Caterpillar 924K Wheel Loader
Through monitoring by predictive analysis, contamination was observed in the lubricant, causing premature transmission wear.
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%.
86.22%
cost avoided
94,35%
Cost avoided
94,35%
Cost avoided
Analysis
The report revealed water contamination and a high concentration of copper. The result indicated an external or internal contamination by coolant and the occurrence of wear.
Diagnosis
The report detected the occurrence of water contamination with a significant presence of copper. It was recommended a tightness test on the heat exchanger and an inspection of the system to check for damage to the seals, evidence of leaks and the washing procedure of the equipment.
Solution
During the recommended inspections the client identified an internal leak in the heat exchanger causing contamination of the transmission by the coolant. After maintenance, a new sample showed Normal status, proving the effectiveness of the intervention and the importance of monitoring fluids in preventing failures and increasing the life of the equipment.
Result
The cost of replacing the heat exchanger was USD 963.98.
Without the monitoring with fluid analysis, contamination would not be identified, impairing lubrication and causing more wear and tear, leading to early transmission failure. A reforma da transmissão é avaliada em cerca de R$ 37.859,00.
The transmission reform is valued at USD 6,997.02.
Risks without analysis and predictive maintenance:
- Loss of lubricant properties
- Overheating of the compartment
- Wear on discs and plates
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
