John Deere 6180J Tractor Tire Engine
Diesel contamination and high oxidation issues were found through predictive analysis and safely solved before more costly 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%.
78%
COST AVOIDED
94,35%
Cost avoided
94,35%
Cost avoided
Analysis
The reports found diesel in the crankcase and oxidation of the lubricant. This type of fuel contamination reduces the oil viscosity, making a lubrication failure and component wear due to the lack of the lubricating film or film that guarantees protection. In addition to it, there is the additive dilution that fail to protect the machine and the oil, so the lubricant can have a degradation faster (oxidation).
Diagnosis
t was recommended to anticipate the scheduled inspection to evaluate the diesel in the lubrication system, as well as the change in the oil volume in the crankcase and check if there was an increase in blow-by. We also recommend observing the operating conditions of the equipment, such as abnormal working temperatures, increased fuel consumption and injection system adjustments.
Solution
The customer identified that the injection pump had a damaged retainer, and as the oil viscosity was already 50% lower than expected, it was possible to notice the change in the lubricant visibly. Then, there was a maintenance on the injection pump and a change in the oil charge for proper system protection.
Result
The cost of replacing the maintenance of the injection pump with specialized workforce was USD 1,120
If there weren’t any monitoring with predictive maintenance, diesel contamination and oxidation would not be detected and the lubrication of the system would be impaired, with a serious damage in the system, and its failure, with an estimated repair value of USD 5,115 (cost of total engine repair maintenance), without taking into account the costs of machine downtime and loss of production.
The savings generated by predictive maintenance was USD 3,994 (or 78%)
Risks without analysis and predictive maintenance:
- Total fuel contamination
- Ineffectiveness of lubrication
- 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%
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
