IMPROVING ENGINE COOLING SYSTEM TO PREVENT OVERHEATING IN MOTOR GRADER USING IOT

Abstract

Overheating of the Komatsu GD825A-2 motor grader in the mining area is mainly caused by dust accumulation on the radiator fins and the absence of a real-time temperature and pressure monitoring system. This study designs an automatic radiator washing system integrated with IoT-based monitoring using temperature and pressure sensors with delta analysis as the main feature. The method used is Define–Measure–Analyze–Improve–Control (DMAIC), starting from identifying the root cause through Focus Group Discussions (FGD), interviews, and field observations, then analyzed using fishbone diagrams and Failure Mode and Effects Analysis (FMEA). The implementation results show a significant reduction in the Risk Priority Number (RPN), namely the radiator tube from 392 to 96 (~75%) and the radiator fin from 336 to 84 (~75%). In addition, downtime due to overheating in the engine was successfully reduced from 30.3 hours to 0 hours. The implementation of this system has been proven to increase inspection and maintenance efficiency, reduce the risk of overheating, and support the reliability and productivity of heavy equipment in tough mining working conditions.