Analisis Kebocoran Sistem Hidrolik Alat Peraga Mini Excavator Zhugimada dengan Menggunakan Metode Root Cause Analysis

MUHAMMAD HISYAM AR RIZQI, Braam Delfian Prihadianto, S.T., M.Eng.

2025 | Tugas Akhir | D4 TEKNIK PENGELOLAAN DAN PERAWATAN ALAT BERAT

Sistem hidrolik merupakan komponen krusial pada excavator yang memungkinkan operasional alat berat secara efisien. Namun, kebocoran hidrolik sering menjadi masalah signifikan yang dapat menurunkan kinerja, meningkatkan biaya operasional, dan menimbulkan risiko keselamatan serta lingkungan. Penelitian ini berfokus pada alat peraga mini excavator elektrik Zhugimada, yang dikembangkan oleh UGM dan masih mengalami masalah kebocoran pada sistem hidroliknya. Tujuan penelitian ini adalah mengidentifikasi faktor-faktor penyebab kebocoran, menganalisis dampaknya terhadap kinerja excavator, dan memberikan rekomendasi perbaikan. Metode Root Cause Analysis (RCA) dengan bantuan diagram fishbone digunakan untuk mengidentifikasi akar masalah. Hasil analisis menunjukkan bahwa kebocoran disebabkan oleh kombinasi faktor material (keran bocor, fitting aus, seal sobek), faktor elektrikal (RPM motor listrik berlebih 1.491 RPM dari standar 1.224 RPM, daya motor listrik di bawah standar 3 HP dari standar 7,85 HP, dan ketiadaan filter oli), serta faktor manusia (kurangnya perawatan rutin). Dampak kebocoran meliputi penurunan rata-rata silinder speed pada boom (1,41%), arm (1,34%), dan bucket (0,51%), serta penurunan tekanan pada silinder boom sebesar 16,28% pada kondisi tanpa beban. Pengujian silinder drift juga mengindikasikan kebocoran internal pada silinder arm dan boom (perubahan panjang 2 mm). Setelah perbaikan (penggantian seal, perbaikan fitting, penggantian keran), kinerja sistem hidrolik meningkat signifikan: silinder speed pada boom meningkat hingga 2,04%, arm hingga 1,77%, dan bucket hingga 1,12%. Tekanan silinder boom pada zero capacity juga meningkat 16,28%, dan masalah drift pada silinder arm dan boom teratasi. Rekomendasi perbaikan meliputi perawatan rutin, penyesuaian spesifikasi motor listrik, pemasangan filter oli, dan implementasi program inspeksi preventif. Penelitian ini berkontribusi pada pengembangan excavator elektrik yang lebih andal dan efisien melalui pendekatan kuantitatif berbasis performa.

Hydraulic systems are crucial components in excavators, enabling efficient heavy equipment operation. However, hydraulic leakage is a significant and common problem that can degrade performance, increase operational costs, and pose safety and environmental risks. This study focuses on the Zhugimada electric mini excavator training aid, developed by UGM, which experiences hydraulic system leakage issues, particularly in the boom cylinder. The research aims to identify the root causes of leakage, analyze its impact on excavator performance, and provide recommendations for improvement. The Root Cause Analysis (RCA) method, supported by a fishbone diagram, was employed to pinpoint the underlying problems. The analysis revealed that leakage was caused by a combination of material factors (leaky faucet, worn fittings, torn seals), electrical factors (electric motor RPM exceeding the standard of 1.224 RPM, operating at 1,491 RPM; motor power below the standard of 7,85 HP, operating at 3 HP; and the absence of an oil filter), and human factors (lack of routine maintenance). The impact of these leakages included an average decrease in cylinder speed for the boom (1.41%), arm (1.34%), and bucket (0.51%), as well as a 16.28% pressure drop in the boom cylinder under zero-capacity conditions. Cylinder drift tests also indicated internal leakage in the arm and boom cylinders (2 mm length change). Following repairs (seal replacement, fitting repair, faucet replacement), the hydraulic system's performance significantly improved: boom cylinder speed increased by up to 2.04%, arm by up to 1.77%, and bucket by up to 1.12%. The boom cylinder pressure at zero capacity also increased by 16.28%, and the drift issues in the arm and boom cylinders were resolved. Recommendations for improvement include routine maintenance, adjusting electric motor specifications, installing an oil filter, and implementing preventive inspection programs. This research contributes to the development of more reliable and efficient electric excavators through a quantitative, performance-based approach.

Kata Kunci : Kebocoran Hidrolik, Mini Excavator Zhugimada, Root Cause Analysis (RCA), Diagram Fishbone, Kinerja Sistem Hidrolik, Perawatan, Hydraulic Leakage, Mini Excavator Zhugimada, Root Cause Analysis (RCA), Fishbone Diagram, Hydraulic System Performance, Maintena