MATERI

TEKNOLOGI ALAT BERAT

Oleh: Tafakur, S.Pd.,M.Pd.
Hp. 081325322102 e-mail: tafakur@uny.ac.id
Unit kerja: Pendidikan Teknik Otomotif FT UNY

1 tafakur, HP: 081325322102 10/2/2017

INTRODUCTION

Nama

Position

Pengalaman
 CONTOH ALAT BERAT
 Bulldozer
• Dozing, ripping, skidding,
• Land clearing
 Hydraulic excavator
Digging, lifting, loading,
Breaking, scraping
 Dumptruck
Hauling jarak menengah-
pendek
 Motor grader
Scraping, spreading,
ripping
 Wheel loader
Loading pada medan keras
dan rata
 Crane, dll.
Lifting, pemindahan barang
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CAKUPAN MATERI PADA TEKNOLOGI ALAT BERAT
 Safety di alat berat
 Sistem Engine (mostly Diesel engine)
 Dasar dan komponen sistem hidrolik alat berat
 Sistem hidrolik
 Sistem powertrain alat berat
 Sistem vehicle control (Kemudi, Rem, Suspensi)
 Manajemen perawatan alat berat

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 TOPIC 1
DASAR DAN KOMPONEN SISTEM
HIDROLIK

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PENGGUNAAN SISTEM HIDROLIK PADA ALAT BERAT
 Brake system
 Hydraulic implements
 Power steering system
 Powershift/automatic transmission
 Hydrostatic transmission
 Fuel system
 Torque converter

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HUKUM DASAR HIDROLIK
Hukum pascal
Pressure applied to a confined liquid is
transmitted undiminished in all directions
and acts with equal force on all equal areas,
at right angles to those areas

Hukum bernoulli
If flow in a circuit is constant, the sum of
the pressure and kinetic energy must also
be constant. When fluid is forced through
areas of different diameters, the result is
changes in fluid velocity.

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TERMINOLOGI HIDROSTATIK VS HIDRODINAMIK
 Hidrostatik
the science of transmitting force by pushing on a confined
liquid. In a hydrostatic system, transfer of energy takes
place because a confined liquid is subject to pressure
(tempat tertutup): Low fluid movement in high system
pressure
Contoh: sirkuit hidrostatik untuk menggerakkan silinder
berbagai perlengkapan hidrolik, sistem rem

 Hidrodinamik:
the science of moving liquids to transmit energy : high fluid
velocity with lower system pressures.
Contoh: turbine, torque converter

Soal: Bagaimana dengan power steering kendaraan?

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SISTEM SATUAN TEKANAN DAN HUBUNGANNYA
DENGAN GAYA DAN LUAS PENAMPANG

 Tekanan: Bar, Atm, Kg/cm2, Psi, Pascal (N/m2)

 1 Bar = …….
0.987
Atm =…….
1.02
Kg/cm2
= …….
14.504
Psi = …….Pa?
100

 1 Psi = ……..Bar = …….. Pa?

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Contoh soal
 Sebuah sistem hidrolik memiliki kapasitas angkat sebesar 20
ton. Digerakkan dengan silinder dengan luas penampang piston
: 150 cm2. Sistem Diberi beban sebesar 15 ton. berapa tekanan
yang terjadi? (bentuk Kg/cm2, psi, dan pascal)

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Hydraulic components
 􀂙 Fluid
 􀂙 Tanks & Filters
 􀂙 Accumulators
 􀂙 Pumps
 􀂙 Valves
 􀂙 Actuators
 􀂙 Conductors and connectors

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Hydraulic fluid
Functions:
 Power transmission
 Lubrication
 Cooling
 Cleaning
 Sealing
Viscosity: Most hydraulic systems use 10W oil
Types:
Petroleum oil (penurunan volume sekitar 1% pada kenaikan tekanan 2000 psi.
Synthetic oil  Indeks viskositas tinggi
Biodegradable  Pencemaran lingkungan rendah (Aman)

Bagaimana kaitan antara viskositas minyak hidrolik dengan kebutuhan sistem

hidrolik?

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Hydraulic tank
Functions:
 Sebagai penampung minyak.
 Membuang panas minyak hyd.
 Memisahkan gelembung udara
dari minyak.
 Mengendapkan kotoran
Types of hydraulic tank:
 Vented Tank
Berhubungan dengan udara
luar (tekanan: 1 atm)
 Pressurized Tank
Terpisah dari udara luar
(tekanan≠ 1 atm),
Analisis: Apa keuntungan dengan
pressurized tank?

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Accumulators
Functions:
 Menyimpan energi potensial pada Schematic symbol
minyak hidrolik.
 Menyerap kejutan dari tekanan
hidrolik.
 Memperbaiki kestabilan tekanan.
Types:
 Gas loaded accumulator
 Spring loaded accumulator
 Weight loaded accumulator

Sistem apa yang perlu menggunakan

akumulator?

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FILTERS
Schematic symbol

Filters are used to filter dirt from the hydraulic system, the filter can
be placed before or after the pump system (case drain)

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POMPA/PUMP
Fungsi:
 Menghasilkan aliran minyak hidrolik
 Pompa hidrolik mengubah energi mekanik dari sumber energi (engine, motor listrik, dl)
menjadi energi hidrolik.
Klasifikasi pompa:
 Non-positive displacement pump
Non-positive displacement pumps banyak digunakan pada sistem hidrodinamik, di mana jika
oulet ditahan, maka flow akan berkurang bahkan berhenti.
 Positif displacement pump
pompa ini tidak hanya menghasilkan aliran, namun memungkinkan terjadi pembangkitan
tekanan tinggi pada fluida., sehingga digunakan pada sistem hidrostatis.
Types; Fix displacements & Variable displacement pump.
Sebutkan contoh masing-masing!

Pump animation
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Positif displacement pump

 Fixed-displacement pumps
Speed of the pump determines how much hydraulic oil is moved.
 Variable-displacement pumps
Variable-displacement pumps are positive displacement pumps designed to
vary the volume of oil they move each cycle, even when they are run at the
same speed.

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Gear Pumps
Advantage: Disadvantage:
 Simpler system 1. Fixed displacement
 Compact design 2. Input speed must be increased to get more flow
 Handles debris well 3. High horsepower draw
 Low cost
Types :
1. External gear, 2. Internal gear (Crescent gear & Gerotor gear)
External gear Internal gear

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Vane Type Pump
Advantage: Disadvantage:
1.Versatile design 1. Cannot handle as high pressures as other designs
2. Quiet 2. Does not tolerate contamination well

Types of vane pump:

Unbalanced Balanced

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Piston Type Pump
Advantage:
 Capable of high speeds and high pressures
 Variable displacement capability
 Reduced horsepower draw
Disadvantage:
 More complex than vane or gear pumps
 Tightly machined surfaces demand clean hydraulic fluid
 High initial cost
 Does not tolerate contamination well
Types:
 Axial piston
 Bent axis piston
 Radial piston

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Axial piston
 Fix displacement Variable displacement

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Bent axis piston pump

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Radial piston pump

 Radial piston pumps are capable of high pressures, high volumes, and
variable displacement.

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 VALVES
Untuk mengatur minyak hidrolik dari keluaran
24 pompa, katup hidrolik dapat
dikategorikan menjadi:

1. Pressure control valve

 Relief valve
 Pressure reducing valve
 Sequence valve
 Unloading valve
2. Directional control valve
 Spool
 Check valve
 Rotary
3. Flow control valve
 Throttle valve
 Flow control

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PCV: Relief valve
 Digunakan untuk mengatur tekanan sistem hidrolik pada suatu nilai tertentu
(nilai tetap maupun dapat disetel/adjustable)
 Jenis katup:
1. Directly operated (pengaturan tekanan langsung secara langsung)
2. Pilot operated (Pengaturan tekanan dilakukan tidak langsung)
Schematic symbol:

Directly operated Pilot operated

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PCV: Pressure reducing valve

 Digunakan untuk mengurangi tekanan pada sistem hidrolik, baik untuk

mesuplai hidrolik pada sirkuit sekunder, maupun untuk pengurangan tekanan
karena kebutuhan tertentu

Schematic symbol

animation
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Sequence valve
 Sequence valve digunakan untuk mensuplai minyak hidrolik pada aktuator ke-2 ketika
suplai pada aktuator pertama sudah terpenuhi aliran dan tekanannya.

animation
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Unloading valve

Berfungsi untuk mengembalikan suplai hidrolik dalam jumlah

besar sebelum relief valve membuka untuk menjaga tekanan
hidrolik. Biasanya digunakan untuk pompa jenis fix displacement.

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Flow control valve
Flow-control valves digunakan untuk membagi aliran di antara beberapa sirkuit
maupun mengatur aliran dan kecepatan gerak aktuator.
Types:
 Non-compensated or fixed-orifice flow control
 Pressure compensated or bleed-off flow control
 Flow dividers

animation

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Contoh penggunaan Flow control valve

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 Pressure compensated bleed off FCV
Mengatur flow rate/debit minyak hidrolik sesuai dengan
kebutuhan yang ditetapkan

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Flow divider
 Flow dividers are used to supply multiple circuits from one source. The two
design types used are spool type and gear type.

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Directional control valve
Digunakan untuk mengarahkan aliran fluida hidrolik pada sistem.
Jenis DCV:
 Check valve (Katup searah)

Memungkinkan terjadi arah aliran fluida satu arah.

 Rotary valves
Rotary valve menggunakan rotary spool untuk mengatur arah aliran sesuai
kebutuhan (contoh: katup kontrol pada sistem steering)
 Spool valves
Spool valve menggunakan sliding spool untuk membuka, menutup dan
mengarahkan fluida hidrolik pada sirkuit hidrolik, sehingga dapat memungkinkan
terjadinya gerakan start, actuate, stop, floating, dll.

Animation 1
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 Check valve
 Simple check valve

 Pilot operated check valve

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Spool valve
Klasifikasi spool valve:
 Jumlah posisi spool dan port pada katup (4/3, 6/4, dll)
 Jenis sistem hidrolik saat spool valve posisi tengah (open center dan close
center)
 Metode penggeseran spool (manual, pilot, electrohydraulic control)
 Metode pengembalian spool

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 Open center system

 Open center valves permit oil to flow through the valve at all times. In NEUTRAL the
open center passage allows oil to flow from the supply back to the tank at low
pressure. When the valve is shifted, oil flows from supply to an actuator.
 Open center hydraulic systems are always supplying a relatively high flow. This enables
the hydraulic system to quickly respond when the valve is shifted.
Advantages: Fast response
Disadvantages:
Partial shift causes partial flow to the tank and the actuator, which generates more heat •
Control may not be as precise • Typically requires a larger oil cooler

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Closed center system
 Closed center valves block the flow from the pump to the tank in NEUTRAL.
 When the valve is shifted oil flows only to the actuator with a full or partial shift.
 When the valve is centered, flow through the valve stops.
 These valves are typically used with a variable displacement pump to provide flow on
demand.
Advantage: Flow only to circuit activated, • Generates less heat than open center valves, •
More precise flow control
Disadvantage: Requires high flow relief valve or variable displacement pump

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Solenoid operated DCV

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Pilot control DCV
 Schematic diagram

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ACTUATOR

1. Linear actuator (silinder hidrolik) menghasilkan gerak

lurus/translasi.
a. Single acting
b. Double acting
c. Telescopic
2. Rotary actuators, which produces torque or rotary
motion
 Fixed displacement unidirectional motor
 Fixed displacement bidirectional motor
 Variable displacement unidirectional motor
 Variable displacement bidirectional motor

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 Hydraulic cylinder

 SINGLE ACTING

DOUBLE ACTING

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Telescopic cylinder

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Hydraulic motor

Schematic symbol

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 Conductor and connector

Fungsi:
 Menghubungkan antar komponen hidrolik
 Memungkinkan pergerakan yang fleksibel
 Menyerap getaran
 Menahan kenaikan tekanan
 Mudah diinstalasi pada casis kendaraan

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 TOPIC 2
SISTEM DAN SKEMA HIDROLIK
ALAT BERAT

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Hydraulic components symbol
Perhatikan skema di bawah ini
Apa bedanya??
PERAN THROTTLE VALVE & MAKE UP
VALVE
Angle dozer
hydraulic circuit
diagram
 Dozer shovel
hydraulic schematic
diagram
Caterpillar 928G Wheel loader
LOAD SENSING PRESSURE COMPENSATED
HYDRAULIC SYSTEM

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HYDRAULIC SYSTEMS
Berdasarkan sistem kerja spool valve (Directional
control valve):
 Open center system
 Close center system

Berdasarkan sistem kerja dan pengoperasian

hidrolik:
 Fixed Displacement System
 Pressure Compensation (PC) System
 Load sensing pressure compensated system

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HYDRAULIC SYSTEMS
 Fixed Displacement System
 Pressure Compensation (PC) System
 Load sensing pressure compensated system

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Fixed Displacement System
 Gerakan output implement tergantung dari output pompa
secara proporsional
 Pompa yang digunakan model fix displacement pump, seperti
gear, vane, fix displacement piston, dan gerotor
 Gerakan implement tergantung dari pembukaan spool valve,
kecepatan pump, serta beban yang ditumpu

 Contoh: ??

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Dozer shovel circuit

 Jika putaran engine

berubah bagaimana dgn
gerakan implemennya?
 Jika terjadi perubahan
beban, bgmn dgn
kecepatan implemenya?
 Bagaimana dengan
pengoperasiannya?
 Fix displacement system
 Apa peran center spring?
 Jika flow besar membutuhkan
spring yang kuat
 Apa kelemahannya?
 Bagaimana dgn pengontrolan
kecepatan gerak silinder?
 Bgaimana efek terhadap
pengoperasian?

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 Pressure compensation (Closed center
system)

 Apa keuntungan dilihat dari

kecepatan gerak silinder?
 Bagaimana pengoperasiannya?
 Apa kelemahannya?

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Pressure Compensation (PC) system
 Kompensasi tekanan memungkinkan kecepatan implemen
konstan sesuai pembukaan tuas pengontrol.

 Kecepatan implemen tetap, tanpa beban ataupun beban penuh.

 Perbedaan tekanan antara input dan output DCV dibuat

konstan, sehingga flow juga akan konstan.

Definition of PC: “A control system which results in a constant

implement speed for a given lever displacement”

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 Pemasangan dump valve dengan Load Sensing
Hydraulic system

 Apa peran
unloading valve di
system tersebut?
 Berapa nilai
pembukaan
unloading valve tsb?

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 Kondisi katup hold/netral

 Bagaimana suplai
pompa?
 Berapa tekanannya?
 Adakah kerugiannya?

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Variable Displacement Pump
 Energi yang terbuang oleh dump valve dikurangi dengan memanfaatkan
pompa variable
 Flowrate pompa dikontrol dengan katup pengontrol
Work Port Pressure (Signal Pressure)
Pump Supply Pressure
Flow Control
Pressure
Compensator
 Load sensing/Pressure compensation with
variable displacement pump

 Signal pressure
dari beban
mengontrol pump
control valve
untuk
menentukan
pemompaan pump

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Load Sensing Hydraulic System
 Load sensing hydraulic systems receive a signal from each
implement circuit.
 The highest implement signal pressure will control the output
of the pump.
 In NEUTRAL there is no signal pressure and the pump is at
standby.
 When an implement is activated, the signal pressure rises,
causing the pump to increase flow.
 The pump will increase flow based upon implement demand
up to the capacity of the pump.
 When system demands exceed pump capacity, the function
with the lowest pressure receives the most flow.

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D8R BULLDOZER

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 TOPIC 3
SISTEM POWERTRAIN
ALAT BERAT

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JENIS SISTEM POWERTRAIN
 MECHANICAL POWERTRAIN
 HYDROSTATIC POWERTRAIN
 ELECTRIC DRIVE POWERTRAIN

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Mechanical powertrain
 Gears
 Chains and sprockets
 Friction drive
 Belts

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Hydrostatic drive powertrain

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Electric drive

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 SUSUNAN POWERTRAIN PADA ALAT BERAT
Bulldozer
1. Engine
1 2 3 4 5 2. Damper
3. Universal joint
4. Torque converter
6 5. Torqflow transmission
7 6. Steering
7. Brake
8 8. Final drive
9 9. Track shoe

Hydraulic excavator

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Rigid Dump truck Articulated dumptruck

1. Engine
2. Torque converter
1. Engine 3. Torqflow transmission/powershift
2. Damper transmission
3. Torque converter 4. Transfer
4. Torqflow 5. Front axle/propeller shaft
transmission 6. Differential
5. Defferential 7. Final drive
6. Final
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 Questions??

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SEKIAN

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