berfungsi untuk menaikkan tegangan DC untuk pengisian
battery dan juga untuk penerangan ).

Working Principle :
When the rotor is rotating, it will caused magnetic flux onto rotor, then in the
coil of stator make power electricity AC, and then the ampere of
electricity adjusted it in one line by diode became ampere DC.
Prinsip kerja :
Ketika rotor berputar , akan terjadi magnetik fluks pada rotor sehingga pada
kumparan stator menghasilkan arus listrik AC kemudian arus disearahkan oleh
dioda menjadi arus DC.

39
5. Things to do for Electrical connections ( Hal – hal yang harus dilakukan untuk electrical
connections ) Alternator :

Cause of alternator problems are ( sebab alternator bermasalah adalah ):

1. Battery often drop ( Battery sering drop )
2. Lighting often drop ( Lampu sering drop )
3. Battery doesn’t save energy ( Power battery tidak bisa tersimpan power )

Preventive action :
1. Please keep voltage of battery ( mohon dijaga voltage battery )
2. Sometimes it needs by pass connection for starting engine, it is done
once, if emergency case.( kadang – kadang dibutuhan koneksi by pass
untuk menstart engine, ini hanya sekali waktu.
3. Please prepare stock for back up( Mohon disiapkan stock untuk menjaga
atau back up )

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III.2. Pump doesn’t suck ( Pompa tidak bisa menghisap )

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III.2. Pump doesn’t suck ( Pompa tidak bisa menghisap )

Points has to be checked ( Beberapa poin yang harus

3 2 4 6 diperiksa ) :
1. Suction hose
2. Suction Strainer
3. Depth of elevation suction side ( Kedalaman sisi
hisap )
4. Pump casing
5. Vacuum pump and magnetic clutch
6. Gasket stuffing box
7. Check valve
8. Separator tank
Note : for system staging and dredger
1

7
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2. Pump doesn’t suck ( Pompa tidak bisa menghisap )

1. Things to do for suction hose :

a. Please check and make sure suction hose in good condition. No damage , no bending ( Mohon periksa
dan pastikan suction hose dalam keadaan baik. Tidak rusak, tidak bengkok ).

b. Check and ensuring inside hose has no any broken ( Periksa dan pastikan bagian dalam hose tidak ada
kerusakan )

c. Check and ensuring connections among suction hose , pump casing and vacuum tank have no
leakage ( Please see the picture in the points C2 and C1 )( Periksa dan pastikan koneksi antara suction
hose, pump casing dan vacuum tank tidak ada kebocoran. Lihat pada gambar point C2 dan C1 ). Please see
the explanation for that in the next page( harap lihat penjelasannya pada halaman berikutnya )

d. Check and ensuring tightening of bolt is good( Periksa dan pastikan pengencangan baut dalam kondisi
kencang )

e. Check and ensure Floating valve is in good condition (Periksa dan pastikan floating valve dalam keadaan
baik ( C3 ))

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2. Pump doesn’t suck ( Pompa tidak bisa menghisap )

1. Things to do for suction hose ( Hal – hal yang harus dilakukan untuk area suction hose ):

Item 1.C
C1 Item 1.a
C3

C2

Leakage area C1,C2 and C3

Area kebocoran C1,C2 dan C3
Suction hose bend
Suction hose bengkok

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2. Pump can’t sucking ( Pompa tidak bisa menghisap )

Things to do for suction strainer ( Hal – hal yang harus dilakukan untuk suction strainer ):

a. Please check and make sure

suction strainer is clean, there is
no any many particle of coal or
others( Mohon periksa dan pastikan
suction strainer dalam kedaan bersih
, tidak partikel batu bara yang
berada pada strainer).

b. If onto the strainer so many

particles , please install extra
strainer for keeping blocking
suction side. ( jika ditemukan
banyak partike batu bara untuk
mencegah terjadinya blok/buntu
pada sisi hisap )

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2. Pump doesn’t suck ( Pompa tidak bisa menghisap )

3. Things to do for depth of elevation suction side ( Hal – hal yang harus dilakukan untuk kedalaman sisi
hisap ):

a. Please check and make sure the depth of

suction side in the water is suitable as KSB
recommendation. Minimum of depth is 6 x
hose diameter. Please see the picture
beside ( Mohon periksa dan pastikan
kedalaman sisi hisap di dalam air adalah harus
sesuai dengan rekomendasi KSB yaitu
kedalamannya 6 x diameter hose )

46
2. Pump doesn’t suck ( Pompa tidak bisa menghisap )

4. Things to do for Pump casing :

a. Check and ensure pump impeller is not loose. ( Periksa dan pastikan impeller pompa tidak kendor ).
Please see next page for explanation ( Mohon di lihat pada halaman berikutnya untuk penjelasannya )

b. Check and ensure tightening of suction plate, there is no leakage ( Periksa dan pastikan suction plate
pada pompa tidak terdapat kebocoran ).

c. Check and ensure gland packing into stuffing box, there is no fatigue. If we find that , please
replace with new gland packing. Check the tighten of gland bolt. ( Periksa dan pastikan gland packing
pada stuffing box tidak mengeras. Jika kita menemukan yang demikian ganti dengan yang baru. Periksa
pengencangan baut gland)

c
a

b
47
2. Pump doesn’t suck ( Pompa tidak bisa menghisap )
4. Things to do for Pump casing :
a. Check and ensure pump impeller is not loose. ( Periksa dan pastikan impeller pompa tidak kendor ).

Note :
Please see the picture on the beside. That is a
guidance of setting impeller position, If we find
so, it need to reset again and add with additive
special ( Harap lihat gambar di samping. Gambar
tersebut adalah arahan untuk mensetting posisi
impeller, jika kita menemukannya dan dibutuhkan di
setting ulang lagi dan tambahan bahan perekat
khusus)

48
2. Pump doesn’t suck ( Pompa tidak bisa menghisap )

Things to do for Pump casing ( Yang harus dilakukan pada pump casing ) :

d. Please check and make sure condition of shaft sleeve ( Mohon diperiksa kondisi shaft sleeve )Check by
hand, If we find the condition of it such as the picture below, it should be replaced with new parts
immediately ( Periksa dengan tangan , jika kita menemukan kondisinya tersebut seperti gambar di bawah,
maka harus segera diganti dengan yang baru ).

e. Please check and ensure gasket stuffing box is in good condition ( no broken and damage ). ( Mohon
di check dan pastikan gasket stuffung dalam kondisi baik ( tidak rusak dan pecah )

Shaft sleeve damage ( Shaft sleeve rusak49)

2. Pump doesn’t suck ( Pompa tidak bisa menghisap )

e. Please check and ensure gasket stuffing box is in good condition ( no broken and damage ).
( Mohon di check dan pastikan gasket stuffing box dalam kondisi baik ( tidak rusak dan pecah )

50
2. Pump doesn’t suck ( Pompa tidak bisa menghisap )

5. Things to do for Vacuum Pump and magnetic Clutch ( Hal – hal yang harus dilakukan :

a. Check and ensure v-belt (a ) for Vacuum pump and magnetic clutch is not broken ( Periksa dan pastikan
V-belt vacuum pump dan magnetic tidak rusak ).

b. Check and ensure coupling which connect between Vacuum and Magnetic is good installed( Periksa dan
pastikan coupling yang menghubungkan antara vacuum pump dan magnetic valve terpasang dengan baik )

c. Check and ensure magnetic clutch condition in good condition. Check also a cable connection, please
make sure in good ( Periksa dan pastikan magnetic clutch dalam kondisi baik. Periksa kabel koneksi dalam
kondisi baik )

51
5. Things to do for Vacuum Pump and magnetic Clutch ( Hal – hal yang harus dilakukan pada vacuum pump
dan magnetic clutch) :

Note : If necessary we should to check the condition of magnetic

clutch individual. If the magnetic clutch does not work, please
check its cable connection with multitester :
a. Pull out the cable connection from main line.
b. Check connection cable with multi tester. If we see there is
move on the indicator measurement, it means condition of
that is good. If we do not see anything move, it means the
magnetic clutch is damage.

Note : Jika diperlukan kita harus memeriksa kondisi magnetik clutch

secara individu. Jika Magnetic clutch tidak bekerja, mohon
diperiksa kabel tersebut dengan multi tester.
a. Lepaskan kabel dari sambungan utama.
b. Periksa koneksi kabel dengan multi tester. Jika kita melihat ada
pergerakan jarum indicator dari alat ukur tersebut, maka kondisi
tersebut masih baik. Jika kita tidak melihat adanya pergerakan
maka alat tersebut rusak.

52
II.2. Pump doesn’t suck ( Pompa tidak bisa menghisap )

5. Things to do for Vacuum Pump and magnetic Clutch ( Hal – hal yang harus dilakukan ):

d. Please check whether vacuum pump oil is in full condition ( Periksa oli vacuum pump pada kondisi penuh )

e. Please check and ensure the pressure discharge of vacuum pump is so strong. Please check clogged
by hand, If our hand can not clogged, it means the vacuum pump is good. If not strong, please open
up the top cover of vacuum and check condition of finger valve, If necessary replace with new parts (
Periksa dan pastikan tekanan pada sisi tekan pompa vacuum dengan tangan dan pastikan sangat kuat. Bila
tidak kuat , mohon dibuka cover atas dan periksa kondisi finger valve, bila perlu ganti finger valve tersebut
dengan yang baru ).

Finger valve

53
II.2. Pump doesn’t suck ( Pompa tidak bisa menghisap )

6. Things to do Vacuum tank ( Hal – hal yang harus dilakukan pada vacuum tank ) :

a. Please check and ensure condition of vacuum tank is not full with the water and mud. If we find so
many water and slurry , please take out that substance by opening gate valve ,then ensure there is
no water and slurry.( Mohon periksa dan pastikan kondisi vacuum bahwa tidak penuh dengan air dan lumpur,
jika ada mohon dikeluarkan air dan lumpur tersebut dengan membuka gate valve dan pastikan tidak ada lagi air
dan lumpur ).

a. Please check the condition of gate valve ( under vacuum tank ), please ensure the condition of that is
good and no leakage ( Periksa kondisi gate valve, pastikan dalam kondisi baik dan tidak ada kebocoran )

Vacuum tank

Gate valve

54
II.2. Pump doesn’t suck ( Pompa tidak bisa menghisap )

7. Things to do Check valve ( Hal – hal yang harus dilakukan check valve ) :

a. Please check and ensuring condition of check valve is good. ( Harap

diperiksa dan pastikan kondisi atau keadaan check valve baik.

b. If we find the pump cannot suck, open up top cover to check valve ( item
160 ) , then check the condition valve disc ( item : 746 ). Please keep
clean and no more particle left.( Jika kita menemukan pompa tidak bisa
menghisap, buka top cover check valve ( item 160 ), kemudian check kondisi
valve disc ( item 746 ). Mohon dijaga kebersihan dan tidak ada lagi
particle di dalamnya.

55
II.2. Pump doesn’t suck ( Pompa tidak bisa menghisap )

7. Things to do separator / Air filter ( Hal – hal yang harus dilakukan check valve ) :

a. The main function of separator is to separate among air and water. The vacuum
pump only suck the air . ( Fungsi utama daru separator adalah memisahkan antara
udara dan air. Vacuum pump hanya menghisap udara )

b. Please check and ensure into tank of separator , whether there is water. If inside
the tank full of water, the process of priming cannot be done.
( Mohon diperiksa dan pastikan didalam tangki separator , tidak ada air, jika didalam tangki
ada air , maka proses priming tidak akan sukses ).

c. Please always when the pump stops after running to take out water which is inside
of separator tank.
( Mohon selalu setiap pompa berhenti setelah running untuk membuang air yang ada di
dalam tangki separator )

d. Keep the separator tank from mud or slurry, this substances will disturb the
potency for vacuum process ( Mohon dijaga tangki separator dari lumpur cair atau
padat, akan mengakibatkan potensi menghalangi untuk proses vacuum ).

Air filter

56
II.2. Pump doesn’t suck ( Pompa tidak bisa menghisap )

8. Things to do for staging and dredger system ( Yang harus dilakukan untuk sistem staging dan dredger ) :

Please making sure no air trap into the pipe, and the air is gone or blew
through pipe venting from discharge pipe o others connections.
( Pastikan tidak udara terjebak didalam pipa, dan udara sudah habis atau keluar
lewat pipe venting ( pembuangan angin ) dari pipa discharge atau koneksi
lainnya.

57
III.3.Pump low flow rate ( Debit pompa kecil )

58
III.3.Pump low flow rate ( Debit pompa kecil )

There are some points need to check

( Ada beberapa poin yang harus diperiksa ) :

1. Suction hose
2. Standard operation of pump
3. Suction side ( jalur hisap )
4. Leakage of sealing ( kebocoran sealing pompa )

59
III.3. Pump low flowarate ( Debit pompa kecil )

1. Things to do for suction hose :

a. Please check and make sure suction hose in good condition. No damage , no bending ( Mohon periksa
dan pastikan suction hose dalam keadaan baik. Tidak rusak, tidak bengkok ).

b. Check and ensuring inside hose has no any broken ( Periksa dan pastikan bagian dalam hose tidak ada
kerusakan )

c. Check and ensuring connections among suction hose , pump casing and vacuum tank have no
leakage ( Please see the picture in the points C2 and C1 )( Periksa dan pastikan koneksi antara suction
hose, pump casing dan vacuum tank tidak ada kebocoran. Lihat pada gambar point C2 dan C1 ). Please see
the explanation for that in the next page( harap lihat penjelasannya pada halaman berikutnya )

d. Check and ensuring tightening of bolt is good( Periksa dan pastikan pengencangan baut dalam kondisi
kencang )

e. Check and ensure Floating valve is in good condition (Periksa dan pastikan floating valve dalam keadaan
baik ( C3 ))

60
1. Things to do for suction hose ( Hal – hal yang harus dilakukan untuk area suction hose ):

Item 1.C
C1 Item 1.a
C3

C2

Leakage area C1,C2 and C3

Area kebocoran C1,C2 dan C3
Suction hose bend
Suction hose bengkok

61
II.3.Pump low flow rate ( Debit pompa kecil )
2. Things to do for standard operation of pump ( Hal – hal yang harus dilakukan untuk standard
pengoperasian pompa ):

a. Please check and make sure the standard of operation of

pump with standard operation. ( Mohon diperiksa standard
pengoperasian pompa )
b. Before check it, please for making sure the pipe pressure
since the pump stopped. ( Sebelum diperiksa , mohon
dipastikan tekenan pipa saat pompa stop )
c. After we got pipe pressure please see the tabel and
standard of operation. ( setelah kita mendapatkan tekanan
pipa , lihat tabel dan standard pengoperasian )
d. Please running the pump by the data pipe pressure (
range of operation ). ( pompa di jalankan sesuai dengan data
tekanan pipa ( range pengoperasian )

62
2. Pump low flow rate ( Aliran atau debit pompa kecil )

3. Things to do for suction side ( Hal – hal yang harus dilakukan untuk jalur hisap ):

a. Please check and make sure the depth of

suction side in the water is suitable as KSB
recommendation. Minimum of depth is 6 x
hose diameter. Please see the picture
beside ( Mohon periksa dan pastikan
kedalaman sisi hisap di dalam air adalah harus
sesuai dengan rekomendasi KSB yaitu
kedalamannya 6 x diameter hose )

63
Pump low flowrate (Debit pompa kecil )

1. Things to do for suction side ( Hal – hal yang harus dilakukan untuk jalur hisap ):

Please check and make sure suction hose in good condition. No

damage , no bending ( Mohon periksa dan pastikan suction
hose dalam keadaan baik. Tidak rusak, tidak bengkok ).

Check and ensuring inside hose has no any broken ( Periksa dan
pastikan bagian dalam hose tidak ada kerusakan )

Suction hose bend

Suction hose bengkok

64
III.3. Pump low flow rate ( Aliran atau debit air kecil )

1. Things to do for suction side ( Hal – hal yang harus dilakukan untuk jalur hisap ):

a. Please check and make sure suction

strainer is clean, there is no any
many particle of coal or others( Mohon
periksa dan pastikan suction strainer
dalam kedaan bersih , tidak partikel batu
bara yang berada pada strainer).

b. If onto the strainer so many particles ,

please install extra strainer for
keeping blocking suction side. ( jika
ditemukan banyak partike batu bara
untuk mencegah terjadinya blok/buntu
pada sisi hisap )

65
III.3. Pump Low flow rate ( Aliran atau debit pompa kecil )

2.Things to do for sealing pump ( Yang harus dilakukan pada sealing pump ) :

a. Please check and make sure condition of shaft sleeve ( Mohon diperiksa kondisi shaft
sleeve )Check by hand, If we find the condition of it such as the picture below, it
should be replaced with new parts immediately ( Periksa dengan tangan , jika kita
menemukan kondisinya tersebut seperti gambar di bawah, maka harus segera diganti dengan
yang baru ).
b. Please check and ensure gasket stuffing box is in good condition ( no broken and
damage ). ( Mohon di check dan pastikan gasket stuffung dalam kondisi baik ( tidak rusak dan
pecah )

Shaft sleeve damage ( Shaft sleeve rusak

66
)
III.3. Pump low flow rate ( Debit pompa kecil )

Please check and ensure gasket stuffing box is in good condition ( no broken and
damage ).
( Mohon di check dan pastikan gasket stuffing box dalam kondisi baik ( tidak rusak dan pecah )

67
III.4.Pump high flow rate/over flow ( Debit pompa terlalu besar )

68
II.4.Pump high flow rate/over flow ( Debit pompa terlalu besar )
Things to do for standard operation of pump ( Hal – hal yang harus dilakukan untuk standard pengoperasian
pompa ):
a. Please check and make sure the standard of operation of pump with standard operation. ( Mohon diperiksa standard
pengoperasian pompa )
b. Before check it, please for making sure the pipe pressure since the pump stopped. ( Sebelum diperiksa , mohon
dipastikan tekenan pipa saat pomp stop )
c. After we got pipe pressure please see the list and standard of operation. ( setelah kita mendapatkan tekanan pipa ,
lihat tabel dan standard pengoperasian )
d. Please running the pump by the data pipe pressure ( range of operation ). ( pompa di jalankan sesuai dengan data
tekanan pipa ( range pengoperasian )
e. Note : Please pay attention if the pump condition have not high of elevation , but there is use the longer of pipe
discharge. Please run the pump carefully , running the pump with speed of engine with low speed the first and
check step by step flow rate of pump ( Mohon perhatiannya jika kondisi pompa tidak terdapat ketinggian elevasi, tetapi
menggunakan pipa discharge yang lebih panjang, harap berhati – hati menjalankan pompa, jalankan pompa dengan speed
rendah dahulu dan periksa secara bertahap keluaran air dari pipa ).

69
Pump speed, Fuel Consumption & Total Dynamic Head
– Pump speed 1300 Rpm
– Fuel Rate (consumption) 70 Liter/ Hours
– Total Dynamic Head +/- 100 Meter (Static Head 87 Meter, Loses 13
Meter)
Note : Static head = pipe pressure ( pump stopped )
Keterangan : static head ( ketinggian tetap ) = tekanan pipa ( saat
pompa stop )

70
III.5. High temperature of bearing pump ( Suhu bearing pompa tinggi )

71
II.5. High temperature of bearing pump ( Suhu bearing pompa tinggi )
Things to do for high temperature of bearing pump ( Hal – hal yang harus dilakukan untuk suhu bearing
pompa tinggi ):
a. Please check and make sure the oil specification for
bearing ( please check at the page : )( Mohon periksa
dan pastikan specifikasi oli untuk bearing pompa ( mohon
dilihat pada halaman : )
b. The pump forbidden to run since the pump position
have an angle forward, backward or beside. Please see
the picture beside. ( Pompa dilarang running dengan posisi
pompa terdapat kemiringan depan, belakang dan samping.
Mohon dilihat pada gambar di samping )
c. Please check speed of engine , please follow to standard
of operation of the pump ( mohon diperiksa kecepatan
engine, mohon mengikuti standard pengoperasian pompa )
d. d. Please check to parallelism of bearing bracket and
symmetries position between shaft and stuffing box
housing. ( mohon diperiksa kesejajaran posisi bearing
bracket dan kesamaan jarak antara shaft dan rumah gland
packing.
e. There is indication oil leakage from bearing, oil came
out from inproseal ( ada indikasi oli bearing bocor, oli keluar
dari inproseal )
72
d. Please check to parallelism of bearing bracket and symmetries position between shaft and stuffing box housing. (
mohon diperiksa kesejajaran posisi bearing bracket dan kesamaan jarak antara shaft dan rumah gland packing )

Bearing bracket
Gap housing
Stuffing box and
shaft sleeve
Stuffing box
housing

Point of gap

Shaft + Shaft
sleeve
73
Bearing bracket have an angle forward . Forward Bearing bracket have an angle backward . Backward
higher than backward ( bearing bracket miring ke higher than forward ( bearing bracket miring ke belakang.
depan. Depan lebih tinggi dari belakang) Belakang lebih tinggi dari pada depan )

Bearing position must be to parallel and

symmetries, it has to measure by depth
caliper/bore gauge caliper every time reassembly
and setting gap impeller. ( Posisi bearing bracket
harus sama dan simetris, harus diukur dengan depth
caliper/bore gauge setiap kali akan dilakukan
reassembly atau setting gap impeller )

74
II.6. High vibration pump ( Getaran pompa tinggi )
II.7. High noise Pump ( pompa suara kasar )

75
II.6. High vibration pump ( Getaran pompa tinggi )
II.7. High noise Pump ( pompa suara kasar )

Things to do for high vibration pump and hig noise ( Hal – hal yang harus dilakukan untuk getaran pompa
dan suara kasar tinggi ):

a. Alignment of pump
b. Please check speed of engine , please see to standard of operation of the pump ( mohon diperiksa
kecepatan engine, mohon mengikuti standard pengoperasian pompa )
c. Please check tightening foot of pump and engine.
d. Nose gap, please recheck again to nose gap standard. Please to refer nose gap standard from
manufacture. ( Celah impeller, mohon diperiksa kembali setting celah standard impeller. Mohon lihat pada
standard celah impeller dari manufaktur pompa : 0,5 – 1 mm )
e. Please check to parallelism of bearing bracket and symmetries position between shaft and stuffing
box housing. ( mohon diperiksa kesejajaran posisi bearing bracket dan kesamaan jarak antara shaft dan rumah
gland packing )

76
II.6. High vibration pump ( Getaran pompa tinggi )

a. Alignment of pump.

Please check and ensure alignment of pump and engine no more than : 0,1 mm ( Axial and radial )
( Mohon diperiksa dan pastikan kesejajaran pompa dan engine tidak lebih dari 0,1 mm ( axial dan radial )

77
b. Please check speed of engine , please see to standard of operation of the pump ( mohon diperiksa
kecepatan engine, mohon mengikuti standard pengoperasian pompa )

78
c. Foot of pump and engine.

Please check and ensure for tightening bolt of foot pump( 3 ), pedestal ( 2 ), back casing (3) and engine (
foot of engine (5 ) and mounting engine ( 4 ) ). Please the picture below for points to check.
( Mohon diperiksa dan pastikan pengencangan baut kaki pompa (3 ), pedestal(2 ) , back casing ( 3 )dan engine ( kaki
engine ( 5 ) dan mounting engine (4). Mohon lihat gambar di bawah poin – poin untuk diperiksa )

LCC Pump Engine

79
d. Check and ensure nose gap impeller. ( Periksa dan pastikan impeller pompa tidak kendor ).

Note :
Please see the picture on the beside.
That is a guidance of setting impeller
position, If we find so, it need to reset
again ( Harap lihat gambar di samping.
Gambar tersebut adalah arahan untuk
mensetting posisi impeller, jika kita
menemukannya dan dibutuhkan di
setting ulang lagi )

80
e. Please check to parallelism of bearing bracket and symmetries position between shaft and stuffing box housing. (
mohon diperiksa kesejajaran posisi bearing bracket dan kesamaan jarak antara shaft dan rumah gland packing )

Bearing bracket
Gap housing
Stuffing box and
shaft sleeve
Stuffing box
housing

Point of gap

Shaft + Shaft
sleeve
81
Bearing bracket have an angle forward . Forward Bearing bracket have an angle backward . Backward
higher than backward ( bearing bracket miring ke higher than forward ( bearing bracket miring ke belakang.
depan. Depan lebih tinggi dari belakang) Belakang lebih tinggi dari pada depan )

Bearing position must be to parallel and

symmetries, it has to measure by depth
caliper/bore gauge caliper every time reassembly
and setting gap impeller. ( Posisi bearing bracket
harus sama dan simetris, harus diukur dengan depth
caliper/bore gauge setiap kali akan dilakukan
reassembly atau setting gap impeller )

82
III.8. Smoked Pump ( Pompa berasap )

83
III.8. Smoked Pump ( Pompa berasap )

Things to do for smoked pump ( Yang harus dilakukan untul pompa berasap )

1. Please check tightening of bolt gland packing ( mohon

diperiksa pengencangan baut gland packing ( 45 )

2. If they are very tight, please loosen of bolts and resetting

it, and monitor of leakage of water from there ( jika kedua
baut terlalu kencang, kendorkan baut tesebut dan ulangi
pengencangan baut, dan dipantau kebocoran air dari gland ).

3. Please ensure the capacity of leakage is not bigger ( harap

dipastikan kapasitas kebocoran tidak terlalu besar ).

84
III.9. Pump casing is hot ( rumah pompa panas )

85
II.9. Pump casing is hot ( rumah pompa panas )

Things to do for pump casing is hot ( Yang harus dilakukan untuk rumah pompa panas )

1. Nose gap impeller ( Settingan gap impeller )

2. Capacity of flow rate the pump ( Kapasitas debit pompa )

3. Elevation of discharge pipe ( ketinggian pipa discharge )

86
1. Nose gap impeller ( settingan gap impeller ).

Note :
Please see the picture on the beside. That is a
guidance of setting impeller position, If we find
so, it need to reset again ( Harap lihat gambar di
samping. Gambar tersebut adalah arahan untuk
mensetting posisi impeller, jika kita menemukannya
dan dibutuhkan di setting ulang lagi )

87
1. Capacity of flow rate the pump ( Kapasitas debit pompa )

2. Elevation of discharge pipe ( ketinggian pipa discharge )

Total Head losses = Head Static + Pipe losses ( Lp )

Hs ( Total nilai kerugian ketinggian = Ketinggian Static +
nilai kerugian pipa discharge )

For capacity and elevation of pipe discharge are very important. If the water doesn’t came out from discharge pipe in long time ,
there are very important to consider about installation of discharge pipe. There are some of points to pay attention ( Untuk kapasitas
dan elevasi pipa discharge adalah sangat penting untuk di perhatikan. Jika air tidak bisa keluar dari pipa discharge dalam waktu yang lama,
adalah sangat penting untuk mempertimbangakan instalasi pipa, ada beberapa point yang harus diperhatikan :

The angle and height of pipe installation. If we found discharge pipe installation have an angle like as figure ( A ) or extreme almost
90o. The first we have to know the elevation of that. Then pump running after idle run and success priming, set up speed of
engine to suitable of standard tabel performance related, no step by step. ( Sudut dan ketinggian instalasi pipa. Jika kita menemukan
instalasi pipa dengan sudut seperti pada gambar A atau ekstrim hampir 90o. Pertama kita harus tahu dahulu elevasi tersebut. Kemudian
setelah pompa running idle dan proses priming sudah sukses, maka setting kecepatan langsung dengan standard ketinggian dan tabel
perfromance terkait, tanpa bertahap. 88
1. Capacity of flow rate the pump ( Kapasitas debit pompa )

2. Elevation of discharge pipe ( ketinggian pipa discharge )

If the discharge pipe not extreme like figure A, the pump

can to run step by step suitable to standard pump
performance ( Jika pipa discharge tidak extrim seperti gambar a,
pompa bisa di running secara bertahap sesuai dengan standard
performance pompa.)

89
III.10. Pump operation doesn’t work automatically ( Kerja Pompa tidak bisa otomatis )

90
II.10. Pump operation doesn’t work automatically ( Kerja Pompa tidak bisa otomatis )

Things to do for pump operation doesn’t work automatically ( yang harus dilakukan pada pompa beroperasi

tidak dapat bekerja otomatis )

1. Battery

2. Vacuum panel

3. Magnetic clutch

91
II.10. Pump doesn’t work automatically ( Engine tidak bisa distart/dihidupkan )

1. Things to do for battery ( Hal – hal yang harus dilakukan untuk battery ):

a. We need the special tools for measuring ampere . Battery the most important
for accu is ampere not voltage. ( kita butuh alat khusus untuk mengukur arus
aki. Pada aki sangat penting adalah ampere bukan voltase/ tegangan).
b. Model of testing of battery can be seen on the picture below, see direction of
arrow . Let it start from a to c( Cara pengetesan battery bisa dilihat pada
gambar di bawah, lihat arah panah. Dimulai dari a sampai c )
c. a. Model of testing ( cara pengetesan )
d. b. Clamp ampere ( tang ampere )
e. c. Result of ampere battery ( hasil pengetesan )

b c

92
2. Things to do for magnetic Clutch ( Hal – hal yang harus dilakukan pada magnetic clutch) :

Note : If necessary we should to check the condition of

magnetic clutch individual. If the magnetic clutch does
not work, please check its cable connection with
multitester :
a. Pull out the cable connection from main line.
b. Check connection cable with multi tester. If we see
there is move on the indicator measurement, it
means condition of that is good. If we do not see
anything move, it means the magnetic clutch is
damage.

Note : Jika diperlukan kita harus memeriksa kondisi magnetik

clutch secara individu. Jika Magnetic clutch tidak bekerja,
mohon diperiksa kabel tersebut dengan multi tester.
a. Lepaskan kabel dari sambungan utama.
b. Periksa koneksi kabel dengan multi tester. Jika kita
melihat ada pergerakan jarum indicator dari alat ukur
tersebut, maka kondisi tersebut masih baik. Jika kita
tidak melihat adanya pergerakan maka alat tersebut
rusak.
93
2. Things to do for magnetic clutch ( Hal – hal yang harus dilakukan pada magnetic clutch) :

Note : If necessary for emergency condition , pull out

from main line. Connect directly magnetic to battery. After
the water came out or process priming already succes,
taken out connection from battery.
Catatan : Bila diperlukan dalam keadaan terdesak, lepaskan
kabel magnetic clucth dari sambungan utama. Konek
langsung ke battery. Setelah air sudah keluar atau proses
priming sudah berhasil , lepaskan kembali koneksi magnetic
clutch dari battery.

94
2. Things to do for magnetic clutch ( Hal – hal yang harus dilakukan pada magnetic clutch) :

There are several points to pay attention for Vacuum panel :

( Ada beberapa point yang harus diperhatikan untul vacuum panel ) :
1. PLC
2. Fuse
3. Cable connections

95
2. Things to do for magnetic clutch ( Hal – hal yang harus dilakukan pada magnetic clutch) :
1. PLC :
* PLC is one of parts important for networking system in vacuum panel.PLC is
managing working automatically of panel system.
• The system of working PLC is managing of time system ( time for stopping and
running ).
• Due to working from PLC unit can run by automatically.
• Please check of condition, If we found it is blank or no shown display. It means the
spare parts is damage. It is need to repalce with new part
PLC adalah salah satu bagian terpenting dalam sistem jaringan kerja vacuum panel. PLC
mengatur kerja system otomatis panel.
• Sistem kerja PLC mengatur sistem waktu kerja ( waktu stop dan running )
• Karena kerja PLC , unit dnd dapat bekerja otomatis.
• Mohon diperiksa kondisinya, if kita menemukan PLC tersebut blank atau tidak keluar
diplay. Berarti spare part ini rusak. Harus diganti dengan yang baru.

96
2. Things to do for fuse and cable connections ( Hal – hal yang harus dilakukan pada fuse dan cable
connections ) :
1. The problem fuse and cable connections , the system of panel doesn’t
“ON”.
2. Open up cover panel, check the box of fuse ( please see in circle red ).
Open up the cover box and taken out it. Look it at the color grape and
orange.
• Problem fuse dan kable koneksi, sistem kerja panel tidak dapat “ON”/”Nyala”.
• Buka tutup panel , periksa kotak fuse( lihat pada lingkaran merah ). Buka tutup
cover fuse dan keluarkan. Lihat pada warna ungu dan oranye

97
A
1.Please took the fuse and measure with multitester. Please set up the multitester by
ohm, touch it on the fuse with stick it ( black and red ). If the result measuring of
resistance of it “ 0 “ ( similar zero ). It is OK.
Ambil fuse tersebut dan ukur dengan multitester. Atur multitester dengan sistem ohm, sentuh
fuse tersebut dengan stik multitester ( waran hitam dan merah ). Jika hasil pengukuran
tahanan adalah nol ( 0) ( atau mendekati nol ). Hasilnya OK

B
2. Please took the fuse and measure with multitester. Please set up the multitester by
ohm, touch it on the fuse with it ( black and red ). If the result measuring of
resistance of it bigger than zero “0”. It is Not OK. Please replace with new parts. If
we see by visual the condition fuse is damage, please replace with parts
immediately.
Ambil fuse tersebut dan ukur dengan multitester. Atur multitester dengan sistem ohm, sentuh
fuse tersebut dengan stik multitester ( waran hitam dan merah ). Jika hasil pengukuran
tahanan adalah lebih besar darinol ( 0) ( atau mendekati nol ). Hasilnya Tidak OK. Harus
diganti dengan yang baru. Jika kita melihat dengan visual kondisi fuse putus, harus diganti
yang baru segera.

98
II.11. Engine high temperature ( Suhu engine tinggi )

99
II.11. Things to do for engine high temperature ( yang harus dilakukan pada engine mengalami
suhu tinggi )
There are several items to pay attention for checking :
1. Level coolant to low
2. Air coolant system
3. Blocked charge air cooled
4. High back pressure in the exhaust system
5. High temperature charge air cooler
6. Blocked radiator
7. No pressure cooling system
8. Check waste gate function
9. Coolant temperature sensor ( Item 12 )

Preventive action :
1. Please check level water coolant ( item 1 ) , making sure it in high level
(8)
2. Please check and making sure the filter air cleaner is clean ( 3 ). If we
found it is dusty, please change it with new parts immediately.
3. Please check the radiator coolant is clean , not blocked by dust.
4. Please check and making sure onto display DCU to keep monitor
Pressure cooling system.
5. Please check and making sure draining system water coolant, please
change it every 6000 hours.
6. Please check sensor air filter, If we see in red please change it with new
part ( please look at page 94, item no 3 )
7. Please check and see temperature range onto display, if we see the
temperature still high, please change it with new part. Please see on the
picture in page 94, item 12 100
II.11. Things to do for engine high temperature ( yang harus dilakukan pada engine mengalami suhu tinggi )
Ada beberapa item yang harus diperhatikan untuk diperiksa :
1. Level air radiator kurang ( item 1 )
2. System pendinginan engine
3. Udara pendingin tersumbat
4. Terdapat tekanan balik pada sistim pembuangan.
5. Udara pendingin pembuangan bersuhu tinggi
6. Blocked radiator Tangki radiator tersumbar
7. Tidak ada sistem pendinginan
8. Periksa sistem pembuangan air radiator
9. Sensor temperature pendingin ( Item 12 )

Tindakan perawatan dan pencegahan :

1. Mohon diperiksa level air pendingin ( item 1 ), pastikan pada level high ( 8 ).
2. Mohon diperiksa dan pastikan filter udara dalam kondisi bersih ( 3 ). Jika kita
menemukan dalam keadaan penuh dengan debu, harap segera ganti yang baru.
3. Mohon diperiksa kisi-kisi radiator harus dalam kondisi bersih, tidak boleh
tersumbat oleh debu.
4. .Mohon diperiksa dan pastikan pada display DCU bahwa tekanan sistem
pendingin masih dalam range normal operasi.
5. Mohon diperiksa dan pastikan sistem pembuagan air pendingin , mohon diganti
setiap 6000 jam engine running.
6. Mohon diperiksa sensor filter udara, jika kita melihat sensor tersebut dalam
kondisi merah maka harus diganti dengan yang baru ( lihat pada halaman 99
item no 3 )
7. Mohon diperiksa dan lihat temperature coolant pada display DCU, jika kita lihat
temperature tetap tinggi harap segera ganti ganti. Lihat pada gambar di halaman
99item 12.
101
Items of sensor engine

No Description
1 Coolant level sensor, in the expansion tank

3 Under pressure sensor, air filter

12 Coolant temperature sensor

102
II.12. Engine oil leakage ( Engine terdapat kebocoran )

103
Things to do for Engine oil leakage ( Engine terdapat kebocoran )

1. If we see and found indication of oil

leakage, please immediate replace of
seal crank shaft and top cover engine.
• Jika kita melihat dan menemukan
indikasi kebocoran dari seal crank
shaft dan top cover shaft, harap
segera mengganti seal tersebut.

Preventive action :
1. Replace the oil engine every 250
hours, please making sure the oil free
from dust, solid particle , water .
2. Please be aware for changing of
element filter water separator
additional filter
• Tindakan perawatan :

• Ganti oli tiap 250 jam, pastikan bersih

Seal camshaft Seal top cover engine dari debu, partikel dan air.
• Mohon diperhatikan untuk penggantian
element filter water separator
tambahan filter. 104
II.13. Engine doesn’t take high speed ( Kecepatan engine tidak dapat dinaikkan )

105
II.13. Engine doesn’t take high speed ( Kecepatan engine tidak dapat dinaikkan )

Things to do for engine doesn’t take high speed ( yang harus dilakukan untuk speed engine yang tidak dapat

dinaikkan )

There are several point of item to do inspection :

1. Pre filter and filter fuel of engine are blocked or not.
2. Air in the fuel system
3. Contamination of fuel
4. Injector damage ( one or some injectors damage )
5. Blocked air filter
6. Air leakage between turbo and intake manifold ( turbocharger is glowing )
7. Turbocharger problem ( inner part dirty / rusty )
8. System engine working (versatile /genset )

Ada beberapa point item yang harus dikerjakan :

1. Pre filter dan filter fuel engine tersumbat atau tidak.
2. Sistem pendinginan engine
3. Kontaminasi material fuel.
4. Injector rusak ( satu atau beberapa injector rusak )
5. Filter air filter tersumbat.
6. Kebocoran udara pada turbo dan intake manifold ( turbocharger membara )
7. Turbocharger problem ( spare part dalam kotor atau berkarat )
8. Sistem kerja engine ( versatile / genset )
106
II.13. Engine doesn’t take high speed ( Kecepatan engine tidak dapat dinaikkan )

Things to do for engine doesn’t take high speed ( yang harus dilakukan untuk speed engine yang tidak dapat

dinaikkan )

Frequently they were found so many contamination with other materials(

water, slurry, particles etc ). Please change it ( element of filter )every 250
hours.
Sering ditemukan banyak terkontaminasi dengan material lain ( air, lumpur, partikel
dan lain – lain ). Mohon untuk dilakukan penggantian ( element filter )tiap 250 HM.

Filter separator
107
II.13. Engine doesn’t take high speed ( Kecepatan engine tidak dapat dinaikkan )

Things to do for engine doesn’t take high speed ( yang harus dilakukan untuk speed engine yang tidak dapat

dinaikkan )

If the engine does not get supply of fuel, please pump the fuel with
hand pump. Then please loosen the bleeding nozzle ( red arrow ) ,
please ensure the fuel come out from nozzle. Please check and see
the material blowing is fuel not bubbles or air. Tighten again the
nozzle, and the engine is ready to start.

Jika engine tidak mendapat tersuplai fuel, mohon fuel dipompa dengan
pompa tangan . Kendorkan nozzle bleeding ( Arah panah ), pastikan yang
keluar adalah fuel dan bukan gelembung atau udara dari nozzle.
Kencangkan kembali nozzle tersebut dan engine siap untuk dinyalakan.

108
 Injector working system

Injector

Fuel was supplied by supply pump, before entry into supply pump the fuel through fuel filter for making sure the fuel
separately others material. After that the supply fuel was pumping of fuel to common rail or accumulator of fuel. From that
the fuel distributed to each injector. Onto common rail there is pressure sensor and the pressure of fuel will be shown in
DCU panel. Function of injector for managing of splash of fuel, the splash it to control by ECU. If one or some injector
damage , the engine run will hunting / not smooth.

BBM disuplai oleh pompa suplai , sebelum masuk ke dalam supply pump, solar melewati filter ( fuel filter ) untuk memastikan fuel
memisahkan dengan material lain. Setelah itu fuel dipompakan ke tiap injector. Pada common rail terdapat sensor dan pembacaan
pressure ini akan terlihat pada display DCU. Fungsi injector adalah mengatur semburan fuel, semburan fuel ini dikontrol oleh ECU.
Jika sat atau beberapa injector rusak, engine akan running hunting atau tidak halus ( agak menggantung atau kasar ) 109
Set up engine type :

Please check and making sure the set up of engine. Press “ ON “, then
please press the select “SEL” , then choose to setup and select the set
application : Versatile or genset.
Please choose Versatile and press enter for finishing set u p.

Mohon diperiksa dan pastikan set up engine . Tekan tombol “ON”, kemudian
tekan tombol select “ SEL”, kemudian pilih set up dan pilih set up application :
Versatile atau genset.
Pilih Versatile dan tekan enter untuk menyelesaikan pilihan set up engine.

110
II.14. Engine doesn’t work suddenly ( Engine tiba – tiba Mati/OFF )

Things to do for doesn’t work suddenly ( engine tiba – tiba mati / OFF )

5 There are some points need to check

( Ada beberapa poin yang harus diperiksa ) :
3
6 1. Battery ( accu )
2 2. Engine oil ( oli engine )
3. Engine coolant ( Air radiator )
4 4. Fuel ( BBM )
5. Electrical connections ( Sambungan
1 kelistrikan )

111
II.14. Engine doesn’t work suddenly ( Engine tiba – tiba Mati/OFF )

Things to do for doesn’t work suddenly ( engine tiba – tiba mati / OFF )

There are several items to pay attention ( Ada beberapa item yang penting unfuk diperhatikan ):
1. Please check to Level oil engine ( Harap diperiksa level oli engine )
2. Please check to level water coolant engine ( Harap diperiksa level air pendingin engine )
3. Please check to condition of air filter ( Harap diperiksa kondisi air filter )
4. Please check to level fuel engine ( Harap diperiksa level BBM engine )
5. Please check to fuel condition ( Harap diperiksa kondisi BBM )
6. Please check to battery condition ( Harap diperiksa kondisi aki )
7. Please check to pre filter and filter of fuel and also line for fuel there is no blocked. ( Periksa pre filter dan filter juga jalur fuel tidak
ada yang tersumbat )

1. Please check and making sure level oil engine is already to limit operation onto stick engine fuel ( Mohon diperiksa dan pastikan
level oli engine sudah mencapai batas “ operation “ pada stick fuel engine )
2. Please check and making sure the capacity of water coolant engine is already on top level ( Mohon diperiksa dan pastikan
kapasitas air pendingin engine sudah pada ketinggian puncak level ).
3. Please check and making sure condition of air filter is clean, if we found it in dirty please clean it or replace with new part (
Mohon diperiksa dan pastikan kondisi filter udara adalah bersih, Jika kita menemukan kondisi kotor, harap dibersihkan atau ganti dengan
yang baru )
4. Please check and making sure level fuel of engine is full( Mohon diperiksa dan pastikan level bahan bakar ( solar ) dalam kondisi
penuh)
5. Please check and making sure the fuel condition is clean, no contaminated with others material ( Mohon diperiksa dan pastikan
kondisi BBM adalah bersih, tidak ada kontaminasi dengan material lain )
6. Please check and making the battery condition is good condition, if necessary recharging the battery or replace with new
battery.( Mohon diperiksa dan pastikan kondisi battery adalah kondisi laik pakai, bila perlu di charge ulang atau ganti baru).
112
II.14. Engine doesn’t work suddenly ( Engine tiba – tiba Mati/OFF )

Things to do for doesn’t work suddenly ( engine tiba – tiba mati / OFF )
a. We need the special tools for measuring ampere . Battery the most
important for accu is ampere not voltage. ( kita butuh alat khusus untuk
mengukur arus aki. Pada aki sangat penting adalah ampere bukan voltase/
tegangan).
b. Model of testing of battery can be seen on the picture below, see
direction of arrow . Let it start from a up to c( Cara pengetesan battery bisa
dilihat pada gambar di bawah, lihat arah panah. Dimulai dari a sampai c )
c. a. Model of testing ( cara pengetesan )
d. b. Clamp ampere ( tang ampere )
e. c. Result of ampere battery ( hasil pengetesan )
c

a
b

113
II.14. Engine doesn’t work suddenly ( Engine tiba – tiba Mati/OFF )

Things to do for doesn’t work suddenly ( engine tiba – tiba mati / OFF )

a. Please check the specification of oil. Please refer to the standard oil for
engine. ( Mohon diperiksa spesifikasi oli. Mohon mengacu pada standard oli
dari engine ).

b. Please check level oil with dipstick . Make sure the level of oil is “
OPERATION LEVEL” as a recommendation of engine or make sure it has
reached oil level from stick ( Mohon dicheck level oli dengan stik check oli.
Pastikan oli engine pada “ level operasi “ sesuai dengan rekomendasi engine atau
pastikan sudah mencapai batas oli dari stick )

2. Engine oil

114
II.14. Engine doesn’t work suddenly ( Engine tiba – tiba Mati/OFF )

Things to do for doesn’t work suddenly ( engine tiba – tiba mati / OFF )

a. Please check the specification of engine coolant. Please refer to recommendation

coolant standard of engine coolant ( Mohon diperiksa spesifikasi oli. Mohon mengacu
pada standard coolant dari engine ).

b. Please make sure the level of coolant engine on top level as a recommendation of
engine or make sure it is on coolant top level. ( Pastikan coolant engine pada “ top
level“ sesuai dengan rekomendasi engine atau pastikan sudah mencapai batas coolant
).

c. Please open up cap No.1 for checking level of coolant ( Buka cap no.1 untuk
memeriksa level coolant )

3. Engine coolant

115
II.14. Engine doesn’t work suddenly ( Engine tiba – tiba Mati/OFF )

Things to do for doesn’t work suddenly ( engine tiba – tiba mati / OFF )
The Fuel is taken from fuel tank of unit Dnd before
it comes into the engine, it should through to
separator additional filter for keeping particles,
solid or water. Although from the original engine, it
has already installed of water separator. ( Fuel
diambil tangki unit DnD, sebelum masuk ke engine
harus masuk dahulu ke filter tambahan untuk
mencegah masuknya partikel, pasir atau air.
Walaupun dari engine sudah terpasang filter water
separator )

Filter separator

Filter separator form engine Fuel tank

116
II.14. Engine doesn’t work suddenly ( Engine tiba – tiba Mati/OFF )

Things to do for doesn’t work suddenly ( engine tiba – tiba mati / OFF )

If the engine does not get supply of fuel, please pump

the fuel with hand pump. Then please loosen the
bleeding nozzle ( red arrow ) , please ensure the fuel
come out from nozzle. Please check and see the
material blowing is fuel not bubbles or air. Tighten
again the nozzle, and the engine is ready to start.

Jika engine tidak mendapat tersuplai fuel, mohon fuel

dipompa dengan pompa tangan . Kendorkan nozzle
bleeding ( Arah panah ), pastikan yang keluar adalah fuel
dan bukan gelembung atau udara dari nozzle.
Kencangkan kembali nozzle tersebut dan engine siap
untuk dinyalakan.

117
II.14. Engine doesn’t work suddenly ( Engine tiba – tiba Mati/OFF )

Things to do for doesn’t work suddenly ( engine tiba – tiba mati / OFF )

Frequently they were found so many contamination with other

materials( water, slurry, particles etc ). Please change it ( element of
filter )every 250 hours.
Sering ditemukan banyak terkontaminasi dengan material lain ( air,
lumpur, partikel dan lain – lain ). Mohon untuk dilakukan penggantian (
element filter )tiap 250 HM.

Filter separator
118
II.15. Engine black smoke ( Asap engine hitam )

119
II.15. Engine black smoke ( Asap engine hitam )

Things to do for engine black smoke ( Yang harus dilakukan untuk engine berasap hitam )
1. Check injector condition ( Periksa kondisi injector ).
2. Check the quality of fuel ( Periksa kualitas bahan bakar / solar )
3. Filter condition ( air filter, fuel filter, oil filter ) ( Periksa kondisi semua filter )

Preventive action :
1. Stop the engine , then check and open up the injector. If necessary change it with new parts.
2. Making sure the quality of fuel is good no contamination with others material
3. Please making sure all of filters are in good, such as :
a. Air filter
b. Fuel filter
c. Oil filter
d. Pre filter ( Separator water filter )
e. By pass filter
Note : For engine running with black smoke , there is indication high consumption of fuel.

Tindakan perawatan dan perbaikan :

1. Hentikan engine , kemudian periksa dan buka injector. Bila perlu ganti dengan yang baru.
2. Pastikan kualitas atau mutu bahan bakar adalah bagus, tidak ada kontaminasi material lain.
3. Pastikan semua filter dalam kondisi baik, seperti : Air filter, Fuel filter, Oil filter, Pre filter ( separator water filter, By pass filter
).
Note : Untuk engine bekerja dengan asap hitam, ada indikasi konsumsi bahan bakar sangat tinggi.
120
II.16. Engine white smoke ( Asap engine putih )

121
II.17. Engine white smoke ( Asap engine putih )
Things to do for engine white smoke

1. Check injector condition

2. Turbocharger ( Leakage ) or entry the water into turbocharger system )
3. Quality of fuel ( contaminated fuel with other material )
4. Piston crankshaft has indicated damage
5. Water coolant too low
6. Level oil engine too high

Preventive action :
1. Stop the engine , then check and pull out the injector. Please check the injector condition, if there is any contamination
with water of slurry. Please change it with new parts.
2. Making sure the quality of fuel is good no contamination with others material
3. Please check point of leakage, which to make it others material come into turbo system. Please replace the sealing of
turbo and could not any problem anymore.
4. Since the engine run with like that, please monitor and hearing that is indicated the crank shaft have a problem or the
performance of engine is rough, not smooth. Please stop the engine and check it in detail.
5. Please keep and always monitor the level of water coolant, If necessary we add it every we found indication to down, or
please to checking leakage to getting condition of radiator tank is good.
6. Please always monitor the level of oil engine is in range “ operation “.

122
II.17. Engine white smoke ( Asap engine putih )

( Yang harus dilakukan untuk engine berasap putih )

1. ( Periksa kondisi injector )
2. ( Turbocharger bocor atau kemasukan air pada turbocharger system )
3. ( Kualitas bahan bakar )
4. ( Ada indikasi crankshaft rusak )
5. ( Kapasitas atau volume air radiator sangat berkurang )
6. ( Oli engine terlalu penuh )

Tindakan perawatan dan perbaikan :

1. Matikan engine , kemudian periksa dan lepaskan injector. Periksa kondisi injector, jika pada injector terdapat kontaminasi dengan
air atau lumpur. Ganti injector dengan yang baru.
2. Pastikan kualitas BBM adalah baik, tidak ada kontaminasi dengan material
3. Periksa titik kebocoran, yang membuat ada material lain masuk kedalam sistem turbo. Ganti sealing turbo dan pastikan tidak ada
kebocoran lagi.
4. Bila engine berjalan seperti hal yang disebut diatas, monitor dan dengarkan bahwa ada indikasi problem dari crank shaft atau
kinerja engine sangat kasar , tidak halus. Stop engine dan periksa secara terperinci.
5. Harap selalu monitor level water coolant, bila perlu kita tambahkan water coolant jika kita melihat ada indikasi menurun, periksa
kebocoran pada tangki radiaotor untuk memastikan bahwa tangki radiator dalam kondisi baik.
6. Harap selalu menjaga level oli engine masih dalam batas “ Operation “.

123
II.17. Database of engine is blank ( data base engine hilang/operation )

124
II.17. Database of engine is blank ( data base engine hilang/operation )

Things to do for data base of engine is blank ( Yang harus dilakukan data base engine hilang )

1. The engine doesn’t run/ start ( Engine tidak bisa running / start )
2. Data of engine is gone or all of parameter is zero “ 0”. ( Semua
data engine hilang atau Nol ( 0 )

Preventive action :
1. Please open up the cover ( red arrow ), check the relay of panel
DCU.
2. Please replace with new relay by original of engine.
3. Please keep in stock for back up operation of engine.

Tindakan perbaikan dan perawatan :

1. Buka cover ( tanda panah merah), periksa relay panle DCU
2. Ganti dengan relay yang baru , original dari engine.
3. Harap menyediakan relay untuk back up operasi engine

125
126
Position pump set on pontoon ( Penempatan pompa diatas pontoon )

127
Items of sensor engine

No Description
1 Coolant level sensor, in the expansion tank
2 Combined charge air pressure and charge air temperature

3 Under pressure sensor, air filter

4 Flywheel position and engine speed sensor

5 Fuse
6 Extra stop ( aux stop )
7 Oil pressure sensor
8 Water in fuel sensor
9 Combined oil level and temperature sensor
10 Fuel pressure sensor
11 Crankcase pressure sensor
12 Coolant temperature sensor
13 Piston cooling pressure sensor
14 Camshaft position sensor

128
Spare Parts recommendation

Spare Parts recommendation :

1. For back up LCC pump
2. For back up engine
3. For regular maintenance

129
Spare Parts recommendation

No Description
For Back up LCC Pump ( Untuk persediaan pompa LCC )

1 Suction plate
2 O-ring suction plate
3 Impeller
3 Gasket impeller
4 Shaft sleeve
5 Pump shaft
6 Gland packing
7 Stuffing box
8 Gasket stuffing box
9 Radial Inproseal
10 Axial Inproseal
11 Radial bearing
12 Axial thrust bearing
13 Bearing bracket housing
14 Gasket for cover bearing radial
15 Gasket for cover axial bearing 130
Spare Parts recommendation

No Description
For Back up LCC Pump ( Untuk persediaan pompa LCC )

16 Vacuum pump
17 Finger valve – vacuum pump
18 V-belt for vacuum pump
19 Magnetic clutch
20 Vacuum panel
21 Oil bearing
22 Fuse for vacuum panel
23 Stuffing box
24 Suction hose
25 Water separator tank
27 High and Low sensor vacuum tank
28 Check valve
29 Rotary Lamp
30 Silicon red
31 Additive dextone/Loctite
32 Loctite anti seize 131
Spare Parts recommendation

No Description

For Back up Engine

1 Motor starter
2 Alternator
3 Battery
4 V-belt for fan
5 V-belt for alternator
6 Injector
7 Crank shaft seal
8 Top cover seal
9 Pre fuel filter
10 Water separator filter
15 Pump supply for fuel
11 Oil filter
16 Turbocharger
12 Air filter
17 Muffler
12 Fuel filter
13 By pass filter 18 Water coolant

14 Relay DCU 19 Fuel hand pump

132
Spare Parts recommendation

No Description
For regular maintenance 50 hours
1 Oil bearing
For regular maintenance 250 hours
1 Oil bearing
2 Gland packing
3 Fuel filter
4 Bypass filter
5 Oil filter
6 Element water separator filter
7 Oil engine
For regular maintenance 500 hours
11 Gland packing
12 Oil bearing
13 By pass filter
14 Oil filter
15 Fuel filter
16 By pass filter
17 Element water separator filter
18 Oil engine
133
19 Air filter
Spare Parts recommendation

For regular maintenance 750 hours

1 Gland packing
2 Oil bearing
3 By pass filter
4 Oil filter
5 Fuel filter
6 By pass filter
7 Element water separator filter
8 Oil engine
9 Shaft sleeve
10 Air filter
For regular maintenance 1500hours
1 Gland packing
2 Oil bearing
3 By pass filter 7 Element water separator filter

4 Oil filter 8 Oil engine

5 Fuel filter 9 Shaft sleeve

6 By pass filter 10 Air filter

134
Spare Parts recommendation
For regular maintenance 2000hours

1 Gland packing
2 Oil bearing
3 By pass filter
4 Oil filter
5 Fuel filter
6 By pass filter
7 Element water separator filter
8 Oil engine
9 Shaft sleeve
10 Air filter
11 Check turbocharger
12 Check valve play/ adjust 6 By pass filter

13 Check injector 7 Element water separator filter

For regular maintenance 4000hours 8 Oil engine

1 Gland packing 9 Shaft sleeve

2 Oil bearing 10 Air filter

3 By pass filter 11 Check turbocharger

4 Oil filter 12 Check valve play/ adjust

5 Fuel filter 13 Check injector 135
Thank you

136