Engine of a Tyre Tractor John Deere 7225J
With monitoring by predictive analysis, severe engine wear problems were found and resolved before causing more issue.
Through fluid analysis, ALS promotes predictive maintenance to prevent damage and inconvenience to your equipment.
Result
This action cost USD$14,40. If the inspection was not carried out, this problem would not be identified, and it is known that wear generates more wear (abrasive effect), which could cause breakage or loss of the engine and system shutdown. Therefore, the estimated cost according to the customer for corrective maintenance would be approximately USD$5.685,80. The savings generated by predictive maintenance was USD$5.671,40 (or 99,7%
95%
COST
AVOIDED
94,35%
Avoided cost
94,35%
Avoided cost
Analysis
The sample presented high concentration of Iron, Chromium and Silicon, and the result indicates external contamination and possible wear on segment rings, pistons and cylinder liners.
Diagnosis
It was recommended that the customer check the conditions of the air filters, cover laying, clamping of the clamps, oil level in the crankcase, Blow-by increase, loss of power and possible presence of wear particles in the oil filter. And then change the oil.
Solution
According to the customer, it was inspected and identified that the engine air filter was damaged, so it was replaced.
Result
This action cost USD$14,40.
If the inspection was not carried out, this problem would not be identified, and it is known that wear generates more wear (abrasive effect), which could cause breakage or loss of the engine and system shutdown. Therefore, the estimated cost according to the customer for corrective maintenance would be approximately USD$5.685,80.
The savings generated by predictive maintenance was USD$5.671,40 (or 99,7%)
Risks if predictive maintenance was not performed:
- Worsening wear of the compartment
- Compromising the lubrication system
- 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%
Avoided cost
94,35%
Avoided cost
94,35%
Avoided cost
94,35%
Avoided cost
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%
Avoided cost
94,35%
Avoided cost
94,35%
Avoided cost
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 works in predictive maintenance to ensure, through these analyses, that your equipment avoids major issues or damage.
- Increased contamination ingress
- Impairment of the lubrication system
- Accelerated engine wear
