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OPTIMIZATION OF THE HYDRAULIC SYSTEM IN THE

EXCAVATOR ARM SIMULATOR

Abdul Azis Abdillah1✉, Jiyad Iqbal Risqullah2, Rahmat Subarkah2, Haidir Juna2,
Memed Sumatono2, Imam Wahyudi2, Fuad Zainuri2, Asep Apriana2
1,2
Politeknik Negeri Jakarta.
✉
e-mail :abdul.azis.a@mesin.pnj.ac.id

Abstract
Most of the heavy equipment units use a hydraulic system, even including systems that are essential for
working with a heavy equipment unit. The hydraulic system is a system that utilizes a liquid medium in
the form of fluid or oil to generate pressure, which is used to implement, the power train system, the
disconnection system, the steering system (PT Trakindo Utama, Fundamental Hydraulic System, 2003).
The working principle of hydraulics is to utilize the pressure exerted on the tool (which is used for this
actuator / cylinder / tube) so that the pressure pushes the piston which is connected to the rod. The
hydraulic system in this study is an arm excavator. This simulator is like a hydraulic system in general
which consists of a power unit, in this simulator the power unit used is a type of electric motor that is
connected to a hydraulic pump. The control unit is in the form of a control valve. The drive unit is an
actuator / cylinder / tube. This simulator has been disabled for a long time due to a malfunction. Then the
authors performed a simple analysis and improvements to the excavator arm simulator. So the research
that is done is to do the 8 step troubleshooting method on the simulator. This step aims to facilitate the
repair process in the simulator.

Keywords : Hydraulic, cylinder, excavator arm, troubleshooting, learning media, simulator

Abstrak
Hampir kebanyakan unit alat berat menggunakan sistem hidrolik, bahkan termasuk sistem yang penting
pada unit alat berat untuk bekerja. Sistem hidrolik merupakan sebuah sistem yang memanfaatkan media
zat cair berupa fluida atau oli untuk menghasilkan tekanan, yang digunakan untuk implement, power
train system, breaking system, steering system (PT Trakindo Utama, Fundamental Hydraulic System,
2003). Prisip kerja dari hidrolik yaitu memanfaatkan tekanan yang diberikan pada implement (pada
penulisan ini digunakan actuator/cylinder/tube) sehingga tekanan tersebut mendorong piston yang
berhubung dengan rod. Sistem hidrolik pada penelitian ini berupa bagian arm excavator. Simulator ini
seperti sistem hidrolik pada umumnya yang terdiri dari unit tenaga, pada simulator ini unit tenaga yang
digunakan adalah jenis motor listrik yang disambungkan ke pompa hidrolik. Unit pengontrol berupa
control valve. Unit penggerak berupa aktuator/silinder/tube. Simulator ini sudah lama tidak bisa
berfungsi karna terdapat kerusakan. Kemudian penulis melakukan analisa sederhana dan perbaikan
pada simulator arm excavator. Maka penelitian yang dilakukan adalah melakukan metode 8 step
troubleshooting pada simulator. Langkah ini bertujuan untuk memudahkan proses perbaikan pada
simulator.

Kata kunci : Hidrolik, silinder, arm excavator, troubleshooting, media pembelajaran, simulator.

Introduction To support practical lectures in the

Heavy Equipment Engineering study
program, the Jakarta State Polytechnic
(PNJ), especially in the Hydraulic
Fundamental and Intermediate Hydraulic
courses, requires a simulator as a
learning medium so that students can
understand directly what is being learned
in class. In the early stages, this
simulator was developed by a team of
heavy equipment engineering students
and lecturers in 2008 in the form of
power packs and control panels. In 2013,
a redevelopment was carried out by
making an excavator arm. Finally, in
2016 the team returned to rebuild the
simulator control panel.
In 2020, the lecturer team experienced
problems when using the simulator, the
problem was that the simulator could not
be used. Based on preliminary
observations it was found that the tool
could not be used because several
components of the hydraulic system
were damaged and not installed. In
addition, based on the results of
interviews with students and technicians,
information was obtained that the pump
could not suck oil and the cylinder was
leaking.
Based on the background described
above, the author tries to do some
troubleshooting to solve the problems in
the simulator. The purpose of this paper
is to determine the root of the problem
and repair damage to the excavator arm
simulator.
Research Methodology
The research method in this writing
refers to the 8 steps of troubleshooting
which is owned by PT.Trakindo Utama.
1. Make sure the problem really occurs.
- Gather / collect information
- Listening to customer complaints: like
what happened? What does the customer
do when a problem arises? Before the
problem occurred, was the machine
working properly?
2. Determine the problem by taking
notes
- Compile the facts gathered
- Interpret the information obtained
- Operating conditions
- Machine / engine history
3. Check visually
- Gather additional information as
needed
- Verify operational problems
- Gather evidence
4. List all possible causes
- Identify possible defects
5. Perform the test and record the results
- Check for all possible damage
6. Find the root of the problem
- Narrow down the causes of the
problem
7. Repair damage
- Perform the recommended procedure
8. Analyze why the problem occurs
- Check the solutions obtained by testing
- If the damage still appears or new
problems arise, do the troubleshooting
procedure again (PT Trakindo Utama T.,
2008)
Result and Discussion
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1. Make Sure Problems Really Occur
From customer complaints (Students of
class 2019 and Intermediate Hydraulic
Lecturer), information was obtained that
the simulator could not be used because
the pump did not want to suck oil and
the cylinder had a leak. The picture of
simulator was shown in figure 1.
2. Determine the Problem With Notes
- From the results of the field
information collected, it is found that the
cylinder is leaking, the hose is not
installed, and the hydraulic pump is not
installed because this simulator was
previously used as practical material for
heavy equipment students in 2019.
- The last powerpack was operated in
2017, and the last excavator arm was
operated in 2013. In 2016, improvements
were made to the control panel.
3. Visually Check
From the results of the visual
examination, the hydraulic cylinder had
a leak mark (figure 2). This sign can be
seen by the presence of oil that has been
contaminated by thick enough dust
around the hydraulic cylinder cover, on
the rod, and around the wiper seal there
are dry oil drips. This mark is found on
the 3 cylinders namely boom, stick and
bucket.
4. List All Possible Causes
- Drive motor
The 3 phase electric motor (Figure 3) is
still in a functional state when it is given
an electric current. The serial number of
a 3 phase motor in the form of a plate
attached to the motor is 64151965,
specifications of rotation per minute of
1720 rpm and power of 1.5 kW and
voltages of 380v, 60 Hz and 3.3 AMP.
The author suspects that the motor is the
cause of the pump not being able to suck
because the rotation is not in accordance
with the pump specifications (clockwise
from the back side of the pump).
However, the test cannot be done
because there is no 3-phase electricity at
the author's house.
- Hydraulic Cylinders
Another possibility is the contaminant
that gets into the hydraulic system and
sticks to the rods and then rubs the
wiper seal, causing damage to the wiper
seal. Causes of damage to the seals
include age, wear and heat. Age factor is
a major factor because the older the seal
will cause brittle, wear and brittle. This
can also be caused by hydraulic oil or
friction between the rod and the seal.
Dirt that gets into the hydraulic cylinder
also causes seal damage. Another cause
is due to the heat in the hydraulic fluid /
oil, or because the hot rods also cause
the seal to be damaged. (Ardi &
Setiawan, 2010).
5. Perform Tests and Record Results
Because the powerpack cannot be used,
the testing is not carried out with the
powerpack simulator, but is carried out
using a manual pump to push the
cylinder, when the cylinder is in the
extand position there is a leak through
the cylinder head through the wiper seal.
6. Find the Roots of the Problem
- Hydraulic Cylinders
In finding the root cause of the leak, the
cause is the seal component, it is
necessary to use the 8 step applied
failure analysis method.

a. State the problem clearly and
concisely
The problem was found, which is a sign
of a leak in the hydraulic cylinder.
b. Compile the facts found
Figure 6 Leak in cylinder
It is known that the simulator has not
been used for a long time because in
2017 the powerpack was moved to the
final project of the 2015 class of
students.
c. Check and record all the facts
Testing is done to find out the leak, by
retracting and extending the cylinder,
when the extand there is fluid coming
out through the wiper seal.
d. Think logically according to facts
The fact that that the wiper seal was
already in a fragile state, it was proven
when the extand wiper seal was pulled
too, but when the rod was in the retract
position the wiper seal also dropped
following the rod.
Fishbone diagram about this problem
can be seen in figure 4. Fishbone
diagram is used to find the root of the
problem based on the facts that can be
gathered.
e. Identify the most likely root causes
Another possibility is the contaminant
that gets into the hydraulic system and
sticks to the rod and then rubs the wiper
seal, causing damage to the wiper seal.
Causes of damage to the seals include
age, wear and heat. Age factor is a major
factor because the older the seal will
cause brittle, wear and brittle. This can
also be caused by hydraulic oil or
friction between the axles and seals. Dirt
that gets into the hydraulic cylinder also
causes seal damage. Another cause is
due to the heat in the hydraulic oil, or
because the hot axles are also the cause
of the seal damage. (Ardi & Setiawan,
2010).
f. Delivering to the responsible party
This step aims to get approval from the
customer for further repairs.
g. Fix as agreed
The improvements made are in
accordance with the approval from the
customer. The improvements made were
replacing piston seals, wiper seals and
adding a cylinder head, referring to the
caterpillar service information system.
h. Follow Up
The final step is to provide an
explanation to the customer (class 2019
students) and include photo evidence to
convince the customer.
B. Control Panel
Figure 12 Control Panel
It was found that the wire from R S T to
U V W (figure 12) was switched in
position on the MCB, this caused the
motor rotation to reverse so that the
pump did not suck oil.
7. Repair Damage
This repair process refers to the
caterpillar service information system.
- Hydraulic Cylinders
Figure 13 New Cylinder Piston
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Figure 13 is a new piston, if previously
the piston only used 1 seal, now the rod
and piston have been replaced by using 2
seals.
Figure 14 Cylinder Head which will be
attached to the cylinder cap
The picture above shows the cylinder
head which will be installed on the
hydraulic cylinder, because previously
the cylinder did not use the head cylinder
/ bushing and replaced the cylinder cap
seal.
The reason is that the piston only has 1
piston seal with a fragile state (wear)
(figure 18) the piston seal comes out of
the seal area on the piston. So that in the
extended condition the position of the
rods is not straight parallel to the
cylinder but falls following gravity so
that it will press and rub against the
wiper rods. The precautions that must be
taken to maintain the seal are
maintenance, maintaining contaminants
and working temperature at the operation
of the simulator.

The cause of brittle piston seals is due to

Figure 15 Hydraulic Cylinder the use of simulators with excess heat
The picture above is an example of a and also because of the presence of
hydraulic cylinder that uses a 2 piston contaminants that can damage the seal.
seal and uses a cylinder head /
commonly called a bushing on the
hydraulic cylinder.
Conclusion
- Control Panel
Figure 16 Control Panel
So then the authors change the position
of the wire (figure 16) so that the motor
rotation is in accordance with the pump
rotation in order to suck oil.

8. Analysis of Why Problems Occur

- Hydraulic Cylinders
Figure 17 Wiper Seal
From the results of field observations, it
was determined that the cause of the leak
was due to the wiper rods that were
already in a brittle state (wear).

Figure 18 Old piston and piston seals

Based on the analysis that has been Researchers would like to thank the
done, it can be concluded that the cause Jakarta State Polytechnic, for providing
of the leak in the hydraulic cylinder is research grants so that this research can
because the rod wiper seal is already in a be completed.
fragile state. The cause of the wiper seal
is brittle, the piston seal is already brittle
and only has 1 seal. Furthermore, there is References
no cylinder head / bushing on the
<Times New Roman, 12 , Bold>
cylinder. This causes the piston seal to
Dibuat dengan menggunakan Mendeley
come out of the seal area so that when
atau Endnote, menggunakan format
extending, the rod is not straight parallel
IEEE.
to the cylinder but falls following gravity
Contoh:
which causes the rod to press and rub
[1] Indartomo Y.S., dkk. 2009. Energi
against the wiper rod.
dan Lingkungan Sebuah Keterkaitan
yang Erat. Prosiding Seminar
The root of the problem is contaminants,
Nasional 4 – 5 Maret 2009 Dies
because of the dusty environment. Then
Emas ITB, Bandung.
the cause of the pump does not suck is
[2] Setiawan A.F., dkk, 2009. Rancang
due to human error in the installation of
Bangun Unit Analisa Penggunaan
the cable, which causes the motor
Energi pada Lampu Penerangan,
rotation to reverse which results in
Tugas Akhir Mahasiswa Teknik
reversing the pump rotation. The
Konversi Energi, Perpustakaan PNJ,
corrective action taken to the hydraulic
Depok.
cylinder is to replace the wiper rod, rod
[3] Yoshuaki UDA, 1999. Energy
seal, rod, piston, and add the cylinder
Management, New Energy and
head. For motor rotation, wire positions
Industrial Technology Development
are exchanged so that the motor rotation
Organization Training Program on
matches the pump suction rotation.
Industry and Evironmental
Protection for ASEAN (Program on
Energy Conservation).
Acknowledgement
[4] www.pln-jabar.co.id, 2009. Tips
Hemat Listrik, PT PLN (persero).
[5] Http://www.eur.lighting.philips.com/
contacts/contavts.shmt. 2009. Philips
Lighting, Philips TL5 Lamps, 29
Juni 2009.

Tabel – Tabel atau Gambar dapat ditampilkan diakhir artikel atau di dalam body
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Gambar 1. Konsumsi Energi dari 10 Unit Komputer Aktif dan Stand By

<Margin disetting “Mirror” dengan detail : Top 2.54cm, Bottom 2.54cm, Inside 3.5cm, Outside 2.5cm>

Figure 1. Simulator of Arm Excavator

Figure 2. leak in cylinder

Figure 3. The 3 phase electric motor

 Figure 4. leak in cylinder

Tabel 1. Jumlah Total Orang

No Nama Total
1 Anto 2
2 Joko 7
3 Desi 13