2. Mengapa Umumnya Brand New Cylinder
Mempunyai Umur Lebih Panjang Dibanding
Refubish Cylinder ?
• 90% Umur kerja cylinder ditentukan oleh umur kerja seal.
• Umur kerja seal sangat ditentukan oleh kondisi kerja seal tersebut.
• Refurbish cylinder yang ada umumnya tidak mengembalikan kondisi
komponen cylinder sesuai yang diperlukan seal, seperti ;
1. Fits & Tolerance Mencegah seal mengalami Compression setting atau extrusion
2. Surface finish Meperlambat kehausan seal serta menurunkan Coofesien of friction
3. Cross – Hatch pattern Membuat sistem lubrikasi pada seal
4. Dll.
Jika hasil refurbish cylinder sesuai
dengan yang diperlukan seal maka
umur kerja cylinder akan jauh lebih
panjang.
3. Some Major Points to Consider
When Rebuilding A Cylinder
• General Condition – Cracking, Bending, Dimension,
Stroke & retract length, Clevis condition, etc.
• Concentricity - Rod straightness, Side-loading, alignment,
seal and Bearing wear.
• Fits - Equipment clearances, Roundness, Extrusion gaps,
Bearing clearance, Rods, Rams and Piston heads.
• Surface finishes - surface roughness of sealing Areas and
grooves, bore finish, rod/ram finish and Cross-hatch
pattern.
Work guidance should
follow observation result
4. Why we should Re Honing and Re Hard
Chrome every time we refurbish Hydraulic
Cylinder ?
Re Hard Chrome;
- Dimension
- Hardness
- Thickness
- Roughness
- Cross-hatch pattern
- Micro crack
Re Honing ;
- Dimension
- Roundness
- Roughness
- Cross-hatch pattern
Crosshatch angle is important, but not as critical
to creating a perfect bore as roundness,
straightness and surface finish. Typical
crosshatch angles are 45 or 30 degrees, +/-5
degrees.
5. Cross-Hatch Pattern
A "cross-hatch" pattern is used to retain oil or
grease to ensure proper lubrication for ring
seal in hydraulic cylinders.
6. Micro Crack
Corrosion follows the pathway of microcracks
since these represent a more easily corrodible
environment.
The hard chrome process should produces many
shallow & narrow microcracks, so less corrosion.
7. Company History
• Initial works started in 1999
• Officially established in 2000
• Initial Main Objective of the Establishment
is to provide full engineering services to
the Customers through Cylinder Up Grade
Program that supports Chesterton
Strategy to increase Sales
8. Main Service
HydraulicPneumatic Cylinders Upgrade.
Upgraded cylinders are cylinders that have been
subjected to Chesterton’s unique cylinder upgrade
procedures. These procedures include conducting a root
cause failure analysis when the cylinder first enters the
workshop, the engineering division then design
improvements for the cylinder, in both design and
materials used, with the cylinder’s application being the
guide for this upgrade, followed by correct seal selection
suitable to the cylinder’s service. This approach is unique
in the world of cylinder repair.
Chesterton Engineered Cylinder Solutions is the
program to increase customer efficiency.
9. Other Services
Machined And Imported Seals .
Seals are manufactured up to 600mm on site, using world’s best CNC machines.
Thousands of sizes and profiles are machined, some being same day delivery
service. We also supply imported molded and machined seals for hydraulic /
pneumatic and rotary seal.
Custom and Standard Designed Cylinders.
Custom and Standard designed cylinders are also offered to meet customer’s
specific requirements. Why pay for a high price imported cylinder, which has a
history of early failure, when a Custom and Standard designed and manufactured
cylinder can be sourced sometimes at a lower cost, but have a longer service life.
10. Other Services
Cylinder Contract Service Program
A cylinder contract service program is a service offered to customers that includes
maintenance outsourcing, e.g. cylinder removal from and re-assembly to the
equipment,
A cylinder parts management system, which documents each cylinder’s service
life history, thereby showing a total service cost, and maintenance scheduling etc.
Sumatera Ega Mekinka is responsible for customer’s cylinders performance
during their life time within the service contract period, by conducting daily, weekly
and monthly on site cylinder inspection.
11. SEM Focus Customers
1. Cement Industry
2. Tire Industry
3. Automotive Industry
4. Mining Industry
5. Paper Industry
6. Palm Oil Industry
12. Succes Record
• PT. Goodyear Indonesia ( Line BTA, Line BTC, Banburry, Line KL, Line AB 300-42, Line 300-40.5, Line AB 265-
42, Hyd. Open Close, Bead Lift, Loader In Out, Loader Up Down, Segmented, dll )
• PT. Bridgestone ( Warimold, Inner Bead Setter, Outter Bead Setter, Banburry, Center Post, Clamer Lock QCT,
Former Bladder 100 & 150, Dry Ice Paletizer, Flap Press, Die Lock, Wind Up, PCI Rotasi, dll )
• PT. Sumi Rubber ( Wind Up, Center Post, Cutting Scrap Tire, Multi Press, dll ).
• PT. Multi Strada ( Center Post 3.5”, Press Krupp, Tension Calendar, Uniformity, Cushion Roll, dll.)
• PT. Gajah Tunggal ( Loader Lift, Segmented, Main Cyl Banburry, dll ).
• PT. Indocement ( ITP MHED, ITP P1&2, ITP P3&4, ITP P6, ITP P7&8, ITP P9&10, ITP P11, ITP P12 ).
• PT. Holcim Plant Narogong, Plant Cilacap, Plant Ciwandan ( Raw Mill, Grate Cooler, Roller HRC, Pregrinding,
Tipping Valve, Excavator RH 40, CAT 385, Reclaimer, Triple Gate, Coal Mill, Trust Roller, Slide Gate, dll)
• PT. Semen Gresik ( Raw Mill, Pneu. Packer, Triple Gate, Rooler Crusher, Grate Cooler, Actuator HRC, dll ).
• PT. Semen Padang ( Hammer Brook, Roler Press, Feed Gate, Pregrinding, Spring Raw Mill, Spring Coal Mill,
Actuator K2L01, Pneu. EPI Indarung V, Grate Cooler, dll ).
• PT. Toyota Motor Manufacturing ( Chusion Z1, Bolster Clamp, Equalizing, Balancer 500T Z2-Z3, dll ).
• PT. United Tractors ( Excavator PC 2000, Excavator PC 3000 Shovel&Backhoe, Excavator PC 4000
Shovel&Backhoe, Excavator PC 1250, Excavator PC 800 STD & PC 800-7, Rock Breaker, Dump Truck, dll ).
• PT. Thiess ( Excavator Liebherr, Excavator 5500 Hitachi, Dozer D8R, Dozer D10R, Dump CAT 740, Dump CAT
777D, Dump CAT 785B, Dump CAT 785C Low Bead Trailer, Terex TR 100,dll ).
• PT. INCO / VALE ( Jaw Haul Master, Outter Dump, Inner Dump, Steering Forklift, Steering Volvo, Sleeping Small,
Sleeping Big, Excavator CAT 320 C&D, Dozer D10R, Dozer D8R, Dozer WA 4470-3,
• PT. TOR GANDA ( Roundo Roll Press, Screw Press, Tadano Cylinder, Slide Gate Cylinder , dll)
14. Competitive Advantage
• Integrated Workshop Facilities & Services
• Customer Intimacy and Relationship
• Certified Raw Material
• High precision machine & tools
• Chesterton Global Technical Support
• Warranty and 24 Hours Services
• Engineering Database
• Capable infrastructure to support cylinder management
system
• Implementing latest technology
• ROI guarantee for customers
24. Repair Pusher Centrifuge pada PT. Lontar
Papyrus di Jambi
Proses repair pada pusher centrifuge PT.
Lontar Papyrus. Proses melingkupi New
Tube, Hard Chrome Rod , New Bushing dan
New Sealkits.
25. Repair & Upgrade design Cyl. Chip Stocker
pada PT. Toba Pulp Lestari
Proses repair pada Cylinder Chip stocker
PT. Toba Pulp Lestari. Proses melingkupi
New Tube, Hard Chrome Rod , New Piston,
New Gland dan New Sealkits.
26. Repair & Upgrade design Cyl. Clamp Shell
pada PT. Pertamina cabang Dumai.
Proses repair pada Clamp Shell. Proses
melingkupi Repair Cylinder, Body Clamp,
Mekanikal System.
27. Repair & Maintenance Cyl. Open Close pada
PT. Indo Sawit cabang Kaban Jahe Aceh.
Proses maintenance pada mesin Boiler sawit.
Proses melingkupi Repair Cylinder,
Maintenance HPU, Mekanikal System.
28. Repair & Upgrade System mesin roll press
roundo PT. TOR GANDA Site GBT.
Proses repair mesin roll melingkupi proses
penggantian baru part hydraulic system,
hydraulic cylinder dan electrical system.
29. Repair Hydraulic Boom Cylinder Tadano
Crane PT. Torganda
Proses repair melingkupi upgrade design
part piston dan head cylinder untuk
menanggulangi kerusakan yang sering
terjadi.
30. Repair Telescoping Cylinder 9 Meter
Tadano Crane PT. Torganda
Proses repair melingkupi upgrade design
penggantian piston dan head cylinder,
rehard chrome dan rehoning id tube.
31. Pembuatan mesin PX 54, PX 57, PX 63
pertamina RU II Dumai Riau
Pembuatan baru mesin melingkupi
penggantian rangka, system hydraulik,
gearbox, hydraulik lifting cylinder, dan
perbaikan rel mesin.
32. Penggantian seal pada cylinder rexroth PT.
Riau Andalan Pulp & Paper, Tbk di Kerinci
Pekanbaru Riau
Proses repair melingkupi pengechekan
kondisi part , penggantian seal dan test
pressure.
33. Penggantian main seal pada mesin press
paper ahlstrom pada Pt. Toba Pulp Lestari,
Tbk.
New main seal ini hanya dibuat oleh
chesterton dikarenakan dimensi yang besar
yaitu id 39” x od 42”. Seal red polymer
adalah seal yang digunakan oleh perusahaan
eropa pada produk mesin mereka.
34. Maintenance mesin filter press pada PT.
Wilmar di Dumai
Maintenance proses melingkupi rekondisi
cylinder, hydraulik system, pengechekan
dan perbaikan linier sensor.
35. Repair hydraulik screw press dan hydraulik
slide door pada PT. Tor Ganda site Batang
Kumuh.
Repair melingkupi penggantian rod, tube,
sealkits, dan pembuatan new cylinder
penggantinya.
36. Mesin mesin yang digunakan semua dalam
kondisi baru dengan tingkat kepresisian
yang tinggi
37. Alat ukur menggunakan produk Mitutoyo
dengan tingkat kepresisian mencapai 0.001
mm – 0.005 mm
38. Alat ukur menggunakan produk Mitutoyo
dengan tingkat kepresisian mencapai 0.001
mm – 0.005 mm
39. OFFICE : RUKO CEMARA KUTA 88E JL.HAJI ANIF
DEPAN PINTU TOL HAJI ANIF
MEDAN ESTATE SAMPALI
PHONE : 061-66933090
WORKSHOP : SALIM NASUTION – SAMPALI
DELI SERDANG
CONTACT PERSON : HARJO 0811608989
THANK YOU
