International Conference on Engineering.
Applied Science And Technology ANALYSIS OF LOW POWER ISSUES IN KOMATSU
D85ESS-2 DOZER ENGINES
Hendro Purwono1*.
Rasma2.
Ari Aryadi3.
Bambang Setiawan4.
Ade Darmaji5 12345Department of Heavy Equipment and Automotive Engineering.
Faculty of Engineering.
Universitas Muhammadiyah Jakarta.
Jl.
Cempaka Putih Tengah 27.
Jakarta 10510.
Indonesia
ARTICLE INFO
Keywords:
Bulldozzer Troubleshooting Engine System
ABSTRACT
The Komatsu D85ESS-2 dozer is one of the heavy machines employed by PT.
Andhifa Kharisma Borneo Pratama (AKBP) at the PT.
Prolindo Cipta Nusantara (PCNS) site in coal mining operations.
This dozer is utilized for tasks such as excavation, grading, material pushing, and hauling logs or portable camps.
However, due to several factors, this unit has experienced an "engine low power" issue, impacting its performance.
This report addresses the root causes of this problem and proposes solutions to prevent recurrence.
This study uses an observational approach aimed at identifying and analyzing the factors causing the low power issue.
Data collection was conducted by gathering relevant information about the unitAos operational conditions as experienced by operators in the field.
systematic troubleshooting procedure was applied to detect and resolve issues, allowing for precise repairs to restore the unit's performance.
The study follows an 8-step troubleshooting process and uses a troubleshooting chart to assess the symptoms of the low-power issue.
Findings indicate that engine low power was caused by sediment buildup in the fuel filter, which restricted fuel flow to the nozzle, leading to reduced fuel injection.
A 2024 International Conference on Engineering.
Applied Science And Technology.
All rights reserved Introduction Heavy equipment plays a crucial role in the mining industry, as mining operations are large- scale undertakings that require efficient machinery to support productivity and ensure operational success.
Heavy equipment enables tasks that would otherwise be time-consuming and labor-intensive to be completed more effectively, thus enhancing overall efficiency .
One such machine, the Komatsu D85ESS-2 dozer, is integral to the coal mining operations at PT.
Adhifa Kharisma Borneo Pratama, where it is primarily utilized for tasks such as pushing material in disposal areas and supporting various other functions across the site .
Given the importance of this machine in maintaining workflow, it is essential for the dozer to operate reliably and consistently to prevent disruptions in mining productivity .
Corresponding author.
E-mail address: hendro.
purwono@umj.
However, like all heavy machinery, the D85ESS-2 dozer is susceptible to issues over time, especially when preventive maintenance is inadequate or when maintenance practices fail to address certain critical aspects, such as cleanliness around key components.
As operations continue, the accumulation of minor maintenance oversights can result in significant mechanical issues, which in turn impact the performance and availability of the equipment .
The Komatsu D85ESS-2 is a formidable and versatile heavy equipment machine that has earned a strong reputation among construction and mining professionals for its impressive performance, reliability, and capability .
With its robust design and powerful engine, the D85ESS-2 has become a popular choice for those who require a dependable and productive tool to tackle a wide range of challenging tasks in their operations .
However, as with any complex machinery, the Komatsu D85ESS-2 dozer is not without its challenges, and one of the primary concerns is the issue of low power .
This issue can significantly International Conference on Engineering.
Applied Science And Technology impact the machine's productivity and efficiency, leading to decreased performance and higher operational costs .
in the D85ESS-2.
It is anticipated that these findings will serve as a guide for improving maintenance practices and enhancing the overall operational reliability of heavy equipment in mining Methods Figure 1.
Komatsu D85ESS-2 Dozer Engines This study will examine the underlying causes of these low power problems in the Komatsu D85ESS-2 dozer engines, such as engine wear, fuel system issues, and air intake restrictions.
Additionally, the study will explore potential solutions to enhance the overall performance of this critical piece of equipment, including engine maintenance, fuel system upgrades, and air filtration system improvements .
By addressing the root causes of the low power problems, this analysis aims to provide recommendations that can help operators and maintenance teams optimize the performance and reliability of the Komatsu D85ESS-2 dozer .
This study is motivated by the need to understand and resolve performance issues affecting the D85ESS-2 dozer, specifically the "engine low power" problem that has become a frequent concern.
The machine's reduced efficiency has notable implications for PT.
Adhifa Kharisma Borneo Pratama, as it can slow down operations and affect the companyAos ability to meet production targets.
conducting a systematic analysis of the problem, this study aims to identify the underlying causes of the low-power issue, develop a clear troubleshooting strategy, and provide actionable solutions.
These steps are intended to not only restore the dozerAos performance but also to establish preventive measures that will help avoid similar problems in the future .
This paper will outline the troubleshooting methodology applied, the data collected during observations, and the subsequent analysis that led to identifying the primary cause of engine low power The purpose of troubleshooting is to systematically identify the source of an issue so that it can be resolved effectively, preventing further damage and ensuring the reliability of the equipment.
Effective troubleshooting requires not only a methodical approach but also a comprehensive understanding of the equipment's structure and This understanding allows technicians to accurately diagnose potential issues and address root causes, rather than treating only the symptoms .
In this study, troubleshooting was conducted using a structured troubleshooting chart, which provides a step-by-step process to isolate and verify each possible cause of engine low power.
The troubleshooting chart served as a diagnostic roadmap, guiding the analysis from initial observations to the identification of specific faults in the equipment.
Each step in the chart outlines a sequence of actions and checks that help to narrow down possible sources of the problem based on observable symptoms .
A crucial component of this troubleshooting approach was gathering firsthand information from the equipment operators, as they are most familiar with the dozerAos daily performance and operational Interviews with operators focused on documenting their observations and experiences, such as specific symptoms they noticed during operation, recent maintenance history, and any changes in performance.
By combining these operator insights with systematic data collection, this approach allowed for a comprehensive analysis of the potential causes of engine low power .
This study applied an 8-step troubleshooting methodology to systematically address the "engine low power" issue on the Komatsu D85ESS-2 dozer, aiming to identify the root cause and implement preventive measures.
The process began with Problem Identification, recognizing the low power issue and its operational impact.
Next.
Identify Possible Causes involved listing potential issues like fuel contamination or airflow restriction.
Observation and Diagnosis, detailed observations were made of the unit's performance, incorporating operatorsAo insights.
Data Collection followed, gathering maintenance history and recent Hendro Purwono.
Rasma.
Ari Aryadi.
Bambang Setiawan.
Ade Darmaji International Conference on Engineering.
Applied Science And Technology performance records.
In the Analysis phase, patterns and anomalies were examined to correlate with the Subsequently.
Identify Root Cause pinpointed sediment buildup in the fuel filter as the primary cause, restricting fuel flow and diminishing Conclusion was drawn to assess the impact and suggest preventive steps, leading to Corrective Actions where the fuel filter was replaced and recommendations were made for regular fuel system checks .
the low power issue stemmed from a malfunction in one or more components associated with the engineAos power system.
Figure 2.
Troubleshooting This structured approach allowed for accurate problem resolution and reinforced the need for systematic troubleshooting to maintain equipment reliability in mining operations.
Through this structured approach, the troubleshooting process was able to pinpoint sediment accumulation in the fuel filter as a significant cause of low power, as it restricted fuel flow to the nozzle, impairing engine performance .
By applying the troubleshooting chart in conjunction with operator feedback and targeted inspections, the study was able to establish a detailed understanding of the issue and propose preventive maintenance measures to avoid similar problems in the future .
This method highlights the importance of combining systematic tools like the troubleshooting chart with operator input and technical knowledge to conduct effective troubleshooting.
The findings from this process not only address the current problem but also provide a framework for more proactive and efficient maintenance practices in heavy equipment operations .
Results and Discussions Upon receiving information that one of the units operated by PT.
Andhifa Kharisma Borneo Pratama (AKBP) was experiencing issues, we promptly visited the affected unit to investigate.
The first step was to consult with the operator to gather insights regarding the initial occurrence of the issue.
Based on the information provided, we conducted an operational test on the unit to accurately diagnose the Observations from this test indicated that the unit was indeed experiencing low power.
Following this discovery, we aimed to determine if Figure 3.
Troubleshooting Chart The possible causes of the low power issue were identified using the troubleshooting chart, which provided a systematic approach to analyze potential Based on the chart, several factors were considered that could contribute to the reduced engine These potential causes included a clogged air cleaner element, which could restrict airflow and reduce combustion efficiency, and worn piston rings, which could lead to compression loss and diminished power output.
Another possibility was a clogged fuel filter, which would restrict the fuel flow and impact engine performance.
Additionally, the feed pump filter might be obstructed, further limiting fuel delivery to the International Conference on Engineering.
Applied Science And Technology A malfunctioning or clogged nozzle was also identified as a possible cause, as it could dis fuel injection, leading to inefficient combust Lastly, valve seat damage was considered, as could interfere with proper valve sealing and dis engine Each of these potential issues carefully evaluated to identify the root cause guide corrective measures, ensuring that all asp related to engine performance were thorou examined.
Subsequent to the operational test, a series of targeted checks were performed on the unit, focusing specifically on components related to fuel and air systems, as these are commonly associated with engine power issues.
The preliminary findings suggested that the low power condition might be linked to problems within the fuel system or possibly the air intake system.
To gain a clearer understanding, additional data were collected and examined, including performance parameters and maintenance records related to these systems.
This structured approach allowed us to systematically investigate and document the potential sources of the problem, ensuring a comprehensive analysis and supporting accurate diagnosis for appropriate corrective actions.
Conclusions Air Cleaner No damage or dirt detected on air Engine Speed Low Idle: 809 RPM.
High Idle: 2080 RPM.
Stall Speed: 1792
RPM
Strainer Fuel Tank Dirt present in fuel tank strainer.
Water Separator Strainer Feed Pump No water mixed with Strainer feed pump in good and clean condition, no dirt.
Fuel Filter Sediment in fuel filter obstructing optimal fuel flow.
Clean and Low Idle:
RPM.
High Idle: 2,0502,150 RPM.
Stall Speed:
1,600-1,850
RPM
Clean and NOT No water mixed with Clean and Clean and NOT This table presents an assessment of key components in the fuel and air intake systems of the unit, focusing on cleanliness, integrity, and operational performance.
Each item was evaluated against a set standard, with deviations noted:
The inspection results, as detailed in the troubleshooting table, revealed that several components in the fuel system, particularly the filters and strainers, were contaminated with debris.
This buildup of impurities obstructed the flow of fuel through the system, leading to a decrease in fuel supply to the nozzles during injection.
The restricted fuel flow caused the engine to experience low power, as the reduced fuel delivery impacted the combustion process and, subsequently, the overall engine A Dust Indicator: The reading of 2.
5 kPa is within the acceptable range .
5 kP.
, indicating no clogging or excessive dust accumulation, which confirms the intake system is effectively sealed from dust Air Cleaner: Found to be clean and intact, which ensures unimpeded air intake necessary for optimal engine combustion and This finding highlights the critical role of maintaining clean fuel pathways to ensure efficient engine operation.
Regular cleaning and replacement of filters and strainers are essential to prevent similar issues in the future, supporting optimal fuel injection and preserving engine power.
Engine Speed: All idle and stall speeds fall within the specified range, indicating proper throttle and fuel-air mixture adjustments.
Strainer Fuel Tank: Presence of dirt in this component suggests contamination in the fuel system, potentially leading to restricted fuel flow and reduced engine performance.
This issue requires cleaning to restore full Table 1.
Analysys Data
ITEM
ACTUAL
STANDARD
CONDI
TION
Dust Indicator No damage found on dust indicator.
5 kPa Reading 5 kPa Water Separator: No water was detected in the fuel, which is ideal for preventing corrosion and ensuring efficient combustion.
Hendro Purwono.
Rasma.
Ari Aryadi.
Bambang Setiawan.
Ade Darmaji International Conference on Engineering.
Applied Science And Technology A Strainer Feed Pump: This component is in good condition without any dirt, which supports uninterrupted fuel delivery to the A Fuel Filter: The sediment found here restricts fuel flow, likely contributing to the low power Cleaning or replacement is needed to ensure full, consistent fuel supply to the injection system.
This diagnostic data suggests that, while most components are in optimal condition, issues with the fuel tank strainer and fuel filter are impairing engine Proper maintenance, including cleaning and possibly replacing these parts, would likely resolve the low-power issue and improve the unit's operational efficiency.
"Low Power Issues in Komatsu D85ESS-2 Dozer Engines.
" My deepest thanks go to my team for their invaluable guidance and advice throughout this We are also grateful to our family and friends for their continuous encouragement and Finally.
We would like to acknowledge all those who contributed directly or indirectly to this work, including our colleagues and everyone who helped with the data and insights, as your support was crucial to the completion of this Funding This research received no external funding Author Contributions Hendro Purwono.
: Conceptualized the study, designed the experimental procedures, and conducted the primary data analysis.
Provided critical insights into the failure mechanisms and developed the framework for the analysis.
Ari Aryadi.
Pd.
: Assisted in drafting and editing the manuscript, including figures and tables.
Reviewed and contributed to the final revision and formatting of the paper.
Figure 4.
Fuel Filter Problem Based on the inspection results, it was concluded that the occurrence of low engine power was primarily due to a blockage in the fuel filter, which restricted optimal fuel flow to the engine.
This restriction hindered fuel delivery, leading to a decrease in engine performance.
As an initial step, the fuel filter was cleaned to temporarily restore fuel however, to prevent recurring issues and to optimize engine performance, it was determined that replacing the fuel filter entirely would be the most effective solution.
By installing a new filter, the engineAos fuel supply will be ensured, promoting consistent and efficient operation in the long term.
This proactive replacement strategy is essential to maintaining the reliability of the unit and avoiding fuel-related Acknowledgment We would like to express my sincere gratitude to everyone who has supported and contributed to the completion of this journal on Conflicts of Interest The authors declare that there are no conflicts of interest regarding the publication of this paper.
All research and analysis were conducted with impartiality and without any external influence or financial interests that could have affected the Any potential conflicts of interest have been disclosed, and the study adhered to ethical standards in research and reporting.
References