Dozer Engine Main Water Pump & Aux Water Pump Failure
What Did Oil Analysis Show?
- The engine oil had been trending quite smoothly, with only some slight rises and falls in contaminants and wear metals.
- On the 18th November 2005 sodium had spiked from 8ppm to 489ppm, indicating coolant entry into the engine oil, all other predictors were within limits.
- A priority 1 work order was raised by Dingo, stand machine down immediately, and a detailed standard job was issued relating to the diagnostics steps needed.
- The machine was immediately shut down and was floated to the work shop, where the diagnostics began.
567 Tractor Engine Stats
• Fitted on 26-07-04
• Expected replacement date 03-06-2007
• Current life achieved 7,800 hrs 43
• Budgeted life 18000hrs
• Component Cost $188,000 including labor
• Duration in hours to change 96hrs
• Remaining life 10,200 hrs.
• Remaining Value $106,488.00 What was found?
· The first task on the detailed standard job is to inspect the tell tale hole in the water pump housing. To achieve this the belly guards need to be removed. Once the belly guards were removed from the machine, the guards were found to be completely full of dirt and debris.
· This built up debris had blocked the tell tale holes on both the main water pump and auxiliary water pump, which put pressure on the oil seals.
· Both water pumps were changed, the engine oil and filters were also changed, and the belly guards were cleaned and washed out.
· Three more work orders were created from the next three samples as residual coolant was still in the engine, and two more oil changes were carried out
· Once we had confirmation through the oil results the original work order was closed with
all relevant event history recorded. Improvements made or required
· The PM sheets for all dozers were amended to instruct all belly guards to be removed and cleaned at every service.  The bottom line:
• Engine had spent less than 500 hours in exception. Due to the close monitoring of trends, and the quick responses of the workshop personnel.
• Remaining value: $104,638.00
• $106,488.00, assuming engine achieves budgeted life
• Minus $1850.00 replacement costs of main and auxiliary water pumps.
• Downtime saved: 72hrs
• 96 hours of downtime was avoided, by not having to replace the engine.
• Minus 24 hrs duration to replace two water pumps.
• An exceptional example of employing the detailed standard jobs.
• By having consistent oil samples taken correctly and from recommended locations it makes the oil analysis program function for what it is design to do.
• Due to the quick actions of the workshop personnel we have avoided a catastrophic failure.
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