John Deere 3520 Harvester Motor
With monitoring by predictive analysis, problems of external contamination, fuel contamination and engine wear were found and resolved before causing more issue.
Through fluid analysis, ALS promotes predictive maintenance to prevent damage and inconvenience to your equipment.
Result
The cost of inspection actions was U$629,53. If the monitoring was not carried out with the predictive maintenance and the necessary repairs, this problem with Diesel contamination, external contamination and wear would not be detected and the lubrication of the system would be impaired, causing serious damage to the system and its failure, with a cost around U$10.791,95, with the rectification of a Diesel engine. The savings generated by predictive maintenance was USD$10.162,42 (or 94%)
94%
COST AVOIDED
94,35%
Cost avoided
94,35%
Cost avoided
Analysis
The reports indicated high concentration of Iron, Silicon and Diesel contamination with drop in oil viscosity. Thus, the results indicated external contamination, fuel contamination and engine wear.
Diagnosis
It was recommended to stop the equipment as soon as possible, to inspect diesel crossing points for the lubrication system, change in the oil volume of the crankcase and check the operating conditions of the equipment as abnormal noises. In addition to inspecting all air intake system such as, damaged air filters, cover laying, clamping of clamps and wear particles in the oil filter.
Solution
The client reported that the technician performed the injection pump revision, where repairs were made to the pump and nozzle. In addition to the refurbishment of the fuel system.
Result
The cost of inspection actions was U$629,53.
3. If the monitoring was not carried out with the predictive maintenance and the necessary repairs, this problem with Diesel contamination, external contamination and wear would not be detected and the lubrication of the system
would be impaired, causing serious damage to the system and its failure, with a cost around U$10.791,95, with the rectification of a Diesel engine.
The savings generated by predictive maintenance was USD$10.162,42 (or 94%)
Risks without analysis and predictive maintenance:
- Compromising the lubrication syste
- 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.
ALS performs fluid analysis so that major damage is avoided, and also to generate savings through predictive maintenance.
- Worsening wear of the compartment
- Compromising the lubrication system
- Accelerated engine wear
