John Deere 2144G Harvester Pump Box
Through predictive monitoring, contamination with abrasive potential and wear was detected.
Through fluid analysis, ALS promotes predictive maintenance to prevent damage and inconvenience to your equipment.
Result
The cost of inspections, revisions and replacements was USD 2,290.38 (labor, changing gears, changing oil and filters). If monitoring was not performed with predictive maintenance, contamination and wear would not be detected, lubrication and system integrity would be impaired, causing serious damage to the system and its failure, with a repair value estimated at USD 5,725.95. The savings generated by predictive maintenance were USD 3,435.57 or 60%
60%
COST AVOIDED
94,35%
Cost avoided
94,35%
Cost avoided
Analysis
The reports signaled the presence of Silicon and Aluminum (dust and sand), in addition to an increase in the concentration of Iron and Chromium, thus indicating external contamination and wear of the compartment.
Diagnosis
It was recommended to identify the point of entry of the contamination, through inspections of the air filters, fitting of the cover and tightening of the clamps. Checking the oil level in the crankcase and the loss of power, to assess the points of wear was also suggested. Due to contamination, an oil change was indicated.
Solution
The client informed that the inspections were carried out to identify the ingress of contamination and noted the need to improve the compartment opening and collection procedures. With this inspection, the problem was solved and the risk of new contamination was avoided. During the inspections, the technician also observed a wear on the gears and then performed their replacement, and also changed the oil and filters.
Result
The cost of inspections, revisions and replacements was USD 2,290.38 (labor, changing gears, changing oil and filters).
If monitoring was not performed with predictive maintenance, contamination and wear would not be detected, lubrication and system integrity would be impaired, causing serious damage to the system and its failure, with a repair value estimated at USD 5,725.95.
The savings generated by predictive maintenance were USD 3,435.57 or 60%.
Risks if predictive maintenance was not performed:
- Higher contamination
- Risks for the lubrication system
- Acceleration of engine wear
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.
- Worsening wear of the compartment
- Compromising the lubrication system
- Accelerated engine wear
