Off Road Truck Engine Komatsu 930E
Through predictive monitoring, it was possible to detect the passage of diesel to the crankcase.
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%.
80%
AVOIDED COST
94,35%
Cost avoided
94,35%
Cost avoided
Analysis
The reports signaled contamination by Diesel, which caused a decrease in the viscosity of the oil.
Diagnosis
It was recommended to check the general operating conditions, possible diesel crossing points, fuel consumption and the injection system settings.
Solution
The technician performed the inspection and detected wear on the injector nozzles, then replaced the 12 injectors and regulated the valves. As the lubricant was contaminated, he also changed it.
Result
Replacement costs were USD 46,498.36.
If the predictive monitoring was not carried out, which made quick actions possible, this problem with contamination by Diesel could cause low pressure of the lubricating oil, causing the catastrophic breakdown of the engine, totaling a cost of USD 231,613.20.
The savings generated by predictive maintenance were USD 185,114.84, or 80%.
Risks without analysis and predictive maintenance:
- Failures in the lubrication of the system
- Increased wear of parts
- Unexpected stop
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
