Truck Scania G440
Contamination problems in the engine were found with monitoring by fluid analysis and was solved before causing bigger problems.
Through fluid analysis, ALS promotes predictive maintenance to prevent damage and inconvenience to your equipment.
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%.
80%
COST AVOIDED
94,35%
Cost avoided
94,35%
Cost avoided
Analysis
The reports shown a diesel contamination with a drop in oil viscosity, high sodium concentration and variation in additives. These contaminants indicate the passage of fuel and coolant to the engine’s lubrication system.
Diagnosis
It was recommended that the equipment be stopped to check: diesel crossing points for the lubrication system, changes in the oil volume in the crankcase, injection system settings, heat exchanger conditions, signs of oil contamination in the cooling system and the washing procedure. It was also indicated to change the oil and send a new sample with half the recommended change mileage to check if the contamination had stopped.
Solution
The client reported that he carried out the recommended inspections and that he identified the need to change the nozzles. It was necessary to change the contaminating oil and filters, paying attention to cleaning, avoiding the presence of residues that could impair the performance of the new lubricant. When it was close to half the exchange mileage, was taken a new sample, where we identified that there was no more contamination.
Result
The cost of exchanges and inspection was 1,953.62 USD.
If monitoring with predictive maintenance was not carried out, contamination would not be detected and the lubrication of the system would be impaired, causing serious damage and its total failure, with a repair value of 9,768.11 USD.
The savings generated by predictive maintenance was 7,814.49 USD.
Risks without analysis and predictive maintenance:
- Risks for the lubrication system
- Accelerated engine wear
- Equipment failures and damage
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.
Through fluid analysis, ALS promotes predictive maintenance to prevent damage and inconvenience to your equipment.
- Higher contamination
- Compromising the lubrication system
- Accelerated engine wear
