Truck Off Road Volvo A30F
With monitoring by predictive analysis, Diesel contamination problems in the engine were identified and solved before causing bigger issues.
ALS performs fluid analysis so that major damage is avoided, and also to generate savings through predictive maintenance. Fluid analysis can prevent:
Result
Replacement costs were around $4,435.86. If monitoring with predictive maintenance was not carried out, this problem with contamination would not be detected and the lubrication of the system would be impaired, causing
serious damage to the system and its failure, with an estimated repair value of $16,634.47, without taking into account the costs of downtime and production loss. The savings generated by predictive maintenance were
USD 12,198.61 (or 73.3%).
73,3%
Cost avoided
94,35%
Cost avoided
94,35%
Cost avoided
Analysis
The reports signaled high contamination by Diesel with a drop in oil Viscosity. Thus, the results indicated the passage of diesel to the crankcase.
Diagnosis
It was recommended to stop the equipment as soon as possible, to inspect the possible diesel points of passage for the lubrication system, as well as changes in the volume of oil in the crankcase; increase in fuel consumption and adjustments of the injection system.
Solution
The customer reported that the technician replaced the equipment’s injection units, as well as changing the lubricant and filters.
Result
Replacement costs were around $4,435.86.
If monitoring with predictive maintenance was not carried out, this problem with contamination would not be detected and the lubrication of the system would be impaired, causing serious damage to the system and its failure, with an estimated repair value of $16,634.47, without taking into account the costs of downtime and production loss.
The savings generated by predictive maintenance were USD 12,198.61 (or 73.3%).
Risks for 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%
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 specializes in predictive maintenance, using analyses to prevent major issues or damage to your equipment.
- Worsening wear of the compartment
- Compromising the lubrication system
- Accelerated engine wear
