Kamaluddin, Ahmad (2026) Rekonstruksi Dan Optimasi Desain Silinder Hidrolik Blade Lift Unit Dozer D155-6 Komatsu (Studi Kasus Di United Tractors Pandu Engineering Plant RBPM-Balikpapan). Other thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Unit Dozer D155-6 Komatsu merupakan alat berat vital dalam industri pertambangan, di mana silinder blade lift menjadi komponen utama untuk pergerakan blade dan penopang unit saat jacking dengan beban mencapai 30 ton. Silinder ini sering mengalami kerusakan operasional seperti kebocoran seal, buckling pada rod, hingga penurunan efisiensi akibat keausan komponen, sementara PT United Tractors Pandu Engineering menghadapi kendala keterbatasan suku cadang OEM dan gambar teknik asli. Penelitian ini bertujuan melakukan rekonstruksi dan optimasi desain silinder untuk memulihkan performa dan mengurangi ketergantungan pada komponen impor. Metode penelitian meliputi observasi lapangan, reverse engineering, serta analisis kekuatan material secara teoritis dengan target efisiensi 85%.Hasil penelitian menunjukkan bahwa kondisi rusak memiliki efisiensi hanya 72% dengan clearance aktual 1,12 mm akibat keausan piston dan tube. Proses rekonstruksi berhasil menetapkan dimensi bore baru sebesar 110 mm yang mengembalikan clearance ke rentang standar 0,55 mm, sehingga secara efektif meningkatkan efisiensi hidrolik menjadi 86,6%. Optimasi material dilakukan dengan memilih substitusi lokal yang lebih ekonomis namun tetap kuat, yaitu Q345B (Tube), AISI 1045 (Piston), S45C (Rod), dan AISI 1020 (Gland & Cap End). Seluruh desain baru tervalidasi aman dengan Safety Factor (SF) 2 pada Tube dan SF 3 pada komponen lainnya. Luaran akhir penelitian ini adalah dokumen gambar teknik lengkap sebagai standar manufaktur dan perawatan mandiri di industri.
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The Komatsu D155-6 Dozer is a vital heavy equipment unit in the mining industry, where the blade lift cylinder serves as a critical component for blade movement and supporting the unit during jacking with loads reaching 30 tons. This cylinder frequently experiences operational failures such as seal leakage, rod buckling, and decreased efficiency due to component wear, while PT United Tractors Pandu Engineering faces challenges regarding OEM spare part availability and the absence of original technical drawings. This study aims to reconstruct and optimize the cylinder design to restore performance and reduce dependence on imported components. The research methodology includes field observation, reverse engineering, and theoretical material strength analysis with a target efficiency of 85%.The results indicated that the damaged state had an efficiency of only 72% with an actual clearance of 1.12 mm due to piston and tube wear. The reconstruction process successfully established a new bore dimension of 110 mm, restoring the clearance to the standard range of 0.55 mm, which effectively increased the hydraulic efficiency to 86.6%. Material optimization was achieved by selecting more economical yet strong local substitutes: Q345B (Tube), AISI 1045 (Piston), S45C (Rod), and AISI 1020 (Gland & Cap End). All new designs were validated as safe with a Safety Factor (SF) 2 for the Tube and SF 3 for other components. The final output of this research is a set of complete technical drawing documents to serve as standards for independent manufacturing and maintenance in the industry.
| Item Type: | Thesis (Other) |
|---|---|
| Uncontrolled Keywords: | Blade Lift Cylinder, Buckling, D155-6 Komatsu, Optimasi Desain, Rekonstruksi, Blade Lift Cylinder, Buckling, D155-6 Komatsu, Design Optimization, Reconstruction. |
| Subjects: | T Technology > TJ Mechanical engineering and machinery > TJ174 Maintenance and repair of machinery T Technology > TJ Mechanical engineering and machinery > TJ230 Machine design T Technology > TJ Mechanical engineering and machinery > TJ840.A2+ hydraulic machinery T Technology > TS Manufactures > TS205 Metals--Heat treatment. |
| Divisions: | Faculty of Vocational > Mechanical Industrial Engineering (D4) |
| Depositing User: | Ahmad Kamaluddin |
| Date Deposited: | 03 Aug 2026 07:20 |
| Last Modified: | 03 Aug 2026 07:20 |
| URI: | http://repository.its.ac.id/id/eprint/142479 |
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