p–ISSN: 2723 – 6609 e-ISSN: 2745-5254
Vol. 5, No. 12, December 2024 http://jist.publikasiindonesia.id/

Indonesian Journal of Social Technology, Vol. 5, No. 12, December 2024 5701

Patria Mud Body Modification Study on Komatsu HD785-7
Unit for Overburden Transportation

Supriyanto1*, Joshua Pribadi Wikan2, Steven Tammu3, Aadjudia Prida Pratama4,

Muhammad Rafly Adha5, Anggun Azis Mulyanti6

PT Antareja Mahada Makmur, Indonesia
Email: [email protected]*, [email protected], [email protected],

[email protected], [email protected], [email protected]

*Correspondence
ABSTRACT

Keywords: mud body
modification; Komatsu
hd785-7; overburden
transportation.

Coal mining activities require reliable means of
transportation to support productivity and safety. PT AMM
site ABP Energy uses a Komatsu HD785-7 off-highway
dump truck with a Mud Body vessel and a Std Light Vessel
which has significant differences in empty weight and
payload capacity. The heavier Vessel Mud Body increases
fuel consumption and the risk of overloading. This study
aims to examine the modification of the Mud Body vessel to
be lighter without reducing the payload capacity. The
methods used include secondary data collection from
technical specifications and modification simulation
analysis. The results of the study show that the partial cutting
of the side wall vessel of the Mud Body can reduce the empty
weight by up to 3,345 kg, close to the specifications of the
standard vessel. These modifications improve fuel
efficiency, minimize the risk of overloading, and maintain
the reliability of the unit. In conclusion, planned
modifications are effective in improving operational
efficiency and lowering operational costs without sacrificing
safety and productivity.

Introduction

In coal mining activities, PT. ABP Energy's AMM site uses the Open Pit mining
method with the operation of mechanical equipment such as excavators for loading and
dump trucks for transporting overburden and coal (Manurung, Joko, & Santosa, 2020).
Overburden transportation is carried out from the front to disposal using an off-highway
dump truck Komatsu HD785-7, through a mining road that is unsurfaced. In
overburdened transportation activities, it is necessary to carry them out safely, effectively,
and efficiently to support productivity and safety aspects. (Farahpoor, Esparza, &
Soriano, 2023).

The off-highway dump truck unit Komatsu HD785-7 is owned by PT. ABP
Energy's own AMM site has different unit configurations. Of the total HD785-7 units

Supriyanto, Joshua Pribadi Wikan, Steven Tammu, Aadjudia Prida Pratama, Muhammad Rafly
Adha, Anggun Azis Mulyanti

Indonesian Journal of Social Technology, Vol. 5, No. 12, December 2024 5702

available, there are 5 units that have a Mud Body vessel configuration from the Patria
carousel manufacturer. As for the other units, it has a Std Light Vessel vessel
configuration which is also made by the carousel manufacturer Patria (McFarlane et al.,
2017).

In terms of specifications, there is a difference between a Mud Body vessel and a
Std Light Vessel. Units with Mud Body vessels have a tailgate and the purpose of its
application is to transport materials in the form of mud or mud and has a relatively
stronger vessel structure so that the empty weight of the Mud Body vessel is also
relatively heavier. (Wang, Yang, Chen, & Shah, 2015). Meanwhile, the unit with the Std
Light Vessel vessel does not have a tailgate and its application is to transport
overburdened materials and has a lighter empty weight than the Mud Body vessel. With
a larger empty weight of the Mud Body vessel, there is a potential for the HD785-7 unit
to carry a larger carryback load, and this will certainly affect the increase in fuel
consumption of the unit. Modifications need to be made so that the empty weight of the
Mud Body vessel becomes lighter, to get more efficient fuel consumption. (Felsch et al.,
2019).

In addition, there are also significant or striking differences in geometry. The most
striking difference is that the Mud Body Vessel can be seen to be taller in size compared
to the Std Light Vessel. (Mustopa & Wiratama, 2022). The shape of the hull or hull of the
vessel in the two types of vessels also has a striking difference. The Vessel Std Light
Vessel has a convex hull or hull when compared to the Mud Body vessel when viewed
from the rear of the unit. (Sari, 2021).

With the field conditions as described above, as well as to maximize the utilization
of Komatsu HD785-7 unit assets at ABP Energy's job site and to optimize the productivity
efficiency of HD785-7, PT. ABP Energy's AMM site decided to study related to the
modification of the Patria Mud Body on the Komatsu HD785-7 unit for overburdened
transportation. The preparation of this technical study prioritizes the safety and security
aspects of operators when operating the unit, as well as considering the reliability factor
of the unit based on existing technical specifications. (Patria, 2019).

The purpose of the Patria mud body modification study on the Komatsu HD785-7
unit for overburden transportation is as follows:
1. Ensuring the safety aspect of mining operations
2. Know the benefits & costs to operations.

Method
Data Collection

Secondary data collection was carried out in the preparation of a technical study on
the modification of the Patria mud body on the Komatsu HD785-7 unit for overburden
transportation. Secondary data is in the form of Komatsu HD785-7 unit specifications,
and Patria mud body specifications.

Patria Mud Body Modification Study on Komatsu HD785-7 Unit for Overburden
Transportation

Indonesian Journal of Social Technology, Vol. 5, No. 12, December 2024 5703

Methodology

The methodology used in the preparation of this technical study uses a literature
study. Literature study is done by developing and calculating technical studies in
accordance with the engineering data of Komatsu and Patria manufacturers.

Activity Stages (Flowcart)

Figure 1

Activity Stages (Flowcart)

Results and Discussion
Unit Specifications
The Komatsu HD785-7 unit specification data is as follows:

Supriyanto, Joshua Pribadi Wikan, Steven Tammu, Aadjudia Prida Pratama, Muhammad Rafly
Adha, Anggun Azis Mulyanti

Indonesian Journal of Social Technology, Vol. 5, No. 12, December 2024 5706

Figure 3
General Assembly Drawing vessel standard Komatsu manufacturer

Mud Body Modification Design

Initially, the Mud Body vessel installed on the Komatsu HD785-7 unit was designed
by the Patria manufacturer to transport mud or mud materials. However, along with
operational needs, the Mud Body is planned to be used for transporting overburdened
materials.

Figure 4
Illustration of the Komatsu HD785-7 unit with Mud Body attached

Based on Patria's Mud Body specification data, the volume capacity of the Mud
Body vessel is 60 M3, with a vessel and tailgate weight of 18,445 kg. Based on Komatsu
standard vessel specification data, the volume capacity of the vessel is 40 M3 and the
weight of the standard Komatsu vessel is 15,100 kg. If the Mud Body is compared to the
standard vessel, there is a volume difference of 20 M3, and the weight difference reaches
3,345 kg. If the two vessels both function as overburden carriers, then there is a potential
loss of 3,345 kg of payload weight per trip and greater fuel use, because there is a
difference in the weight of the vessel empty. Therefore, to increase productivity to prevent
overloading the Komatsu HD785-7 unit chassis and to achieve fuel efficiency, the Mud
Body vessel will be modified to reduce volume by cutting part of the side wall of the Mud
Body vessel, so that the empty weight of the vessel becomes lighter, but still has a volume
capacity that is not much different from the Komatsu standard vessel so that it is expected
not to reduce operational productivity.

Patria Mud Body Modification Study on Komatsu HD785-7 Unit for Overburden
Transportation

Indonesian Journal of Social Technology, Vol. 5, No. 12, December 2024 5707

Figure 6

Specifications of Patria's Mud Body vessel on the Komatsu HD785-7 unit

Based on the data of the Mud Body Patria vessel specifications on the Komatsu
HD785-7 unit, the Mud Body vessel has a height of 5620 mm or equivalent to 5.6 meters
as shown in the image above. When compared to the standard Komatsu vessel height
specification as in the picture below, which has a height of 4295 mm, there is a difference
of 1325 mm or about 1.3 meters.

Supriyanto, Joshua Pribadi Wikan, Steven Tammu, Aadjudia Prida Pratama, Muhammad Rafly
Adha, Anggun Azis Mulyanti

Indonesian Journal of Social Technology, Vol. 5, No. 12, December 2024 5708

Figure 7

Komatsu standard vessel high-specification

If a modification simulation is carried out in the form of cutting part of the side
wall of the Mud Body Patria vessel, right at the top of the longitudinal side wall
member, then the illustration of the vessel is shown in the following figure.

Figure 8

Illustration of Cutting the Mud Body Patria vessel

Patria Mud Body Modification Study on Komatsu HD785-7 Unit for Overburden
Transportation

Indonesian Journal of Social Technology, Vol. 5, No. 12, December 2024 5709

Figure 9
Illustration of the estimated height of the vessel after modification

In accordance with the drawing vessel of Patria's Mud Body, the overall length of

the unit is 10.59 meters by 6.3 meters wide. With the dimensions of the unit, the planned
location of the Mud Body modification activity is in an outdoor base with a flat surface
and with location dimensions reaching 12.8 meters x 17.2 meters.

Supriyanto, Joshua Pribadi Wikan, Steven Tammu, Aadjudia Prida Pratama, Muhammad Rafly
Adha, Anggun Azis Mulyanti

Indonesian Journal of Social Technology, Vol. 5, No. 12, December 2024 5710

Figure 10
Layout Plan Location of Mud Body Modification Activity

Load Calculation and Load Distribution
The load calculation and load distribution were carried out to determine the impact

of vessel modifications on the change in load distribution on the Komatsu HD785-7
chassis. After modifications, it is estimated that the volume of the Mud Body vessel will
be the same as the volume of the standard Komatsu vessel. Therefore, the load distribution
will also be the same according to the standard conditions of the unit as in the
specifications below. This load distribution is by the technical specifications of the unit
capacity of the Komatsu HD785-7 vessel is loaded according to the vessel capacity.

Figure 11

Specification of Weight Distribution unit with Komatsu standard vessel

Risk Analysis
Risk analysis was carried out to determine the potential hazards, and risks that arise

and control/control of the potential hazards and risks that exist from the modification
work of the Patria Mud Body vessel on the Komatsu HD785-7.

Patria Mud Body Modification Study on Komatsu HD785-7 Unit for Overburden
Transportation

Indonesian Journal of Social Technology, Vol. 5, No. 12, December 2024 5711

Activity
Details

Potential
Hazards

Risks Arising Contro
l/Cont

rol
1 Parking the

HD785 Unit
1.
1

Unit
Maneuver

1.1.
1

Ran over Engineering:
-

Administration:
-

Work practices:
- The driver is the one who has the SIMPER
unit and has been tested for eligibility

- 2-way communication with the driver
- Spotter helps with traffic flow and gives cues
to unit testers

- AMM-ABP-IK-PLANT-085-R0 DIRECTS
THE PARKING UNIT AND OR MOVES

- Not in the maneuvering area of the unit
Personal Protective Equipment:

Safety Boots, Safety Helmet, Safety Glasses,
Hand Gloves, Mask

1.1.
2

Hit Engineering:
-

Administration:
-

Work practices:
- The driver is the one who has the SIMPER
unit and has been tested for eligibility

- 2-way communication with the driver
- Spotter helps with traffic flow and gives cues
to unit testers

- AMM-ABP-IK-PLANT-085-R0 DIRECTS
THE PARKING UNIT AND OR MOVES

- Not in the maneuvering area of the unit
Personal Protective Equipment:

Safety Boots, Safety Helmet
2 Washing Unit

HD785
2.
1

Pressurized
water canon

2.1.
1

Sprayed
water canon

Engineering:
-

Administration:
-

Work practices:
- P5M
- AMM-ABP-IK-PLANT-62 – Washing the
unit in the Wash Pad

Personal Protective Equipment:
Safety Boots, Safety Helmet, Safety Glasses

2.
2

Slippery work
area

2.2.
1

Slip Engineering:
-

Administration:
-

Work practices:
- P5M
- AMM-ABP-IK-PLANT-62 – Washing the
unit in the Wash Pad

Personal Protective Equipment:
Safety Boots, Safety Helmet, Safety Glasses

3 Cutting
Vessels
Using

Oxygen &
Acetylene

3.
1

Sparks from
cutting

3.1.
1

Burn Engineering:
- Substitution of hose material by standards
- Modified Tube Equipped with Flashback
Arrestor

Administration:
-

Supriyanto, Joshua Pribadi Wikan, Steven Tammu, Aadjudia Prida Pratama, Muhammad Rafly
Adha, Anggun Azis Mulyanti

Indonesian Journal of Social Technology, Vol. 5, No. 12, December 2024 5712

Work Practice:
- Implementation of P5M
- Implementation of the initial inspection of the
supervisor's shift

- Socialization of cutting procedures using Oxy
Acetilyne

- Socialization of oxygen acetylene welding
procedures

- Setting up the fire extinguisher
- Welder Certification

Personal Protective Equipment:
Welding Masks, Welding Masks, Welding

Aprons, Welding Gloves, Safety Shoes
3.
2

Part of a hot
workpiece

3.2.
1

Exposure to
Heat

Engineering:
- Substitution of hose material by standards

Administration:
-

Work practices:
- Implementation of P5M
- Implementation of the initial inspection of the
supervisor's shift

- Use fire blanked
- Use a welding mask
- Use a blower
- Socialization of cutting procedures using Oxy
Acetilyne

- Welder Certification
- AMM-ABP-IK-PLANT-055-R0 CUTTING
USING CUTTING TORCH

Personal Protective Equipment:
Welding Masks, Welding Masks, Welding

Aprons, Welding Gloves, Safety Shoes
3.
3

Work at
height

3.3.
1

Fall Engineering:
- Provide Hand Rail

Administration:
-

Work practices:
- Using Body Harnes
- Training working at height
- Implement 3 points of contact

Personal Protective Equipment:
Welding Masks, Welding Masks, Welding

Aprons, Welding Special Gloves, Safety Shoes,
Body Harness

4 Smoothing
the surface
with hand
grinding

4.
1

Non-
standard

cable
condition
(frayed)

4.1.
1

Electrocuted Engineering:
- Compliant cable material substitution

Administration:
-

Work Practice:
Work Practice:

- Implementation of the initial inspection of the
supervisor's shift

- AMM-ABP-IK-PLANT-120 OPERATION OF
HAND GRINDING MACHINE

Personal Protective Equipment:

Patria Mud Body Modification Study on Komatsu HD785-7 Unit for Overburden
Transportation

Indonesian Journal of Social Technology, Vol. 5, No. 12, December 2024 5713

Welding Masks, Welding Masks, Welding
Aprons, Welding Gloves, Safety Shoes

4.
2

Sparks from
the grinder

4.2.
1

Burn Engineering:
-

Administration:
-

Work Practice:
Work Practice:

- Implementation of the initial inspection of the
supervisor's shift

- AMM-ABP-IK-PLANT-120 OPERATION OF
HAND GRINDING MACHINE

Personal Protective Equipment:
Welding Masks, Welding Masks, Welding

Aprons, Welding Gloves, Safety Shoes
4.
3

Work at
height

4.3.
1

Fall Engineering:
- Provide Hand Rail

Administration:
-

Work practices:
- Using Body Harnes
- Training working at height
- Implement 3 points of contact

Personal Protective Equipment:
Welding Masks, Welding Masks, Welding

Aprons, Welding Special Gloves, Safety Shoes,
Body Harness

5 Welding
Using

Electric
Welding

5.
1

The
condition of
the wires on
the welding
machine is

not standard
(chipped)

5.1.
1

Electrocuted Engineering:
- Substitution of welding machine cable

material by standards
Administration:

-
Work Practice:
Work Practice:

- Implementation of the initial inspection of the
supervisor's shift

- Making check sheet P2H welding machine
- Socialization of electric arc welding
procedures

- The welding process is not in a muddy
place/Waterlogged

- Welder Certification
- AMM-ABP-IK-PLANT-054-R0 WELDING
USING A WELDING MACHINE

- AMM-ABP-SP-PLT-005-R0 CABLE CLASSIFICATION AND MAXIMUM CURRENT DELIVERED
Personal Protective Equipment:

Welding Masks, Welding Masks, Welding
Aprons, Welding Gloves, Safety Shoes

5.
2

Sparks from
welding

5.2.
1

Burn Engineering:
- Modification with welding mask during

welding
Administration:

Supriyanto, Joshua Pribadi Wikan, Steven Tammu, Aadjudia Prida Pratama, Muhammad Rafly
Adha, Anggun Azis Mulyanti

Indonesian Journal of Social Technology, Vol. 5, No. 12, December 2024 5714

Work practices:
Work Practice:

- Implementation of the initial inspection of the
supervisor's shift

- Making check sheet P2H welding machine
- Socialization of electric arc welding
procedures

- The welding process is not in a muddy
place/Waterlogged

- Welder Certification
- AMM-ABP-IK-PLANT-054-R0 WELDING
USING A WELDING MACHINE

- AMM-ABP-SP-PLT-005-R0 CABLE CLASSIFICATION AND MAXIMUM CURRENT DELIVERED
Personal Protective Equipment:

Welding Masks, Welding Masks, Welding
Aprons, Welding Gloves, Safety Shoes

5.
3

Work at
height

5.3.
1

Fall Engineering:
- Provide Hand Rail

Administration:
-

Work practices:
- Using Body Harnes
- Training working at height
- Implement 3 points of contact

Personal Protective Equipment:
Welding Masks, Welding Masks, Welding

Aprons, Welding Special Gloves, Safety Shoes,
Body Harness

Benefit & Cost Analysis
1. Benefit

The modification of the Patria Mud Body vessel on the Komatsu HD785-7 unit for
overburden transportation provides advantages including:
1) Minimizing the potential for overload due to reduced empty vessel weight.
2) Minimizing the potential for reduced unit reliability with reduced overload potential.
2. Cost Analysis

The modification of the Patria Mud Body vessel on the Komatsu HD785-7 unit for
overburden transportation completes the estimated cost of Rp 3,220,000 per unit and
requires an estimated allocation of work time for 4 shifts carried out by a total of 4
manpower people.

It Items Volu
me

Estimated Cost

Man Power
1 Labour 4 Rp

1.920
.000

Patria Mud Body Modification Study on Komatsu HD785-7 Unit for Overburden
Transportation

Indonesian Journal of Social Technology, Vol. 5, No. 12, December 2024 5715

Material
1 Mild Steel Plate th: 0.8

mm
0,5 Rp

250
.000

2 Oxygen 2 Rp
220

.000
3 Acetylene 2 Rp

830
.000

Total Cost Rp
3.220

.000

Implementation Plan and Monitoring
If the modification of the Patria Mud Body vessel on the Komatsu HD785-7 unit

for overburden transportation is implemented, then a form of cargo monitoring, payload
monitoring, and productivity monitoring of the Komatsu HD785-7 unit will be carried
out.

Conclusion

Based on the results of calculations, simulations, and risk analysis that have been
carried out, the following conclusions are obtained:
1. The volume specification of the Mud Body Patria vessel is 60 M3, with a height of

5620 mm. The volume specification of the Mud Body Patria vessel is 40 M3, with a
height of 4295 mm.

2. The design of the modification of the Patria Mud Body vessel is to cut part of the side
wall, which is right at the top of the longitudinal side wall member on the Mud Body
vessel, and the volume specification of the vessel will change to around 40 M3 or in
accordance with the standard Komatsu vessel volume.

3. Vessel modification is predicted to have no negative impact on the reliability and
safety aspects of the Komatsu HD785-7 unit if loaded according to the vessel's
capacity.

Supriyanto, Joshua Pribadi Wikan, Steven Tammu, Aadjudia Prida Pratama, Muhammad Rafly
Adha, Anggun Azis Mulyanti

Indonesian Journal of Social Technology, Vol. 5, No. 12, December 2024 5716

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