• Seven engines saved in 24 weeks at a total saving to the customer of $641,000.
• An average of one engine saved every 3.4 weeks.
• 8 day’'s to the first save, from the start of the contract.
• All issues were either fuel dilution or coolant and a detailed standard job was issued which all of them.

What Did Oil Analysis Show?

	The oil results showed continuous levels of Sodium, indicating coolant entry into the oil. All other predictors were within the limits of the three different trending software groups, KOWA (Komatsu), OIL TEST, and Dingo Fleet Oil. Dingo/Customer/MTU had developed, and issued, a detailed standard job, outlining the diagnostic steps to take in the pursuit of coolant entry.
	In November Dingo had noticed a slight increase in Soot, it was still well within the limits, but it was the only other predictor that was on the move, albeit ever so slowly. With these particular engines having water cooled exhaust manifolds it was first suggested to inspect the cylinder heads for cracks, as the bulk of the coolant would be blowing out of the exhaust.
	By January/February wear metals were starting to trend upwards, but were erratic. Oil and filter change frequencies were reduced to once weekly and sampling twice weekly. In Feb/March Dingo had issued another detailed standard job and also instructed site personnel to extract some carbon scrapes from the exhaust’s of 742 and also from a control engine that was healthy, in this case it was unit 733. The results came back from Oil Test confirming a large presence of sodium in the exhaust of 742, and zero presence in 733.
	The machine was immediately shut down and was floated to the work shop, where the diagnostics began.
	By April/May sodium had accelerated to critical levels over 2300ppm, Dingo issued a third detailed standard job to aid in the diagnostics and another set of exhaust scrape samples were taken, this time one from each exhaust bank on 742. The test were conclusive that the left bank ,’A’ bank, was the problem as large amounts of sodium were detected.
	On the 26th of May a boroscope was performed on the left bank and it was found that six out of the eight heads were cracked, as a precaution all eight cylinder heads were changed out. The engine had achieved 6675 hours.

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Case Study B:
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.

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