Coupler Modification for Periodic Preventive Maintenance on Sakai SV526D and SV700TF Compactor Units to Improve The Efficiency and Reliability of Hydraulic System Inspection

Abstract

Hydraulic pressure inspection is essential for the preventive maintenance of heavy equipment; however, incompatible diagnostic connections can prevent mechanics from completing scheduled inspections. At PT Antareja Mahada Makmur, Mifa Jobsite, the hydraulic test ports on Sakai SV526D and SV700TF compactors were incompatible with the available Komatsu pressure gauge equipment, while the procurement of dedicated Sakai diagnostic tools was constrained by uncertain availability. This study aimed to identify the hydraulic pressure inspection constraint, implement a hydraulic test coupler modification, and evaluate its implications for preventive maintenance activities. A descriptive qualitative case study was conducted using the Suggestion System framework, encompassing problem identification, improvement planning, technical implementation, and field evaluation. Data were obtained from maintenance documentation, component damage records, dealer quotations, and field observations conducted before and after the modification. The intervention involved replacing the original hydraulic test couplers with Genuine Komatsu couplers, thereby enabling the existing pressure gauges to be connected to the compactors. Field observations indicated that the modification restored hydraulic pressure inspection capability, improved test-port cleanliness, reduced the observed risk of hydraulic oil spillage, and facilitated easier connection and disconnection of the pressure gauge equipment. These findings suggest that adapting diagnostic interfaces can address equipment compatibility constraints while supporting scheduled hydraulic system inspections. However, reductions in breakdown frequency, improvements in equipment reliability, and financial savings were not quantitatively established. The study concludes that hydraulic test coupler modification represents a practical improvement for preventive maintenance activities; however, further quantitative evaluation is required to determine its effects on maintenance efficiency, operational performance, cost savings, and equipment reliability.