Manual Book WT Fm260 20kl [PDF]

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OPERATION AND MAINTENANCE MANUAL BOOK WATER TRUCK HINO FM 260 CAP. 20.000 LITER



Manufactured by:



PT. PRIMA USAHA DAYATAMA (PUD) Metland Menteng Jl. Menteng Utama Komplek Niaga Metland Blok i-1 No. 29 Jakarta 13960 Telp. +62 21-22860136 E. [email protected] http://www.primausahadayatama.com



WATER TRUCK Operation & Maintenance Manual Book WATER TRUCK HINO FM260 CAP. 20.000 Liter



Manual Book ini memuat Instruksi dalam pengoperasian secara benar dan perawatan dari Water Truck unt HINO FM 260 cap. 20.000 Liter, yang mana unit ini memiliki fungsi sebagai berikut : 



Untuk support penyiraman jalan (pressurized spray system & gravity system)







Untuk support pencucian unit (washing system)







Untuk Pemadam kebakaran (fire fighting system)



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WATER TRUCK Operation & Maintenance Manual Book DAFTAR ISI Bab 1



: DESKRIPSI UNIT



Bab 2



: KOMPONEN UTAMA



Bab 3



: PANDUAN INSTRUKSI PENGOPERASIAN



Bab 4



: SPESIFIKASI TEKNIK



Bab 5



: DAFTAR KOMPONEN



Bab 6



: PERIODIC MAINTENANCE & LEMBAR INSPEKSI



IMPORTANT! Water Truck HINO FM 260 Cap. 20.000 Liter Necessary care and respect should always be taken when operating special equipment. Read the Operating Instruction before operate this unit.



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WATER TRUCK Operation & Maintenance Manual Book BAB 1 DESKRIPSI UNIT WATER TRUCK HINO FM 260 merupakan Supporting Equipment yang di desain khusus untuk melayani kebutuhan support penyiraman jalan hauling batubara di lokasi Mining (On site), Washing/Pencucian unit dan support pemadam kebakaran. Unit ini dilengkapi dengan tangki air berkapasitas 20.000 Liter dan modul yang dimensinya disesuaikan dengan Unit Hino FM260. Terdiri dari Hydraulic Displacement System dan Water Displacement System.



Aplikasi Unit Unit Water Truck Hino FM260 Cap. 20.000 Liter , memiliki fungsi yang bisa diaplikasikan dalam berbagai area, antara lain :  Mining (Pertambangan)  Power Plants  Construction (konstruksi)  Forestry (Perkebunan)



Keunggulan / manfaat penggunaan unit  Unit ini memiliki kapasitas tangki yang cukup besar yaitu lebih dari 20.000 Liter  System operasi water truck dari dalam cabin sangat mudah dikontrol dan dioperasikan  System support penyiraman dengan pressure sehingga proses penyiraman lebih baik  System support penyiraman manual/gravitasi  System water canon/manual monitor MM40 support washing dan fire fighting



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WATER TRUCK Operation & Maintenance Manual Book PRODUCT FEATURES



2” Safety Valve Water Canon



Oil Cooler 24 VDC



Maktech Sprayer 3”



Vickers Hyd. Motor 26M



4’ Pipe Manual Sprayer 4” Y-Strainer



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Southern Cross Centrifugal Pump 100x65-250



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WATER TRUCK Operation & Maintenance Manual Book BAB 2 KOMPONEN UTAMA 1. HINO FM 260 JD (RANGER 500 SERIES 6X4)



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WATER TRUCK Operation & Maintenance Manual Book



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WATER TRUCK Operation & Maintenance Manual Book 2. Water Pump Southern Cross 100x65-250 Pump Sealed for Life Bearings



Australian made to ISO 2858 International Standard, Superior hydraulic design and high technology manufacturing methods produce significantly higher efficiencies for less power consumption and minimum maintenance. Features which guarantee Southern Cross “ISO Sovereign” Pump users continuing saving in all applications.



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WATER TRUCK Operation & Maintenance Manual Book



Applications : 



Design for efficient and reliable general purpose water transfer in industry, building services and irrigation



Features : 



Superior hydraulic design and manufacturing methods produce significantly higher efficiencies for lower running costs and reduced maintenance







Australian designed and manufactured







32 to 220mm discharge







Up to 250 liters per second discharge







Heads to 160 meters



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WATER TRUCK Operation & Maintenance Manual Book



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WATER TRUCK Operation & Maintenance Manual Book



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WATER TRUCK Operation & Maintenance Manual Book



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WATER TRUCK Operation & Maintenance Manual Book



3. SPRAYER HEAD MMV/B MAXI VALVE , MAKTECH 3”



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WATER TRUCK Operation & Maintenance Manual Book



M-SH-80 - Maxi Valve Feature:  Weighs 9 kilograms (20lbs)  Compact design and shape for fast and easy  installation - see dimensions  Manufactured from marine grade alloy  Low maintenance polymer inserts control the water valve operation  Fits to any existing piping configuration from 80mm (3") nominal bore  Eliminates the need for additional water control valves (ball, butterfly, knife)  Supplies a flat, dense and variable spray pattern  Provides an even fan spray throughout the entire spray pattern  Manually adjustable spray pattern via a fitted adjustable ring  Can control output water flow from 0 - 1350 l/min (approx)  Up to 12 metre distance spray throw  Up to 11 metre spray width  360° adjustable swivel rotation can be fitted  3" BSP F threaded baseplate to accept any preferred quick release mounting  0 - 90° manually controlled fan width spray setting  S/steel spring and fasteners  Water pressure opens the valve  Air pressure controls closing of the valve  Spring pressure keeps valve closed when air pressure not present and pump not operating  Can use electric or pneumatic cabin switching to control valve operation  Valves are fully pressure tested prior to packaging  Serial numbered and engraved with uniqueidentification for traceability  Full warranty on parts ,Spare parts readily available , Fully serviceable



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WATER TRUCK Operation & Maintenance Manual Book



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WATER TRUCK Operation & Maintenance Manual Book 4. HYDRAULIC PUMP, VICKERS 35VQ



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WATER TRUCK Operation & Maintenance Manual Book



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WATER TRUCK Operation & Maintenance Manual Book



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WATER TRUCK Operation & Maintenance Manual Book



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WATER TRUCK Operation & Maintenance Manual Book



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WATER TRUCK Operation & Maintenance Manual Book 5. HYDRAULIC VANE MOTOR, MODEL VICKERS 26M-65A-1C-20



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WATER TRUCK Operation & Maintenance Manual Book



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WATER TRUCK Operation & Maintenance Manual Book



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WATER TRUCK Operation & Maintenance Manual Book



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WATER TRUCK Operation & Maintenance Manual Book



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WATER TRUCK Operation & Maintenance Manual Book



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WATER TRUCK Operation & Maintenance Manual Book 6. JOINT COUPLING , FENNER F60



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WATER TRUCK Operation & Maintenance Manual Book 7. OIL COOLER MODEL AH1470-A2



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WATER TRUCK Operation & Maintenance Manual Book 8. HYDRAULIC DIRECTIONAL VALVE 1” NUCLEO DP 120 1/1



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WATER TRUCK Operation & Maintenance Manual Book 9. SUCTION FILTER 1.5”



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WATER TRUCK Operation & Maintenance Manual Book 10. RETURN FILTER PN. HF6710



Indicator penggantian catridge filter (jika jarum menunjukkan area kuning atau merah)



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WATER TRUCK Operation & Maintenance Manual Book 11. AIR FILTER REGULATOR, SMC MODEL



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WATER TRUCK Operation & Maintenance Manual Book 12. SAFETY VALVE



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WATER TRUCK Operation & Maintenance Manual Book BAB 3 PANDUAN INSTRUKSI PENGOPERASIAN Bacalah dengan Seksama sebelum mengoperasikan Unit WT Baca dan Pahami baik-baik diagram berikut 20



18



19



19



21



17



17



16



22 (-)



30



(-)



30 17 10 22



9



15 13



33



11



33



14 12



26



13 25



34 12



23



12



8



24



5



(+)



31 (-)



32



7



31



Keterangan : Hydraulic Oil Line Water Line Pneumatic Line Electrical Line



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2



PTO Transmisi



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6



3



4 1



WATER TRUCK Operation & Maintenance Manual Book Part List: 1. Hydraulic Oil Tank 200 L



18. Ball Valve 2”



2. Suction Filter 1.5”



19. Nozzle Gun 0.5”



3. Oil Level / Sight Glass



20. Water Canon 1.5”



4. Oil Filler & Breather



21. Water Sprayer 3”



5. Return Filter 1.25”



22. River Suction Port 2”



6. Hydraulic Vane Pump



23. Manual Sprayer 4”



8. Hydraulic Control Valve 1”



24. High Pressure Piston Pump



9. Hydraulic Vane Motor



25. Hose Reel 3/8” x 15m



10. Motor Coupling



26. Nozzle Gun for 250 Bar



11. Water Tank 16 KL



30. Solenoid Valve 5/2



12. Butterfly Valve 4”



31. Mechanical Valve 3/2



13. Flexible Joint 4”



32. Solenoid Valve 2/2



14. Y-Strainer 4”



33. Toggle Switch NO



15. Centrifugal Pump



34. Push Button Switch NC



16. Safety Valve 2”



35. Level Switch ½” NPT



17. Butterfly Valve 3”



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WATER TRUCK Operation & Maintenance Manual Book 1. Langkah Pra Operasi Untuk alasan keselamatan dan keamanan beberapa koneksi dilepas , silahkan ikuti petunjuk berikut ini sebelum unit dioperasikan No 1.



Deskripsi Pastikan Tangki Air (11) terisi penuh



2.



Pastikan Tangki Oli Hidraulik (1) terisi penuh



3.



Buka Valve Supply Udara untuk Modul



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Gambar



WATER TRUCK Operation & Maintenance Manual Book 4.



Set Air Regulator, Maksimum di 7 Bar



5.



Buka Valve Supply Oli Hidrolik pada Tangki



6.



Buka Valve Supply Air untuk Pompa Southern Cross



7.



Tutup Valve Return Line air ke tangki



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WATER TRUCK Operation & Maintenance Manual Book 8.



Buka Butterfly Valve untuk sprayer



9.



Pastikan oil cooler ON pada saat engine di hidupkan



Mohon perhatian !! Ketidakpatuhan terhadap langkah-langkah diatas akan dapat mengakibatkan system bekerja secara tidak normal. Dan fatalnya dapat merusak componen yang lainnya.



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WATER TRUCK Operation & Maintenance Manual Book 2. Instruksi Pengoperasian Unit LANGKAH PENYEMPROTAN JALAN HAULING ( Manual ) 1.



Buka Valve untuk penyemprotan secara manual, tutup kembali jika selesai



Sebagai catatan bahwa untuk menggunakan Manual Sprayer, tidak harus menghidupkan PTO, air akan bergerak secara gravitasi ke bawah untuk melakukan penyemprotan melalui lubang sprayer. LANGKAH PENYEMPROTAN JALAN HAULING ( dengan Head Sprayer ) Karena unit ini menggunakan PTO Engine, setiap anda melakukan starter engine maka PTO otomatis ikut menggerakan sistem Hidraulik modul. 1.



- Hidupkan unit HINO FM260 - Aktifkan PTO dengan posisi berhenti, transmisi posisi Netral, Injak Coupling dan Tekan Switch PTO - Pastikan PTO aktif dan propeller drive memutarkan hydraulic pump



2



Buka Valve 3” Pipa Sprayer



(Pastikan Valve 3” untuk water canon dan hose reel 1” dalam kondisi tertutup) Tutup kembali jika selesai digunakan



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WATER TRUCK Operation & Maintenance Manual Book 3.



Hidupkan Pompa Air MAXI dengan memutar Switch ON/OFF “Pompa ” ke kanan



4.



Hidupkan Sprayer dengan Meng-ONkan 2 buah toggle switch. Jika



diinginkan hanya 1 buah sprayer yang dihidupkan, maka dapat dihidupkan hanya 1 toggle switch baik kiri maupun kanan



5.



Semprotan Optimum pada RPM engine 1500-2500 Untuk penyemprotan putus-putus gunakan tombol intermiten Yang berwarna “ merah”



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WATER TRUCK Operation & Maintenance Manual Book LANGKAH PENYEMPROTAN WATER CANON 1. Buka Valve 3” Pipa untuk Water Canon (Pastikan Valve 3” untuk sprayer dan



hose reel 1” dalam kondisi tertutup) Tutup kembali jika selesai digunakan



2.



Hidupkan Pompa Air Southern Cross dengan memutar MAIN SWITCH + SOLENOID PUMP Semprotan Optimum pada RPM engine 1500-2500



LANGKAH PENGISAPAN AIR DARI SUNGAI ( Additional ) 1.



Pasang Selang Sambungan ke koneksi flange 4” (tidak disediakan misitama)



2.



Tutup valve 4” supply air dari tangki ke pompa southern cross



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WATER TRUCK Operation & Maintenance Manual Book 3.



Buka Valve 3” By Pass ke Tangki



4.



Buka Valve 4” Supply dari Luar



5.



Hidupkan Engine Unit



6.



Hidupkan Pompa Air Southern Cross dengan memutar “ MAIN SWITCH + SOLENOID “ Hisapan Optimum pada RPM engine 1500-2500



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WATER TRUCK Operation & Maintenance Manual Book



GUNAKAN DENGAN HATI-HATI, KARENA KERUSAKAN DAPAT DIKURANGI DENGAN PENGGUNAAN YANG BENAR SERTA PERAWATAN YANG RUTIN DAN TEPAT



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WATER TRUCK Operation & Maintenance Manual Book BAB 4 SPESIFIKASI TEKNIK Technical Specification Unit Truck Jumlah Muatan



: HINO FM 260 (6X4 / 10 WHEEL) : 2 Orang



Kapasitas Tangki Air



: 20.000 Liter



Kapasitas Tangki Oli Hydraulic Spesifikasi Oli Hydraulic system



: 120 Liter : SAE 10 / ISOVG32 : PTO Transmission



Southern Cross Pump Max. Head Max. Rpm Discharge



: model 100x65-250 : 160 meters : 2900 RPM : 250 liter / detik



MAKTECH Sprayer Head 3” Jarak Semprotan Spray Head : 12 meter Lebar Semprotan Spray Head : 11 meter MAKTECH water Canon Working Lamp Voltage



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: MM40 connection 1.5” (manual monitor) : LED Type 12/24VDC : 24 VDC



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WATER TRUCK Operation & Maintenance Manual Book



BAB 5 DAFTAR KOMPONEN No. 1 2



Description



Part Number



Model 100x65-250 Water Centrifugal Pump M-SH-80



Sprayer Head 3”



QTY



BRAND



APPLICATION



1



Southern cross



For Water Canon, Sprayer



2



Maktech



For Water Sprayer



3



35VQ-65A-1C-20 Hydraulic Vane Pump



1



Vickers



For PTO Transmission



4



26M-65A-1C-20 Hydraulic Vane Motor



1



Vickers



For Centrifugal Pump



Hydraulic Control Valve 1”



1



Nucleo



For Hydraulic



Solenoid Valve 24VDC



2



EMC



For Pneumatic



Level Switch ½” Drat



1



Japan



For Water



Oil Cooler 11/4”-24VDC



1



Jaguar



For Hydraulic



Return filter 120 lpm



1



Fleetguard



For Hydraulic



Drive Coupling



1



Fenner



For SC Pump



Suction Filter 1.5” 200 lpm



1



CLC



For Hydraulic



5



DP120/1-G



6



RV5211-08Q



7



RFS-12



8



AH1470A



9



HF6710



10



F-60



11



MF-12



12



Y-4”



Y Strainer 4”



1



For Centrifugal Pump



13



S-2”



Safety Valve 2”



1



For Centrifugal Pump



14



M-WC-MM40



Water Canon 1.5”



1



15



Kitz



Butter fly valve



16



SV-B27



Safety valve 2”



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Maktech



For Centrifugal pump



Kitz 1



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137



For safety valve



WATER TRUCK Operation & Maintenance Manual Book BAB 6 PERIODIC MAINTENANCE DAN LEMBAR INSPEKSI Tujuan dasar dari pembuatan Unit Misitama Water HINO FM260 cap. 20.000 liter adalah untuk menyediakan water service untuk melayani kebutuhan penyiraman jalan di site/lapangan secara ekonomis dan efektif. Untuk itu proses perawatan unit water truck secara teratur akan sangat membantu optimalisasi fungsi dan performance unit tersebut.



6.1



Pengecekan & Perawatan Harian



Setiap sebelum memulai penggunaan unit, cek item-item berikut: 1. Tidak ada kebocoran / tetesan oli dari sambungan, conector, hose & fitting. 2. Pastikan semua sambungan tidak ada yang kendor 3. Pastikan semua valve berfungsi dengan baik 4. Check level tangki oli, pastikan oli terisi dengan cukup (tidak diperkenankan mengoperasikan pompa tanpa oil). 5. Check ketersediaan air pada tangki air 6. Pastikan Supply udara berfungsi dengan baik 7. Bersihkan setiap saat kondisi unit Water Truck baik di bagian pompa PTO maupun di area dispensing.



6.2



Service Rutin Bulanan



Tidak ada petunjuk secara spesifik mengenai perawatan rutin bulanan.



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WATER TRUCK Operation & Maintenance Manual Book



Lembar Inspeksi Tanggal: N o



No. Seri Unit :



Item



Method



MECHANICAL CHECK All connection in 1 condition



good



Free oil leakage of unit



Visual Check



3



Hoses Supported / Fittings Tight



Check



Hydraulic Motor in Good condition Dispensing Valve in good condition All Ball valve in good condition & operation



Visual Check



6 7 8



Working condition of Pump No Leak at Pneumatic Fittings



9



Measured Value



Press & Touch



2



5



Reference Value



Visual Check Visual Check Visual Check Visual and Hearing Chek



10



Fill the judge column with



For good



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For fail



Judge



Remark



WATER TRUCK Operation & Maintenance Manual Book Lembar Inspeksi Tambahan Tanggal: No



No. Seri Unit: Item



Method



Reference Value



Measured Value



Judge



Term



Mechanical Check



1



Y-Strainer 4”



Visual & By Tool



Clean



250 jam



2



Hydraulic Oil Tank Cap. 150 Liter



Visual & by tool



200 Liter SAE 10 / ISO VG 32



250 jam



3



Suction Filter For Hydraulic Oil (located inside tank)



Visual & by tool



Clean



250 jam



4



Return Filter



Visual & By tool



Clean



250 jam



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Picture



WATER TRUCK Operation & Maintenance Manual Book Kami, sekali lagi mengucapkan terima kasih kepada Anda yang telah menjatuhkan pilihannya kepada salah satu produk PT. Prima Usaha Dayatama (PUD) Bila ada komentar, keluhan, pertanyaan atau masukan yang sudah atau belum tercantum dalam buku Manual Instruction & Maintenance ini, silahkan menghubungi kami



Hormat Kami, PT. PRIMA USAHA DAYATAMA (PUD) Metland Menteng Jl. Menteng Utama Komplek Niaga Metland Blok i-1 No. 29 Jakarta 13960 Telp. +62 21-22860136 E. [email protected] http://www.primausahadayatama.com



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WATER TRUCK Operation & Maintenance Manual Book WARRANTY STATEMENT For : WATER TRUCK HINO FM 260 CAP. 20.000 LITER SERIAL NUMBER: PUD-WT-001 MANUFACTURED DATE OKTOBER 2016 Thanks for your ordering Special Equipment to Us To support and achieve of Customer Satisfactions We would like to give Product Warranty of Our Product as mention Since 1 Year Start On



: October 2016 to September 2017



We provide our product warranty for all system and equipment of unit as in normal operating And it should be avoid for disoperation Thanks for your cooperation Best Regards, Suwandi Director PT. Prima Usaha Dayatama



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WATER TRUCK Operation & Maintenance Manual Book WARRANTY / CLAIM PROCEDURES TITLE



: WATER TRUCK 20 KL / 20.000 liter



UNIT



: HINO FM 260



NO. UNIT



:



PRODUCT NO.



: PUD-WT-001



CUSTOMER



: PT. MITRA ABADI MAHAKAM



PO. REFF



: 000416/MAM/VIII/2016



 Notify the PRIMA USAHA DAYATAMA customer service development upon discovery of the claimed defect : T. 021-22860136 E. [email protected]  Provide the following information : 1. Product name 2. Model 3. Name of customer 4. Description of problem  If the problem is a vendor supplied component, Prima Usaha Dayatama will advised and assist contracting the vendor for warranty consideration  If the problem is a manufacturing defect, Prima Usaha Dayatama will pay the labor and part replacement costs, or repair and Prima Usaha Dayatama facility, a case by case consideration will apply  If the claim is approved under the term of warranty, an approved number will be provided  Note : any authorized work or part appearing on claim are subject to review/delay and may not honored  Customer must provide warranty approval number on invoice in order to be reimbursed



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WATER TRUCK Operation & Maintenance Manual Book



WARRANTY GUIDELINES TITLE



: WATER TRUCK 20 KL / 20.000 Liter



UNIT



: HINO FM 260



NO. UNIT



:



PRODUCT NO.



: PUD-WT-001



CUSTOMER



: PT. MITRA ABADI MAHAKAM



PO. REFF



: 000416/MAM/VIII/2016



 All items manufactured are warranted against defect and workmanship for 1 year  Warranty is limited to original owner, not transferable  Improperly maintained, altered, work or abused will void warranty  Corrosion of steel/aluminum component is not warrantable after one year or improper maintenance or abuse  Purchase part, accessories and components are subject to the warranty term and conditions of that supplier  Equipment that is operated or used in service after the claimed defect is, or ought to have been discovered, warranty is void on that component or assembly  PT. Prima Usaha Dayatama’s liability does not extend to unit loss, loss of us, warehousing, transportations costs, labor, handling or service charges  Labor must not exceed what established prior to work beginning after claim is approved This list does not supercede the published 1 year warranty certificate



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