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<p>The Caterpillar C9 engine on the Furukawa HCR 1500 D20 hydraulic drilling unit at PT XYZ experienced fuel dilution, resulting in an average downtime of 78 hours, which significantly impacted mining operations. This study aims to analyze the effects of fuel dilution on engine performance, identify the root causes, and formulate preventive actions. A case study approach was employed using both quantitative and qualitative methods through trend analysis of Scheduled Oil Sampling (SOS) data, supported by historical maintenance records, condition monitoring data, and the results of cutout and leak tests. Root Cause Analysis was conducted using a fishbone diagram and the 5 Whys method. The results indicate that fuel dilution reached 51.8%, primarily caused by internal leakage in the cylinder head due to engine operation exceeding 22,000 hours without an overhaul. Corrective actions were carried out in stages, culminating in a complete engine replacement. As preventive measures, the implementation of a preventive maintenance strategy is recommended, including regular replacement of the secondary fuel filter, establishment of component lifetime targets, and routine monitoring of ECM data.</p>

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Failure Analysis of Caterpillar C9 Engine in Hydraulic Drill Unit Due to Fuel Dilution Through Scheduled Oil Sampling (SOS) Data Evaluation and Root Cause Analysis (RCA) Approach

  • 期刊论文

  • 发表日期：

    2026年2月4日

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  • Tubagus Vikky,
  • Nyayu Aisyah,
  • Sugiyanto,
  • Braam Delfian Prihadianto

摘要

The Caterpillar C9 engine on the Furukawa HCR 1500 D20 hydraulic drilling unit at PT XYZ experienced fuel dilution, resulting in an average downtime of 78 hours, which significantly impacted mining operations. This study aims to analyze the effects of fuel dilution on engine performance, identify the root causes, and formulate preventive actions. A case study approach was employed using both quantitative and qualitative methods through trend analysis of Scheduled Oil Sampling (SOS) data, supported by historical maintenance records, condition monitoring data, and the results of cutout and leak tests. Root Cause Analysis was conducted using a fishbone diagram and the 5 Whys method. The results indicate that fuel dilution reached 51.8%, primarily caused by internal leakage in the cylinder head due to engine operation exceeding 22,000 hours without an overhaul. Corrective actions were carried out in stages, culminating in a complete engine replacement. As preventive measures, the implementation of a preventive maintenance strategy is recommended, including regular replacement of the secondary fuel filter, establishment of component lifetime targets, and routine monitoring of ECM data.