INFORMATION ON ICE 525 & D6H DOZER

1. ICE 525

a) https://www.lectura-specs.com/en/model/structural-and-civil-engineering-equipment/diesel-hydraulic-
drive-units-ice/525-pp-rf-1012565
b) The photo for ICE 525 is seen above.

ENGINE:
1. Year make, manufacturer and model No.
1. Year make: 2006, Manufacturer: ICE, Model No: 525.
(The engine manufacturer is not ICE, please find out the correct information)

2. Workhours of the engine since new or last overhaul.

2. N.A (Very important to have this information. We are sure you can find it. Thank you)

3. Grade, the name or full specs of the motor oil used.

3. Total oil, Rubia S 40.

4. Every how many workhours is the oil changed.

4. 240 work hours (Does the unit have workhours gauge ?)

5. Do you consider the quality of the diesel fuel used, high, medium, or low quality.
5. High quality (NNPC). (What is the colour of the motor oil when it is drained, would you say it is brown dark or black
dark, does it look or feel thicker than the new oil? Does it look very dirty? There would be no need to ask these
questions if you would have used oil analysis).
 6. Does the engine smoke much heavier or reasonably acceptable for diesel engine
6. Reasonably acceptable. (What is the colour of the smoke, in idle, routine operation, full gas?
Use the following colours: light white-greyish, thick white-greyish, dark grey, light black, thick black?)

7. Does it require top-ups between oil changes ? If yes, how much and how often.
7. No, it doesn’t require top up.

8. Is this engine still in operation, or close to being repaired / overhauled ?

8. Close to being repaired. (If it is close to being repaired, what are the symptoms, what is the reason you think it has to
be repaired? I guess if it does not require top-ups, it does not require overhaul, is it correct?)

9. Typically, every how many work hours such an engine is overhauled ?

9. We don’t overhaul until when necessary. (Irrelevant answer. From your experience or statistical data of the
manufacturer, usually every how many workhours the engine is overhauled. Usually the manufacturer indicated the
service life expectancy of the engine. Please find this information.)

10. Does your company conduct used oil analysis as part of its condition monitoring program ?
10.a. Does your company conduct oil filter metal particles count?
10. No, we don’t conduct such tests. 10.(a) No, we do not conduct the test.
(Can you find out if in Nigeria there is used oil analysis lab, it would be very helpful to equipment condition
monitoring, and of course to monitor the performance of Polytron products. It would be like an open book. It would
show concentration of wear metals, to show that in presence of Polytron MTC the concentration of wear particles
goes down considerably, the specs of the used oil in presence of Polytron MTC extended at least 4 times, and more)

11. Can you please describe specific problems that your technical team observed in the most
resent service / maintenance operation.
11. The technical team observed issues with the injector and nozzle. (What were the symptoms, what was the problem,
what did you do to take care of it ?)

12. Does the engine overheat sometimes in hot weather and high loads?
12. No overheating is observed in the engine. (Don't you have in Nigeria sometimes temperature of 40 to 45 deg C ? So, it
never happened that this specific engine overheated ?).

13. What is the average fuel consumption of the engine per workhour.
13. N.A (Don't you have a log of fuel consumption ?)

14. What is the oil sump capacity ?

14. The oil sump capacity is 40 litres.

15. What is the fuel tank capacity

15. N.A (Please find out because this information must be available. Thank you)

16. Every how many workhours do you service the fuel system.
16. The system is serviced in 240 work hours, and we replace injectors when they have problems. (From your experience,
every how many workhours, usually, do you replace the injectors, for example the last time, how many workhours
they were in service before you replaced them. What are the symptoms based on which you decide to replace
them?)

17. Please list the parameters you want to monitor and what improvements / problems solved do you expect
from using Polytron products during the test period? (Please do your best to answer this specific
question)
HYDRAULIC SYSTEM:

1. ISO grade, name and full specs of the hydraulic oil used
1. ISO 6743/4 HM, TOTAL AZOLLA ZS 68

2. Every how many workhours do you change the oil / service the hydraulic system. What does the service
include?
2. Changing the hydraulic oil, hydraulic filters. (Every how many workhours? You most likely have this
information)

3. Any top-ups ? How much and how often.

3. Yes, we normally top-up 25 litres, every 3weeks. (So it is fair to assume that the loss of oil is due to leaks ?)

4. The capacity of the oil sump.

4. The capacity of the oil sump is 1200 litres.

5. Does the hydraulic system (pump, control system parts) overheat sometimes in hot weather or high
loads.
5. The hydraulic system does not overheat. (Is the oil temperature monitored and recorded ? Does the hydraulic
oil circulate through a cooling system? What is the average temperature of the oil?

6. Does your company conduct used oil analysis as part of its condition monitoring program ?If yes, does
this hydraulic system have any recent used oil analysis test results ?
6. No, we do not conduct such tests.

7. Can you please describe specific problems that your technical team observed in the most resent service.
7. The hammer motor pump/hydraulic pump was changed. (What was the reason it was replaced ? What is a
known service life, in workhours, of such a hydraulic motor ? )

8. Is there a considerable pressure drop along the system due to leaks and clogged oil ways ?
8. Yes, there is pressure drop. (Besides the regular reasons for drop in pressure in lines, what are the other
reasons that you observed, and what do you do to overcome this problem ? )

9. Do you flush the system from time to time ? If yes, how often ?
9. Yes, 6 months interval. (What is the main reason you flush the system, what are the symptoms that
you observe before you flush the system. Do you use special chemicals, detergents or solvents, to flush the
system ?)
2. D6H DOZER

a) https://fulcrum.ug/product/cat-d6h-lgp
b) The photo for D6H DOZER is seen above

ENGINE:

1. Year make, manufacturer and model No (It is very important to have this information)
1. Year make: N.A model No: N.A manufacturer: CAT

2. Workhours of the engine since new or last overhaul.

2. N.A (It is very important to have this information)

3. Grade, the name or full specs of the motor oil used.

3. Total oil, Rubia S 40.

4. Every how many workhours is the oil changed.

4. 240 work hours. (Does the control panel have workhours meter ? On the average, How many hours a day
is this equipment in operation? )

5. Do you consider the quality of the diesel fuel used, high, medium, or low quality
5. High (NNPC). (What is the colour of the motor oil when it is drained, would you say it is brown dark or black
dark, does it look or feel thicker than the new oil? Does it look very dirty? There would be no need
to ask these questions if you would have used oil analysis)

6. Does the engine smoke much heavier or reasonably acceptable for diesel engine
6. It smokes heavier. (What is the colour of the smoke, in idle, routine operation, full gas?
Use the following colours: light white-greyish, thick white-greyish, dark grey, light black, thick black?)

7. Does it require top-ups between oil changes ? If yes, how much and how often.
7. Yes it requires top-up of 10 litres every 2 days.

8. Is this engine still in operation, or close to being repaired / overhauled ?

8. Close to being overhauled. (Is it still in operation? Are you planning major overhaul or minor overhaul ? How
many more workhours do you estimate until overhaul ?)
9. Typically, every how many work hours such an engine is overhauled ?
9. We don’t overhaul until when necessary. (Of course you do not overhaul if it is not necessary, this was not
our question, the question was, according to the manufacturer or from your experience, how many
workhours on the average such an engine, if maintained properly, can last until its first overhaul.
Was this engine overhauled in the past ?)

10. Does your company conduct used oil analysis as part of its condition monitoring program ?
If yes, does this specific engine have any recent used oil analysis test results ?
10. No, we do not such test. 10.(a). No, we do not conduct the count. (Can you find out if in Nigeria there is used
oil analysis lab, it would be very helpful to equipment condition monitoring, and of course to monitor the
performance of Polytron products. It would be like an open book. It would show concentration of wear
metals, to show that in presence of Polytron MTC the concentration of wear particles goes down
considerably, the specs of the used oil in presence of Polytron MTC extended at least 4 times, and more)

11. Can you please describe specific problems that your technical team observed in the most resent
service / maintenance operation.
11. The technical team observe issues with the transmission vavle and turbo charger. (Regarding turbo charger,
what were the symptoms, what was the problem, what did you do to take care of it ? Does the turbocharger
have its own oil, or motor oil lubricates its parts also ? )

12. Does the engine overheat sometimes in hot weather and high loads?
12. No, the engine doesn’t overheat (Don't you have in Nigeria sometimes temperature of 40 to 45 deg C ?
So, it never happened that this specific engine overheated ?).

13. What is the average fuel consumption of the engine per workhour.
13. N.A (Don't you have a log of fuel consumption ?)

14. What is the oil sump capacity ?

14. The oil sump capacity is 30 litres.

15. What is the fuel tank capacity.

15. The fuel tank capacity is 380 litres.

16. Every how many workhours do you service the fuel system.
Every how many workhours on the average do you replace the fuel injectors ?
16. 240 work hours, we only replace fuel injectors when they are bad. (Irrelevant answer. From your experience,
every how many workhours, usually, do you replace the injectors, for example the last time, how many
workhours they were in service before you replaced them. What are the symptoms based on which you
decide to replace them?)

Please list the parameters you want to monitor and what improvements / problems solved
do you expect from using Polytron products during the test period?
(Please do your best to answer this specific question)

TRANSMISSION

1. Grade, name and full specs of the transmission fluid used.

1. We make use of Automatic transmission fluid (ATF) (Please find out the information)

2. Every how many workhours do you change the fluid / service the transmission. What does the service
include?
2. 3 months (2160 hours), the service includes changing the transmission filter and oil. (So, it is regardless the
workhours, automatically you service it every 3 months?)
3. Any top-ups ? How much and how often
3. There is no need for top-ups.

4. The capacity of the transmission fluid sump.

4. The transmission fluid sump capacity is 200 litres.

5. Does the transmission overheat sometimes in hot weather or high loads.

5. There is no overheating observed in the transmission. (Is there any temperature gauge that indicates
transmission fluid temperature?)

6. Does your company conduct used oil analysis as part of its condition monitoring program ?
6. No, we do not conduct such test. (Is there used oil analysis lab in Nigeria that you can use? With used oil
analysis the task of establishing the performance of Polytron products will so much easier and simpler,
unless you have other ways to evaluate it).

7. Can you please describe specific problems that your technical team observed in the most resent
service / maintenance operation. Does it have unusual noise during operation and gear shifting.
7. The technical team observed issues with the transmission valve/pump. (What were the symptoms, what kind
of issue and how it was handled? What do you think was the root cause to this problem)

8. Do you flush the transmission from time to time ? If yes, how often ? Do you see high concentration
of metal particles / shavings ?
8. Yes, the system is flushed in 3 months interval. There were no metal particles/shavings
(When you drain the transmission fluid, do you actively look for metal particles or just dump the fluid, flush
the transmission, and put new fluid in. If there are no metal particles, and no other contaminants, because
the transmission is completely sealed, what is the reason that you flush it every 3 months, is it based on the
manufacturer's maintenance instructions ?)

9. In the last fluid change, was there observed excessive concentration of metal particles
in the fluid ?
9. No, we didn’t observe such.

Please list the parameters you want to monitor and what improvements / problems solved
do you expect from using Polytron products during the test period?
(Please do your best to answer this specific question)

NOTE: N.A = NOT AVAILABLE

Do you use electrical generators ? If yes, can we include one in the trial tests, because it can be used
very effectively to test fuel consumption per KWh, which is difficult, or even impractical to do on any other
equipment.

Thank you for your kind cooperation.

Looking forward to your response as soon as possible.

David Glass

Comment:
In your response document please keep all the text above as is, including the colors, and add your new
responses in different color (maybe green), so not to lose the connection. (In your first response document
we had to put back our questions to make the connection to our questions clear.
If the file we email is PDF, just copy and paste the text in new document.