Jurnal Teknologi dan Rekayasa Alat Berat

Exhaust Brake Optimization on Hino 500 FM 260 JD Unit to Reduce Potential Lost Costs on The Hauling Unit at The PT PP Presisi Tbk Weda Bay Nickel Site

2025-02-28T15:37:42+07:00

Based on field observations, the exhaust brake component on the Hino 500 FM 260 JD unit frequently experiences breakdowns. One of the primary causes of failure is the ingress of mud into the exhaust chamber, which disrupts the functionality of the component. This study aims to compare the performance of exhaust brake components with and without a protective cover to enhance their lifetime, analyze the failure rate, and calculate the potential lost cost associated with exhaust brake failures in hauling units. Data collection was conducted directly in the field, and protective covers were installed on three dump truck units in the hauling fleet. The test results indicate that when the exhaust brake component was used without a cover, 14 failures were recorded, whereas with the cover installed, only 4 failures occurred. These findings demonstrate that the protective cover significantly impacts the lifetime and failure rate of the exhaust brake component. Following the testing phase, a potential lost cost analysis was conducted, considering four cost variables: spare parts, production losses, operator costs, and mechanic costs.

Development of TREPOS (Travel Protection System) for Shortening Travel Dispatch on Small Excavators

2025-02-28T15:37:42+07:00

Excavators primarily perform digging, loading, and swinging operations, while travel operations are intended to support mobility within the work area and should not exceed the primary operations. The operational data of the PC210-10M0 excavator, accessed through KOMTRAX, was utilized in this study as part of Komatsu's monitoring service. The objective was to design, develop, and install a travel protection system (TREPOS) and analyze travel dispatch data as an indicator of travel operations. The TREPOS development process included system design, wiring diagram creation, assembly, installation, and system testing. TREPOS employs a Programmable Logic Controller (PLC) to process inputs and outputs. Its function is to provide an audible warning and reduce the engine speed to low idle if the travel operation exceeds 15 minutes. The PDCA method was used in travel dispatch data analysis as an evaluation tool for TREPOS development. Initial results indicated no reduction in travel durations exceeding 20 minutes, necessitating further improvements. The second installation showed a reduction in the number of travel durations exceeding 20 minutes from 13 to 8 occurrences.

Analysis of Crack Formation in Coil Spring Track Adjuster on the Undercarriage of CAT 320GC Excavator

2025-02-28T15:37:43+07:00

Heavy equipment, such as excavators, plays a crucial role in infrastructure and mining projects. The demanding worksite conditions and production targets require excavators to maintain high productivity, which can lead to material failures. A critical failure observed in the CAT 320GC excavator was the fracture of the coil spring in the undercarriage system. Several factors can contribute to coil spring failure, including worksite conditions, material defects, inadequate maintenance, and operational errors. This study aims to identify the root causes of coil spring fracture by analyzing its mechanical properties. The research methodology includes chemical composition analysis, visual and microstructural examination, hardness testing, and impact testing. The findings indicate that material failure was primarily caused by corrosion on the surface, which accelerated the fracture process. Additionally, repeated excessive loads from track shoe movements contributed to fatigue failure. The coil spring material was identified as high-carbon steel, closely resembling the 51xx (Chromium Steels) type. The fracture exhibited brittle characteristics with a granular or crystalline pattern, and the average impact energy was measured at 0.1541 J/mm². The coil spring material demonstrated an average hardness of 522.83 VHN, confirming its high hardness but brittle nature. The microstructural analysis revealed a predominance of fine lamellar pearlite in the dark regions of the fractured area.

Material Failure Analysis of Coil Spring Fracture on The Track Adjuster Excavator PC 78

2025-02-28T15:37:44+07:00

One of the critical components of an excavator's undercarriage is the coil spring, which frequently breaks due to extreme working conditions, lack of routine maintenance, and material defects. This coil spring failure often occurs in the PC 78 excavator unit. The resolution of this issue requires an undetermined period of time. This problem can lead to decreased and suboptimal excavator productivity. The objective of this study is to identify the causes of coil spring fractures, evaluate its mechanical strength, and determine the type of material used. The methods applied include chemical composition analysis, microstructure examination, hardness testing, and impact testing. Visual observations indicate that the coil spring failure is caused by material fatigue, crack initiation, propagation, and final fracture characterized by beach marks and striations. Chemical composition analysis reveals the dominance of iron (Fe), carbon (C), chromium (Cr), and manganese (Mn), classifying the material as AISI 51xx steel. Microstructural examination shows a dominance of bainite, which contributes to the material's hardness. Vickers hardness testing indicates high hardness values consistent with the observed microstructure. Impact testing results suggest that the fractured specimen exhibits ductile behavior.

Cause Damage Analysis on Transmission of Dump Truck LGMG CMT 96 DT 060-032 at PT Ansaf Inti Resources

2025-02-28T15:37:44+07:00

Dump truck LGMG CMT 96 is employed by PT Ansaf Inti Resources for overburden transportation, operating up to 22 hours per day. In the unit coded DT 060-032, a transmission failure was detected at 2,143.5 hours, significantly below the company's target of 20,000 hours. The symptoms of the failure included the activation of the transmission warning indicator, fault codes, excessive jolts during operation, transmission overheating, and gear shifting failures. This study identifies the primary causes of the failure through monitor checks, visual inspections, historical maintenance data, the Machine Inspection Program (PPM), the Lubricant Analysis Program (PAP), and transmission overhaul results. The applied failure analysis method revealed brittle fracture of the lock-up clutch and excessive clutch wear due to deformation, heat spots, and blue temper. Operational errors were concluded to be the main cause of the transmission failure, leading to clutch slip and the appearance of fault code F:191 S:8.