Caterpillar 140K Motor Grader Engine
With monitoring by predictive analysis, problems with diesel contamination and alteration of oil viscosity in the engine were found and solved safely before causing more issues.
ALS performs fluid analysis so that major damage is avoided, and also to generate savings through predictive maintenance.
Result
The cost of this inspection action was $4,913.73. If monitoring was not performed with predictive maintenance, this problem with diesel contamination and the drop in oil viscosity would not be detected and the lubrication of the system would be impaired, causing serious damage to the system and its failure, with an estimated repair value of $21,838.80.
97%
COST AVOIDED
94,35%
Cost avoided
94,35%
Cost avoided
Analysis
The reports signaled diesel contamination with a drop in oil viscosity. The result indicated the passage of diesel to the crankcase.
Diagnosis
It was recommended to check the possible diesel crossing points for the lubrication system. Given the high contamination, it was requested to replace the lubricating oil with special attention to cleaning the system.
Solution
The client reported that the excess diesel was caused by a leak, so he had to replace the injector units. Due to contamination, the lubricant and oil filter were also changed.
Result
The cost of this inspection action was $4,913.73.
If monitoring was not performed with predictive maintenance, this problem with diesel contamination and the drop in oil viscosity would not be detected and the lubrication of the system would be impaired, causing serious damage to the system and its failure, with an estimated repair value of $21,838.80.
The savings generated by predictive maintenance were $16,925.07 (or 77.5%).
Risks without analysis and predictive maintenance:
- Iron concentration
- High PQi level
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%
Cost avoided
94,35%
Cost avoided
94,35%
Cost avoided
94,35%
Cost avoided
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%
Cost avoided
94,35%
Cost avoided
94,35%
Cost avoided
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 specializes in predictive maintenance, using analyses to prevent major issues or damage to your equipment.
- Worsening wear of the compartment
- Compromising the lubrication system
- Accelerated engine wear
