Development of a Special Service Tool for Hydraulic Piston Maintenance on Excavator PC 210-10M0
DOI:
https://doi.org/10.24853/sintek.18.2.121-128Keywords:
special service tools, hydraulic excavators, maintenance efficiency, Seven Up methodAbstract
Excavators are essential machinery widely utilized in mining, construction, plantation, and other industries. The Komatsu PC210-10M0, a small-sized excavator model, performs critical operations such as material digging and transportation. However, during component overhauls, particularly for the boom cylinder, bucket, and arm, significant challenges arise due to the absence of suitable tools for efficiently removing and installing hydraulic cylinder pistons. The current reliance on generic tools such as screw wrench sets (L-keys) is suboptimal, leading to inefficiencies, increased risks of workplace accidents due to tool slippage, and longer processing times. This study addresses these limitations by employing the Seven Up++ method to develop a specialized service tool specifically designed for hydraulic cylinder piston maintenance. The methodology encompasses three critical phases: Analysis, Solution, and Results, ensuring a systematic and innovation-focused approach. The developed tool securely positions itself on the piston cylinder, utilizing two pins inserted into pre-existing holes on the piston surface. The results demonstrate significant improvements: maintenance processing time is reduced by up to 70%, operational safety is enhanced due to the tool's secure attachment, and labor requirements are halved, with manpower reduced from two operators to one. These findings highlight the tool's potential to optimize maintenance operations and improve overall efficiency in the use of Komatsu PC210-10M0 excavators.References
Dewan Energi Nasional, Bauran Energi Nasional, Sekretaris Jenderal Dewan Energi Nasional, Jakarta, 2020.
A. P. Afin and B. F. T. Kiono, "Potensi Energi Batubara serta Pemanfaatan dan Teknologinya di Indonesia Tahun 2020–2050: Gasifikasi Batubara," Jurnal Energi Baru Dan Terbarukan, vol. 2, no. 2, pp. 144-122, 2021.
D. Bogdanov, A. Gulagi, M. Fasihi, and C. Breyer, "Full energy sector transition towards 100% renewable energy supply: Integrating power, heat, transport and industry sectors including desalination," Applied Energy, vol. 283, p. 116273, 2021.
X. Chen, F. Chen, J. Zhou, L. Li, and Y. Zhang, "Cushioning structure optimization of excavator arm cylinder," Automation in Construction, vol. 53, pp. 120-130, 2015.
L. Solazzi, A. Assi, and F. Ceresoli, "Excavator arms: Numerical, experimental and new concept design," Composite Structures, vol. 217, pp. 60-74, 2019.
H. Basri and Rasma, "Analisa Service Brake Malfunction pada Unit Dump Truck (HD) 1500–7," in Prosiding Semnastek, 2019.
H. Purwono, R. F. Armas, and A. R. Mubarok, "Pembuatan Alat Bantu Khusus Pelepasan Dan Pemasangan Piston Seal Cylinder Hydraulic Unit Excavator PC200-8M0," in Prosiding Semnastek, 2022.
PT. United Tractors, Basic Mechanic Course, 2016.
Rasma, R. Rasma, A. Aryadi, and M. G. Kurniawan, "Pembuatan Alat Remove Dan Install Track Roller Pada Unit PC200-8M0 Untuk General Over Haul," in Prosiding Semnastek, 2022.
M. Khosroniya, R. Hosnavi, and M. R. Zahedi, "Enhancing operational performance in Industry 4.0: The mediating role of total quality management and total productive maintenance at Zarharan Industrial Complex," Int. J. Ind. Eng. Oper. Res., vol. 6, no. 1, pp. 96-122, 2024.
M. Javaid, A. Haleem, R. P. Singh, and R. Suman, "Significance of Quality 4.0 towards comprehensive enhancement in manufacturing sector," Sensors Int., vol. 2, p. 100109, 2021.
PT. United Tractors, Guide Book, 2016.
M. Coccia, "The Fishbone diagram to identify, systematize and analyze the sources of general purpose Technologies," Journal of Social and Administrative Sciences, vol. 4, no. 4, pp. 291-303, 2018.
D. Stoll, "Some Essential Principles of Effective Troubleshooting," LCGC North America, vol. 38, no. 10, pp. 505-509, 2020.
M. Tanelli, G. Panzani, S. M. Savaresi, and C. Pirola, "Transmission control for power-shift agricultural tractors: Design and end-of-line automatic tuning," Mechatronics, vol. 21, no. 1, pp. 285-297, 2011, doi: 10.1016/j.mechatronics.2010.11.006.
R. F. Armas, A. Aryadi, and N. P. Pratama, "Design and Build Special Service Tools for Remove & Install Drive Shaft for Komatsu HD785-7 Dump Truck," Jurnal E-Komtek (Elektro-Komputer-Teknik), vol. 8, no. 1, pp. 199-206, 2024, doi: 10.37339/ekomtek.v8i1.1857.
R. Rasma, R. F. Armas, H. Purwono, B. Setiawan, and M. Adnan, "Analysis Abnormal of Engine Noise in UD Truck Quester CWE 370 Unit," in International Conference on Engineering, Construction, Renewable Energy, and Advanced Materials, July 2024, [Online]. Available: https://jurnal.umj.ac.id/index.php/icecream/article/view/22826/10554.
J. R. Davidson and H. I. Krebs, "An electrorheological fluid actuator for rehabilitation robotics," IEEE/ASME Transactions on Mechatronics, vol. 23, no. 5, pp. 2156-2167, 2018, doi: 10.1109/TMECH.2018.2869126.
F. Hendra, D. Rarasanti, K. Putranto, A. Saptari, and R. Effendi, "Assesment for technical disruption priority of facilities by used DMAIC approach with FMEA tool for commuter electric train," in AIP Conference Proceedings, vol. 2485, no. 1, AIP Publishing, 2023, doi: 10.1063/5.0105280.
R. Ruspendi and R. Effendi, "Product design simplification to increase competitiveness with a value engineering approach to the wastafel flean industry," Jurnal Polimesin, vol. 19, no. 2, pp. 116-121, 2021.
B. Fu, T. Zhu, J. Liu, and X. Hu, "Research on Clamping Force Control of CVT for Electric Vehicles Based on Slip Characteristics," Sensors, vol. 22, no. 6, p. 2131, 2022, doi: 10.3390/s2206213.
J. V. Cruzat and M. A. Valenzuela, "Integrated modeling and evaluation of electric mining trucks during propel and retarding modes," IEEE Transactions on Industry Applications, vol. 54, no. 6, pp. 6586-6597, 2018, doi: 10.1109/TIA.2018.2854258.
J. B. Snoy, M. W. Dundore, and P. A. Pelligrino, "The TDMC-33-7002: A 1500 HP Transmission for Shuttle Type Vehicles," SAE Technical Paper, no. 750818, 1975, doi: 10.4271/750818.
J. Mazumdar, W. Koellner, and R. Moghe, "Interface issues of mining haul trucks operating on trolley systems," in 2010 Twenty-Fifth Annual IEEE Applied Power Electronics Conference and Exposition (APEC), 2010, pp. 1158-1165, doi: 10.1109/APEC.2010.5433357.
G. Wu, F. Liu, and S. Xu, "Compiling method of automobile fault diagnosis information," in MATEC Web of Conferences, vol. 355, p. 03073, EDP Sciences, 2022, doi: 10.1051/matecconf/202235503073.
Downloads
Published
How to Cite
Issue
Section
License
- Articles published in SINTEK JURNAL are licensed under a Creative Commons Attribution-ShareAlike 4.0 International license. You are free to copy, transform, or redistribute articles for any lawful purpose in any medium, provided you give appropriate credit to the original author(s) and SINTEK JURNAL, link to the license, indicate if changes were made, and redistribute any derivative work under the same license.
- Copyright on articles is retained by the respective author(s), without restrictions. A non-exclusive license is granted to SINTEK JURNAL to publish the article and identify itself as its original publisher, along with the commercial right to include the article in a hardcopy issue for sale to libraries and individuals.
- By publishing in SINTEK JURNAL, authors grant any third party the right to use their article to the extent provided by the Creative Commons Attribution-ShareAlike 4.0 International license.
