IVECO Trakker 420 Truck Engine
Through predictive monitoring via oil analysis, external contamination and consequent wear were found. The root cause was identified and eliminated before the contaminants caused more issues.
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%.
97,33%
cost avoided
94,35%
Cost avoided
94,35%
Cost avoided
Analysis
The reports signaled the presence of Silicon and Aluminum, in addition to wear in ferrous alloys for the concentration of Iron and the high index of PQi. Thus, the result indicated external contamination and marked engine wear.
Diagnosis
It was recommended to inspect the entire air intake system such as damaged air filters, cover seating, hoses and even tightening the clamps. These checks, in conjunction with typical inspections, would make it possible to identify the point of entry of contaminants.
Solution
The client carried out all the recommended inspections in the air intake circuit and identified a hole in the air filter tube, which allowed contaminants to pass through. The tube and air filter were replaced due to the damage found.
Result
The cost of replacing the tube was USD 143.09, and for the external air filter was USD 68.86. As it was contaminated, the lubricating oil and oil filter were also changed, totaling USD 142.34.
. If the monitoring was not carried out with the predictive maintenance and necessary changes, this problem with external contamination would not be detected, which would aggravate the wear and cause serious damage to the system and its failure. The engine repair has an average cost of USD 13.269,16 in addition to stopping the equipment for 60 days.
The savings generated by predictive maintenance were $12,914.89 (or 97.33%).
Risks without analysis and predictive maintenance:
- Equipment shutdown for 60 days
- Risks for the lubrication system
- Engine wear and 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%
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
