John Deere 8270R Tractor Engine
High contamination by sodium and potassium was detected through predictive analysis monitoring and resolved safely before causing larger and more costly problems.
Result
The cost to replace the heat exchanger, engine oil, and filter was USD 1,629 (≈ R$ 9,284).
Without predictive maintenance monitoring and the necessary replacements, radiator fluid would have continued to leak, impairing proper cooling and potentially leading to engine failure and equipment shutdown. Damage of this magnitude would require a complete engine overhaul, costing USD 21,053 (≈ R$ 120,000), not including downtime losses. The savings generated by predictive maintenance totaled USD 19,401 (≈ R$ 110,716), equivalent to 92.3%.
92,30%
Savings
94,35%
Avoided cost
94,35%
Avoided cost
Analysis
The reports indicated a high concentration of Sodium and Potassium, as well as the presence of Copper, suggesting external contamination in the engine lubrication system. The most likely source was the engine’s own cooling fluid.
Diagnosis
Inspection of the heat exchanger was recommended, looking for holes or cracks that could compromise its integrity. For safety, it was also suggested to verify whether any washing procedures had been carried out near the equipment, since residues of degreasing agents could produce a similar effect.
Cross-contamination of oil in the radiator system was also suggested to confirm whether there was more severe damage inside the engine.
Solution
Following the recommended checks, the mechanic removed the heat exchanger to perform a leak test and immediately identified the hole.
Additional inspections were carried out on the other components, which were found to be in good condition. Due to the damage identified, it was necessary to replace the heat exchanger, the engine oil, and its filter.
Result
The cost to replace the heat exchanger, engine oil, and filter was USD 1,629 .
Without predictive maintenance monitoring and the necessary replacements, radiator fluid would have continued to leak, impairing proper cooling and potentially leading to engine failure and equipment shutdown. Damage of this magnitude would require a complete engine overhaul, costing USD 21,053 , not including downtime losses.
The savings generated by predictive maintenance totaled USD 19,401, equivalent to 92.3%.
Risks Without Analysis and Predictive Maintenance
- Fluid contamination
- Cooling system failure
- Engine failure
EPIROC DM30 Drill Engine Analysis
The reports indicated to the customer the presence of external dust contamination due to high silicon concentration, as well as increased levels of Iron, Chromium, and the PQI index, suggesting possible wear on the piston rings, pistons, and cylinder liners.
94,35%
avoided cost
94,35%
Custo evitado
94,35%
avoided cost
94,35%
avoided cost
EPIROC DM30 Drill Rig Motor Diagnosis
It was recommended to identify the source of contamination ingress by inspecting the air filters, checking the seating/integrity of the cover and the tightening of the clamps, verifying the oil level in the crankcase, and assessing possible power loss.
Solution – EPIROC DM30 Drill Rig Engine
The customer reported that inspections were carried out and, based on them, signs of exhaust gases were found in the intake coming from the cylinder head return. The cylinder head was removed, allowing the detection of valves and seats with poor sealing. The engine was repaired and the seals were replaced.
94,35%
avoided cost
94,35%
avoided cost
94,35%
Avoided cost
EPIROC DM30 Drill Rig Engine Video
EPIROC DM30 Drill Rig Engine Result
The cost to replace the heat exchanger, engine oil, and filter was USD 1,629.
Without predictive maintenance monitoring and the necessary replacements, radiator fluid would have continued to leak, impairing proper cooling and potentially leading to engine failure and equipment shutdown. Damage to this magnitude would require a complete engine overhaul, costing USD 21,053, not including downtime losses. The savings generated by predictive maintenance totalled USD 19,401, equivalent to 92.3%.
Through predictive monitoring and oil analysis, recurring ingress of contamination with abrasive potential and increased wear was observed.te.
ALS works in predictive maintenance to ensure, through these analyses, that your equipment avoids major issues or damage.
- Increased contamination ingress
- Impairment of the lubrication system
- Accelerated engine wear
